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: 0° 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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