Research On Microstructure Machining Technology Of Roller Mold Based On Fast Tool Servo

Microstructured surface is a kind of functional surface with microscopic features and macroscopic arrangement,which has a wide range of applications in the fields of precision measurement,new energy and optics.Roller molding is a low-cost and high-efficiency microstructure processing technology.The key to this technology is the processing of roller molds with microstructures on the surface.Among them,the fast-tool servo machining technology can efficiently process the microstructure on the surface of the roller mold,which has become a research hotspot in various countries.In this thesis,the micro-structure fast-tool servo machining technology of roller die is studied,the hardware design and software development of CNC system are carried out,and the tool path planning of micro-structure machining of roller die is studied.Finally,through experiments,It is verified that the CNC system developed in this thesis can meet the requirements of fast-tool servo machining of roller mold microstructure.The specific research contents are as follows:(1)Control system design.According to the control requirements of the micro-structure fast tool servo machining of the roller mold,a control system consisting of the CNC system of the roller machine tool and the fast tool servo system is designed.The key components such as the controller,servo drive system,and fast tool servo device were determined,and the design of the electronic control loop was completed,which provided the hardware basis for the subsequent processing experiments.(2)CNC software development.Taking Qt5.12 as the development tool,the numerical control software suitable for the microstructure processing of the roller mold is developed.The developed software has the functions of axis status display,motion control,program running,etc.It can combine the motion of the roller machine tool with the motion of the fast-tool servo device for the processing of the microstructure of the roller mold.(3)Research on tool path planning.The machining characteristics of the microstructured surface described by the formula and the array-like microstructured surface are respectively studied,and the corresponding tool path calculation method is given.According to the characteristics of fast tool servo machining,the traditional tool arc radius compensation method is improved,so as to ensure the shape accuracy of microstructure surface machining.(4)System debugging and processing experiments.In order to ensure the machining accuracy of the microstructure,the servo loop parameters of the spindle and linear axis of the roller machine tool are debugged and optimized to ensure that each axis has a good control accuracy.The performance of the fast tool servo system is tested,and it is verified that its performance can meet the processing requirements.On this basis,the surface cutting of the roller mold,the sine wave surface and the spherical microstructure array processing experiments were carried out respectively.The processing results are tested.The surface roughness of the roller mold is Ra 6.4nm,the average surface roughness of the sine wave surface is Ra 28.3nm,the contour accuracy PV is better than 0.62?m,the average surface roughness of the spherical microstructure is Ra 43 nm,and the contour accuracy is The PV is better than 0.75?m.