Investigation on High-performance Non-contact Shape Profiling Polishing for Array Diffuser Mold

doi:10.3901/JME.2024.01.127

Abstract

Abstract: Diffusers is widely used in projection, lighting, and imaging systems because of its excellent beam diffusion performance. Polishing can effectively remove the tool marks on the mold surface, thereby improving its performance. However, the existing polishing methods often failed to improve surface quality while maintaining the shape accuracy. To solve this problem, a non-contact shape profiling polishing method using non-Newtonian fluids is proposed in this paper to achieve ultra-precision processing of array microstructured surface mold. The effects of working gap and tool speed on material removal is studied by finite element simulation and mathematical modeling. The relationship between different processing methods and component properties is indirectly characterized by optical properties test. The surface morphology, roughness, and shape accuracy of the mold before and after polishing are analyzed. The results show that polishing has a significant positive effect on the diffuser performance, and the proposed high-performance non-contact shape profiling polishing method can improve the mold precision and improve uniform performance of the diffusers. After polishing, the surface roughness of groove microstructured surface is reduced from the initial Ra 164.2 nm to 8.1 nm, less than 0.8 μm shape accuracy are achieved, while the tool marks and burrs are effectively removed. After polishing, the performance of the diffuser is greatly improved, the brightness of the diffuser increased by 40.4%, and the uniformity increased by 67.1%. The proposed non-contact shape profiling polishing method provides an effective technical approach for high-performance optical microstructured surface manufacturing.

Key words: diffusers, array microstructud surface mold, non-contact shape profiling polishing, tool mark remove, shape retention

CLC Number:

TG175

GUO Jiang, ZHANG Pengfei, YANG Zhe, ZHAO Yong, LI Linguang, JING Zhao, ZHANG Meng, PANG Guibing. Investigation on High-performance Non-contact Shape Profiling Polishing for Array Diffuser Mold[J]. Journal of Mechanical Engineering, 2024, 60(1): 127-136.

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