Study on the Tool Path Generation of an Automotive Headlamp Reflector in Ultra-Precision Raster Milling
Nowadays faceted reflector design has become popular in automotive illumination systems. The advantage of a compound surface enables it to achieve the required hot spot intensity by directing more than 60% of the generated light towards the road, thereby largely illuminate the area through the aperture. The research is oriented to fabricating the mold insert on ultra-precision raster milling (Freeform 705G). In this paper, the tool path generation method for automotive headlamp reflectors is studied, and a practical gouging detection and avoidance algorithm is proposed. The surface roughness and form accuracy (peak-to-valley height) are then calculated theoretically using mathematical formulae. Through the tool path generation of a small but representative surface patch with a gap, a possible way is finally found to generate the tool path for such a class of freeform surface with special equipment.
Chengyu Jiang, Geng Liu, Dinghua Zhang and Xipeng Xu
S. To et al., "Study on the Tool Path Generation of an Automotive Headlamp Reflector in Ultra-Precision Raster Milling", Materials Science Forum, Vols. 532-533, pp. 673-676, 2006