Development of a Large Surface Mechanical Micro Machining System & Machine
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The large surface micro machining system includes the equipments and processes for manufacturing the ultra precision micro patterned products with large surface through the mechanical machining. Recent major issue on the micro machining technology may be the development of optical parts for the back light unit of display which has the largest market. This special issue makes up with three parts; the large surface micro machining system and machine, machining process and forming process. In this paper, the state-of-the-art and core technology of large surface micro machining system is introduced with focus on the manufacturing technology for the back light unit of LCD TV. Then, some research results on the development of a roll die lathe is introduced which involves the concept of machine design, improvement of thermal characteristics in the spindle system, improvement of relative parallelism and straightness between spindle system and long stroke feed table, machining of micro pitch patterns. Finally, the direct forming process is introduced as the future work in the large surface micro machining field.Keywords:
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In micro-parts machining, the clamping workpieces and the reorientation is high difficulty. Complete machining is an ideal method for improving the machining precision and efficiency. Theoretical analysis on complete machining process and cutting experiments on the high-speed turn-milling machining centre show that, the turn-milling machining technology can realize complete machining and there are special advantages in machining complex micro-parts based on rotationally symmetrical body.
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In order to cope with the requirements of smaller patterns, larger surfaces and lower costs in the fields of displays, optics and energy, greater attentions is now being paid to the development of micro-pattern machining technology. Compared with flat molds, roll molds have the advantages of short delivery, ease of manufacturing larger surfaces, and continuous molding. This paper presents the state-of-the-art of the micro pattern machining technology on the roll molds and introduces some research results on the machining process technology. The copper and nickel-phosphorous-alloy plating process, machining process technology for uniform micro patterns. micro cutting simulation and the real time monitoring system for micro machining are summarized. The developed technologies have led the complete localization of the prism sheets and will be applied to the direct forming process with succeeding research & development.
Molding (decorative)
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Recent ultra-precision machining systems have nano-scale resolution, and can machine various shapes of complex structures using five-axis driven modules. These systems are also multi-functional, which can perform various processes such as planing, milling, turning et al. in one system. Micro machining technology using these systems is being developed for machining fine patterns, hybrid patterns and high aspect-ratio patterns on large-area molds with high productivity. These technology is and will be applied continuously to the fields of optics, display, energy, bio, communications and et al. Domestic and foreign trends of micro machining technologies for flat molds were investigated in this study. Especially, we focused on the types and the characteristics of ultra-precision machining systems and application fields of micro patterns machined by the machining system.
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Difficulties in grasping micro parts and in the reorientation have great effect on machining precision and efficiency.So it is necessary to realize complete machining for micro-parts.Turn milling machining centre(MC) is the typical machine tool to realize complete machining and there are special advantages of turn milling technology in cutting micro rotationally symmetrical workpieces,which makes the complete machining of micro parts come true.The experiments show that,for micro components based on rotatory parts,turn milling technology and complete machining are combined together ideally in turn milling machining center.
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The reverse machining process is a new principle of machining process in the recent years. It makes machine configuration and structure more simple,the chips and coolant take out more easy and machining accuracy higher.This paper introduces three typical reverse machining systems,the vertical turning machines;the vertical and horizontal machine center;and flexible machining system and typical application technology.
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Turn-milling machining centre(MC) is the typical machine tool to realize complete machining and there are special advantages of turn-milling technology to cutting micro rotationally symmetrical workpieces,which make the complete machining of micro-parts come true.Experiments show that,for micro components based on rotatory parts,micro turn-milling technology and complete machining are combined together ideally in turn-milling machining center.
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This paper reveals the main technology difficulty of micro- h ol e machining,introduces the study and application of special machining technology of micro- hole.The crucial technology and suitable range of every special type in machining micro- hole is expoumded.At last,the existing problems and study direction of micro- hole machinimg are pointed out.
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The prototype hybrid micro machine tool developed in this study. It is a tabletop size machine tool which has five changeable machining units. To study the basic performance of hybrid micro machine tool, a complex machining experiment is carried out. The complex machining has 3 steps: electrode machining by milling, hole shaping by EDM, and hole finishing by ECM. These steps are performed in sequence on the same machine tool The complex machining is successfully carried out. In order to evaluate a hybrid micro machine tool from the environmental point of view, machining energy, the volume of machining liquid, and installation space of hybrid micro machine tool are measured. The measured values are compared with estimated values with conventional machine tools, and found to be smaller. Another type of complex machining with hybrid micro machine tool is investigated. It is unnecessary to prepare a form electrode in the complex machining, and the machining covers a variety of machining shape.
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