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6CCVD Research

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

At a Glance

Section titled ā€œAt a Glanceā€
MetadataDetails
Publication Date2018-09-25
JournalMaterials
AuthorsYutao Liu, Zheng Qiao, Da Qu, Yangong Wu, Jiadai Xue
InstitutionsHarbin Institute of Technology
Citations24

Abstract

Section titled ā€œAbstractā€

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-Ī¼m height and 700-Ī¼m 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 Ī¼m, which validate the feasibility of the new machining method.

Tech Support

Section titled ā€œTech Supportā€

Original Source

Section titled ā€œOriginal Sourceā€

References

Section titled ā€œReferencesā€
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