Study Of Micro Prism Reflective Array Planing Process

With the development of society, micro prism reflective film has been widely used in ourdaily life. At present only the USA Allie-Denison,3M and Nippon carbide industries masteredthe manufacturing technology of micro prism reflector array. Because of the technologyblockade to China, although the domestic knows the processing method of micro prism reflectivearray the core processing is difficult to learn. It still stays in its infancy in the processingtechnology of micro prism reflector array.The planing prism reflector array processing technology has been studied in this paper. Tooldesign, tool sharpening, tool vibration correction and craft knife of the ultrasonic vibrationcutting processing of micro prism reflector array have been researched. In order to analysis theinfluence of the original die (artifacts) materials, tool material, tool front angle, cutting speed andthe third cutting depth on the tool life and the surface quality of micro prism array the orthogonaltest of the micro prism-array was machined by ultrasonic vibration planing. The main contentsare as follows:1）Micro prism reflective array structure size, reflective properties and processing method.This section the structure size of micro prism reflective array and the reflective properties isstudied. Through comparing the prism reflector array processing methods a new cuttingmachining tool path used in this paper has been put forward which provides theoretical basis forthe tool design, grinding and the research of the micro prismatic planning processing technology.2） The experiment system of the micro prism reflective array planning. Sandwich typebending vibration transducer clamping device is designed in order to introduce the ultrasonicvibration cutting system into the CNC engraving and milling machine and the experiment systemof the micro prism reflector array planing is built.3）Planing tool. Firstly, planing tool is designed according to the structure size characteristicsof the micro prism reflective array. Secondly the influence of sharpening direction and polishingon the tool profile accuracy is studied and the results showed that the grinding wheel along thecutting edge grinding tool flank and the mild polishing are conducive to guarantee cutter contouraccuracy. Thirdly, a kind of tool vibration correcting method is proposed and the experimentalresults showed that this method can effectively correct the tool and workpiece vibration directionof movement direction angle. Finally, three kinds of tool setting process are provided. A bettertool setting scheme is acquired after many experiments by comparing the advantages anddisadvantages. 4）Microprism reflective array planing experiment. The general planning and ultrasonicvibration cutting experiment is conducted, and the effect of the general planning and ultrasonicvibration cutting on the microprism surface machining quality and brittle collapse reason areanalyzed. The results showed that the brittle material machining is more favorable for theultrasonic vibration cutting and reducing the cutting speed in the ultrasonic vibration cutting canavoid the collapse of brittle materials. Then different materials are used in conducting ultrasonicvibration cutting processing experiment in order to select the appropriate micro prism reflectorarray raw materials. The results show that T2red copper,6061aluminum alloy and the6061aluminum alloy in PMMA are more suitable for the micro prism reflective array die materials.Last the reasonable cutting tool rake angle, cutting tool materials and cutting elements areobtained by ultrasonic vibration cutting orthogonal experiment. The influencing factors of microprism surface quality and tool life are analyzed, and finally it was fond that the influencingfactors are cutting tool material, cutting speed, cutting depth and tool thir rake angle. When thetool material is PCD, cutting speed is about900mm/min, the third cutting depth is about2μmand the tool rake angle is3.8, the micro prism reflector array will be better and the tool wearwill be smaller.