A Study of Surface Generation in Ultra-Precision Machining of Precision Rollers with Patterned Microstructures

Precision rollers with patterned microstructures are increasingly adopted in the embossing process for manufacturing large dimensional optical plastic plates such as backlight guide used in LCD/LED displays. Due to the heavy load and high precision requirement at the same time, it is difficult to machine such precision rollers with patterned microstructures, and the machining process is thus also very expensive and time consuming. Research on the surface generation in ultra-precision machining of precision rollers is in demand so as to make the machining process more controllable and hence improve the machining accuracy. This paper presents a study on the analysis of surface generation in ultra-precision machining of precision rollers with patterned microstructures. Machining mechanism of the roller machining is explained, and then a kinematic error model is proposed, in which slide and spindle error motions are taken into account to predict the machining errors. Cutting experiments is conducted to machine V-groove microstructures on the precision roller. It is interesting to note that the model is able to predict and explain portion of the errors contributed to the overall errors in machining of the V-groove microstructure on the precision roller. The proposed research work is helpful for process optimization and control in ultra-precision machining of rollers with patterned microstructures, as well as the precision equipment development.