Open AccessFabrication and evaluation of complicated microstructures on cylindrical surface
Author(s) -
Jiahao Yong,
Junfeng Liu,
Chaoliang Guan,
Yifan Dai,
Fēi Li,
Fan Zhang
Publication year - 2020
Publication title -
plos one
Language(s) - English
Resource type - Journals
SCImago Journal Rank - 0.99
H-Index - 332
ISSN - 1932-6203
DOI - 10.1371/journal.pone.0242918
Subject(s) - microstructure , fabrication , materials science , machining , machinability , surface (topology) , diamond turning , interpolation (computer graphics) , cross section (physics) , radius , optics , mechanical engineering , composite material , computer science , metallurgy , engineering , geometry , physics , mathematics , medicine , alternative medicine , pathology , frame (networking) , quantum mechanics , computer security
Various items of roll molds are popularly used to fabricate different kinds of optical films for optoelectronic information and other new and high-tech fields, while the fabrication and evaluation of optical microstructures on a cylindrical roller surface is more difficult than ecumenically manufactured products. In this study, the machinability of microstructures on the roll based on a fast tool servo (FTS) system is investigated. First, the flexible hinge holder for a FTS is designed and its structural parameters are optimized with finite-element analysis and fatigue reliability theory. The tool radius compensation algorithm for complicated microstructures is then deduced based on the surface fitting and bilinear interpolation algorithm of discrete data. Meanwhile, the evaluation index and method are proposed by the medium section method. Finally, a machining test of aspheric arrays on a cylindrical aluminum surface is carried out, and the high quality of the microstructure indicates that the proposed method is able to be used to fabricate optical microstructures.