Study of the tool path generation on an automotive headlamp reflector in ultra-precision raster milling

Suet To, H. Wang, B. Li, Chi Fai Cheung, S.J. Wang

Research output: Chapter in book / Conference proceedingConference article published in proceeding or bookAcademic researchpeer-review


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.
Original languageEnglish
Title of host publicationMaterials science forum
PublisherTrans Tech Publications Ltd
Number of pages4
ISBN (Electronic)9783038130512
ISBN (Print)9780878494217, 9783908453512
Publication statusPublished - 2006
EventInternational Manufacturing Conference in China [IMCC] -
Duration: 1 Jan 2006 → …


ConferenceInternational Manufacturing Conference in China [IMCC]
Period1/01/06 → …


  • Automotive Headlamp Reflector
  • Gouge-Free Tool Path
  • Ultra-Precision Raster Milling

ASJC Scopus subject areas

  • Mechanical Engineering
  • Mechanics of Materials
  • Materials Science(all)
  • Condensed Matter Physics


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