Process Optimization for Ultra-Precision Machining of HUD Freeform Surface Mold Cores Based on Slow Tool Servo
Tianji Xing, Naiming Qi, Huanming Gao, Longkun Xu, Xuesen Zhao, Tao Sun
TL;DR
This paper presents an optimized process for manufacturing high-precision freeform mold cores used in vehicle HUD systems, improving accuracy and surface quality.
Contribution
A systematic framework integrating design, tool path planning, and vibration analysis for ultra-precision machining of HUD freeform surfaces.
Findings
A hybrid trajectory planning method improved tool path smoothness and accuracy in SPDT STS processes.
Z-axis vibration was quantitatively shown to affect surface roughness and waviness.
High-precision mold cores were successfully fabricated, validating the proposed process.
Abstract
With the rapid development of Head-Up Display (HUD) technology for vehicles, optical freeform mirrors, as its core optical components, are crucial for achieving system compactness and high imaging quality. However, their complex surface shapes and large-aperture characteristics pose significant challenges to ultra-precision manufacturing. This study presents a systematic optimization framework for the ultra-precision machining of HUD optical freeform mold cores, integrating surface design, tool path planning, vibration analysis, and process parameter optimization. Firstly, based on the XY polynomial freeform surface model, an off-axis three-mirror HUD system was designed, and the surface parameters and machining dimensions of the mold core were determined. For the Single-Point Diamond Turning (SPDT) Slow Tool Servo (STS) process, a hybrid trajectory planning method combining equidistant…
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Taxonomy
TopicsAdvanced Surface Polishing Techniques · Advanced machining processes and optimization · Advanced Measurement and Metrology Techniques