Ultra-precision machining machine tool of double-tool-rest oppositely-arranged roller mold and machining method of ultra-precision machining machine tool

Abstract

The invention provides an ultra-precision machining machine tool of a double-tool-rest oppositely-arranged roller mold and a machining method of the ultra-precision machining machine tool. The ultra-precision machining machine tool comprises a main shaft system, a double-tool-rest system, an intelligent quick-change platform and a control system. The two tool rest systems are located on the two sides of a workpiece and oppositely arranged at 180 degrees, self-balance of radial cutting force is achieved, and machining deformation of the roller with the large length-diameter ratio is effectively restrained. The intelligent quick change platform adopts zero point positioning, RFID identification and medium quick docking technologies to realize quick change and automatic parameter reconstruction of functional modules such as turning, fly cutting and measurement. Self-adaptive control over the posture of the cutter is achieved. The machining precision and efficiency of the large-size roller mold are effectively improved, and turning, milling and measuring integrated manufacturing of a complex microstructure is achieved.

Description

Technical Field

[0001] This invention relates to the field of ultra-precision machining technology, and in particular to an ultra-precision machine tool and machining method for a double-tool-positioned opposed roller mold. Background Technology

[0002] With the rapid development of display technology and the new energy industry, the market demand for large-size optical functional films (such as brightness enhancement films, diffusion films, and photovoltaic concentrating films) is increasing. Using ultra-precision machine tools to process roller dies with microstructures, combined with roll-to-roll imprinting, is the core technological route to achieve mass production and low cost of such optical films. The microstructure precision and surface quality of the roller die directly determine the performance indicators of the final optical film product. In recent years, as products have developed towards larger sizes and greater complexity, roller dies have shown a trend towards larger dimensions (length > 1500 mm), higher aspect ratios, and more complex microstructures, placing higher demands on ultra-precision machining technology.

[0003] Large-size roller molds are typically heavy and long, making them susceptible to bending deformation during machining due to gravity and cutting forces. In traditional single-tool-post machining, the cutting forces cannot be counteracted, leading to a "tool deflection" phenomenon in the middle of the roller, severely impacting the consistency of the microstructure along its entire length. Furthermore, existing machining equipment has relatively limited functionality, making it difficult to complete multiple processes such as turning, milling, and inspection on a single machine tool. Frequent disassembly and re-clamping introduce significant positioning errors.

[0004] Currently, there are numerous technological explorations and practices in the field of ultra-precision machining of roller molds. Chinese invention patent CN114918440A discloses a high-rigidity ultra-precision single-point diamond machine tool for roller molds. This technology improves the static stiffness and dynamic response performance of the system by optimizing the feed system layout, mounting the tool holder on a vertical guide rail, and adopting a short cantilever structure. While this solution has achieved positive results in structural stiffness optimization, when machining rollers with large aspect ratios, the single-tool holder layout causes the workpiece to bear unilateral radial cutting force during the cutting process, potentially leading to bending deformation. Furthermore, the limited single-tool cutting results in a longer workpiece machining cycle.

[0005] Chinese invention patent CN116079083A discloses a six-axis cylindrical Fresnel ultra-precision machining roller device. This device utilizes a series of dual rotary tables (A-axis and B-axis) to achieve multi-angle oscillation and rotation of the cutting tool, providing a technical means for machining complex cylindrical microstructures. This technology has advantages in flexible control of the cutting tool posture, enabling precision machining of complex structures such as Fresnel lenses. However, the structure of this type of equipment is highly integrated and specialized, lacking a universal quick-change interface between the cutting tool assembly and the multi-axis motion unit, limiting the device's functionality to a single turning mode.

[0006] Chinese invention patent CN107350817B discloses a method for processing microstructures on the surface of a roller mold. This technology uses high-frequency vibration micro-forging instead of traditional turning, driving a pressure head of a specific shape (such as spherical or pyramidal) to repeatedly vibrate and forge on the roller surface to replicate microstructure units with a shape equivalent to the pressure head. This type of method is essentially a discrete "imprinting" process, which cannot directly calculate and generate processing paths using a general mathematical model, resulting in low flexibility and versatility of the algorithm.

[0007] Analysis of existing technologies reveals that there is still room for improvement in the field of ultra-precision machining of large-size roller molds in the following three aspects:

[0008] First, the resistance to deformation needs to be enhanced. Existing technologies mostly employ a single tool holder structure. When machining rollers with a large length-to-diameter ratio, the cutting force acts on one side, making the workpiece prone to bending deformation under radial cutting force, affecting the consistency of the microstructure along its entire length. How to achieve a balance of cutting forces through structural design and reduce workpiece deformation is one of the key issues in improving machining accuracy.

[0009] Secondly, process integration capabilities can be further improved. Current machining equipment is mostly designed specifically for particular processes (such as turning or milling). When multiple operations need to be completed (such as roughing, finishing, fly cutting, and in-situ inspection), it is often necessary to transfer workpieces or change tooling between different machines. This not only increases the machining cycle but may also introduce secondary clamping errors. Developing technical solutions that can quickly switch between different functional modules and achieve multi-process integration is of great significance for improving machining efficiency and ensuring machining accuracy.

[0010] Third, the versatility of trajectory planning algorithms needs to be improved. Existing slow-tool servo technologies are mostly optimized for specific regular microstructures (such as V-grooves and pyramidal arrays), lacking a unified five-axis linkage trajectory planning framework for free-form surface microstructures of arbitrary shapes. In particular, establishing a universal geometric solution model and algorithm system in areas such as tool attitude adaptive control, tool center point three-dimensional compensation (TCP), and rotation center dynamic compensation (RTCP) is an important direction for expanding machining capabilities and improving machining quality.

[0011] Based on the above analysis, we developed an ultra-precision machine tool that integrates dual-tool-post self-balancing cutting, intelligent quick-change of multi-functional modules, and a general five-axis linkage algorithm. This has significant engineering application value for solving the problems existing in the current technology and improving the manufacturing efficiency and processing accuracy of large-size roller molds. Summary of the Invention

[0012] In view of this, the purpose of this invention is to provide an ultra-precision machine tool and machining method for a double-tool-post opposed roller mold, achieving adaptive control of tool posture. This invention effectively improves the machining accuracy and efficiency of large-size roller molds, realizing integrated milling, turning, and measurement manufacturing of complex microstructures.

[0013] To achieve the above objectives, the present invention adopts the following technical solution: an ultra-precision machining tool for a double-tool-post opposed roller mold, comprising:

[0014] The machine tool base 7, spindle box, machine tool spindle 1, intelligent quick change platform 4, control system, first tool post system and second tool post system are respectively installed on both sides of the machine tool base 7, the spindle box is located at one end of the machine tool base 7, and the machine tool spindle 1 is installed in the spindle box for driving the workpiece to rotate.

[0015] The first tool post system includes a first Z-axis slide 8, a first tool post Z-axis guide plate 2, and a first tool post X-axis guide plate 3; the first tool post Z-axis guide plate 2 is slidably connected to the first Z-axis slide 8 and slides along the length direction of the first Z-axis slide 8; the first tool post X-axis guide plate 3 is slidably connected to the first tool post Z-axis guide plate 2 and slides along the length direction of the first tool post Z-axis guide plate 2.

[0016] The second tool post system includes a second Z-axis slide 9, a second tool post Z-axis guide plate 5, and a second tool post X-axis guide plate 6; the second Z-axis slide 9 is slidably connected to the second tool post Z-axis guide plate 5, and the second Z-axis slide 9 slides along the length direction of the second tool post Z-axis guide plate 5; the second tool post Z-axis guide plate 5 is slidably connected to the second tool post X-axis guide plate 6, and the second tool post X-axis guide plate 6 slides along the length direction of the second tool post Z-axis guide plate 5;

[0017] The first Z-axis slide 8 and the second Z-axis slide 9 are arranged parallel to each other;

[0018] The intelligent quick-change platform 4 is installed on both the first tool holder X-axis guide plate 3 and the second tool holder X-axis guide plate 6, for quickly changing and equipping different functional modules and slow tool servo devices;

[0019] The control system is electrically connected to the machine tool spindle 1, intelligent quick-change platform 4, first tool post system and second tool post system, and is used for multi-axis linkage control and intelligent identification and parameter reconstruction of functional modules;

[0020] The control system integrates a general cylindrical microstructure trajectory planning algorithm, which is used to solve the geometric data of arbitrary patterns into motion commands for each axis.

[0021] In a preferred embodiment, the intelligent quick-change platform 4 includes a universal motherboard and a functional carrier board;

[0022] The general-purpose motherboard includes a quick-change platform motherboard base 41, a zero-point positioning module 42, a high-voltage spring pin 43, a low-voltage spring pin 44, an RFID reader / writer head 45, and a flat, overflow-free valve head 46. The quick-change platform motherboard base 41 is fixedly installed on the first tool holder X-axis guide plate 3 and the second tool holder X-axis guide plate 6.

[0023] The functional carrier board includes a zero-point positioning rivet 47, a high-voltage contact plate 48, a low-voltage contact plate 49, an RFID chip 410, a flat overflow-free valve male connector 411, and a quick-change platform daughterboard base 412. The functional carrier board is used to mount different processing or testing equipment. The zero-point positioning rivet 47 is rigidly connected to the zero-point positioning module 42, so that the high-voltage spring pin 43 is connected to the high-voltage contact plate 48, the low-voltage spring pin 44 is connected to the low-voltage contact plate 49, and the RFID reader / writer head 45 is connected to the RFID chip 410.

[0024] In a preferred embodiment, the planar non-overflow valve female head 46 and the planar non-overflow valve male head 411 adopt a combination structure of planar quick connector and electrode array; during the locking process of the functional carrier board and the general mother board, the downward pulling force of the zero-point positioning rivet 47 and the zero-point positioning module 42 overcomes the internal spring force of the connector, thereby realizing the automatic conduction of coolant, compressed air and electrical signal.

[0025] In a preferred embodiment, the functional modules mounted on the functional carrier board include at least: a turning module for rough machining or auxiliary turning, a high-speed flying cut module for intermittent microstructure machining, and a non-contact measurement module for on-machine surface inspection.

[0026] In a preferred embodiment, the universal mother plate is made of high-rigidity Invar alloy material, and its upper surface is machined with countersunk holes distributed in a rectangular array. The zero-point positioning rivet 47 and the zero-point positioning module 42 are interference-fitted into the countersunk holes.

[0027] In a preferred embodiment, the control system has a dual-tool radial force self-balancing control mode: during the roughing or semi-finishing stage, the first tool post system and the second tool post system are controlled to feed synchronously along the workpiece diameter direction, so that the radial cutting forces generated by the two tools cancel each other out.

[0028] This invention also provides an ultra-precision machining method for a double-tool-positioned opposed roller mold, based on the aforementioned ultra-precision machining machine tool for a double-tool-positioned opposed roller mold, comprising the following steps:

[0029] Step S1: Pattern geometry modeling. Define the arbitrary pattern to be processed as the radius variation function r=f(φ,z) in the cylindrical coordinate system, where φ is the workpiece rotation angle and z is the axial position.

[0030] Step S2: Calculate the normal vector and slope. For any machined point on the patterned surface, calculate its axial slope. and circumferential slope And based on this, construct a local unit normal vector;

[0031] Step S3: Generate five-axis linkage command. Based on the calculated slope, solve for the target deflection angles of the A-axis and B-axis to ensure that the tool axis always tracks the pattern surface along the normal direction. Combine the tool tip radius and the rotation center offset of the A / B axes to calculate the compensation position of the tool center point in the cylindrical coordinate system.

[0032] Step S4: Inverse coordinate transformation and execution. The compensated position coordinates are inversely transformed into motion commands for each axis of the machine tool, driving the machine tool to perform cutting.

[0033] In a preferred embodiment, the target deflection angles of the A-axis and B-axis in step S3 are calculated using the arctangent function based on the axial slope and circumferential slope.

[0034] In a preferred embodiment, the compensation calculation for the tool center point in step S3 includes:

[0035] Three-dimensional tool tip radius compensation: the theoretical machining point is offset outward by the tool tip radius along the normal vector direction, and the ideal spatial coordinates of the tool sphere center are calculated.

[0036] Dynamic compensation of the rotation center, combined with the rotation center offset of the A / B axes, uses the inverse kinematic equation to calculate the mechanical displacement error generated when the A / B axes rotate, and then adds the compensation amount to the linear axis command.

[0037] In a preferred embodiment, the method further includes a multi-process integrated processing flow based on an intelligent quick-change platform:

[0038] Roughing stage: The turning module is installed on the intelligent quick-change platform and performs synchronous cutting in opposition to the first tool post system to remove most of the material;

[0039] Finishing stage: The first tool post system uses a five-axis linkage slow tool servo device for micro-structure precision turning;

[0040] Irregular feature processing stage: The intelligent quick-change platform is replaced with a high-speed flying cut module, and the C-axis indexing function is used to process non-rotational symmetric features;

[0041] In the in-machine inspection and compensation stage: The intelligent quick-change platform is used to replace the non-contact measurement module, which scans the processing surface and feeds back the error data to the geometric model in step S1 for correction and compensation.

[0042] Compared with the prior art, the present invention has the following beneficial effects:

[0043] First, the invention achieves radial force self-balancing through a dual-tool holder opposing layout, effectively suppressing machining deformation. This invention employs a dual-tool holder system positioned 180° opposite each other on both sides of the workpiece. During roughing or semi-finishing, the two tools feed synchronously along the workpiece diameter, ensuring that the radial cutting forces generated on both sides are similar in magnitude and opposite in direction, canceling each other out at the workpiece cross-section. This fundamentally solves the problem of workpiece bending deformation caused by unilateral cutting force during single-tool holder machining. This force balancing mechanism is particularly suitable for machining large aspect ratio roller dies, maintaining stable machining accuracy throughout the entire length and ensuring the consistency of the microstructure.

[0044] Secondly, the intelligent quick-change platform enables rapid switching of multi-functional modules, significantly improving process integration capabilities. This invention integrates an intelligent quick-change platform into the tool holder system. This platform uses a zero-point positioning locking unit to achieve rapid loading and unloading and high-precision repeatable positioning of functional modules, employs RFID technology for automatic module identification and parameter loading, and uses a planar overflow-free quick connector for automatic conduction of coolant, compressed air, and electrical signals. By changing different functional carrier plates, multiple processes such as turning, flying cutting, and measurement can be completed on the same machine tool without secondary workpiece clamping, eliminating clamping errors, shortening the processing cycle, and realizing integrated manufacturing of roughing, finishing, irregular feature processing, and in-machine inspection.

[0045] Third, the universality and machining adaptability of the algorithm are enhanced by employing a general five-axis linkage trajectory planning method for cylindrical microstructures. This invention establishes a pattern geometric model based on a cylindrical coordinate system and calculates the local normal vector of the machining point in real time using differential geometry methods. It adaptively solves for the target deflection angles of the A and B axes in the five-axis linkage slow-motion servo device, ensuring that the tool posture always tracks the microstructure surface along the normal direction. Simultaneously, the system integrates three-dimensional compensation algorithms for the tool center point and dynamic compensation algorithms for the rotation center, ensuring the accuracy of the tool trajectory. This method eliminates the dependence of traditional algorithms on specific regular structures, enabling the processing of geometric data for arbitrary free-form surface patterns and converting them into motion commands for each axis, significantly expanding the machining capabilities and applicability of machine tools. Attached Figure Description

[0046] Figure 1 This is a schematic diagram of the overall structure of the machine tool of the present invention;

[0047] Figure 2 This is a schematic diagram of the structure of the intelligent quick-change platform motherboard of the present invention;

[0048] Figure 3 This is a schematic diagram of the structure of the intelligent quick-change platform subboard of the present invention;

[0049] Figure 4 This is an exploded view of the assembly structure of the intelligent quick-change platform of the present invention;

[0050] Figure 5 This is a cross-sectional view of the locking and media docking principle of the intelligent quick-change platform of the present invention;

[0051] Figure 6 This is a schematic diagram of the technical route for the five-axis linkage machining method for cylindrical surface microstructures of the present invention;

[0052] Figure 7 This is a flowchart illustrating the five-axis linkage machining method for cylindrical surface microstructures according to the present invention.

[0053] The meanings of the labeled components in the diagram are as follows:

[0054] 1-Machine tool spindle; 2-First tool post Z-axis guide plate; 3-First tool post X-axis guide plate; 4-Intelligent quick-change platform; 5-Second tool post Z-axis guide plate; 6-Second tool post X-axis guide plate; 7-Machine tool base; 8-First Z-axis slide; 9-Second Z-axis slide; 41-Quick-change platform mother plate base; 42-Zero-point positioning module; 43-High-voltage spring ejector pin; 44-Low-voltage spring ejector pin; 45-RFID reader / writer head; 46-Flat-faced overflow-free valve female head; 47-Zero-point positioning pull stud; 48-High-voltage contact plate; 49-Low-voltage contact plate; 410-RFID chip; 411-Flat-faced overflow-free valve male head; 412-Quick-change platform daughter plate base. Detailed Implementation

[0055] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0056] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0057] It should be noted that the terminology used herein is for the purpose of describing particular implementations only and is not intended to limit the exemplary implementations according to this application; as used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise; furthermore, it should be understood that when the terms “comprising” and / or “including” are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0058] like Figures 1-7As shown, the present invention provides a large-size roller mold ultra-precision machining machine tool with dual-tool holders and intelligent quick-change platform. It adopts a dual-tower layout structure and includes a machine tool spindle 1, a first tool holder system, a second tool holder system, a machine tool base 7, and an intelligent quick-change platform 4.

[0059] The machine tool base 7 is made of natural granite and is supported by passive air springs for vibration isolation. The machine tool spindle 1 is mounted on one side of the machine tool base 7 and is used to clamp and drive the rotation of large-sized roller mold workpieces. The first tool post system is located in front of the workpiece and includes a first tool post Z-axis guide plate 2 and a first tool post X-axis guide plate 3 stacked together. The first tool post Z-axis guide plate 2 is slidably mounted on a first Z-axis slide 8 of the machine tool base 7 in a direction parallel to the spindle axis, and the first tool post X-axis guide plate 3 is slidably mounted on a second Z-axis slide 9 of the first tool post Z-axis guide plate 2 in a direction perpendicular to the spindle axis. A five-axis linkage slow tool servo device can be installed on the first tool post X-axis guide plate 3. This device has an A-axis (vertical swing axis) that rotates around the X-axis and a B-axis (horizontal swing axis) that rotates around the Y-axis, and is used to mount diamond tools for high-precision micro-structure cutting. The second tool post system is located behind the workpiece (non-operating side) and is arranged 180° opposite to the first tool post system. Its structure includes a second tool post Z-axis guide plate 5 and a second tool post X-axis guide plate 6, and the connection method is the same as that of the first tool post system.

[0060] The intelligent quick-change platform 4 has its mother plate fixedly mounted on the top surface of the first tool post X-axis guide plate 3 and the second tool post X-axis guide plate 6. For example... Figures 2 to 5As shown, the intelligent quick-change platform 4 includes a quick-change platform mother plate and a detachable quick-change platform daughter plate. Quick-change platform mother plate: The quick-change platform mother plate base 41 is a high-rigidity Invar alloy plate, with four countersunk holes machined on its upper surface, arranged in a 3-rectangular array. Four zero-point positioning modules 42 are interference-fitted into the countersunk holes to provide positioning reference and locking force. At the center of the quick-change platform mother plate base 41, a high-voltage spring pin 43, a low-voltage spring pin 44, and an RFID reader / writer head 45 are embedded. The sensing surface of the RFID reader / writer head 45 is slightly lower than the upper surface of the mother plate by 0.5mm-1.0mm and covered with a PEEK wave-transparent protective cover for reading daughter plate information. A flat, overflow-free valve head 46 is provided on one edge of the quick-change platform mother plate base 41. The planar overflow-free valve female head 46 is connected to the external coolant circulation system; the high-voltage spring pin 43 is used to transmit power (such as driving the flying cutter spindle); the low-voltage spring pin 44 is used to transmit sensor signals. Quick-change platform daughterboard: The lower surface of the quick-change platform daughterboard base 412 is provided with four zero-point positioning rivets 47 corresponding to the position of the motherboard zero-point positioning module 42. When the rivets are inserted into the positioning module, automatic centering and locking with micron-level precision is achieved through elastic deformation. The locking force can reach 20kN, and the repeatability is better than 3μm. At the center of the lower surface of the quick-change platform daughterboard base 412, a high-voltage contact plate 48, a low-voltage contact plate 49, and an RFID chip 410 (anti-metal tag) are embedded. The RFID chip 410 stores the identity ID and geometric offset parameters of the functional module mounted on the daughterboard. At the corresponding edge of the quick-change platform daughterboard base 412, a planar overflow-free valve male head 411 is provided.

[0061] This invention also provides a general method for fabricating cylindrical microstructures, comprising the following steps:

[0062] S1. Cylindrical coordinate geometric modeling: The arbitrary patterned microstructure to be processed is defined as a radius-height function in cylindrical coordinates. Calculate its axial slope. and circumferential slope k φ =1 / r·∂r / ∂φ

[0063] S2. Differential geometric normal calculation: The system calculates the local slope of the machining point on the cylindrical surface in real time, including the axial slope. and circumferential slope .

[0064] S3. Adaptive Tool Posture Planning: Based on the calculated normal vector, the target angle of the rotation axis in the slow-moving tool servo is determined, ensuring that the tool rake face is always perpendicular to the surface normal of the microstructure. B-axis deflection is controlled. To compensate for the axial tilt of the microstructure and control the A-axis deflection. This is to compensate for the tilt of the microstructure in the circumferential tangential direction.

[0065] S4. Three-dimensional tool tip radius and RTCP linkage compensation: Tool tip radius compensation is to offset the theoretical machining point outward along the normal vector direction. Calculate the ideal spatial coordinates of the tool center. Dynamic Rotation Center Compensation (RTCP) combines machine tool parameters, including the rotation center offset of the A / B axes. The mechanical displacement error generated during the rotation of the A / B axes is calculated using the inverse kinematics equations. , Finally, the compensation amount is superimposed on the linear axis command to generate motion control signals for each axis. .

[0066] The present invention will be further described below with reference to a specific embodiment:

[0067] The dual-tool radial force self-balancing roughing method addresses the problem of bending deformation in roller dies with large aspect ratios (e.g., length > 1500 mm). This embodiment employs a dual-tool opposing synchronous machining strategy, with the specific steps as follows:

[0068] Step 1: Module Loading. The robotic arm installs the quick-change platform subplate equipped with the roughing tool onto the mother plate of the second tool post. The zero-point positioning module 42 locks in place, the RFID reader / writer 45 reads the module ID, and the control system confirms that the current mode is "roughing mode".

[0069] Step 2: Tool Setting and Synchronization. The first tool post (finishing tool) and the second tool post (roughing tool) are set separately. The control system establishes dual-channel synchronous control logic and sets the X2 axis movement command for the second tool post. ,in This refers to the difference in cutting depth between roughing and finishing processes.

[0070] Step 3: Balanced Cutting. Machining begins with the X1 and X2 axes feeding in opposite directions along the diameter. This is due to the radial cutting force applied by the two tools in the diameter direction. and With similar sizes and opposite directions, the two cancel each other out on the workpiece cross-section, thus making the deflection deformation of the long roller theoretically approach zero, ensuring the cylindricity accuracy throughout the entire length of the roller.

[0071] Furthermore, arbitrary free-form surface microstructures are machined using a general five-axis linkage trajectory planning method for cylindrical surface microstructures, utilizing the slow-tool servo device of the first tool post. For example... Figure 6 and Figure 7 As shown, this method is integrated into the CNC system of a machine tool, and the specific steps are as follows:

[0072] S1. Geometric Modeling and Discretization: The cylindrical microstructure to be processed is unfolded into a two-dimensional plane, and its geometric height is defined as a function in the cylindrical coordinate system. .in The polar radius is is the polar angle (corresponding to the C-axis), and z is the axial coordinate. The system discretizes this function into a high-density sequence of tool position points.

[0073] S2, Differential geometric normal solution for machining points within each interpolation cycle. The control system calculates the partial derivative of the point on the cylindrical surface in real time to determine the local slope: axial slope is calculated. ; Calculate the circumferential slope Based on the aforementioned slope, construct the unit normal vector for that point. (Normalization is required).

[0074] S3. Adaptive tool attitude planning: To ensure that the rake face of the diamond tool is always perpendicular to the normal of the microstructure surface (normal tracking machining), the system calculates the target deflection angles of the A-axis and B-axis based on the slope calculated in step S2: B-axis (horizontal swing angle) command: Used to compensate for axial undulations in the microstructure; A-axis (vertical sway angle) command: It is used to compensate for the undulations of the microstructure along the circumferential tangential direction.

[0075] S4, Three-dimensional tool tip radius and RTCP linkage compensation: Because the tool has a physical tool tip radius Furthermore, there is a mechanical offset between the tool tip rotation center and the machine tool A / B axis rotation center. The system performs dual position compensation: 3D TCP compensation: along the normal vector Direction: Offset the theoretical machining point outward by a tool tip radius. Calculate the ideal spatial coordinates of the tool sphere center. RTCP dynamic compensation: Utilizing inverse kinematics equations, it calculates the displacement error of the tool center relative to the machine tool coordinate origin when the A / B axes rotate to the target angle. , Generate the final instruction: Add the compensation amount to the linear axis instruction: , The control system drives the five axes of X, Z, C, A, and B to achieve high-precision replication of microstructures.

[0076] After the turning process is completed, the second tool post moves to the tool change position. Further flying cut machining can then be performed, with the daughter plate equipped with the high-speed flying cut electric spindle mounted on the mother plate. After RFID identification, the system switches to "indexing milling mode," the C-axis angle is locked, the flying cut spindle starts and is powered by the high-voltage spring-loaded ejector pin 43, and the coolant automatically circulates through valves 46 / 411. The second tool post performs Z-axis feed, machining the pyramidal array features on the rollers.

[0077] After processing, the sub-plate is replaced with one equipped with a spectral confocal probe. After RFID identification, the system switches to "measurement mode." The second tool holder drives the probe to scan along the roller surface, and the low-voltage contact plate 49 transmits surface data in real time. The control system compares the measurement error with the theoretical model, generates a compensation strategy, and guides the first tool holder to perform local adjustments.

Claims

1. A high-precision machine tool for machining double-tool-post opposed roller molds, characterized in that, include: The machine tool base (7), spindle box, machine tool spindle (1), intelligent quick change platform (4), control system, first tool post system and second tool post system; the first tool post system and the second tool post system are respectively installed on both sides of the machine tool base (7), the spindle box is set at one end of the machine tool base (7), and the machine tool spindle (1) is installed in the spindle box for driving the workpiece to rotate; The first tool post system includes a first Z-axis slide (8), a first tool post Z-axis guide plate (2), and a first tool post X-axis guide plate (3); the first tool post Z-axis guide plate (2) is slidably connected to the first Z-axis slide (8), and the first tool post Z-axis guide plate (2) slides along the length direction of the first Z-axis slide (8); the first tool post X-axis guide plate (3) is slidably connected to the first tool post Z-axis guide plate (2), and the first tool post X-axis guide plate (3) slides along the length direction of the first tool post Z-axis guide plate (2); The second tool post system includes a second Z-axis slide (9), a second tool post Z-axis guide plate (5), and a second tool post X-axis guide plate (6); the second Z-axis slide (9) is slidably connected to the second tool post Z-axis guide plate (5), the second Z-axis slide (9) slides along the length direction of the second tool post Z-axis guide plate (5), the second tool post Z-axis guide plate (5) is slidably connected to the second tool post X-axis guide plate (6), and the second tool post X-axis guide plate (6) slides along the length direction of the second tool post Z-axis guide plate (5); The first Z-axis slide (8) and the second Z-axis slide (9) are arranged parallel to each other; The first tool holder X-axis guide plate (3) and the second tool holder X-axis guide plate (6) are both equipped with the intelligent quick-change platform (4) for quick replacement and mounting of different functional modules and slow tool servo devices; The control system is electrically connected to the machine tool spindle (1), intelligent quick change platform (4), first tool post system and second tool post system, and is used for multi-axis linkage control and intelligent identification and parameter reconstruction of functional modules; The control system integrates a general cylindrical microstructure trajectory planning algorithm, which is used to solve the geometric data of arbitrary patterns into motion commands for each axis.

2. The ultra-precision machining tool for a double-tool-post opposed roller mold according to claim 1, characterized in that, The intelligent quick-change platform (4) includes a general motherboard and a functional carrier board; The general-purpose motherboard includes a quick-change platform motherboard base (41), a zero-point positioning module (42), a high-voltage spring pin (43), a low-voltage spring pin (44), an RFID reader / writer head (45), and a flat, overflow-free valve head (46). The quick-change platform motherboard base (41) is fixedly installed on the first tool holder X-axis guide plate (3) and the second tool holder X-axis guide plate (6). The functional carrier board includes a zero-point positioning rivet (47), a high-voltage contact plate (48), a low-voltage contact plate (49), an RFID chip (410), a flat overflow-free valve male connector (411), and a quick-change platform sub-board base (412). The functional carrier board is used to mount different processing or testing equipment. The zero-point positioning rivet (47) is rigidly connected to the zero-point positioning module (42), so that the high-voltage spring pin (43) is connected to the high-voltage contact plate (48), the low-voltage spring pin (44) is connected to the low-voltage contact plate (49), and the RFID reader / writer head (45) is connected to the RFID chip (410).

3. The ultra-precision machining tool for a double-tool-post opposed roller mold according to claim 2, characterized in that, The planar overflow-free valve female head (46) and the planar overflow-free valve male head (411) adopt a combination structure of planar quick connector and electrode array; during the locking process of the functional carrier board and the general mother board, the downward pulling force of the zero-point positioning pull stud (47) and the zero-point positioning module (42) overcomes the internal spring force of the connector, thereby realizing the automatic conduction of coolant, compressed air and electrical signal.

4. The ultra-precision machining tool for a double-tool-post opposed roller mold according to claim 2, characterized in that, The functional modules mounted on the functional carrier board include at least: a turning module for rough machining or auxiliary turning, a high-speed flying cutting module for intermittent microstructure machining, and a non-contact measurement module for on-machine surface inspection.

5. The ultra-precision machining tool for a double-tool-post opposed roller mold according to claim 2, characterized in that, The general-purpose mother plate is made of high-rigidity Invar alloy material, and its upper surface is processed with countersunk holes distributed in a rectangular array. The zero-point positioning rivet (47) and the zero-point positioning module (42) are interference-fitted into the countersunk holes.

6. The ultra-precision machining tool for a double-tool-post opposed roller mold according to claim 1, characterized in that, The control system has a dual-tool radial force self-balancing control mode: during the roughing or semi-finishing stage, the first tool post system and the second tool post system are controlled to feed synchronously along the workpiece diameter direction, so that the radial cutting forces generated by the two tools cancel each other out.

7. A method for ultra-precision machining of a double-blade-post opposed roller mold, characterized in that, An ultra-precision machining tool for a double-tool-post opposed roller mold according to any one of claims 1-6 includes the following steps: Step S1: Pattern geometry modeling. Define the arbitrary pattern to be processed as the radius variation function r=f(φ,z) in the cylindrical coordinate system, where φ is the workpiece rotation angle and z is the axial position. Step S2: Calculate the normal vector and slope. For any machined point on the patterned surface, calculate its axial slope. and circumferential slope And based on this, construct a local unit normal vector; Step S3: Generate five-axis linkage command. Based on the calculated slope, solve for the target deflection angles of the A-axis and B-axis to ensure that the tool axis always tracks the pattern surface along the normal direction. Combine the tool tip radius and the rotation center offset of the A / B axes to calculate the compensation position of the tool center point in the cylindrical coordinate system. Step S4: Inverse coordinate transformation and execution. The compensated position coordinates are inversely transformed into motion commands for each axis of the machine tool, driving the machine tool to perform cutting.

8. The ultra-precision machining method for a double-blade-post opposed roller mold according to claim 7, characterized in that, In step S3, the target deflection angles of the A-axis and B-axis are calculated using the arctangent function based on the axial slope and circumferential slope.

9. The ultra-precision machining method for a double-blade-post opposed roller mold according to claim 7, characterized in that, The compensation calculation for the tool center point in step S3 includes: Three-dimensional tool tip radius compensation: the theoretical machining point is offset outward by the tool tip radius along the normal vector direction, and the ideal spatial coordinates of the tool sphere center are calculated. Dynamic compensation of the rotation center, combined with the rotation center offset of the A / B axes, uses the inverse kinematic equation to calculate the mechanical displacement error generated when the A / B axes rotate, and then adds the compensation amount to the linear axis command.

10. The ultra-precision machining method for a double-blade-post opposed roller mold according to claim 7, characterized in that, The method also includes a multi-process integrated processing flow based on an intelligent quick-change platform: Roughing stage: The turning module is installed on the intelligent quick-change platform and performs synchronous cutting in opposition to the first tool post system to remove most of the material; Finishing stage: The first tool post system uses a five-axis linkage slow tool servo device for micro-structure precision turning; Irregular feature processing stage: The intelligent quick-change platform is replaced with a high-speed flying cut module, and the C-axis indexing function is used to process non-rotational symmetric features; In the in-machine inspection and compensation stage: The intelligent quick-change platform is used to replace the non-contact measurement module, which scans the processing surface and feeds back the error data to the geometric model in step S1 for correction and compensation.

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