Diamond machining of freeform-patterned surfaces on precision rollers

Abstract

Rapid development of freeform surfaces faces the challenges of not only higher form accuracy and smoother surface finishing, but also high machining efficiency and lower manufacturing cost. Combining diamond turning and roll-toroll embossing technologies is a promising solution to fulfil these requirements. This paper presents a generic method to design and machine freeform surfaces on precision rollers. The freeform surface designed on the flat substrate is first transferred onto the cylindrical roller surface. The freeform-patterned roller surface is then diamond turned using the toolpath generated by a purposely developed toolpath generator. With the proposed method, the complex freeform surfaces designed on flat substrate can be transferred to and precisely machined on the cylindrical roller surfaces. A cutting experiment has been conducted to demonstrate the capability of the proposed method. In the experiment, a sinusoidal surface was designed and diamond turned on a precision roller. The results demonstrate that the proposed method is accurate and effective. The proposed method provides guidance for the design and precision manufacturing of freeform-patterned surfaces on precision rollers.

Continuous roller nanoimprinting: next generation lithography

“…In direct roller mold processing, the seamless pattern can be formed on the cylindrical surface of the roller through direct laser writing, electron beam writing, 31 etching, 32 electroforming, 31,33 lateral silicon oxidation, 34 chemical vapour deposition (CVD) 35 or diamond blade writing. 36 As shown in Fig. 2b, the UV laser hybrid lithography direct writing system combining interference, projection, and immersion operating modes can write complex micro-nano structures (100 nm to 10 μm) on 65-inch substrates.…”

Investigation of Segment Turning Process based on Single-amplitude-frequency Criterion for Complicated Multi-Scale Surface Structure

“…The multi-scale microstructure has been increasingly applied on various state-of-the-art fields, e.g., optical elements [1,2], superhydrophobic coatings [3,4] and bio-surface mimicking [5], etc., where the ultra-precision diamond turning is prone to obtain this kind of structures with high machining quality [6,7]. However, as the dramatically increased complexity of geometry of multi-scale microstructure, there is a great challenge for the dynamic capability of machine tool to meet the high requirement of machining accuracy and surface finish [8].…”