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High speed lens array for automotive headlamp mold

Goal:
Demonstrate high speed machining of a lens array on nickel plated steel

Process:
Use a Nanoform® X (Freeform L, Nanoform 700, or Nanoform L 1000) and Fast Tool Servo (FTS500) to machine an array of concave asheres on an aspheric nickel plated steel mold for automotive headlamps

*also applicable to Nanoform® 700, Nanoform® L 1000

FTS Details:
Peak acceleration: 200 m/sec2
Travel: 500 µm
Typical form: < 0.3 µm PV
Typical finish: < 5 nm Ra

Part Details:
Material: NiP
Size: 65 x 55 mm
Shape: Concave asphere

Tool Details:
Radius: 0.505 mm
Rake angle:

Process Details:
Spindle speed: 500 mm/min (constant surface speed)
Feed per revolution: 4 µm/rev
Coolant: OMS

 
                                                           Setup Photo


                                                               Part Photo

Results:
Machining Time: 3 hrs.
Surface finish: 1.74 nm Ra (0.08 mm gaussian filter) 
2.15 nm Rq (0.08 mm gaussian filter)
Cosmetics: Good
Form accuracy: < 1 µm PV

Metrology:



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