Electroless nickel is an excellent material for making optical molding dies, because of its machinability with both single-point diamond turning and polishing, as well as its suitable hardness and durability. This paper deals with the ultra-precision polishing of molding dies for telescope mirrors with a super smooth surface with a roughness below 1 nm root-mean- square (rms). According to the probability density distribution function of different sizes of abrasive grains cut into the workpiece, a surface roughness model combining the micro contact model and the force balance principle was established. A surface roughness of 0.316 nm Ra was obtained on slab molding dies of 30 mm in diameter.
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