A surface data generation method of optical micro-structure and analysis system for Fast Tool Servo fabricating

ABSTRACT High-precision optical micro-structured components are now widely used in the field of military and civilian use. Ultra-precision machining with a fast tool ser vo (FTS) is one of the leading methodologi es for fabrication of such surfaces. The first important issue that faced in ultra-precision and high-eff ectively fabricating is how to properly describe the complex shapes based on the principle of FTS. In order to meet the demands of FTS machining that need for tool high-frequency response, high data throughput and huge memory space, an of f-line discrete data points generation method for micro-structure surfaces is presented which can avoid on-line shape calculation in fabrica ting process. A new analysis software package is developed to compute the speed, acceleration and spectrum over the generated data points which helps to analysis the tool tracking characteristics needed in fabricating. Also a new mechanism for FTS machining data transmission based on the huge-capacity storage device is proposed. Experiments show that the off-line surface data generation method and data transfer mech anism can effectively improve FTS fabri cating efficiency, the surface analysis software can help to determine the machining ability of tool -holder and to guide and optimize the processing parameters such as spindle speed, feed rate, etc. Keywords: Fast Tool Servo fabricating, micro-structured surface, data generation, analysis software