一种加工微棱镜阵列新方法及其刀具的研究

Research for a new method of machining micro prism array and its tool

针对微棱镜阵列尺寸小,表面粗糙度值小,刀具要求高的特征,研究利用超声振动刨削加工微棱镜阵列。研究内容主要包括:设计一种可以加工出高质量微棱镜阵列的刨刀;加工出微棱镜并分析微棱镜反光膜微观几何结构;最后通过检测被加工微棱镜阵列的表面粗糙度值、角度以及刨刀磨损情况,来判断超声振动刨削刀具是否满足加工出微棱镜阵列的要求。研究结果表明,在刀具刃磨方法合理、刀尖速度方向和工件速度方向共线、刀尖与主轴在X-Y平面内的偏差测量准确的前提下,角度γf为25°、α0为9°、kr为54.75°的刨刀可以在尺寸为25mm×25mm×10mm的6061铝合金板上加工约3万个微棱镜阵列。

This study aims to obtain micro prism array by ultrasonic vibration planning machining. And it high points the requirements of small micro prism array size, tiny surface roughness value and high-perform- ance tool. The research includes the following aspects. First of all, a kind of planer tools, which can make micro prism array with high quality, was designed . Then the micro prism array was processed out and analyzed. And last a judgment that if the ultrasonic vibration cutting tools meet the processing requirements of micro prism array was made by measuring the surface roughness value and pyramid angle of the micro prism array and the condition of tool wear. The result indicated that 30,000 micro prism array was obtained in a 25mm×25mm×10mm 6061aluminium alloy board under the use of the planning tool, which own 25°front angle, 9° back-off angle and 54.75° cutting edge angle, in the condition of reasonable tool sharpening method, tip velocity direction and the workpiece velocity direction being collinear, and accuracy deviation measurement of the tip and the spindle in the X-Y plane.