Tool Path Generation for Multi-Degree-of-Freedom Fast Tool Servo Diamond Turning of Optical Freeform Surfaces

Fast tool servo diamond turning is one of the most important techniques for machining optical freeform surfaces. The tool path has a significant effect on roughness, waviness and profile errors. However, the mapping mechanism between the tool path and the surface form error is not precisely expressed. The paper presents a novel approach for modelling and simulation of the tool path generation in fast tool servo diamond turning. The approach, by analyzing scallop-height, linearization error and tool nose radius compensation, models the tool path generation process. The effects and characteristic of an optimized tool path are investigated through simulations. Experiments have been carried out to show that the model is feasible.

[1]  Suet To,et al.  A review of machine-tool vibration and its influence upon surface generation in ultra-precision machining , 2015 .

[2]  Qiang Liu,et al.  A new tool path for optical freeform surface fast tool servo diamond turning , 2014 .

[3]  Wei Gao,et al.  An in-process measurement method for repair of defective microstructures by using a fast tool servo with a force sensor , 2015 .

[4]  Jannick P. Rolland,et al.  Freeform Optical Surfaces: A Revolution in Imaging Optical Design , 2012 .

[5]  Lei Zhu,et al.  Development of a piezoelectrically actuated two-degree-of-freedom fast tool servo with decoupled motions for micro-/nanomachining , 2014 .

[6]  F. Fang,et al.  Cylindrical coordinate machining of optical freeform surfaces. , 2008, Optics express.

[7]  Geok Soon Hong,et al.  Profile error compensation in fast tool servo diamond turning of micro-structured surfaces , 2012 .

[8]  Shan Ming Luo,et al.  Optimization Algorithm of Tool Radius Compensation in Fast Tool Servo Machining of Microlens Arrays , 2014 .

[9]  Mahmudur Rahman,et al.  A novel surface analytical model for cutting linearization error in fast tool/slow slide servo diamond turning , 2014 .

[10]  Chi Fai Cheung,et al.  Theoretical and experimental analysis of the effect of error motions on surface generation in fast tool servo machining , 2014 .

[11]  Jochen Stollenwerk,et al.  Algorithm for irradiance tailoring using multiple freeform optical surfaces. , 2012, Optics express.

[12]  Mali Gong,et al.  Beam shaping system design using double freeform optical surfaces. , 2013, Optics express.

[13]  Deug-Woo Lee,et al.  Modeling and machining evaluation of microstructure fabrication by fast tool servo-based diamond machining , 2014 .

[14]  Lei Li,et al.  Fabrication of continuous diffractive optical elements using a fast tool servo diamond turning process , 2013 .

[15]  Tong Yang,et al.  Direct design of freeform surfaces and freeform imaging systems with a point-by-point three-dimensional construction-iteration method. , 2015, Optics express.

[16]  Geok Soon Hong,et al.  Optimized tool path generation for fast tool servo diamond turning of micro-structured surfaces , 2012 .