Roll Cutting Control for Burr-Free Microlens Transfer Patterns
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Solution Overview
Problem
Existing methods for forming transfer patterns on rolls to manufacture microlens arrays suffer from burr formation, leading to quality deterioration, and require inefficient multiple cuts to prevent burrs, limiting incident angles and increasing machining time.
Innovation Solution
A roll manufacturing method and apparatus that uses a rotary device and cutting tool stage to rotate and reciprocate a cutting blade with precise control, allowing multiple cuts at predetermined depths and angles without burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cutting blade is used to form transfer patterns on a roll, then the transfer pattern can be created, but burrs occur on the roll surface leading to quality deterioration
Solution Approach 1:
The patent applies preliminary action by performing multiple cutting passes at progressively shallower depths. Before the final cut, several preliminary cuts are made at controlled depths to gradually remove material and reduce stress, preventing burr formation in the final pass while still achieving the desired transfer pattern geometry
Solution Approach 2:
The cutting process is segmented into multiple discrete cutting passes rather than a single deep cut. Each pass removes a portion of the required depth, with the total depth achieved through cumulative cuts. This segmentation allows stress distribution and prevents the material from deforming and creating burrs
2Manufacturing precision
If multiple cuts are performed to prevent burrs, then surface quality improves, but machining time increases enormously
Solution Approach 1:
The patent optimizes preliminary action by performing only the necessary number of preliminary cuts at calculated depths, then transitioning to the final cut. The cutting depths are precisely controlled to achieve burr-free surfaces without unnecessary additional passes, balancing quality requirements with production efficiency
Solution Approach 2:
The patent applies parameter changes by systematically varying the cutting depth parameter across multiple passes. The depth parameter is adjusted from larger values in preliminary cuts to a precise final value, optimizing both burr prevention and machining time by avoiding both excessive and insufficient cutting depths
3Manufacturing precision
If the same cutting portions are cut accurately multiple times, then burr formation is prevented, but the cutting precision requirements become extremely stringent
Solution Approach 1:
The patent applies self-service by using the workpiece itself as a reference for positioning. The roll serves as its own locator, with cutting features referenced to the roll's rotational axis and surface, eliminating the need for external precision fixtures and reducing positioning errors across multiple cutting passes
4Ease of manufacture
If a cutting blade with bit relief angle is used, then the blade can cut effectively, but the incident angle of cutting holes is limited and cannot be greater than or equal to the bit relief angle
Solution Approach 1:
The patent applies preliminary action by making multiple preliminary cuts that gradually shape the cutting holes. These preliminary cuts create a pre-formed geometry that allows the final cut to achieve the desired incident angle greater than the bit relief angle, as the material has already been partially removed and stressed in controlled ways
Solution Approach 2:
The patent applies dynamics by using a rotating cutting blade rather than a stationary one. The rotation of the blade introduces dynamic cutting conditions that differ from static cutting, allowing the effective cutting angle to exceed the static bit relief angle and achieve the required incident angles for optimal cutting hole geometry
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
Accurate and efficient formation of cutting holes with larger incident angles, reducing machining time and preventing burrs, thus enhancing the quality of microlens arrays.
Implementation Method 1
a rotary device configured to rotate a cylindrical or columnar roll in a circumferential direction and including a rotary encoder that output a signal corresponding to a rotational position of the roll
Implementation Method 2
a cutting tool stage movable in a radial direction of the roll, the cutting tool stage being configured to hold a spindle unit reciprocatable in the radial direction of the roll
Implementation Method 3
cutting the predetermined cutting portions once or multiple times with the reciprocating cutting blade at a predetermined cutting depth
Data Source
AI summary
A roll manufacturing apparatus includes a rotary device including a rotary encoder, a cutting tool stage that holds a spindle unit, which includes a rotatable cutting blade, reciprocatably in a radial direction of a roll and is movable in the radial direction of the roll, a signal generator that generates, based on signals output from the rotary encoder, a control waveform indicating a movement pattern to reciprocate the cutting blade at positions corresponding to predetermined cutting portions, and a controller that moves the cutting tool stage so that a cutting process of reciprocating the cutting blade in the radial direction of the roll while rotating the cutting blade, according to the control waveform, to perform cutting once or multiple times with the cutting blade at a predetermined cutting depth is performed multiple times.