光学自由曲面超精密飞刀加工数控代码生成的研究-机械电子工程专业论文.docxVIP

NC CODE GENERATION OF FREE-FORM SURFACE IN ULTRA-PRECISION RASTER MILLING by HAO WANG A thesis submitted in conformity with the requirements for the degree of Master of Science at Shenzhen Graduate School Harbin Institute of Technology December, 2006 ABSTRACT Nowadays freeform surfaces have been widely used in aircraft, ship building, and automotive industries. Due to the intrinsic feature of variable curvature, freeform surfaces are especially ideal representation for optics design and modeling. With the advanced fabrication process and the adoption of new optical materials, freeform surfaces with sub- micron form accuracy and nanometric surface roughness has been applied in mass production of advanced optical components such as f-theta lenses for laser scanners, aspheric CCD camera lenses, LED collimators, progressive lenses, multi-layer diffraction optical elements, and even automotive headlamp reflectors. The thesis is dedicated to solve the key problems encountered in the fabrication of freeform surfaces in ultra-precision raster milling (UPRM). A survey of prior related work focuses on the tool path generation (TPG) and NC code generation processes in ultra-precision machining. A variety of machining strategies and CAM software kits are listed and compared. The thesis further proposes the tool path generation method, geometric cutter compensation, and a practical gouge-avoiding algorithm in UPRM. The thesis takes as example the machining process of an f-theta lens prototype to explain the constant scallop-height TPG method in UPRM, based on the specific configuration of the equipment and the geometry of the diamond cutter. The verification experiment has proven the correctness and effectiveness of the method. Furthermore, the thesis studies the machining errors caused by the condition of the diamond tool and the axis motions in UPRM. With an empirical approach, the error sources are investigated and distinguished based on their effects on the surface finish.