Development of an analysis system for geometric contour error evaluation in ultra-precision machining for microlens arrays

A basic principle for acquiring precisely shaped machined parts is to create dense tool path data. However, as the density of tool paths increases, the volume of data increases. The significant increase in data consumes more memory and machining time. Therefore, the creation of tool path data of unlimited density is impractical. This paper proposes a contour error evaluation system. The system makes correct decisions based on the expected quality of a workpiece. Specifically, the user creates tool path data by calculating deviations in the contour in relation to variations in the intervals of the tool path. The user can create tool paths by adjusting the amount of tool path data within the desired quality level. Accordingly, before the start of the machining process, the user can predict any machining loss likely to result from the excessive amount of data created in the creation phase. In addition, the tool path data of the proposed system are experimentally compared with the actual shape of a part machined with a microlens array machining system.