Systems And Methods For Machining Materials

• US 20110027032A1
• Filed: 09/18/2009
• Published: 02/03/2011
• Est. Priority Date: 09/18/2008
• Status: Active Grant

• Current Assignee: FLIR Systems Trading Belgium BVBA (Teledyne Technologies Incorporated)
• Original Assignee: FLIR Systems Trading Belgium BVBA (Teledyne Technologies Incorporated)
• Inventors: Keller, David, Brocato, Brett
• Granted Patent: US 9,207,662 B2
• Time in Patent Office: Days
• US Class Current: 409/131
• CPC Class Codes: B23D 7/08 of work-tables
• CPC Class Codes: B23Q 15/013 Control or regulation of feed movement B23Q15/12 takes precedence
• CPC Class Codes: B23Q 5/28 Electric drives
• CPC Class Codes: B24B 13/046 using a pointed tool or scraper-like tool B24B13/015 and B24B13/065 take precedence
• CPC Class Codes: B29D 11/00932 Combined cutting and grinding thereof
• CPC Class Codes: G02B 3/0031 Replication or moulding, e.g. hot embossing, UV-casting, injection moulding
• CPC Class Codes: G02B 5/1819 Plural gratings positioned on the same surface, e.g. array of gratings plural diffractive elements positioned sequentially along the optical path G02B27/4272
• CPC Class Codes: G05B 19/182 characterised by the machine tool function, e.g. thread cutting, cam making, tool direction control G05B19/21 - G05B19/40 take precedence
• CPC Class Codes: G05B 2219/43129 Speed as function of curvature, in curves, corners smaller than in straight line
• CPC Class Codes: G05B 2219/45247 Diamond turning, tool is diamond point
• CPC Class Codes: G05B 2219/50353 Tool, probe inclination, orientation to surface, posture, attitude
• CPC Class Codes: Y10T 409/303752 Process
• CPC Class Codes: Y10T 409/30868 Work support

Abstract

Embodiments of systems, methods, and computer-readable media for machining materials are disclosed. For example, one embodiment of the present invention includes a method for machining a feature on a work piece (100) along a curving tool path having the steps of controlling a relative translational movement between a tool table and the work piece (100) along the curving tool path and controlling a corresponding angle of rotation of the tool table with respect to the work piece (100) to maintain a substantially constant angle between the tool table and the corresponding relative translational movement between the tool table and the work piece (100) along the curving tool path. In another embodiment, a computer-readable media includes code for a carrying out such a method.

Claims

1. A method for machining a feature on a work piece along a curving tool path, comprising:

controlling a relative translational movement between a tool table and the work piece along the curving tool path, comprising controlling a dynamic feed rate of the tool table along the curving tool path to substantially maintain a target centripetal acceleration of the tool table with respect to the work piece; and

controlling a corresponding angle of rotation of the tool table with respect to the work piece to maintain a substantially constant angle between the tool table and the corresponding relative translational movement between the tool table and the work piece along the curving tool path.

2. The method of claim 1, wherein the substantially constant angle comprises a perpendicular relationship.

3. The method of claim 1, further comprising:

determining the corresponding angle of rotation of the tool table at a plurality of positions along the curving tool path based on a set of coordinates defining the plurality of positions along the curving tool path.

5. The method of claim 1, wherein the target centripetal acceleration comprises a constant centripetal acceleration.

6. The method of claim 1, further comprising:

determining the dynamic feed rate of the tool table at a plurality of positions along the curving tool path based on a set of coordinates defining the plurality of positions along the curving tool path.

7. The method of claim 1, further comprising:

determining the dynamic feed rate of the tool table at a plurality of positions along the curving tool path based on a plurality of radii of curvatures along the curving tool path.

8. The method of claim 1, wherein the curving tool path comprises a spiral tool path.

9. The method of claim 1, wherein the curving tool path comprises a rectangular tool path comprising a radiused corner.

10. The method of claim 1, wherein the curving tool path is substantially axisymmetric about a first localized coordinate axis on the work piece.

11. The method of claim 10, wherein the feature comprises a lens feature and the curving tool path further comprises a substantially spiral tool path beginning at the outside edge of the lens feature, following the substantially spiral path with a decreasing radius, and ending at the center of the first localized coordinate axis.

12. The method of claim 1, wherein the feature comprises a refractive lens feature.

13. The method of claim 1, wherein the feature comprises a diffractive lens feature.

14. The method of claim 1, wherein the feature comprises a refractive-diffractive lens feature.

15. The method of claim 14, wherein the work piece comprises a previously-machined refractive lens feature and the refractive-diffractive lens feature is provided by machining a diffractive lens feature onto the work piece such that the diffractive lens feature overlaps at least a portion of the refractive lens feature.

16. The method of claim 1, wherein the method is carried out using a CNC machining apparatus.

4. (canceled)

17. A computer-readable medium comprising program code configured to cause a CNC machining apparatus to execute a method for machining a work piece along a curving tool path, comprising:

code for controlling a relative translational movement between a tool table and the work piece along the curving tool path, comprising code for controlling a dynamic feed rate of the tool table along the curving tool path to substantially maintain a target centripetal acceleration of the tool table with respect to the work piece; and

code for controlling a corresponding angle of rotation of the tool table with respect to the work piece to maintain a substantially constant angle between the tool table and the corresponding relative translational movement between the tool table and the work piece along the curving tool path.

18. The computer-readable medium of claim 17, wherein the substantially constant angle comprises a perpendicular relationship.

20. The computer-readable medium of claim 17, wherein the target centripetal acceleration comprises a constant centripetal acceleration.

19. (canceled)

21. A method for creating a program for a CNC machining apparatus, comprising:

determining an angle of rotation of a tool table with respect to a work piece to maintain a substantially constant angle between the tool table and a corresponding translational movement between the tool table and the work piece at a plurality of positions along a curving tool path;

determining a corresponding dynamic feed rate of the tool table with respect to the work piece at the plurality of positions along the curving tool path to substantially maintain a target centripetal acceleration of the tool table with respect to the work piece; and

formatting the calculated angle of rotation and dynamic feed rate in a form recognized by the CNC machining apparatus.

22. The method of claim 21, wherein determining the angle of rotation of the tool table comprises inputting a set of coordinates defining the plurality of positions along the curving tool path.

23. The method of claim 22, wherein determining the corresponding dynamic feed rate of the tool table comprises:

determining the target centripetal acceleration along the curving tool path;

inputting a set of coordinates defining the plurality of positions along the curving tool path and the angle of rotation of the tool table at the plurality of positions along the curving tool path;

determining a tool path radius of curvature for each of the plurality of positions along the curving tool path; and

determining a tangential velocity for each of the plurality of positions along the curving tool path.

24. A work piece comprising:

a feature scribed while varying an angle of rotation of a tool table with respect to the work piece to maintain a substantially constant angle between the tool table and a corresponding relative translational movement between the tool table and the work piece along a curving tool path.

25. The work piece of claim 24, wherein the substantially constant angle comprises a perpendicular relationship.

26. The work piece of claim 24, wherein the feature was scribed while varying a dynamic feed rate of the tool table with respect to the work piece along the curving tool path to substantially maintain a target centripetal acceleration of the tool table with respect to the work piece.

27. A replication master for use in the production of an array of lenses comprising:

a surface comprising a plurality of features thereon, wherein at least one of the plurality of features was scribed while varying an angle of rotation of a tool table with respect to the replication master to maintain a substantially constant angle between the tool table and a corresponding relative translational movement between the tool table and the replication master along a curving tool path.

28. The replication master of claim 27, wherein the substantially constant angle comprises a perpendicular relationship.

29. The replication master of claim 27, wherein the at least one of the plurality of features was scribed while varying a dynamic feed rate of the tool table with respect to the replication master along the curving tool path to substantially maintain a target centripetal acceleration of the tool table with respect to the replication master.

30. The replication master of claim 27, wherein the at least one of the plurality of features comprises a refractive lens feature.

31. The replication master of claim 27, wherein the at least one of the plurality of features comprises a diffractive lens feature.

32. The replication master of claim 27, wherein the at least one of the plurality of features comprises a refractive-diffractive lens feature

33. A lens formed at least in part by application of a replication master comprising a feature for defining at least a portion of the optical element, wherein the feature was scribed while varying an angle of rotation of a tool table with respect to the replication master to maintain a substantially constant angle between the tool table and a corresponding relative translational movement between the tool table and the replication master along a curving tool path.

34. The lens of claim 33, wherein the feature was scribed while varying a dynamic feed rate of the tool table with respect to the replication master along the curving tool path to substantially maintain a target centripetal acceleration of the tool table with respect to the replication master.