Research On The Milling Process Of Micro-lens Array

With the rapid development of manufacturing technology, miniaturization and high-quality products have become a trend, and correspondingly the precise machine-cutting technology has also become a hot topic in this field. Micro milling technology is an advanced manufacturing technology, using micro-cutters to cut the work pieces and proceed parts processing, which is an extension of traditional application of techniques in the field of micro-machining.This paper mainly focuses on the following parts:Firstly, by consulting a large number of academic research data on micro milling technology, we have studied and analyzed the theories of micro milling, including the size effects of micro machining, the minimum thickness and the main factors influencing the surface roughness.Secondly, under the current experimental conditions, a single factor experiment on micro-milling with 6061 aluminum alloy material has been carried out using the DMG processing center machine tools. According to the analysis based on experimental results, we have identified the main factors and the rules for the impact on surface roughness of the micro-lens array spherical cavity. In addition, the optimum cutting parameters for processing micro-lens array have been derived from the experiment using micro milling technology under the existing experimental conditions.Furthermore, in strict accordance with orthogonal design scheme, the orthogonal experiment of micro-lens array milling has been carried out. Using analysis of range and variance of orthogonal experiment, we have obtained the primary and secondary sequence of the impact of every experimental factor on experimental indicators and the optimal level and the optimum processing parameter combination of every experimental factor, and also evaluated the significance of the factors of experimental indicators.Finally, based on the data of orthogonal experiment and multiple regression analysis, we have proposed and established a mathematical prediction model of surface roughness and proceeded the prediction.This paper focuses on the experimental research on micro milling processing with micro-lens array and analyzes the impact factors of surface roughness while processing a micro-lens array. Rules for surface roughness changing with milling parameters during processing have been obtained and a surface roughness prediction model has been established. Therefore a scheme for optimizing micro-milling parameters has been proposed. The new data obtained and discovery will be helpful to improve the micro-lens array mold in micro milling as accumulated experience.