Optical Lens Machining Tool Window Angle Optimization
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Solution Overview
Problem
Current methods for machining optical surfaces using machining tools with synthetic monocrystal diamond tips are limited by the need for larger radii to increase infeed, which increases costs and degrades surface quality, particularly when dealing with non-rotationally symmetrical surfaces.
Innovation Solution
A method for determining movement data for machining tools in optical lens lathing devices that includes selecting tools with window angles matching the greatest radial slope amplitude of the surfaces, allowing for reduced tool volume and cost, and optimizing movement along multiple axes to maintain surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the radius of the machining tool is increased to allow greater infeed, then the infeed can be increased without degrading surface quality, but the volume and cost of the synthetic monocrystal diamond tool increases significantly
Solution Approach 1:
The patent changes the geometric parameters of the machining tool, specifically the window angle, to optimize the relationship between infeed capability and tool volume. By adjusting the window angle parameter, the tool can achieve greater infeed without requiring a proportional increase in radius, thus controlling volume growth.
Solution Approach 2:
The patent introduces dynamic control of the machining tool through multiple movement axes (parallel translation, perpendicular translation, and rotation about second axis) in addition to the standard rotation about first axis. This dynamic capability allows the tool to maintain optimal contact conditions with varying infeed rates without requiring a larger radius.
2Productivity
If the infeed of the machining tool is increased to reduce machining time, then productivity improves, but the quality of the produced surface degrades
Solution Approach 1:
The patent employs dynamic movement control along multiple axes (parallel translation axis, perpendicular translation axis, and rotation about second rotation axis) synchronized with the rotation about the first axis. This multi-axis dynamic control allows the machining tool to maintain optimal surface quality even at increased infeed rates by continuously adjusting the contact point and tool orientation.
3Productivity
If the radius of the diamond tip is increased to allow greater infeed, then the infeed capability improves, but the cost of the machining tool increases due to the volume increase to the power of 2 to 3
Solution Approach 1:
The patent optimizes the window angle parameter of the machining tool to decouple infeed capability from tool radius. By changing this geometric parameter, the tool achieves improved infeed capability without the cubic cost increase that would result from increasing the radius, making the tool more cost-effective while maintaining productivity.
4Productivity
If a larger radius machining tool is used to increase infeed, then productivity improves, but the window angle requirements increase leading to larger tool volume
Solution Approach 1:
The patent optimizes the window angle parameter to achieve the desired infeed capability without requiring a larger tool radius. By adjusting this geometric parameter, the tool maintains a compact volume while still providing sufficient infeed for high-productivity machining operations.
Data Source
AI summary
Methods of determining movement data representing the movement of a machining tool of an optical lens lathing device for machining one or more optical surfaces or parts thereof of a set of optical surfaces are described. The methods comprise a greatest radial slope amplitude determining step during which the greatest radial slope amplitude of the optical surfaces of the set of optical surfaces is determined. The methods also comprise a machining tool selecting step during which a machining tool having a window angle greater than or equal to the greatest radial slope amplitude of the optical surfaces of the set of surfaces to be manufactured is selected. The methods further comprise a movement data determining step during which movement data representing the movement of the selected machining tool are determined and synchronized with the angular position of the optical surface driven in rotation.