Characteristic Study on Micro Aspheric Surface Using Diamond Tool Cutting

Abstract:

Due to performance improvement and the trend of miniaturized sizes in optical devices, the need for micro lenses is increasingly presented. In this paper, characteristic study of a micro aspheric mold having a diameter of only 0.3 mm was performed. According to the experimental results of rough cuttings using a diamond tool, the machined surfaces were with a mean peak-to-valley (PV) form error of 1.47 µm. The Taguchi Method was employed to determine the optimal cutting parameters by selecting the cutting depth, work spindle speed, and compensation ratio as the control factors. Experimental trials were conducted according to the L9(34) orthogonal array (OA), and a mean PV form error of 0.79 µm was obtained due to compensation cuttings. Based on signal-to-noise (S/N) ratios, the optimal levels of control factors were determined. By performing the confirmation test, the PV form error was reduced from rough cutting of 1.49 µm to 0.60 μm. The effectiveness of using the Taguchi Method was demonstrated. The systematic approach performed in this paper can be applied to micro-fabrications for precision components in molds and dies industry.

• Periodical: Advanced Materials Research (Volumes 264-265)
• Pages: 1887-1892
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.264-265.1887
• Online since: June 2011
• Authors: Yung Tien Liu, Wei Che Chang
• Keywords: Aspheric Surface, Compensation, Taguchi Method, Ultra-Precision Machining

References

[1] T. Masuzawa, State of the art of micromachining, Ann. CIRP, Vol. 49 (2000), 473-488.

DOI: 10.1016/s0007-8506(07)63451-9

[2] W.K. Chen, T. Kuriyagawa, H. Huang, N. Yosihara, Machining of micro aspherical mould inserts, Prec. Eng., Vol. 29 (2005), 315-323.

DOI: 10.1016/j.precisioneng.2004.11.002

[3] C. -C.A. Chen, C. -M. Chen, J. -R. Chen, Toolpath generation for diamond shaping of aspheric lens array, J. Mater. Process. Technol., Vols. 192-193 (2007), 194–199.

DOI: 10.1016/j.jmatprotec.2007.04.024

[4] H. Suzuki, T. Moriwaki, Y. Yamamoto, Y. Goto, Precision cutting of aspherical ceramic molds with micro PCD milling tool, CIRP Annals Manufact. Technol., Vol. 56 (2007), 131-134.

DOI: 10.1016/j.cirp.2007.05.033

[5] E. Brinksmeier, O. Riemer, Measurement of optical surfaces generated by diamond turning, Int. J. Mach. Tools Manufact., Vol. 38 (1998), 699-705.

DOI: 10.1016/s0890-6955(97)00120-x

[6] Z.J. Yuan, M. Zhou, S. Dong, Effect of diamond tool sharpness on minimum cutting thickness and cutting surface integrity in ultraprecision machining, J. Mater. Process. Technol., Vol. 62 (1996), 327-330.

DOI: 10.1016/s0924-0136(96)02429-6

[7] Z. -C. Lin, S. -P. Lo, Ultra-precision orthogonal cutting simulation for oxygen-free high-conductivity copper, J. Mater. Process. Technol., Vol. 65 (1997), 281-291.

DOI: 10.1016/s0924-0136(96)02416-8

[8] W.B. Lee, C.F. Cheung, W.M. Chiu, T.P. Leung, An investigation of residual form error compensation in the ultra-precision machining of aspheric surfaces, J. Mater Process. Technol., Vol. 99 (2000), 129-134.

DOI: 10.1016/s0924-0136(99)00403-3

[9] Y. Arai, A. Shibuya, Y. Yoshikawa, W. Gao, Online measurement of micro-aspheric surface profile with compensation of scanning error, Key Eng. Mater., Vols. 381-382 (2008), 175-178.

DOI: 10.4028/www.scientific.net/kem.381-382.175

[10] Y. -T. Liu, W. -C. Chang, Y. Yamagata, A study on optimal compensation cutting for an aspheric surface using the Taguchi method, CIRP J. Manufact. Science and Technol., Vol. 3 (2010), p.40–48.

DOI: 10.1016/j.cirpj.2010.03.001