Fabrication of optical microstructures on roller surface based on fast tool servo system

2020 ◽  
Vol 15 (13) ◽  
pp. 892-897
Author(s):  
Chaoliang Guan ◽  
Jiahao Yong ◽  
Junfeng Liu ◽  
Yifan Dai ◽  
Zhanbin Fan ◽  
...  
Keyword(s):  
Servo System ◽  
Fast Tool Servo ◽  
Roller Surface

scholarly journals Fabrication of Sinusoidal Microstructures on Curved Copper Surface by Ultra-Precision Diamond Cutting with a Rotary B-Axis and Fast Tool Servo System

2021 ◽  
Vol 11 (21) ◽  
pp. 10302
Author(s):  
Xuesen Zhao ◽  
Haiping Du ◽  
Wenda Song ◽  
Qiang Zhang ◽  
Zhenjiang Hu ◽  
...  
Keyword(s):  
Tool Path ◽  
Servo System ◽  
Copper Surface ◽  
Curvature Radius ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Fast Tool Servo ◽  
Diamond Cutting ◽  
Sinusoidal Modulation ◽  
Ultra Precision

While curved surface microstructures have wide applications in optical components and devices, how to achieve high machining accuracy of the microstructures is crucial for their applications. In the present work, we fabricate sinusoidal modulation microstructures on a curved copper surface by ultra-precision diamond cutting, with the combination of a rotary B-axis and a fast tool servo system. Specifically, tool path planning, together with the consideration of a curved, sinusoidal surface meshing and tool tip arc segmentation compensation, is carried out. Preliminary cutting experiments are firstly carried out on a homemade four-axis ultra-precision lathe, which demonstrates the advantages of additionally applying the rotary B-axis in suppressing burr formations and over-cutting phenomenon over the sole utilization of the fast tool servo system. Subsequent experiments are carried out to evaluate the effects of feed rate and the number of sampling points on the machining accuracy of the microstructures under the combination of a rotary B-axis and a fast tool servo system. With the optimized machining parameters, sinusoidal modulation microstructures, which have a wavelength of 700.6 μm, a peak-to-valley of 18.7 μm, a surface roughness of 18.9 nm and a deviation of profile tolerance of 4.326 μm, are successfully fabricated on a curved copper surface with a face radius of 10 mm and a curvature radius of 500 mm.

Model Identification and Dynamic Performance Analysis of Fast Tool Servo System with High Frequency Response

2013 ◽  
Vol 669 ◽  
pp. 273-278 ◽  
Author(s):  
Ke Jie Wen ◽  
Gui Lin Wang ◽  
Fan Yang
Keyword(s):  
Frequency Response ◽  
Natural Frequency ◽  
Dynamic Performance ◽  
Model Identification ◽  
Servo System ◽  
Fast Tool Servo ◽  
Micro Structure ◽  
Unknown Parameters ◽  
High Frequency Response ◽  
Dynamic Performance Analysis

Fast tool servo system could achieve precise and efficient processing of fine micro-structure for its fast and accuracy response to input control signal, which will directly affect the processing quality of the workpiece surface. Different structural forms of fast tool servo system have been designed and presented in China and overseas, with which generally low the stiffness and natural frequency, only can be used for the rule and the characteristic scale of the larger surface processing. A fast tool servo system whose thrust was up to 12500N, stiffness was 280N/μm, the natural frequency was more than 3kHz , was developed in this paper, as well as the analytical expression of time domain and frequency domain output，which were presented by the modeling analysis; The unknown parameters of the system model were identified by frequency response test. The theoretical and experimental results indicated that the system has good dynamic performance to meet the fine micro-structure of highly efficient, high-precision processing needs.

Structure design and performance analysis of double piezoelectric ceramic drive fast tool servo system

2021 ◽  
Author(s):  
Tiancong Luo ◽  
Xiaoqiang Peng ◽  
Chaoliang Guan ◽  
Jiahao Yong ◽  
Yupeng Xiong
Keyword(s):  
Performance Analysis ◽  
Piezoelectric Ceramic ◽  
Servo System ◽  
Structure Design ◽  
Fast Tool Servo ◽  
And Performance

Turning of Micro-Structured Surfaces Based on a Fast Tool Servo System

2014 ◽  
Vol 684 ◽  
pp. 308-312 ◽  
Author(s):  
Xiao Hui Wang ◽  
Zhi Ding ◽  
Yu Zhen Ma
Keyword(s):  
Piezoelectric Actuator ◽  
Closed Loop ◽  
Tracking Error ◽  
Servo System ◽  
Diamond Turning ◽  
Fast Tool Servo ◽  
Precision Engineering ◽  
Loop Control ◽  
Structured Surfaces ◽  
Grid Surface

A fast tool servo system is developed for the fabrication of micro-structured surface on a diamond turning machine. The fast tool servo (FTS) system in this investigation employs a piezoelectric actuator to actuate the diamond tool and a capacitance probe as the feed back sensor. To compensate the inherent nonlinear hysteresis behavior of the piezoelectric actuator, Proportional Integral (PI) closed loop control with a feed-forward predictor is implemented. The result of closed loop experiment in FTS demonstrates that the tracking error has been reduced to a level of less than 150nm. Actual experiment of fabricating the sinusoidal grid surface was performed on an ultra-precision diamond turning machine designed by Center of Precision Engineering of HIT. The fabrication of a sinusoidal grid surface has indicated the effectiveness of the fabrication system.

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.

Sign in / Sign up

Export Citation Format

Share Document