Generation of reference softgauges for minimum zone fitting algorithms: Case of aspherical and freeform surfaces

Optical aspherical lenses with high surface quality are increasingly demanded in several applications in medicine, synchrotron, vision, etc. To reach the requested surface quality, most advanced manufacturing processes are used in closed chain with high precision measurement machines. The measured data are analysed with least squares (LS or L₂-norm) or minimum zone (MZ) fitting (also Chebyshev fitting or L_∞-norm) algorithms to extract the form error. Performing data fitting according to L_∞-norm is more accurate and challenging than L₂-norm, since it directly minimizes peak-to-valley (PV). In parallel, reference softgauges are used to assess the performance of the implemented MZ fitting algorithms, according to the F1 algorithm measurement standard, to guarantee their traceability, accuracy and robustness. Reference softgauges usually incorporate multiple parameters related to manufacturing processes, measurement errors, points distribution, etc., to be as close as possible to the real measured data. In this paper, a unique robust approach based on a non-vertex solution is mathematically formulated and implemented for generating reference softgauges for complex shapes. Afterwards, two implemented MZ fitting algorithms (HTR and EPF) were successfully tested on a number of generated reference pairs. The evaluation of their performance was carried out through two metrics: degree of difficulty and performance measure.