Abstract
Various items of roll molds are popularly used to fabricate different kinds of optical films for optoelectronic information and other new and high-tech fields, while the fabrication and evaluation of optical microstructures on a cylindrical roller surface is more difficult than ecumenically manufactured products. In this study, the machinability of microstructures on the roll based on a fast tool servo (FTS) system is investigated. First, the flexible hinge holder for a FTS is designed and its structural parameters are optimized with finite-element analysis and fatigue reliability theory. The tool radius compensation algorithm for complicated microstructures is then deduced based on the surface fitting and bilinear interpolation algorithm of discrete data. Meanwhile, the evaluation index and method are proposed by the medium section method. Finally, a machining test of aspheric arrays on a cylindrical aluminum surface is carried out, and the high quality of the microstructure indicates that the proposed method is able to be used to fabricate optical microstructures.
Highlights
Optical films with various kinds of microstructures are extensively used in optical instruments, LED lighting, liquid-crystal display, and other applications [1,2,3]
In this study, a tool radius compensation algorithm and an evaluation method for complicated microstructures are proposed, and a machining experiment of aspheric arrays on a cylindrical aluminum surface based on a designed fast tool servo (FTS) with the consideration of fatigue reliability performed
The results indicate that the proposed FTS system and method are able to effectively process and evaluate the complicated microstructures on cylindrical surfaces
Summary
Optical films with various kinds of microstructures are extensively used in optical instruments, LED lighting, liquid-crystal display, and other applications [1,2,3]. In this study, a tool radius compensation algorithm and an evaluation method for complicated microstructures are proposed, and a machining experiment of aspheric arrays on a cylindrical aluminum surface based on a designed FTS with the consideration of fatigue reliability performed. For more complicated microstructure surfaces such as sinusoidal grids and aspherics, the obtainment of the related tool center paths by Eq (6) is complicated.
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