Error compensation of five-axis roller machine tool for manufacturing Fresnel mold

Fresnel optical films can be efficiently produced in large quantities by manufacturing molds on roller machine tools, using Roll-to-Roll manufacturing technology, and copying the microstructure on the roller mold surface to PET films. The accuracy of the mold determines the quality of the optical films. This paper analyzes the manufacturing principle and processing process of a rotating-tool diamond turning roller mold on roller machine tools. Considering turning efficiency and freedom, two tandem rotating axes were added to the traditional three-axis roller machine tool to form a five-axis roller machine tool. The tandem rotating axis adjusts the tool angle so that the cutting edge directly cuts the Fresnel working surface, increasing the processing efficiency and accuracy. In order to improve manufacturing accuracy, this paper uses spinor theory to establish an error model for machine tools. It uses the Fourier amplitude sensitivity test (FAST) to find the five geometric errors. Finally, an error compensation iterative algorithm is proposed, which quickly and accurately calculates the error compensation amount. Experiments were conducted to study the chatter phenomenon during turning and analyze multiple influencing factors that cause cutting chatter. The experimental results revealed that except for the impact of the stiffness of the workpiece-tool system on cutting chatter, other factors have relatively little influence. Enhancing stiffness can significantly reduce the generation of cutting vibration marks and improve the surface quality of the workpieces. Finally, the Fresnel microstructure was turned on the roller mold. As a result, with reasonable process parameters on the surface, the cutting chatter phenomenon was improved, and the error compensation effect was significant, which verified the reliability of the error compensation method.