Research progress on grinding contact theory of axisymmetric aspheric optical elements

Aspherical optical components are critical in precision optical systems (e.g., aerospace, medical, astronomy) for superior aberration correction and imaging performance. Fabricated from hard, brittle materials like ceramics and silicon, these components offer exceptional hardness, thermal stability, and wear resistance. Current machining methods—molding, diamond turning, grinding-polishing, and ultra-precision grinding—face challenges due to material brittleness and hardness. Ultra-precision grinding emerges as an effective approach for shaping aspherical optics, necessitating fundamental insights into grinding contact theory to optimize material removal and precision. This paper systematically reviews aspherical grinding techniques and their characteristics, followed by an in-depth analysis of contact theory advancements, including contact arc length, maximum undeformed chip thickness, and residual height in hard-brittle material grinding. Finally, it summarizes current research limitations and proposes future directions for advancing precision grinding theory, aiming to enhance the fabrication of high-performance aspherical optical components.