CN113732638A - Machining method of mold core with micro truncated pyramid array on surface - Google Patents
Machining method of mold core with micro truncated pyramid array on surface Download PDFInfo
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- CN113732638A CN113732638A CN202111086033.9A CN202111086033A CN113732638A CN 113732638 A CN113732638 A CN 113732638A CN 202111086033 A CN202111086033 A CN 202111086033A CN 113732638 A CN113732638 A CN 113732638A
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Abstract
The invention discloses a processing method of a mold core with a micro truncated pyramid array on the surface, which comprises the following steps: s1, taking a metal workpiece, and processing the surface of the metal workpiece to a smooth plane; s2, performing array machining of a linear path on the machined smooth plane along a first direction by using a machining tool to obtain a primary machined surface, wherein the array machining is engraving or planing; s3, rotating the machining tool according to an angle alpha, wherein the angle alpha is 80-100 degrees, and then performing array machining on a snake-shaped path on the primary machining surface along a second direction by utilizing the machining tool, so that a micro truncated pyramid array is formed on the surface of the metal workpiece, a mold core with the micro truncated pyramid array on the surface is obtained, and the array machining is engraving or planing. The mold core with the micro truncated pyramid array on the surface is prepared by the method, the processing efficiency is greatly improved, the processing process is greatly simplified, and the precision of the obtained micro truncated pyramid array appearance can be effectively ensured.
Description
Technical Field
The invention relates to the field of microstructure array processing, in particular to a method for manufacturing a mold core with a micro truncated pyramid array on the surface for a road traffic reflective membrane.
Background
The microprism reflecting film is manufactured by utilizing the refraction and total reflection principle of a microprism array structure, the inner side surface of the microprism reflecting film is arrayed with a fine pyramid structure through a micro-nano duplicating and transferring technology, when an external illumination light source irradiates the reflecting film, incident light can be reflected back along the incident direction of the light through multiple reflection and refraction of the pyramid structure inside the reflecting film. The LED light source has the advantages of no need of built-in power supply or light source, no stray light interference of reflected light, strong warning property in dark environment, high identification degree, energy conservation and environmental protection, and is widely applied to the fields of road traffic safety facilities, vehicles and personal active protective devices and used as decorative materials in shoes, hats, bags and the like.
The mold core with the microstructure array on the surface is a key core for producing the microprism reflective film, and the shape, the size and the processing precision of the microstructure array on the mold core determine the reflective performance of the reflective film obtained by copying. The microprism reflective film usually adopts a mold core with a surface array provided with a micro-triangular pyramid, the mold core processing technology is relatively simple and mature, only a cutter needs to be used for planing the surface of a workpiece along one direction during processing, the workpiece rotates for 3 times according to a design angle, and each direction is two-dimensional planing processing. The reflective film produced by the mold core has greatly improved reflective performance compared with the traditional glass bead type reflective film, greatly improved identifiability in dark environment and greatly prolonged identification distance.
With the great change of modern urban environment, urban night light sources are complex and road conditions are complex and changeable; the continuous expansion of highway lanes, the great increase of traffic flow and the influence of external environmental factors such as sand, dust, haze and the like all put forward new requirements on the reflective performance and the recognizable performance of the reflective film, and the reflective film is required to have better retro-reflection performance on light incident at a long distance and a large angle so as to enhance the capability of remote discovery and large-angle recognition of markers. The effective reflective aperture of the reflective film with the micro-triangular-cone array structure only occupies about 67% of the total reflective area, which seriously restricts the capability of remote finding and large-angle identification. The part of the micro triangular pyramid which cannot achieve light reflection is cut and spliced again to form an array of the micro truncated pyramid, and the reflection efficiency of the reflection film with the array structure can reach 100% theoretically, so that the reflection film has the capabilities of remote discovery and large-angle identification. However, the conventional two-dimensional planing method for machining the micro-triangular pyramid array structure cannot machine the micro-truncated pyramid array on the surface of a workpiece to manufacture the mold core.
At present, the similar structures are processed at home and abroad by processing microstructures one by one on the tops of a plurality of metal sheets and then splicing the metal sheets. For example, US patent No. US6767102B1, chinese patent application No. CN97196930.2, US patent No. US7329012B2, and chinese patent application No. CN200480006052 all disclose methods for manufacturing a mold core having an array of micro-truncated pyramids on the surface by processing microstructures at the top of a metal sheet and then splicing the microstructures. The requirements on the thickness uniformity, the smoothness, the rigidity and the like of the metal sheet are very high by the method, and suitable processing sheets are difficult to obtain; during processing, each metal sheet needs to be cut one by one to process corresponding shapes, the processing period is long, and the precision requirement on a tool clamp used for processing is very high; after the single metal sheets are processed, the metal sheets need to be spliced one by one at least hundreds of times, a high-precision tool fixture needs to be adopted for splicing each time to ensure splicing precision, a final mold core can be obtained, the time of nearly two months needs to be spent at least in the front and at the back, the efficiency is low, and the quality of the mold core is difficult to guarantee. And the splicing error at the later stage easily causes the appearance and the size of the micro truncated pyramid to change, so that the reflective performance of the reflective film produced by the mold core cannot meet the design requirement. Generally, the processing method has the advantages of complex process, extremely high requirement on materials, and low processing efficiency and qualified rate.
Disclosure of Invention
Aiming at the defects of complex process, long processing period, low efficiency, easy change of the appearance and the size of the micro truncated pyramid caused by splicing errors and the like caused by the fact that the micro truncated pyramid is formed by adopting a splicing method in the prior art, the invention provides a novel processing method of a mold core with a micro truncated pyramid array on the surface.
In order to solve the technical problems, the invention is realized by the following technical scheme:
a processing method of a mold core with a micro truncated pyramid array on the surface comprises the following steps:
s1, taking a metal workpiece, and processing the surface of the metal workpiece to a smooth plane;
s2, performing array machining of a linear path on the machined smooth plane along a first direction by using a machining tool to obtain a primary machined surface, wherein the array machining is carving or planing;
s3, rotating the machining tool according to an angle alpha which is 80-100 degrees, and then performing array machining on the snake-shaped path on the primary machining surface along the second direction by using the machining tool, so that a micro truncated pyramid array is formed on the surface of the metal workpiece, a mold core with the micro truncated pyramid array on the surface is obtained, and the array machining is carving or planing.
Compared with the existing splicing method that each metal sheet needs to be cut respectively and then spliced piece by piece, and each metal sheet needs to have extremely high splicing precision, the method has the advantages that the processing efficiency is greatly improved, and the processing process is greatly simplified; the invention can process the metal workpiece integrally but not by sheets, can obtain the required complete morphology without secondary splicing, and can effectively ensure the precision of the obtained micro truncated pyramid array morphology.
Preferably, in the processing method of the mold core with the micro-truncated pyramid array on the surface, the serpentine path includes a left folding line and a right folding line, the left folding line and the right folding line are sequentially connected, an included angle β between the left folding line and the right folding line is 120 °, and the left folding line and the right folding line are equal in length.
Through the structure of above snakelike route, can once only process out a plurality of face types, promote machining efficiency.
Preferably, in the method for processing a mold core having a micro truncated pyramid array on a surface, in step S2, the specific steps of the array processing are as follows:
a1, processing the processing cutter along the smooth plane in a first direction, and cutting a first groove;
a2, lifting the machining cutter and separating the machining cutter from the metal workpiece, and then returning the machining cutter to the initial position;
a3, translating the processing cutter to make the edge of the processing cutter aligned with the edge of the first cut groove, then processing along the first direction to cut the next same first groove;
a4, repeating the steps A1-A3 until the machining tool finishes machining the smooth plane;
in step S3, the array processing specifically includes:
b1, processing the processing cutter along the primary processing surface in a second direction, and cutting a second groove;
b2, lifting the machining cutter to separate the machining cutter from the metal workpiece, and then returning the machining cutter to the initial position;
b3, translating the machining cutter to enable the edge of the machining cutter to be aligned with the edge of the cut second groove, then machining along a second direction, and cutting the next same second groove;
b4, repeating the steps B1-B3 until the machining tool finishes machining the primary machined surface.
Through the steps, on one hand, the large-size mold core with the micro truncated pyramid array can be obtained at one time, and the processing efficiency is improved; on the other hand, the appearance machining precision can be effectively guaranteed, and therefore the optical performance of the whole mold core is improved.
Preferably, in the method for processing a mold core having a micro-truncated pyramid array on a surface, the width of the first groove and the second groove is 0.05mm to 2mm, the depth of the first groove and the second groove is 0.01mm to 1mm, and the first groove and the second groove have the same width and the same depth.
Within the width and depth range, the production efficiency of the microstructure copying of the working mold belt made of the mold core on a high polymer film material can be improved, the thickness of the film is reduced, and the production cost is saved.
Preferably, in the method for machining a mold core having a surface with a micro truncated pyramid array as described above, in step S2, the included angle θ of the machining tool is in the range of 30 ° to 150 °.
In the angle range, the waste chips generated in the machining process can be discharged, the pollution to the mold core is reduced, and meanwhile, the optical performance of the mold core can be better ensured in the angle range.
Preferably, in the method for processing a mold core having a micro truncated pyramid array on a surface thereof, the metal workpiece is made of copper, a nickel-phosphorus alloy or electroless nickel.
The material is convenient for cutting, can reduce the wearing and tearing of processing cutter, and is less to the life influence of processing cutter, can promote the uniformity and the machining precision of the appearance that processing obtained simultaneously.
Preferably, in the method for processing a mold core having a surface with an array of truncated pyramids, in step S1, the smooth flat surface has a finish of 5nm to 100 nm.
The fineness is within the range, and the size and shape precision of the obtained micro truncated pyramid array can be further ensured.
Preferably, in the method for machining a mold core having a micro truncated pyramid array on a surface thereof, the machining tool is a sharp knife or a groove knife made of single-point fine steel stones.
The processing cutter adopts above material and cutter type, and it is that single-point finish steel stone material matter durability is good on the one hand, can guarantee the precision and the uniformity of whole processing appearance, and on the other hand sharp sword or groove sword are enough sharp, can further promote cutting efficiency.
Preferably, in the method for processing a mold core having a micro truncated pyramid array on a surface thereof, the metal workpiece has a length and a width of 5cm × 5cm to 10cm × 10 cm.
Within the size range, the processing precision can be guaranteed, the large-size mold core with the micro truncated pyramid array can be obtained, and the production efficiency is improved.
Preferably, in the method for processing a mold core having a micro truncated pyramid array on a surface thereof, in step S3, after the micro truncated pyramid array is formed on the surface of the metal workpiece, the mold core is placed in a cleaning tank having a neutral cleaning agent, and the surface of the mold core is cleaned by ultrasonic waves.
Through the steps, the pollution on the surface of the mold core can be effectively removed, the corrosion to the surface of the micro truncated pyramid array can be reduced by using a neutral cleaning agent, and the smoothness of the surface of the micro truncated pyramid array can be ensured.
Compared with the prior art that the required mold core can be obtained only by adopting a splicing method in about two months, the method can obtain the mold core with the micro truncated pyramid array on the surface only in about one week, greatly improves the processing efficiency and reduces the processing difficulty.
Drawings
FIG. 1 is a schematic structural view of a metal workpiece according to the present invention;
FIG. 2 is a first schematic structural view of the metal workpiece with the first groove cut therein according to the present invention;
FIG. 3 is a first schematic structural diagram of a metal workpiece with a rough surface according to the present invention;
FIG. 4 is a first schematic structural view of the metal workpiece with the second groove cut therein according to the present invention;
FIG. 5 is a first structural diagram of a mold core with a micro-truncated pyramid array on the surface according to the present invention;
FIG. 6 is a top view of a core having an array of truncated pyramids on its surface according to the present invention;
FIG. 7 is an enlarged view of a portion A of FIG. 6;
FIG. 8 is a schematic diagram of a serpentine path according to the present invention;
FIG. 9 is a schematic view of the machining tool of the present invention;
FIG. 10 is a second schematic structural view of the metal workpiece with the first groove cut therein according to the present invention;
FIG. 11 is a second schematic structural view of a metal workpiece with a rough surface according to the present invention;
FIG. 12 is a second schematic structural view of the metal workpiece with the second groove cut therein according to the present invention;
FIG. 13 is a second structural diagram of the mold core with the array of truncated pyramids on the surface obtained by the present invention.
Detailed Description
The invention will be described in further detail with reference to the following figures 1-13 and the detailed description, which are not intended to limit the invention:
example 1
As shown in fig. 1 to 9, a method for processing a mold core having a surface with an array of micro-truncated pyramids includes the following steps:
s1, taking a metal workpiece 1, and processing the surface of the metal workpiece 1 to a smooth plane 11;
s2, performing array machining of a linear path on the machined smooth plane 11 along the first direction 2 by using a machining tool to obtain a primary machined surface 4, wherein the array machining is carving or planing;
s3, rotating the machining tool according to an angle alpha, wherein the angle alpha is 90 degrees, and then performing array machining on the snake-shaped path 8 on the primary machining surface 4 along the second direction 3 by using the machining tool, so that a micro truncated pyramid array 7 is formed on the surface of the metal workpiece 1, and a mold core with the micro truncated pyramid array 7 on the surface is obtained, wherein the array machining is carving or planing.
Preferably, the serpentine path 8 includes a left folding line 81 and a right folding line 82, the left folding line 81 and the right folding line 82 are sequentially connected, an included angle β between the left folding line 81 and the right folding line 82 is 120 °, and the left folding line 81 and the right folding line 82 are equal in length.
Preferably, in step S2, the array processing specifically includes:
a1, processing the processing cutter along the smooth plane 11 in the first direction 2 to cut a first groove 5;
a2, lifting the machining cutter to separate the machining cutter from the metal workpiece 1, and then returning the machining cutter to the initial position;
a3, translating the processing cutter to make the edge of the processing cutter aligned with the edge of the cut first groove 5, then processing along the first direction 2 to cut the next same first groove 5;
a4, repeating the steps A1-A3 until the machining tool finishes machining the smooth plane 11;
in step S3, the array processing specifically includes:
b1, processing the processing cutter along the primary processing surface 4 in the second direction 3 to cut a second groove 6;
b2, lifting the machining cutter to separate the machining cutter from the metal workpiece 1, and then returning the machining cutter to the initial position;
b3, translating the machining tool to make the edge of the machining tool align with the edge of the cut second groove 6, and then machining along the second direction 3 to cut the next same second groove 6;
b4, repeating the steps B1-B3 until the machining tool finishes machining the primary machined surface 4.
Preferably, the widths of the first groove 5 and the second groove 6 are 0.05mm, the depths of the first groove 5 and the second groove 6 are 0.01mm, and the widths of the first groove 5 and the second groove 6 are equal and the depths are equal.
Preferably, in step S2, the included angle θ of the machining tool is in the range of 30 °.
Preferably, the metal workpiece 1 is made of copper, nickel-phosphorus alloy or electroless nickel.
Preferably, in step S1, the smooth flat surface 11 has a finish of 5 nm.
Preferably, the machining tool is a sharp knife or a slot knife made of single-point polished steel stone.
Preferably, the metal workpiece 1 has a length and a width of 5cm × 5 cm.
Preferably, in step S3, after the micro truncated pyramid array 7 is formed on the surface of the metal workpiece 1, the core is placed in a cleaning tank having a neutral cleaning agent, and the surface of the core is cleaned by ultrasonic waves.
Example 2
As shown in fig. 8 to 13, a method for processing a mold core having a surface with an array of micro-truncated pyramids includes the following steps:
s1, taking a metal workpiece 1, and processing the surface of the metal workpiece 1 to a smooth plane 11;
s2, performing array machining of a linear path on the machined smooth plane 11 along the first direction 2 by using a machining tool to obtain a primary machined surface 4, wherein the array machining is carving or planing;
s3, rotating the machining tool according to an angle alpha, wherein the angle alpha is 100 degrees, and then performing array machining on the snake-shaped path 8 on the primary machining surface 4 along the second direction 3 by using the machining tool, so that a micro truncated pyramid array 7 is formed on the surface of the metal workpiece 1, and a mold core with the micro truncated pyramid array 7 on the surface is obtained, wherein the array machining is carving or planing.
Preferably, the serpentine path 8 includes a left folding line 81 and a right folding line 82, the left folding line 81 and the right folding line 82 are sequentially connected, an included angle β between the left folding line 81 and the right folding line 82 is 120 °, and the left folding line 81 and the right folding line 82 are equal in length.
Preferably, in step S2, the array processing specifically includes:
a1, processing the processing cutter along the smooth plane 11 in the first direction 2 to cut a first groove 5;
a2, lifting the machining cutter to separate the machining cutter from the metal workpiece 1, and then returning the machining cutter to the initial position;
a3, translating the processing cutter to make the edge of the processing cutter aligned with the edge of the cut first groove 5, then processing along the first direction 2 to cut the next same first groove 5;
a4, repeating the steps A1-A3 until the machining tool finishes machining the smooth plane 11;
in step S3, the array processing specifically includes:
b1, processing the processing cutter along the primary processing surface 4 in the second direction 3 to cut a second groove 6;
b2, lifting the machining cutter to separate the machining cutter from the metal workpiece 1, and then returning the machining cutter to the initial position;
b3, translating the machining tool to make the edge of the machining tool align with the edge of the cut second groove 6, and then machining along the second direction 3 to cut the next same second groove 6;
b4, repeating the steps B1-B3 until the machining tool finishes machining the primary machined surface 4.
Preferably, the widths of the first groove 5 and the second groove 6 are 0.05mm, the depths of the first groove 5 and the second groove 6 are 0.01mm, and the widths of the first groove 5 and the second groove 6 are equal and the depths are equal.
Preferably, in step S2, the included angle θ of the machining tool is in the range of 30 °.
Preferably, the metal workpiece 1 is made of copper, nickel-phosphorus alloy or electroless nickel.
Preferably, in step S1, the smooth flat surface 11 has a finish of 5 nm.
Preferably, the machining tool is a sharp knife or a slot knife made of single-point polished steel stone.
Preferably, the metal workpiece 1 has a length and a width of 5cm × 5 cm.
Preferably, in step S3, after the micro truncated pyramid array 7 is formed on the surface of the metal workpiece 1, the core is placed in a cleaning tank having a neutral cleaning agent, and the surface of the core is cleaned by ultrasonic waves.
Example 3
A processing method of a mold core with a micro truncated pyramid array on the surface comprises the following steps:
s1, taking a metal workpiece 1, and processing the surface of the metal workpiece 1 to a smooth plane 11;
s2, performing array machining of a linear path on the machined smooth plane 11 along the first direction 2 by using a machining tool to obtain a primary machined surface 4, wherein the array machining is carving or planing;
s3, rotating the machining tool according to an angle alpha, wherein the angle alpha is 80 degrees, and then performing array machining on the snake-shaped path 8 on the primary machining surface 4 along the second direction 3 by using the machining tool, so that a micro truncated pyramid array 7 is formed on the surface of the metal workpiece 1, and a mold core with the micro truncated pyramid array 7 on the surface is obtained, wherein the array machining is carving or planing.
When the angle α is 80 degrees, the morphology of the resulting core having a surface with the array of micro-truncated pyramids 7 is identical to that of the core having a surface with the array of micro-truncated pyramids 7 obtained in example 2.
The other embodiment is the same as example 2.
Example 4
Preferably, the widths of the first groove 5 and the second groove 6 are 2mm, the depths of the first groove 5 and the second groove 6 are 1mm, and the widths of the first groove 5 and the second groove 6 are equal and equal.
Preferably, in step S2, the included angle θ of the machining tool is in the range of 150 °.
Other embodiments are the same as examples 1 to 3.
Example 5
Preferably, the width of the first groove 5 and the second groove 6 is 1mm, the depth of the first groove 5 and the second groove 6 is 0.5mm, and the width of the first groove 5 and the depth of the second groove 6 are equal.
Preferably, in step S2, the included angle θ of the machining tool is in a range of 90 °.
Other embodiments are the same as examples 1 to 3.
Example 6
Preferably, in step S1, the smooth flat surface 11 has a finish of 100 nm.
Other embodiments are the same as examples 1 to 5.
Example 7
Preferably, in step S1, the smooth flat surface 11 has a finish of 50 nm.
Other embodiments are the same as examples 1 to 5.
Example 8
Preferably, the metal workpiece 1 has a length and a width of 10cm × 10 cm.
Other embodiments are the same as examples 1 to 7.
Example 9
Preferably, the metal workpiece 1 has a length and a width of 7cm × 7 cm.
Other embodiments are the same as examples 1 to 7.
In summary, the above-mentioned embodiments are only preferred embodiments of the present invention, and all equivalent changes and modifications made within the scope of the claims of the present invention should be covered by the present invention.
Claims (10)
1. A processing method of a mold core with a micro truncated pyramid array on the surface is characterized in that: the method comprises the following steps:
s1, taking a metal workpiece (1), and processing the surface of the metal workpiece (1) to a smooth plane (11);
s2, performing array machining of a linear path on the machined smooth plane (11) along the first direction (2) by using a machining tool to obtain a primary machined surface (4), wherein the array machining is carving or planing;
s3, rotating the machining tool according to an angle alpha, wherein the angle alpha is 80-100 degrees, and then performing array machining on the snake-shaped path (8) on the primary machining surface (4) along the second direction (3) by using the machining tool, so that a micro truncated pyramid array (7) is formed on the surface of the metal workpiece (1), a mold core with the micro truncated pyramid array (7) on the surface is obtained, and the array machining is carving or planing.
2. The method of claim 1, wherein the mold core has an array of truncated pyramids on its surface, and the method comprises: serpentine path (8) include left broken line (81), right broken line (82), left broken line (81), right broken line (82) connect gradually, contained angle beta between left broken line (81), right broken line (82) is 120, left broken line (81), right broken line (82) isometric.
3. The method of claim 1, wherein the mold core has an array of truncated pyramids on its surface, and the method comprises: in step S2, the array processing specifically includes:
a1, processing the processing cutter along the smooth plane (11) in the first direction (2) to cut out a first groove (5);
a2, lifting the machining cutter to separate the machining cutter from the metal workpiece (1), and then retracting the machining cutter to the initial position;
a3, translating the processing cutter to make the edge of the processing cutter aligned with the edge of the first cut groove (5), and then processing along the first direction (2) to cut the next same first groove (5);
a4, repeating the steps A1-A3 until the machining tool finishes machining the smooth plane (11);
in step S3, the array processing specifically includes:
b1, processing the processing cutter along the primary processing surface (4) in the second direction (3) to cut a second groove (6);
b2, lifting the machining cutter to separate the machining cutter from the metal workpiece (1), and then retracting the machining cutter to the initial position;
b3, translating the machining tool to enable the edge of the machining tool to be aligned with the edge of the cut second groove (6), and then machining along the second direction (3) to cut the next same second groove (6);
b4, repeating the steps B1-B3 until the machining tool finishes machining the primary machining surface (4).
4. The method of claim 3, wherein the mold core has an array of truncated pyramids on its surface, and the method comprises: the width of the first groove (5) and the width of the second groove (6) are 0.05 mm-2 mm, the depth of the first groove (5) and the depth of the second groove (6) are 0.01 mm-1 mm, and the first groove (5) and the second groove (6) are equal in width and equal in depth.
5. The method of claim 1, wherein the mold core has an array of truncated pyramids on its surface, and the method comprises: in the step S2, the included angle θ of the machining tool is in the range of 30 ° to 150 °.
6. The method of claim 1, wherein the mold core has an array of truncated pyramids on its surface, and the method comprises: the metal workpiece (1) is made of copper or nickel-phosphorus alloy or electroless nickel.
7. The method of claim 1, wherein the mold core has an array of truncated pyramids on its surface, and the method comprises: in the step S1, the smooth surface (11) has a smooth finish of 5nm to 100 nm.
8. The method of claim 1, wherein the mold core has an array of truncated pyramids on its surface, and the method comprises: the processing cutter is a sharp knife or a groove knife made of single-point fine steel stones.
9. The method of claim 1, wherein the mold core has an array of truncated pyramids on its surface, and the method comprises: the length and the width of the metal workpiece (1) are 5cm multiplied by 5 cm-10 cm multiplied by 10 cm.
10. The method of claim 1, wherein the mold core has an array of truncated pyramids on its surface, and the method comprises: in the step S3, after the micro truncated pyramid array (7) is formed on the surface of the metal workpiece (1), the mold core is placed in a cleaning tank with a neutral cleaning agent, and the surface of the mold core is cleaned by ultrasonic waves.
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