Large deviation aspherical element refers to an optical element with large asphericity and sharp curvature changes. It plays an important role in constructing modern optical system. However, widely used passive smoothing technology cannot meet the need of producing smooth large deviation aspherical element. Thus, an active smoothing technology was creatively used in the current research, aiming to reduce the mid-spatial frequency (MSF) error of the surface of large deviation aspherical element. To reach the objective, an off-axis smoothly-processing model was constructed. It offers important information about the degree of coincidence between grinding lap and large deviation aspherical element. Finite element analysis was also conducted to examine the relationships among material, thickness, and structure of grinding lap during the active smoothing process, and to obtain optimal active smoothing parameters. Finally, a complete processing process for large deviation aspheric elements was constructed and used for machining experiments. The result suggested that the off-axis smoothly-processing model has high accuracy, and the smoothing technology in this paper is effective to decrease the MSF error of the surface of large deviation aspherical element.
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