Concentric Optical Member Cutting Tool Segmentation
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Solution Overview
Problem
The existing methods for manufacturing optical members with projecting gratings face challenges in achieving efficient surface roughness and preventing tool interference, leading to potential shape failures and reduced optical performance due to limitations in gap angles and feeding speeds.
Innovation Solution
A method involving three steps to process concentric surfaces with varying gap angles and inclinations, ensuring the cutting tool moves from the outer peripheral end to the center, with specific angle relationships to prevent interference and maintain surface quality, using high-hardness tools like diamond for precise cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the gap angle is increased to avoid tool interference with the diffraction surface, then tool interference is prevented, but surface roughness deteriorates due to reduced burnishing effect
Solution Approach 1:
The patent segments the cutting tool into multiple cutting edges with different gap angles. The first cutting edge has a first gap angle for processing outer peripheral surfaces, while the second cutting edge has a second gap angle for processing inner surfaces. This segmentation allows each cutting edge to be optimized for its specific processing zone, preventing tool interference on outer surfaces while maintaining appropriate burnishing effect through the first cutting edge's smaller gap angle.
Solution Approach 2:
The patent applies local quality by assigning different gap angles to different cutting edges based on their processing locations. The first cutting edge uses a smaller gap angle (0-15 degrees) suitable for outer peripheral surfaces requiring burnishing, while the second cutting edge uses a larger gap angle (15-30 degrees) suitable for inner surfaces where burnishing is less critical. This localized optimization resolves the contradiction between preventing interference and maintaining surface quality.
2Productivity
If the feeding speed is increased to improve processing efficiency, then productivity improves, but surface roughness deteriorates due to reduced burnishing effect
Solution Approach 1:
The patent segments the cutting tool's function by assigning different cutting edges to different processing zones with different speed requirements. The first cutting edge processes outer peripheral surfaces at lower feeding speeds to maintain burnishing effect and surface quality, while the second cutting edge processes inner surfaces at higher feeding speeds to maximize productivity where burnishing is less critical.
Solution Approach 2:
The patent applies local quality by setting different feeding speeds for different processing locations. Outer peripheral surfaces receive lower feeding speeds (0.01-0.1 mm/rev) to ensure burnishing effect, while inner surfaces receive higher feeding speeds (0.1-1.0 mm/rev) to improve productivity. This localized speed control resolves the contradiction between productivity and surface quality.
3Manufacturing precision
If the gap angle is decreased to improve surface roughness through burnishing effect, then surface quality improves, but tool interference occurs with the diffraction surface
Solution Approach 1:
The patent segments the cutting tool into multiple cutting edges, each optimized for specific processing zones. The first cutting edge has a smaller gap angle (0-15 degrees) for processing outer peripheral surfaces where burnishing is needed, while the second cutting edge has a larger gap angle (15-30 degrees) for processing inner surfaces where interference is avoided.
Solution Approach 2:
The patent applies local quality by assigning different gap angles to different cutting edges based on their processing locations. The first cutting edge uses a smaller gap angle (0-15 degrees) suitable for outer peripheral surfaces requiring burnishing, while the second cutting edge uses a larger gap angle (15-30 degrees) suitable for inner surfaces where burnishing is less critical. This localized optimization resolves the contradiction between preventing interference and maintaining surface quality.
4Manufacturing precision
If the feeding speed is decreased to maintain burnishing effect, then surface roughness improves, but processing efficiency is lowered
Solution Approach 1:
The patent segments the cutting tool's function by assigning different cutting edges to different processing zones with different speed requirements. The first cutting edge processes outer peripheral surfaces at lower feeding speeds to maintain burnishing effect and surface quality, while the second cutting edge processes inner surfaces at higher feeding speeds to maximize productivity where burnishing is less critical.
Solution Approach 2:
The patent applies local quality by setting different feeding speeds for different processing locations. Outer peripheral surfaces receive lower feeding speeds (0.01-0.1 mm/rev) to ensure burnishing effect, while inner surfaces receive higher feeding speeds (0.1-1.0 mm/rev) to improve productivity. This localized speed control resolves the contradiction between productivity and surface quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively reduces surface roughness and prevents tool interference, enhancing the appearance quality and optical performance of the optical member by maintaining precise control over gap angles and feeding speeds during the cutting process.
Implementation Method 1
a first step of moving a cutting tool so that a gap angle formed between a feeding direction and a side cutting edge of the cutting tool has a constant angle α1 to process a surface having an angle of inclination θ0
Data Source
AI summary
An optical member having a concentric diffraction surface facing the outside, wherein the projection having a inclined surface concentric to the diffraction surface having an angle of inclination θ smaller than the angle of inclination ϕ is provided outside the diffraction surface having the largest ϕ, so that an interference of a cutting tool is avoided, and simultaneously, deterioration of a surface roughness may be restrained.