Diamond turning of high-precision roll-to-roll imprinting molds for fabricating subwavelength gratings

2016 ◽  
Vol 55 (6) ◽  
pp. 064105 ◽  
Author(s):  
Chun-Wei Liu ◽  
Jiwang Yan ◽  
Shih-Chieh Lin
Keyword(s):  
High Precision ◽  
Diamond Turning ◽  
Roll To Roll ◽  
Subwavelength Gratings

Form Accuracy of Optical Mould Inserts Made from Rapidly Solidified Aluminium Alloys

2015 ◽  
Vol 828-829 ◽  
pp. 62-68
Author(s):  
Khaled Abou-El-Hossein
Keyword(s):  
High Precision ◽  
Surface Finish ◽  
Single Point ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Machining Parameters ◽  
Optical Surface ◽  
Form Accuracy ◽  
Optical Surfaces ◽  
Rapidly Solidified

Plastic optical components and lenses produced in mass quantities are usually manufactured using high-precision plastic injection technology. For that, high-precision plastic moulds with aluminium optical inserts made with extremely high dimension accuracy and high optical surface quality are used. Ultra-high precision single-point diamond turning have been successfully used in shaping optical mould inserts from various aluminium grades such as traditional 6061. However, extreme care should be taking when selecting machining parameters in order to produce optically valid surfaces before premature tool wear takes place especially when the machined optical materials has inadequate machining database. The current experimental study looks at the effect of cutting conditions on optical surfaces made from aluminium. The study embarks on helping establish some diamond machining database that helps engineers select the most favourable cutting parameters. The papers reports on the accuracy and surface finish quality received on an optical surface made on mould inserts from a newly developed aluminium alloy. Rapidly solidified aluminium (RSA) grades have been developed recently to address the various problems encountered when being cut by single-point diamond turning operation. The material is characterised by its extremely fine grained microstructure which helps extend the tool life and produce optical surfaces with nanometric surface finish. It is found the RSA grades can be successfully used to replace traditional optical aluminium grades when making optical surfaces. Surface finishes of as low as 10 nanometres and form accuracy of less than one micron can be achieved on RSA.

Modelling of Electrostatic Charge in Ultra-High Precision Diamond Turning of Contact Lens Polymer

2019 ◽  
Vol 298 ◽  
pp. 135-140
Author(s):  
Muhammad Mukhtar Liman ◽  
Khaled Abou El Hossein
Keyword(s):  
High Precision ◽  
Contact Lens ◽  
Feed Rate ◽  
Contact Lenses ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Electrostatic Charge ◽  
Diamond Turning ◽  
Depth Of Cut ◽  
Electrostatic Charges

The electrostatic charges encountered by a cutting tool when turning advanced contact lenses are important as they reflect the quality and condition of the tool, machine, fixture, and sometimes even the surface finished which is responsible for tool wear and poor surface quality. This study investigates the influence of cutting parameters namely cutting speed, feed rate and depth of cut on electrostatic charge (ESC) which play the leading role in determining the machine economics and quality of machining contact lens polymers. An electrostatic charge model based on response surface statistical method is developed for reliably predicting the values of static charging based on its relationship to cutting parameters in ultra-high precision diamond turning of contact lenses. It is clearly seen that all the model terms are significant with cutting speed having the highest degree of significance followed by feed rate and the interaction of speed and feed. However, depth of cut has the lowest degree of significance on the electrostatics charge.

Register mark measurement errors in high-precision roll-to-roll continuous systems: The effect of register mark geometry on measurement error

2016 ◽  
Vol 109 (14) ◽  
pp. 141602 ◽  
Author(s):  
Jongsu Lee ◽  
Pekka Isto ◽  
Hakyung Jeong ◽  
Janghoon Park ◽  
Dongjin Lee ◽  
...  
Keyword(s):  
Measurement Error ◽  
High Precision ◽  
Measurement Errors ◽  
Continuous Systems ◽  
Roll To Roll

High precision fabrication of polarization insensitive resonant subwavelength gratings

2012 ◽  
Author(s):  
R. R. Boye ◽  
D. W. Peters ◽  
J. R. Wendt ◽  
S. Samora ◽  
J. Stevens ◽  
...  
Keyword(s):  
High Precision ◽  
Subwavelength Gratings ◽  
Polarization Insensitive

scholarly journals Roll-to-Roll Embossing of Sunlight Guide Film with Wide Outgoing Angle

2011 ◽  
Vol 5 (2) ◽  
pp. 212-217 ◽  
Author(s):  
Ta-Hsin Chou ◽  
◽  
Wen-Hsien Yang ◽  
Tzu-Yu Huang ◽  
Hong Hocheng ◽  
...  
Keyword(s):  
Total Internal Reflection ◽  
Energy Use ◽  
High Energy ◽  
Diamond Turning ◽  
Curved Surfaces ◽  
Artificial Lighting ◽  
Roll To Roll ◽  
High Energy Efficiency ◽  
Film Microstructure ◽  
Room Model

Artificial lighting consumes over 20% of the total energy used by commercial buildings. Sunlight guides used in windows guide sunlight to the ceilings of indoor rooms. Microstructure film designed and fabricated by roll-to-roll embossing improves solar energy use. A roller mold was fabricated with a diamond turning lathe and used for UltraViolet (UV) cured embossing. After embossing, sunlight guide film 400 mm wide was fabricated. The film microstructure prism and curved surfaces 21 µm high and spaced at 18 µm intervals. When sunlight illuminates the inclined or curved surface, incoming rays are reflected from the outgoing surface in total internal reflection. Specimen performance wasmeasured using measurement installation including a light source, photodetector, and a rotating table. These produced sunlight guide film able to adopt elevation angles of 40°-70°. The outgoing angle exceeded a 30° average above the transom’s outgoing horizontal 90° angle, which is defined by full width at half maximum of outgoing light intensity. Experimental results showed of the microstructure film had high energy efficiency and a broad range of outgoing angles, reducing energy consumption by 19% in artificial building lighting for an ideal room model.

scholarly journals Development of an End-Toothed Disc-Based Quick-Change Fixture for Ultra-Precision Diamond Cutting

Machines ◽  
2021 ◽  
Vol 9 (11) ◽  
pp. 257
Author(s):  
Xuesen Zhao ◽  
Xiangwu Cui ◽  
Zhenjiang Hu ◽  
Qiang Zhang ◽  
Tao Sun
Keyword(s):  
Finite Element ◽  
High Precision ◽  
High Efficiency ◽  
Small Diameter ◽  
Diamond Turning ◽  
Depth Of Cut ◽  
Diamond Cutting ◽  
Positioning Accuracy ◽  
Small Depth ◽  
Ultra Precision

With its standardized and unified interface, the quick-change fixture is an important part for maintaining high efficiency without compensation of precision in the metal-turning process because it can conveniently realize high-precision repeated clamping and multi-station conversion without complex positioning and adjustment steps. However, the existing quick-change fixture products and related research cannot fully meet the needs of repeatability and applicability raised from ultra-precision, single-point diamond turning with ultra-high accuracy and ultra-small depth of cut. In this paper, we develop a quick-change fixture for ultra-precision diamond turning, in which the end-toothed disc acts as the positioning element. Specifically, the main parameters of two key components of the end-toothed disc and slotted disc spring are calculated analytically to ensure the positioning accuracy of the designed fixture used in the rotation condition, which is further ensured by controlling the machining tolerance of the tooth profile of the end-toothed disc. Additionally, finite element simulations are performed to investigate the static and modal states of the quick-change fixture, which demonstrate a maximum deformation of about 0.9 μm and a minimum natural frequency of 5655.9 Hz for the designed fixture. Two high-precision sensors are used to detect the radial jump and end run-out values after repeated clamping actions, which are employed to verify the repetitive positioning accuracy of the fixture. Subsequent finite-element simulation of the clamping of small-diameter copper bar, as well as the diamond turning experiment, jointly demonstrate that the designed fixture can achieve a precision of 1 μm. Current work provides an effective quick-change fixture to reduce the deformation of a weak-stiffness workpiece caused by clamping deformation in ultra-precision diamond cutting.

Effects of Alpha-Cellulose Supply on the Working Life of MCF Slurry in MCF Polishing

2020 ◽  
Author(s):  
Yuta Nonaka ◽  
Mitsuyoshi Nomura ◽  
Tatsuya Fujii ◽  
Tsunehisa Suzuki ◽  
Yongbo Wu
Keyword(s):  
High Precision ◽  
Single Point ◽  
Brittle Materials ◽  
Surface Damage ◽  
Diamond Turning ◽  
Optical Systems ◽  
Smart Devices ◽  
Tool Marks ◽  
Hard And Brittle Materials ◽  
Inspection Systems

Abstract High precision surfaces exhibit prominent capabilities for enhancing the imaging quality, expanding the visibility of equipment, simplifying structures, and reducing total costs of optical systems. Hence, they are regarded as essential optical surfaces for replacing traditional elements to modify optical systems, including space systems, optical inspection systems, and smart devices. Single point diamond turning (SPDT) and ultra-precision grinding have been adopted preliminarily to manufacture high-quality elements. However, these processes create sub-surface damage and tool marks on the work surface. To meet performance requirements, polishing is critical for post-processing to improve the quality of the products. MCF (Magnetic Compound Fluid) polishing, which is one of polishing methods using magnetic fields, is a processing method for finishing hard and brittle materials with high accuracy. Previous research has shown that MCF polishing is effective for hard and brittle materials. However, despite the high cost of the magnetic fluid that is a component of the MCF slurry, the MCF slurry used for polishing has been discarded. Another major issue was that unused MCF slurry could not be used due to drying. The purpose of this study is to recycle MCF slurry to solve this problem, and to develop high precision finishing technology. Therefore, in this study, a novel MCF polishing method using ultrasonic atomization is proposed, and the effects of α-cellulose on the MCF polishing are investigated. In addition, in order to make it possible to reuse the MCF slurry, In addition, experiments are conducted to enable reuse of MCF slurry.

High-precision register error control using active-motion-based roller in roll-to-roll gravure printing

2018 ◽  
Vol 57 (5S) ◽  
pp. 05GB04 ◽  
Author(s):  
Hoeryong Jung ◽  
Ho Anh Duc Nguyen ◽  
Jaeho Choi ◽  
Hongsik Yim ◽  
Kee-Hyun Shin
Keyword(s):  
High Precision ◽  
Error Control ◽  
Gravure Printing ◽  
Active Motion ◽  
Roll To Roll ◽  
Register Error

HIGH PRECISION RING LOCATION FOR A NEW ROTATIONALLY SYMMETRIC TRIANGULATION SENSOR

2005 ◽  
Vol 02 (04) ◽  
pp. 279-289 ◽  
Author(s):  
JUN GAO ◽  
XIAOJIA WANG ◽  
JOHANNES ECKSTEIN ◽  
PETER OTT
Keyword(s):  
High Precision ◽  
Optical System ◽  
Optical Measurement ◽  
Design Method ◽  
Rotational Symmetry ◽  
Distance Measurement ◽  
Diamond Turning ◽  
Measurement Result ◽  
Rotationally Symmetric ◽  
Ring Location

For a growing range of optical measurement task, like gap measurement in automotive industry, traditional triangulation sensors have several disadvantages due to the fact that the measurement result is dependent on the orientation of the sensor because of the non-rotational symmetry of the optics. Consequently a design method was proposed recently for a new class of rotationally symmetric triangulation sensors. Such designs can be realized with aspheric reflection optics and area detectors, such as CCD or CMOS. The optics of the sensor can be extended by an imaging optics which allows at the same time image capturing and distance measurement. In this paper we show the first prototype. This system is based on an optical system of one part manufactured by commercially available diamond turning. The layout of the optical system for distance measurement consists of two reflecting aspheric surfaces. The high precision algorithm for ring location was needed because the performance of the sensor is based on the detection of ring, especially the radius of the ring. In this paper, we try to give the different evaluation function for high precision location of ring. Then we used various methods to solve it and got optimized result. The comparison of algorithms for simulation was listed in the paper. And the measurement result for the real image got by the prototype was also presented. It seems the algorithm meets the precision demand of the sensor.

Friction Isolated Rotary System for High-Precision Roll-to-Roll Manufacturing

2020 ◽  
Author(s):  
Dongwoo Kang ◽  
Xin Dong ◽  
Hyunchang Kim ◽  
Pyungwon Park ◽  
Chinedum.E. Okwudire
Keyword(s):  
High Precision ◽  
Roll To Roll
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