A novel method for layered tool path generation in the fast tool servo diamond turning of noncircular microstructural surfaces

Abstract

Fast tool servo technology plays important roles in manufacturing complex free-form surfaces for the modern optics industry. However, its stroke length is restricted to few tenths of microns due to the limited expansion of piezoelectric actuator. A long-stroke fast tool servo may be one of the possible ways to increase the stroke length for fulfilling the surface height requirement. This article proposes a novel approach to increase the stroke length. This article describes a novel fast tool servo diamond turning method with layered tool trajectories to extend the limited stroke length without modifying an existing fast tool servo system. The proposed method has successfully extended the effective fast tool servo stroke length to about fivefold of its maximum possible stroke length.