An Investigation On The Cutting Mechanism And Cutting Strategy For The Ultra-precision Machining Of Micro Structures Array On Roller Mold

Micro-structure array is a kind of surface with special function and regular distribution based on a certain structure,which has the characteristics of physical,chemical and optical properties of the material transmitted,so it is widely used in various fields.With the development of society,the demand for large-volume and largescale micro-structure array is increasing.The traditional manufacturing method can not meet needs,a new roll-to-roll UV imprinting technology,the key of this technology is to obtain the micro-structure array on the roller mold surface with high quality and high precision.In recent years,many research institutes at home and abroad have invested a lot of money and manpower in the design and machining of the micro-structure array on roller mold,and have made some achievements.This paper uses a combination of simulation and experiment to study the diamond turning mechanism on roller mold and ultra-precision machining method of the micro-structure array on roller mold.The main research contents are as follows:(1)Based on the existing micro-cutting mechanism model,this paper analyzes the factors that affect the surface generation,chip generation and cutting force.A new factor is introduced-micro-unevenness of machining surface,analyzes its influence on the micro-cutting machining and establishes a new micro-cutting theory.Based on the influence of micro-unevenness on micro cutting,analyzes the factors affecting the surface quality in UPM.The influence of machining parameters(feed rate and step size)on surface generation of different workpiece materials in micro-cutting process is analyzed by the Ultra-precision planar machining experiment.And design different micro-unevenness surface for ultra-precision turning machining experiments,verified the theoretical analysis and laid a foundation for subsequent analysis and experiments.(2)Study the finite element simulation of diamond cutting and consider the influence of micro-unevenness in micro cutting,established a finite element simulation model of ultra-precision turning based on micro-unevenness of machined surface.Through the combination of simulation and experiment,analyzes the influence of micro-unevenness on chip generation,main-cutting-force and surface quality in ultraprecision turning,the optimal micro-unevenness mode is obtained and the machining quality is improved.(3)The STS machining method of micro groove array on roller mold is studied,including the surface generation on roller mold,the method of generating linear groove array and curve groove array on roller mold.Firstly,according to the analysis of the influence of the micro-unevenness on micro cutting,studies the quality of the ultraprecision turning of the roller surface and the influencing factors of the micro grooves on roller surface,including machining parameters,micro-unevenness of machined surface and base surface.Secondly,a STS machining method for curved groove array on roller surface is studied to achieve the curve groove machining of nanoscale surface roughness on roller mold surface.Finally,through the machining experiment on roller mold surface,the optimal machining parameters on roller mold surface are obtained,and the curve micro-groove array satisfying the accuracy requirements is machined by using the optimal micro-unevenness of the machined surface.The influence law of different machining parameters and micro-uneven surface on the quality of machined surface is studied in this paper improved the machining quality on roller mold surface,the finite element simulation model based on micro-unevenness surface plays a guiding role in actual machining.A sine micro-groove array was machined on roller mold surface with STS machining method,which proved the feasibility of the curved groove machining method.