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Abstract
Optical components with complex surfaces are more and more widely applied, but it is very difficult to manufacture these components by using traditional mechanical fabricating methods. Fast tool servo system can manufacture these complex surfaces or microstructures efficiently and accurately. The relative position between the tool and workpiece surface will vary continuously in the fast tool servo machining process, owing to the height change of workpiece profile in the same circle, and this will worsen the cutting conditions and debase the machining accuracy. In this paper, the cutting characteristics are studied in the fast tool servo machining process of complex workpiece, including the varying rule of cutting angle, and its influences on the rake angle and back angle, and the choice of machining parameters. Furthermore, the conditions for identifying tool interference are given. On the basis of the above work, two kinds of typical complex workpieces are manufactured by using fast tool servo system, including radial sinusoidal workpieces and lens array. The measuring results indicate that surface accuracy can reach 0.14 μm (peak-to-valley value) and the roughness is less than 10 nm (mean value).
ACKNOWLEDGMENT
Support from our industrial sponsors is acknowledged. The authors also thank Shanyong Cheng for the measurements of machining accuracy and surface roughness, and Dingshi Ren for assistance with the machining process setup.