Investigation on an innovative approach for clamping contact lens mould inserts in ultraprecision machining using an ada
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ORIGINAL ARTICLE
Investigation on an innovative approach for clamping contact lens mould inserts in ultraprecision machining using an adaptive precision chuck and its application perspectives Ali Khaghani1 · Kai Cheng1 Received: 23 March 2020 / Accepted: 21 August 2020 © Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract This paper presents an innovative approach for the accuracy and precision analysis of the ultraprecision machining systems, further supported in experiment trials and data on ultraprecision machining of contact lens mould inserts. Statistical models are developed for analysing the measurement data of geometrical runout of the insert components before and after the ultraprecision machining. The maximum standard deviation of 16 nm and 5 nm residual in geometrical runout is achieved after ultraprecision machining of all 26 contact lens mould insert components. The system obtained 76% of accuracy and precision confident with positioning range of 2–40nm, according to data collected from the experimental trials. The surface finishing is very encouraging with the maximum 4 nm of Ra and 43 nm of PV as achieved from the experiments. Furthermore, it has been found that the clamping stiffness of the smart chuck has a positive effect on the accuracy of the machining system. The experimental trial results show the smart chuck can be used as a universal highly effective device, particularly for ultraprecision production purpose. Keywords Ultraprecision machining · Contact lenses mould inserts · Smart chuck · Machining dynamics · High precision surface · Ultraprecision machining system
1 Introduction Ultraprecision machining (UPM) is well-known as an enabling technology for manufacturing high-resolution optical components and devices. In comparison with conventional machining, dynamic performance and efficiency of ultraprecision machining often have a limitation due to the stability required for the high precision process. Over the last decade or so, however, the ultraprecision machining technology has been experiencing significant developments and advances in machine design and efficiency improvement against the increasing requirement for industrial scale ultraprecision production [1–5].
Ali Khaghani
[email protected] Kai Cheng [email protected] 1
Brunel University London, Kingstone Lane, Uxbridge, UB8 3PH, UK
Ultraprecision machining of freeform surfaces through diamond turning is becoming one of the most reliable enabling processes, as it can deliver high accuracy and efficiency by integrating distinctive precision engineering techniques of fast tool servo (FTS) and slow tool servo (STS). Freeform surfaces are increasingly employed in precision engineering industries, including automotive, optics, electronics, aerospace and biomedical engineering industries [6, 7]. In its ultraprecision machining process chain, it normally starts by using a CAD/CAM tool to generate the toolpath trajectory. The toolpath generation can base on the real form of the freeform surface, and/or us
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