Research On On-machine Measurement Method Of Roller Die Surface Shape Error

Roll-to-Roll is a kind of processing method which is concerned in the micro structure surface processing technology.It can not only process high precision and complex microstructure surface,but also has the characteristics of high production efficiency and low cost.Roller die is the key part of Roll-to-Roll.The machining accuracy of the surface microstructure of the roller die will be directly reflected in the optical film.High precision roller die processing cannot be separated from high-precision measurement technology.Nowadays,the mainstream technology of workpiece contour measurement is to measure the workpiece profile by some high-precision commercial measuring instruments.However,because the volume and quality of roller die are large,it is not easy to measure off-line and it is difficult to compensate after off-line measurement,so it is necessary to develop a new onmachine measurement method.But when measuring in place,the motion error of the drum roll lathe will affect the measurement results,so it is necessary to separate the errors.The research contents of this paper are as follows :(1)The measurement method of surface shape error of roller die was studied.Based on flexure hinge,an on-machine measurement method of die diameter component,surface straightness error component and surface roundness error component is proposed.A method for measuring the taper angle component and diameter deviation component of roller die based on two opposite probes is proposed.(2)A micro-stage platform based on flexure hinge is developed.Micro-stage platform is an important carrier to measure the surface shape error of roller die.The structure design and static simulation analysis of flexure hinge are carried out.The experimental results show that the developed platform can meet the requirements of error separation.(3)Analysis of the factors affecting the accuracy of the measurement system.Aiming at the straightness measurement method,the positioning error of the micro-stage platform,the deflection angle error of the micro-stage platform,the positioning error of the guide rail of the roller machine tool and the noise error of the sensor are analyzed respectively.Aiming at the roundness measurement method,the positioning error of micro-stage platform,spindle rotation positioning error,sensor alignment error and sensor noise error are analyzed respectively.The simulation results show that the straightness measurement accuracy is ± 0.2?m,and the roundness measurement accuracy is ± 0.1?m.(4)The on-machine measurement experiment of roller die surface form error was carried out.The measurement experiments of workpiece diameter,roundness error and straightness error are carried out.The measurement results of micro-stage platform are compared with those of commercial measuring instruments or standard parts,and the diameter measurement error is 44?m.The measurement error of roundness is 0.07?m.The error of straightness measurement is ±0.2?m.The correctness of the simulation analysis is proved.Finally,an on-machine measurement experiment of the surface shape error of a large roller die is carried out.