A Study of Tool Path Generation for Machining of Precision Roller with Wavy Patterned Microstructures by Slow Tool Servo

2016 ◽  
Vol 679 ◽  
pp. 191-197
Author(s):  
Ling Bao Kong ◽  
Chi Fai Cheung ◽  
Wing Bun Lee ◽  
Suet To ◽  
Su Juan Wang ◽  
...  
Keyword(s):  
Tool Path ◽  
Single Point ◽  
Research Work ◽  
Axial Direction ◽  
Diamond Turning ◽  
Machining Process ◽  
Fast Tool Servo ◽  
Roller Surface ◽  
Ultra Precision ◽  
Slow Tool Servo

Embossing by patterned rollers is one of the most efficient machining approaches for manufacturing plastic films with patterned microstructures, and the precision roller with patterned microstructures is the key tooling component in the roll-to-roll process. Single-point diamond turning with a slow or fast tool servo is an enabling and efficient ultra-precision machining process to fabricate microstructures through a simple process to achieve optical surface finish directly. Most of the current studies on slow or fast tool servo machining processes either focus on face machining of patterned microstructures, or on tool servo machining of microstructures in the radial direction of precision rollers. Relatively little research work is found in relation to machining patterned microstructures on a precision roller by using the tool servo in the axial direction. This paper presents a pilot study on the development of a tool path generator for machining precision rollers with wavy patterned microstructures by using slow tool servo machining in the axial direction on a precision roller. The machining mechanism is firstly explained, based on which the tool path generator is developed for machining wavy patterned microstructures on a precision roller surface. Preliminary experimental work was conducted to study the generation of wavy patterned microstructures on a precision roller using a four-axis ultra-precision machine. The machined wavy microstructures on the roller surface are measured and analyzed to successfully validate the performance of the proposed tool path generator.

Experiment and Discussion on Ultrasonic Vibration-Assisted Single Point Diamond Turning of Die Steels

2012 ◽  
Vol 497 ◽  
pp. 1-5
Author(s):  
Xiao Dan Xie ◽  
Yong Li ◽  
Cam Vinh Duong ◽  
Ahmed Al-Zahrani
Keyword(s):  
Tool Wear ◽  
Ultrasonic Vibration ◽  
Single Point ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Machining Process ◽  
Die Steels ◽  
Ultra Precision ◽  
Promising Solution ◽  
Vibration Parameters

Traditionally, single point diamond turning (SPDT) can not process ferreous metals because of acute tool wear. Ultrasonic vibration-assisted cutting(UVC) provides a promising solution for the problem. In this paper, for the aim of directly obtaining mirror surface on die steels, UVC method was used combining with SPDT process. Experiments were carried out on an ultra precision turning machine, cutting parameters and vibration parameters were well-chosen, and two kind of feed rates, two kinds of prevailing die steels were experimented. Mirror surfaces were successfully achieved on face turning, with the best roughness of Ra16.6nm. And the surface roughness, surface texture and tool wear in machining process were discussed.

scholarly journals Ultra-Precision Single-Point Diamond Turning of a Complex Sinusoidal Mesh Surface Using Machining Accuracy Active Control

2021 ◽  
Vol 67 (7-8) ◽  
pp. 343-351
Author(s):  
Peixing Ning ◽  
Ji Zhao ◽  
Shijun Ji ◽  
Jingjin Li ◽  
Handa Dai
Keyword(s):  
Active Control ◽  
Tool Path ◽  
Single Point ◽  
Diamond Turning ◽  
Machining Accuracy ◽  
Machining Error ◽  
Machined Surface ◽  
Mesh Surface ◽  
Slow Tool Servo ◽  
Radius Compensation

Single-point diamond turning (SPDT) assisted with slow tool servo (STS) is the most commonly utilized technique in the fabrication of optical modules. However, the tool path significantly affects the quality of the machined surface. In order to realize the determined machining accuracy effectively, a tool path generation (TPG) method based on machining accuracy active control (MAAC) is presented. The relationship between tool path and machining error is studied. Corner radius compensation (CRC) and the calculation of chord error and residual error are detailed. Finally, the effectiveness of the proposed approach is verified through a machining error simulation and a cutting experiment of a complex sinusoidal mesh surface fabrication.

Freeform machining of ophthalmic toric lens mould using fast tool servo-assisted ultra-precision diamond turning process

2020 ◽  
pp. 251659842093974
Author(s):  
Ishan Anand Singh ◽  
Gopi Krishna S. ◽  
T. Narendra Reddy ◽  
Prakash Vinod
Keyword(s):  
Surface Roughness ◽  
Single Point ◽  
Measurement Data ◽  
Surface Profile ◽  
Diamond Turning ◽  
Fast Tool Servo ◽  
Toric Surface ◽  
Machined Surface ◽  
Ultra Precision ◽  
A Minor

This research aims to establish a methodology for machining of toric lenses, using fast tool servo-assisted single point diamond turning and to assess the generated surface for its characteristics. Using the established mathematical model, toric surface is explained to understand the geometry and to generate the parameters required for fast tool servo machining. A toric surface with a major diameter of 18.93 mm and a minor diameter of 15.12 mm has been cut on the intelligent ultra-precision turning machine (iUPTM). The surface profile and surface roughness were measured. After analysing the measurement data of the machined surface, on two perpendicular axes of the toric lens, form accuracy of 0.49 µm peak-to-valley (PV), and surface roughness of 12 nm in Ra, 4–8 nm in Sa are obtained. From the experimental results obtained, it can be concluded that the proposed method is a reasonable alternative for manufacturing toric lens mould.

Fabrication of Aspheric Micro Lens Array by Slow Tool Servo

2009 ◽  
Vol 76-78 ◽  
pp. 479-484 ◽  
Author(s):  
Chun Chieh Chen ◽  
Choung Lii Chao ◽  
Wei Yao Hsu ◽  
Fong Chi Chen ◽  
Chung Woei Chao
Keyword(s):  
Tool Path ◽  
Diamond Turning ◽  
Lens Array ◽  
Fast Development ◽  
Ultra Precision ◽  
Slow Tool Servo ◽  
Micro Lens Array ◽  
Array Fabrication ◽  
Micro Lens ◽  
Better Than

Owing to the fast development in photonic, telecommunication, and opto-electronic industries, the demand for various micro-lens arrays is rapidly growing. The slow tool servo technique was applied on an ultra-precision diamond turning machine in the present research in conjunction with the tool path generating algorithm for aspheric micro-lens array fabrication. An aspheric lens array of 100% filling factor was successfully produced and the form accuracy and surface roughness were better than 0.15μm and 3nm for all the obtained lenses.

scholarly journals Experimental Investigation on Form Error for Slow Tool Servo Diamond Turning of Micro Lens Arrays on the Roller Mold

Materials ◽  
2018 ◽  
Vol 11 (10) ◽  
pp. 1816 ◽  
Author(s):  
Yutao Liu ◽  
Zheng Qiao ◽  
Da Qu ◽  
Yangong Wu ◽  
Jiadai Xue ◽  
...  
Keyword(s):  
Tool Path ◽  
High Efficiency ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Machining Process ◽  
Discrete Point ◽  
Form Error ◽  
Slow Tool Servo ◽  
Optimal Cutting Parameters ◽  
Micro Lens

Slow tool servo (STS) assisted ultra-precision diamond turning is considered as a promising machining process with high accuracy and low cost to generate the large-area micro lens arrays (MLAs) on the roller mold. However, the chatter mark is obvious at the cut-in part of every machined micro lens along the cutting direction, which is a common problem for the generation of MLAs using STS. In this study, a novel forming approach based on STS is presented to fabricate MLAs on the aluminum alloy (6061) roller mold, which is a high-efficiency machining approach in comparison to a traditional method based on STS. Based on the different distribution patterns of the discrete point of micro lens, the equal-arc method and the equal-angle method are also proposed to generate the tool path. According to a kinematic analysis of the cutting axis, the chatter mark results from the overlarge instantaneous acceleration oscillations of the cutting axis during STS diamond turning process of MLAs. Cutting parameters including the number of discrete points and cutting time of every discrete point have been experimentally investigated to reduce the chatter mark. Finally, typical MLAs (20.52-μm height and 700-μm aperture) is successfully machined with the optimal cutting parameters. The results are acquired with a fine surface quality, i.e., form error of micro lenses is 0.632 μm, which validate the feasibility of the new machining method.

Optimization Algorithm of Tool Radius Compensation in Fast Tool Servo Machining of Microlens Arrays

2014 ◽  
Vol 1039 ◽  
pp. 383-389 ◽  
Author(s):  
Huan Qi Ding ◽  
Shan Ming Luo ◽  
Xue Feng Chang ◽  
Dan Xie
Keyword(s):  
Tool Path ◽  
Single Point ◽  
Transitional Zone ◽  
Tool Path Generation ◽  
Machining Process ◽  
Path Generation ◽  
Fast Tool Servo ◽  
Path Modeling ◽  
Microlens Arrays ◽  
Radius Compensation

This paper analyzes the tool path generation of the microlens arrays by the single point diamond (FTS) turning,while focuses on the algorithm of tool radius compensation. Firstly, the mechanism of the fast tool servo machining process is introduced. Secondly, the tool path generation for FTS is calculated. The algorithm of tool radius compensation and the form error of the microlens is analyzed. Subsequently, the transitional zone is research, base on the algorithm of tool radius compensation, the optimized algorithm is proposed. Finally, using the optimized algorithm generate the tool path. Modeling of the tool path with the optimized algorithm of tool radius compensation is simulated with MATLAB. The simulation of the 3-D microlens arrays with the algorithm of tool radius compensation has done. According to the modeling of the simulation, algorithm of the radius compensation is discussed. The results show the optimized algorithm can improve the form accuracy of the microlens. The optimized algorithm is practical significant in the tool path generation.

Research on Machining Simulation System for Optical Free-Form Surfaces

2010 ◽  
Vol 97-101 ◽  
pp. 3020-3023
Author(s):  
Yong Hu ◽  
Ming Xu Xu ◽  
Jun Zhang ◽  
Bo Mao ◽  
Xiao Qin Zhou
Keyword(s):  
Tool Path ◽  
Simulation System ◽  
Diamond Turning ◽  
Machining Process ◽  
Free Form ◽  
Nc Code ◽  
Development Cycle ◽  
Manufacturing Errors ◽  
Ultra Precision ◽  
Free Form Surfaces

This paper presents a new simulation system for ultra-precision diamond turning of optical free-form surfaces based on fast tool servo (FTS). The functions including evaluation and analysis of optical free-form surfaces manufacturing errors, optimization for tool path, etc, are proposed. The simulation modules and functional structure of the system are designed in accordance with the functions. The errors in the process of machining can be found in advance through the simulation. Then the NC code will be modified timely. The proposed method can be used to improve product quality, shorten the development cycle, reduce costs and optimize machining process.

Finite Element Analysis of Incremental Sheet Forming for Metal Sheet

2018 ◽  
Vol 783 ◽  
pp. 148-153
Author(s):  
Muhammad Sajjad ◽  
Jithin Ambarayil Joy ◽  
Dong Won Jung
Keyword(s):  
Mechanical Properties ◽  
Sheet Metal ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Machining Process ◽  
Machining Parameters ◽  
Forming Process ◽  
Element Analysis ◽  
Tool Diameter

Incremental sheet metal forming, is a non-conventional machining process which offers higher formability, flexibility and low cost of production than the traditional conventional forming process. Punch or tool used in this forming process consecutively forces the sheet to deform locally and ultimately gives the target profile. Various machining parameters, such as type of tool, tool path, tool size, feed rate and mechanical properties of sheet metal, like strength co-efficient, strain hardening index and ultimate tensile strength, effects the forming process and the formability of final product. In this research paper, Single Point Incremental Forming was simulated using Dassault system’s Abaqus 6.12-1 and results are obtained. Results of sheet profile and there change in thickness is investigated. For this paper, we simulated the process in abaqus. The tool diameter and rotational speed is find out for the production of parts through incremental forming. The simulation is done for two type of material with different mechanical properties. Various research papers were used to understand the process of incremental forming and its simulation.

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