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Theoretical and experimental research on error analysis and optimization of tool path in fabricating aspheric compound eyes by precision micro milling

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Abstract

Structure design and fabricating methods of three-dimensional (3D) artificial spherical compound eyes have been researched by many scholars. Micro-nano optical manufacturing is mostly used to process 3D artificial compound eyes. However, spherical optical compound eyes are less at optical performance than the eyes of insects, and it is difficult to further improve the imaging quality of compound eyes by means of micro-nano optical manufacturing. In this research, nonhomogeneous aspheric compound eyes (ACEs) are designed and fabricated. The nonhomogeneous aspheric structure is applied to calibrate the spherical aberration. Micro milling with advantages in processing three-dimensional micro structures is adopted to manufacture ACEs. In order to obtain ACEs with high imaging quality, the tool paths are optimized by analyzing the influence factors consisting of interpolation allowable error, scallop height and tool path pattern. In the experiments, two kinds of ACEs are manufactured by micro-milling with different too path patterns and cutting parameter on the miniature precision five-axis milling machine tool. The experimental results indicate that the ACEs of high surface quality can be achieved by circularly milling small micro-lens individually with changeable cutting depth. A prototype of the aspheric compound eye (ACE) with surface roughness (R a) below 0.12 μm is obtained with good imaging performance. This research ameliorates the imaging quality of 3D artificial compound eyes, and the proposed method of micro-milling can improve surface processing quality of compound eyes.

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Authors and Affiliations

  1. Center for Precision Engineering, Harbin Institute of Technology, Harbin, 150001, China

    Mingjun Chen, Yong Xiao, Wenlan Tian, Chunya Wu & Xin Chu

Authors
  1. Mingjun Chen
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  2. Yong Xiao
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  3. Wenlan Tian
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  4. Chunya Wu
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  5. Xin Chu
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Corresponding author

Correspondence to Mingjun Chen.

Additional information

Supported by National Natural Science Foundation of China (Grant No. 50935003), and National Numerical Control Major Projects of China (Grant No. 2013ZX04001000215)

CHEN Mingjun, born in 1971, is currently a professor at Harbin Institute of Technology, China. He received his PhD degree from Harbin Institute of Technology, China, in 2001. His research interests include ultra-precision machining and micro-nano manufacturing technology.

XIAO Yong, born in 1988, is currently a PhD candidate at Mechanical Manufacturing and Automation, Harbin Institute of Technology, China. He received his master degree of engineering in Harbin Institute of Technology, China, in 2012. His research interests include ultra-precision machining.

TIAN Wenlan, born in 1987, is currently an engineer at Changchun FAW-Volkswagen, China. She received her master degree of engineering from Harbin Institute of Technology, China, in 2012.

WU Chunya, born in 1982, is a lecturer at Harbin Institute of Technology, China. She received her master degree of engineering in Harbin University of Science and Technology, China, in 2008. Her research interests include ultra-precision machining and micro-nano manufacturing technology.

CHU Xin, born in 1982, is currently an engineer at Southwest China Research Institute of Electronic Equipment, China. He received his master degree of engineering in Harbin Institute of Technology, China, in 2011.

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Chen, M., Xiao, Y., Tian, W. et al. Theoretical and experimental research on error analysis and optimization of tool path in fabricating aspheric compound eyes by precision micro milling. Chin. J. Mech. Eng. 27, 558–566 (2014). https://doi.org/10.3901/CJME.2014.03.558

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  • DOI: https://doi.org/10.3901/CJME.2014.03.558

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