A study of tool path generation for machining of precision roller with wavy patterned microstructures by slow tool servo

Embossing by patterned rollers is one of the most efficient machining approaches for manufacturing plastic films with patterned microstructures, and the precision roller with patterned microstructures is the key tooling component in the roll-to-roll process. Single-point diamond turning with a slow or fast tool servo is an enabling and efficient ultra-precision machining process to fabricate microstructures through a simple process to achieve optical surface finish directly. Most of the current studies on slow or fast tool servo machining processes either focus on face machining of patterned microstructures, or on tool servo machining of microstructures in the radial direction of precision rollers. Relatively little research work is found in relation to machining patterned microstructures on a precision roller by using the tool servo in the axial direction. This paper presents a pilot study on the development of a tool path generator for machining precision rollers with wavy patterned microstructures by using slow tool servo machining in the axial direction on a precision roller. The machining mechanism is firstly explained, based on which the tool path generator is developed for machining wavy patterned microstructures on a precision roller surface. Preliminary experimental work was conducted to study the generation of wavy patterned microstructures on a precision roller using a four-axis ultra-precision machine. The machined wavy microstructures on the roller surface are measured and analyzed to successfully validate the performance of the proposed tool path generator.