Design and process of ultra-precision drum roll lathe

In order to improve the domestic roll-to-roll manufacturing level of optical microstructure films and change the fact that the manufacture of nearly all ultra-precision roll machining equipment is monopolized by foreign companies, the first domestic ultra-precision roll lathe is designed and integrated successfully with process experiments for typical microstructures. First, according to the characteristics of optical microstructures for roller mold processing, the key technologies of machine tools were analyzed. From this analysis, the machine's structure and motion control system are designed. After integration of the machine tool system, debugging of the motion control system and linear axis motion resolution tests are carried out. Second, the straightness and positioning accuracy of each axis are measured and compensated using a collimator and laser interferometer. Finally, parameter optimization tests for reducing the burr height when manufacturing V-groove arrays are performed through a cutting experiment by using a multi-step cutting method. Experimental results indicate that the linear motion resolution of the ultra-precision machining lathe can reach 5 nm, full-stroke bi-directional positioning accuracy of the linear axis is better than 1 μm, and the V-groove micro-structure array processed with a final cutting depth of 1-2 μm has excellent surface quality. © 2018, Science Press. All right reserved.