Researchers at Keio University have developed a novel tool path generation method for driving independently controlled Fast Tool Servo Systems (FTS) for freeform surface machining. This method can quickly manufacture high-precision free-form optical components without repeated trials.
The tool path program is generated using ring and grid methods rather than traditional spiral tool paths. Analyze the impact of interpolation errors through shape error prediction and optimize tool paths. Optimization of control point layout consists of two steps. Initially, the number of control points is determined. Then, determine the optimal aspect ratio for your layout parameters. Experimental verification through two-dimensional sine wave and microlens array processing proves the effectiveness of the tool path optimization method proposed in this paper. This method reduces the shape error of two-dimensional sine waves from submicron level to 10 nm level.
Professor Yan Jiwang commented: “FTS-based diamond turning is an amazing method for efficiently manufacturing free-form surfaces, but the traditional FTS unit driven by a piezoelectric actuator has a very small stroke at the micron level, which limits its application. In recent years, development The long-stroke FTS unit equipped with a voice coil driven air bearing can achieve millimeter-level working strokes, thus greatly expanding the application range of FTS diamond turning. In order to improve system compatibility and stability, these voice coil-based FTS units are composed of separate The control system is independently driven. However, the tool path generation method for this type of FTS has not yet been established, which is regarded as a bottleneck.”
Researcher Mr. Yusuke Sato said: “This study aims to propose a new method to generate and optimize the tool path of an independent FTS control system to reduce the shape error of the machined surface caused by two-dimensional interpolation. First, through two Different methods pre-generate control point clouds, namely the ring method and the grid method, and then predict and interpolate the final machined surface profile through simulation by comparing the simulated surface with the designed surface. Obtain the shape error. By repeatedly adjusting the parameters of the control points, the shape error is minimized to the required tolerance.”
This research lays an important foundation for the further development of free-form optical ultra-precision machining technology through diamond turning, achieving high precision without trial and error by using an FTS unit with a separate controller, thereby contributing to high added value Advanced manufacturing of products.
Professor Yan Jiwang said: “The developed tool path generation/optimization system makes the commercial FTS unit more accurate and powerful. It is particularly useful for improving the productivity of free-form optics, which are widely used in VR/AR systems, cameras, scanners , head-mounted displays, and components used in aerospace and biomedical engineering, the rapid fabrication of such freeform surfaces may change the concept of product design in the near future.
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