Tool Offset Flycutting Micro-optics Arrays with High-Aspect-Ratio

Micro-optical arrays (MOAs) with high aspect ratios (AR) provide special benefits when it comes to minimising system of optics by lowering the focus range. It is commonly accepted that fast or slow tool servo (F/STS) is superior for creating MOAs with great form accuracy. However, the Non-smooth cutting track of F/STS causes intense the fluctuation of the tool and the conflict between the side face of the tool and the finished surface when processing MOAs with high AR, which deteriorates surface coarseness. In order to realize flexible manufacture of miniature liberal form lenticles arrays with high AR, this paper proposes a new offset-tool-servo (OTS) diamond processing method and its accompanying cutting tool trail generating method of calculation is suggested in this work. In order to solve the problem of tool conflict caused by rapid tool descent in F/STS system, a four-axis servo mechanism was used to establish the helical path of tools of per lenticles on OTS. Furthermore, the suggested processing approach efficiently prevents the degradation of the surface quality brought on by tool fluctuations by ensuring the flatness of the produced cutting tool trail for every lenticles. This technique is used by creating various MOAs with aspheric and freeform forms. It is shown that the OTS approach may provide smoother and more uniform surface quality while achieving AR values that are two times bigger than those of the F/STS method.