Study on the Tool Path Generation of an Automotive Headlamp Reflector in Ultra-Precision Raster Milling


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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.



Materials Science Forum (Volumes 532-533)

Edited by:

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

Online since:

December 2006




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