FLY-CUTTING HEAD, SYSTEM AND METHOD, AND TOOLING AND SHEETING PRODUCED THEREWITH

摘要

A fly-cutting system is disclosed, and in particular one that comprises a dynamically-controllable actuator for controlling the position, orientation, or both position and orientation of a cutting element carried by a fly-cutting head. In certain embodiments, the actuator can adjust the position or orientation of a cutting element, or both, hundreds or thousands of times per second, enabling precise control over the shape of features formed by the cutting element in a surface of a workpiece.

主权项

1. A method of manufacturing a microreplication tool, the method comprising:
sending, with a control system, a first set of electronic signals to operate a motorized spindle to rotate a cylindrical workpiece mounted to the motorized spindle; sending, with the control system, a second set of electronic signals to operate a continuously rotatable fly-cutting head to form one or more features in the workpiece, the fly-cutting head being rotatable about an axis of rotation, wherein the fly cutting head includes:
a cutting element mounted to an outer radius of the fly-cutting head; anda dynamically-controllable actuator, positioned between the axis of rotation and the cutting element and radially spaced from the axis of rotation; monitoring, with the control system, angular positions of the fly-cutting head while operating the fly-cutting head; sending, based on the monitored angular positions of the fly-cutting head, with the control system, a third set of electronic signals to operate the dynamically-controllable actuator to trace a controllable, predetermined cutting path relative to the position and rotation of the workpiece by changing a position of the cutting element relative to the fly-cutting head during a cutting operation.