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Diamond micro-scraping for the fabrication of polygonal Fresnel lens structure array on roller molds

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Abstract

In roll-to-roll (R2R) manufacturing of optical films, machining the microstructure on the roller mold is a crucial step. However, a trimmed radial Fresnel lens structure is discontinuous, and direct diamond cutting the trimmed radial Fresnel lens structure array on the surface of a roller mold was considered infeasible. Hence, a new machining method, diamond micro-scraping (DMS), combined with the polygonal Fresnel lens structure array characteristics, provides a possible solution for machining the Fresnel lens structure array on the roller molds. Tool path planning and simulation analysis were based on the layout of the polygonal Fresnel structure array. In this paper, a polygonal Fresnel lens structure array is processed directly on the periphery roller surface with a diamond tool. The machining performance of DMS was evaluated by studying the influence of different materials and machining parameters on the machined surface quality. The proposed method guides the design and precision manufacturing of the Fresnel lens structure array on precision rollers.

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All data used in the article are available from the author on reasonable request.

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Funding

This work was supported by the National Natural Science Foundation of China (No.51575520) and the Science and Technology Program of Guangzhou, China (No.201804020040).

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Authors and Affiliations

  1. State Key Laboratory of Precision Electronic Manufacturing Technology and Equipment, Guangdong University of Technology, Guangzhou, 510000, Guangdong, China

    Songtao Meng, Ziqiang Yin, Senbin Xia, Jianhua Yao & Jianwen Zhang

  2. Guangdong Provincial Key Laboratory for Micro-nano Manufacturing Technology and Equipment, School of Electro-mechanical Engineering, Guangdong University of Technology, Guangzhou, 510000, Guangdong, China

    Songtao Meng, Ziqiang Yin, Senbin Xia, Jianhua Yao & Jianwen Zhang

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  1. Songtao Meng
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  2. Ziqiang Yin
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  3. Senbin Xia
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Contributions

Songtao Meng and Ziqiang Yin conceived the idea of the study, analyzed most of the data, and wrote the initial draft of the paper. The remaining authors discussed the results and revised the manuscript.

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Correspondence to Ziqiang Yin.

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Meng, S., Yin, Z., Xia, S. et al. Diamond micro-scraping for the fabrication of polygonal Fresnel lens structure array on roller molds. Int J Adv Manuf Technol 116, 1951–1959 (2021). https://doi.org/10.1007/s00170-021-07581-7

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  • DOI: https://doi.org/10.1007/s00170-021-07581-7

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