Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23B—TURNING; BORING
  • B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
  • B23B27/14—Cutting tools of which the bits or tips or cutting inserts are of special material
  • B23B27/18—Cutting tools of which the bits or tips or cutting inserts are of special material with cutting bits or tips or cutting inserts rigidly mounted, e.g. by brazing
  • B23B27/20—Cutting tools of which the bits or tips or cutting inserts are of special material with cutting bits or tips or cutting inserts rigidly mounted, e.g. by brazing with diamond bits or cutting inserts
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
  • B23Q15/00—Automatic control or regulation of feed movement, cutting velocity or position of tool or work
  • B23Q15/007—Automatic control or regulation of feed movement, cutting velocity or position of tool or work while the tool acts upon the workpiece
  • B23Q15/14—Control or regulation of the orientation of the tool with respect to the work
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23B—TURNING; BORING
  • B23B29/00—Holders for non-rotary cutting tools; Boring bars or boring heads; Accessories for tool holders
  • B23B29/04—Tool holders for a single cutting tool
  • B23B29/12—Special arrangements on tool holders
  • B23B29/125—Vibratory toolholders
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
  • B23Q15/00—Automatic control or regulation of feed movement, cutting velocity or position of tool or work
  • B23Q15/007—Automatic control or regulation of feed movement, cutting velocity or position of tool or work while the tool acts upon the workpiece
  • B23Q15/08—Control or regulation of cutting velocity
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B81—MICROSTRUCTURAL TECHNOLOGY
  • B81C—PROCESSES OR APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OR TREATMENT OF MICROSTRUCTURAL DEVICES OR SYSTEMS
  • B81C99/00—Subject matter not provided for in other groups of this subclass
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23B—TURNING; BORING
  • B23B2260/00—Details of constructional elements
  • B23B2260/108—Piezoelectric elements
• • G—PHYSICS
  • G05—CONTROLLING; REGULATING
  • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
  • G05B2219/00—Program-control systems
  • G05B2219/30—Nc systems
  • G05B2219/41—Servomotor, servo controller till figures
  • G05B2219/41344—Piezo, electrostrictive linear drive
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T82/00—Turning
  • Y10T82/10—Process of turning
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T82/00—Turning
  • Y10T82/16—Severing or cut-off
  • Y10T82/16426—Infeed means
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T82/00—Turning
  • Y10T82/25—Lathe
  • Y10T82/2512—Lathe having facing tool fed transverse to work
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T82/00—Turning
  • Y10T82/25—Lathe
  • Y10T82/2583—Tool and work rest

Definitions

• microreplication tools are commonly used for extrusion processes, injection molding processes, embossing processes, casting processes, or the like ⁇ to create microreplicated structures.
• the microreplicated structures may comprise optical films, abrasive films, adhesive films, mechanical fasteners having self- mating profiles, or any molded or extruded parts having microreplicated features of relatively small dimensions, such as dimensions less than approximately 1000 microns.
• the microstructures can also be made by various other methods.
• the structure of the master tool can be transferred on other media, such as to a belt or web of polymeric material, by a cast and cure process from the master tool to form a production tool; this production tool is then used to make the microreplicated structure.
• Other methods such as electroforming can be used to copy the master tool.
• Another alternate method to make a light directing-film is to directly cut or machine a transparent material to form the appropriate structures.
• Other techniques include chemical etching, bead blasting, or other stochastic surface modification techniques.
• a first cutting tool assembly includes a tool post and an actuator configured for attachment to the tool post and for electrical communication with a controller.
• a tool tip attached to the actuator is mounted for movement with respect to a work piece to be cut.
• the actuator provides for movement of the tool tip in an x-direction into and out of the work piece, and the tool tip is in discontinuous contact with the work piece during cutting of it.
• a second cutting tool assembly includes a tool post and an actuator configured for attachment to the tool post and for electrical communication with a controller.
• a tool tip attached to the actuator is mounted for movement with respect to a work piece to be cut.
• the actuator provides for movement of the tool tip in an x-direction into and out of the work piece.
• the tool tip is in discontinuous contact with the work piece during cutting, and the assembly can vary a taper-in angle of the tool tip into the work piece and a taper- out angle of the tool tip out of the work piece during the cutting.
• FIG. 1 is a diagram of a cutting tool system for making microstructures in a work piece
• FIG. 2 is a diagram illustrating a coordinate system for a cutting tool
• FIG. 3 is a diagram of an exemplary PZT stack for use in a cutting tool
• FIG. 4 A is a perspective view of a tool tip carrier
• FIG. 4B is a front view of a tool tip carrier for holding a tool tip
• FIG. 4C is a side view of a tool tip carrier
• FIG. 4D is a top view of a tool tip carrier
• FIG. 5 A is a perspective view of a tool tip
• FIG. 5B is a front view of a tool tip
• FIG. 5C is a bottom view of a tool tip
• FIG. 5D is a side view of a tool tip
• FIG. 6 A is a top sectional view of an interrupted cut FTS actuator
• FIG. 6B is a front sectional view illustrating placement of a PZT stack in an actuator
• FIG. 6C is a front view of an actuator
• FIG. 6D is a back view of an actuator
• FIG. 6E is a top view of an actuator
• FIGS. 6F and 6G are side views of an actuator
• FIG. 6H is a perspective view of an actuator
• FIG. 7A is a diagram illustrating an interrupted cut with substantially equal taper-in and taper-out angles into and out of a work piece
• FIG. 7B is a diagram illustrating an interrupted cut with a taper-in angle less than a taper-out angle into and out of a work piece
• FIG. 7C is a diagram illustrating an interrupted cut with a taper-in angle greater than a taper-out angle into and out of a work piece
• FIG. 8 is a diagram conceptually illustrating microstructures that can be made using the cutting tool system having an interrupted cut FTS actuator.
• FIG. 1 is a diagram of a cutting tool system 10 for making microstructures in a work piece.
• Microstructures can include any type, shape, and dimension of structures on, indenting into, or protruding from the surface of an article.
• microstructures created using the actuators and system described in the present specification can have a 1000 micron pitch, 100 micron pitch, 1 micron pitch, or even a sub-optical wavelength pitch around 200 nanometers (ran).
• the pitch for the microstructures can be greater than 1000 microns, regardless as to how they are cut.
• Computer 12 has, for example, the following components: a memory 14 storing one or more applications 16; a secondary storage 18 providing for non-volatile storage of information; an input device 20 for receiving information or commands; a processor 22 for executing applications stored in memory 16 or secondary storage 18, or received from another source; a display device 24 for outputting a visual display of information; and an output device 26 for outputting information in other forms such as speakers for audio information or a printer for a hardcopy of information.
• a memory 14 storing one or more applications 16
• secondary storage 18 providing for non-volatile storage of information
• an input device 20 for receiving information or commands
• a processor 22 for executing applications stored in memory 16 or secondary storage 18, or received from another source
• a display device 24 for outputting a visual display of information
• an output device 26 for outputting information in other forms such as speakers for audio information or a printer for a hardcopy of information.
• the cutting of a work piece 54 is performed by a tool tip 44.
• An actuator 38 controls movement of tool tip 44 as work piece 54 is rotated by a drive unit and encoder 56, such as an electric motor controlled by computer 12.
• work piece 54 is shown in roll form; however, it can be implemented in planar form. Any machineable materials could be used; for example, the work piece can be implemented with aluminum, nickel, copper, brass, steel, or plastics (e.g., acrylics). The particular material to be used may depend, for example, upon a particular desired application such as various films made using the machined work piece.
• Actuator 38, and the actuators described below, can be implemented with stainless steel, for example, or other materials.
• Actuator 38 is removably connected to a tool post 36, which is in turn located on a track 32.
• the tool post 36 and actuator 38 are configured on track 32 to move in both an x-direction and a z-direction as shown by arrows 40 and 42.
• Computer 12 is in electrical connection with tool post 36 and actuator 38 via one or more amplifiers 30. When functioning as a controller, computer 12 controls movement of tool post 36 along track 32 and movement of tool tip 44 via actuator 38 for machining work piece 54. If an actuator has multiple PZT stacks, it can use separate amplifiers to independently control each PZT stack for use in independently controlling movement of a tool tip attached to the stacks.
• Computer 12 can make use of a function generator 28 in order to provide waveforms to actuator 38 in order to machine various microstructures in work piece 54, as further explained below.
• the machining of work piece 54 is accomplished by coordinated movements of various components.
• the system under control of computer 12, can coordinate and control movement of actuator 38, via movement of tool post 36, along with movement of the work piece in the c-direction and movement of tool tip 44 in one or more of the x-direction, y-direction, and z-direction, those coordinates being explained below.
• the system typically moves tool post 36 at a constant speed in the z-direction, although a varying speed may be used.
• the movements of tool post 36 and tool tip 44 are typically synchronized with the movement of work piece 54 in the c-direction (rotational movement as represented by line 53). AU of these movements can be controlled using, for example, numerical control techniques or a numerical controller (NC) implemented in software, firmware, or a combination in computer 12.
• NC numerical controller
• the cutting of the work piece can include continuous and discontinuous cutting motion.
• the cutting can include a helix-type cutting (sometimes referred to as thread cutting) or individual circles around or about the roll.
• the cutting can include a spiral-type cutting or individual circles on or about the work piece.
• An X-cut can also be used, which involves a nearly straight cutting format where the diamond tool tip can traverse in and out of the work piece but the overall motion of the tool post is rectilinear.
• the cutting can also include a combination of these types of motions.
• Work piece 54 after having been machined, can be used to make films having the corresponding microstructures for use in a variety of applications. Examples of those films include optical films, friction control films, and micro-fasteners or other mechanical microstructured components.
• the films are typically made using a coating process in which a polymeric material in a viscous state is applied to the work piece, allowed to at least partially cure, and then removed.
• the film composed of the cured polymer material will have substantially the opposite structures than those in the work piece. For example, an indentation in the work piece results in a protrusion in the resulting film.
• Work piece 54 after having been machined, can also be used to make other articles having discrete elements or microstructures corresponding with those in the tool.
• Cooling fluid 46 is used to control the temperature of tool post 36 and actuator 38 via lines 48 and 50.
• a temperature control unit 52 can maintain a substantially constant temperature of the cooling fluid as it is circulated through tool post 36 and actuator 38.
• Temperature control unit 52 can be implemented with any device for providing temperature control of a fluid.
• the cooling fluid can be implemented with an oil product, for example a low viscosity oil.
• the temperature control unit 52 and reservoir for cooling fluid 46 can include pumps to circulate the fluid through tool post 36 and actuator 38, and they also typically include a refrigeration system to remove heat from the fluid in order to maintain it at a substantially constant temperature. Refrigeration and pump systems to circulate and provide temperature control of a fluid are known in the art.
• the cooling fluid can also be applied to work piece 54 in order to maintain a substantially constant surface temperature of the material to be machined in the work piece.
• FIG. 2 is a diagram illustrating a coordinate system for a cutting tool such as system 10.
• the coordinate system is shown as movement of a tool tip 62 with respect to a work piece 64.
• Tool tip 62 may correspond with tool tip 44 and is typically attached to a carrier 60, which is attached to an actuator.
• the coordinate system in this exemplary embodiment, includes an x-direction 66, a y-direction 68, and a z-direction 70.
• the x- direction 66 refers to movement in a direction substantially perpendicular to work piece 64.
• the y-direction 68 refers to movement in a direction transversely across work piece 64 such as in a direction substantially parallel to a plane of rotation of work piece 64.
• the z- direction 70 refers to movement in a direction laterally along work piece 64 such as in a direction substantially parallel to the axis of rotation of work piece 64.
• the rotation of the work piece is referred to as the c-direction, as also shown in FIG. 1.
• the y-direction and z-direction refer to movement in mutually orthogonal directions across the work piece in directions substantially perpendicular to the x-direction.
• a planar form work piece can include, for example, a rotating disk or any other configuration of a planar material.
• the system 10 can be used for high precision, high speed machining.
• This type of machining must account for a variety of parameters, such as the coordinated speeds of the components and the work piece material. It typically must take into consideration the specific energy for a given volume of metal to be machined, for example, along with the thermal stability and properties of the work piece material.
• Cutting parameters relating to machining are described in the following references: Machining Data Handbook, Library of Congress Catalog Card No. 66-60051, Second Edition (1972); Edward Trent and Paul Wright, Metal Cutting, Fourth Edition, Butterworth-Heinemann, ISBN 0-7506-7069-X
• FIG. 3 is a diagram of an exemplary PZT stack 72 for use in a cutting tool.
• a PZT stack is used to provide movement of a tool tip connected to it and operates according to the PZT effect, which is known in the art. According to the PZT effect, an electric field applied to certain types of materials causes expansion of them along one axis and contraction along another axis.
• a PZT stack typically includes a plurality of materials 74, 76, and 78 enclosed within a casing 84 and mounted on a base plate 86. The materials in this exemplary embodiment are implemented with a ceramic material subject to the PZT effect.
• a post 88 is adhered to the disks and protrudes from casing 84.
• the disks can be implemented with any PZT material such as for example, a barium titanate, lead zirconate, or lead titanate material mixed, pressed, based, and sintered.
• PZT material is available from Kinetic Ceramics, Inc., 26240 Industrial Blvd., Hayward, CA 94545, U.S.A.
• the disks can also be implemented with a magnetostrictive material, for example.
• FIGS. 4A-4D are views of an exemplary tool tip carrier 90, which would be mounted to post 88 of the PZT stack for control by an actuator, as explained below.
• FIG. 4A is a perspective view of tool tip carrier 90.
• FIG. 4B is a front view of tool tip carrier 90.
• FIG. 4C is a side view of tool tip carrier 90.
• FIG. 4D is a top view of tool tip carrier 90.
• tool tip carrier 90 includes a planar back surface 92, a tapered front surface 94, and a protruding surface 98 with angled or tapered sides.
• An aperture 96 provides for mounting of tool tip carrier 90 onto a post of a PZT stack.
• Tapered surface 98 would be used for mounting of a tool tip for machining of a work piece.
• tool tip carrier 90 includes a planar surface to enhance stability of mounting it by providing for more surface area contact when mounted to a PZT stack, and it includes the tapered front surfaces to reduce the mass of it.
• Tool tip carrier 90 would be mounted to post 88 of the PZT stack by use of an adhesive, brazing, soldering, a fastener such as a bolt, or in other ways.
• Tool tip carrier 90 is intended to include any type of structure for use in holding a tool tip for machining a work piece.
• Tool tip carrier 90 can be implemented with, for example, one or more of the following materials: sintered carbide, silicon nitride, silicon carbide, steel, titanium, diamond, or synthetic diamond material.
• the material for tool tip carrier 90 preferably is stiff and has a low mass.
• FIGS. 5A-5D are views of an exemplary tool tip 100, which would be secured to surface 98 of tool tip carrier 90 such as by use of an adhesive, brazing, soldering, or in other ways.
• FIG. 5A is a perspective view of tool tip 100.
• FIG. 5B is a front view of tool tip 100.
• FlG. 5C is a bottom view of tool tip 100.
• FIG. 5D is a side view of tool tip 100.
• tool tip 100 includes sides 104, tapered and angled front surfaces 106, and a bottom surface 102 for securing it to surface 98 of tool tip carrier 90.
• the front portion 105 of tool tip 100 is used for machining of a work piece under control of an actuator.
• Tool tip 90 can be implemented with, for example, a diamond slab.
• An interrupted cut FTS actuator can be used to make small microstructures as the tool tip is in discontinuous contact with work piece during cutting, creating non- adjacent microstructures.
• These features can be used to make film light guides, micro- fluidic structures, segmented adhesives, abrasive articles, optical diffusers, high contrast optical screens, light redirecting films, anti-reflection structures, light mixing, and decorative films.
• the actuator can provide for other advantages.
• the features can be made so small as to be invisible to the naked eye. This type of feature reduces the need for a diffuser sheet to hide the light extraction features in a liquid crystal display, for example.
• Use of crossed BEF films above the light guide also causes mixing that would in combination with these small features eliminate the need for the diffuser layer.
• the extraction features can be made linear or circular. In the linear case, they can be used with conventional cold cathode fluorescent lamp (CCFL) light sources, for example. In the circular case, the features can be made on circular arcs with a center point located where an LED would normally be positioned. Yet another advantage relates to programming and structure layout where all features need not lay along a single line as with a continuous groove.
• the area density of the light extraction features can be adjusted deterministically by arranging spacing along the features, spacing orthogonal to the features, and depth. Furthermore, the light extraction angle can be made preferential by selecting the angle and half angles of the cut facets.
• the depth of the features may be in the region of 0 to 35 microns, for example, and more typically 0 to 15 microns.
• the length of any individual feature is controlled by the revolutions per minute (RPM) of the rotating work piece along the c- axis, and the response time of the FTS.
• the feature length can be controlled from 1 to 200 microns, for example.
• the spacing orthogonal to the grooves (pitch) can also be programmed from 1 to 1000 microns.
• FIGS. 6A-6H are views of an exemplary actuator 110 for use in implementing an interrupted cut microreplication system and process.
• FIG. 6A is a top sectional view of actuator 110.
• FIG. 6B is a front sectional view illustrating placement of a PZT stack in actuator 110.
• FIG. 6C is a front view of actuator 110.
• FIG. 6D is aback view of actuator 110.
• FIG. 6E is a top view of actuator 110.
• FIGS. 6F and 6G are side views of actuator 110.
• FIG. 6H is a perspective view of actuator 110. Some details of actuator 110 in FIGS. 6C- 6H have been removed for clarity.
• actuator 110 includes a main body 112 capable holding an x-direction PZT stack 118.
• PZT stack 118 is attached to a tool tip carrier having a tool tip 136 for using in moving the tool tip in an x-direction as shown by arrow 138.
• PZT stack 118 can be implemented with the exemplary PZT stack 72 shown in FIG. 3.
• the tool tip on a carrier 136 can be implemented with the tool tip carrier shown in FIGS. 4A- 4D and the tool tip shown in FIGS. 5A-5D.
• Main body 112 also includes two apertures 1 14 and 115 for use in removably mounting it to tool post 36, such as via bolts, for machining work piece 54 under control of computer 12.
• PZT stack 1 18 is securely mounted in main body 112 for the stability required for precise controlled movement of tool tip 136.
• the diamond on tool tip 136 in this example is an offset 45 degree diamond with a vertical facet, although other types of diamonds may be used.
• the tool tip can be V-shaped (symmetric or asymmetric), round- nosed, flat, or a curved facet tool. Since the discontinuous (non-adjacent) features are cut on a diamond turning machine, they can be linear or circular. Furthermore, since the features are not continuous, it is not required that they even be located along a single line or circle. They can be interspersed with a pseudorandomness.
• PZT stack 1 18 is secured in main body 112 by rails such as rails 120 and 122.
• the PZT stack 118 can preferably be removed from main body 112 by sliding is along the rails and can be secured in place in main body 112 by bolts or other fasteners.
• PZT stack 118 includes electrical connection 130 for receiving signals from computer 12.
• the end cap of PZT stacks 118 includes a port 128 for receiving cooling fluid such as oil from reservoir 46, circulating it around the PZT stack, and delivering the oil back to reservoir 46, via port 132, for maintaining temperature control of it.
• Main body 112 can include appropriate channels for directing the cooling fluid around PZT stack 118, and the cooling fluid can be circulated by a pump or other device in temperature control unit 52.
• FIG. 6B is a front sectional view illustrating placement of PZT stack 118 in main body 112 with the end cap of PZT stack 118 not shown.
• Main body 112 can include a plurality of rails in each aperture for the PZT stacks to hold them securely in place.
• PZT stack 118 is surrounded by rails 120, 122, 142, and 144 in order to hold it securely in place when mounted in main body 112.
• the end cap attached to PZT stack 118 can accommodate bolts or other fasteners to secure PZT stack to one or more of the rails 120, 122, 142, and 144, and the end cap can also provide for sealing PZT stack 118 in main body 112 for use in circulating the cooling fluid around it.
• PZT stack 118 can include one or more Belleville washers positioned between the stacks and the tool tip carrier 136 for preloading of them.
• FIGS. 7A-7C illustrate interrupted cut machining of a work piece using the exemplary actuator and system described above.
• FIGS. 7A-7C illustrate use of variable taper- in and taper-out angles of a tool tip, and those angles can be controlled using, for example, the parameters identified above.
• FIGS. IA-I C illustrate examples of the work piece before and after being cut with varying taper-in and taper-out angles.
• the taper-in angle is referred to as ⁇ i N and the taper-out angle is referred to as ⁇ ou ⁇ -
• the terms taper-in angle and taper-out angle mean, respectively, an angle at which a tool tip enters a work piece and leaves a work piece during machining.
• taper-in and taper-out angles do not necessarily correspond with angles of the tool tip as it moves through a work piece; rather, they refer to the angles at which the tool tip contacts and leaves the work piece.
• the tool tips and work pieces can be implemented, for example, with the system and components described above.
• FIG. 7 A is a diagram illustrating an interrupted cut 150 with substantially equal taper-in and taper-out angles into and out of a work piece 153.
• a taper-in angle 152 of a tool tip 151 into a work piece 153 is substantially equal to a taper- out angle 154 ( ⁇ i>j ⁇ ⁇ ou ⁇ )-
• the duration of the tool tip 151 into work piece 153 determines a length L (156) of the resulting microstructure.
• Using substantially equal taper-in and taper-out angles results in a substantially symmetrical microstructure 158 created by removal of material from the work piece by the tool tip. This process can be repeated to make additional micro structures, such as microstructure 160, separated by a distance D (162).
• FIG. 7B is a diagram illustrating an interrupted cut with a taper-in angle less than a taper-out angle into and out of a work piece 167.
• a taper-in angle 166 of a tool tip 165 into a work piece 167 is less than a taper-out angle 168 ( ⁇ i>j ⁇ ⁇ ou ⁇ )-
• FIG. 7C is a diagram illustrating an interrupted cut with a taper-in angle greater than a taper-out angle into and out of a work piece 181. As shown in FIG.
• a taper-in angle 180 of a tool tip 179 into a work piece 181 is greater than a taper-out angle 182 ( ⁇ i N > ⁇ ou ⁇ )-
• the dwell time of the tool tip 179 in work piece 181 determines a length 184 of the resulting microstructure.
• Using a taper-in angle greater than a taper-out angle results in an asymmetrical microstructure, for example microstructure 186, created by removal of material from the work piece by the tool tip. This process can be repeated to make additional microstructures. such as microstructure 188, separated by a distance 190.
• the dashed lines for the taper-in and taper-out angles are intended to conceptually illustrate examples of angles at which a tool tip enters and leaves a work piece. While cutting the work piece, the tool tip can move in any particular type of path, for example a linear path, a curved path, a path including a combination of linear and curved motions, or a path defined by a particular function.
• FIG. 8 is a diagram conceptually illustrating microstructures that can be made using the cutting tool system having an interrupted cut FTS actuator to make a machined work piece and using that work piece to make a structured film.
• an article 200 includes a top surface 202 and a bottom surface 204.
• Top surface 202 includes interrupted cut protruding microstructures such as structures 206, 208, and 210, and those microstructures can be made using the actuators and system described above to machine a work piece and then using that work piece to make a film or article using a coating technique.
• each microstructure has a length L, the sequentially cut microstructures are separated by a distance D, and adjacent microstructures are separated by a pitch P.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Microelectronics & Electronic Packaging (AREA)
• Turning (AREA)
• Moulds For Moulding Plastics Or The Like (AREA)
• Milling Processes (AREA)
• Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)
• Perforating, Stamping-Out Or Severing By Means Other Than Cutting (AREA)
• Micromachines (AREA)
• Control Of Cutting Processes (AREA)

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• 2005
  • 2005-12-27 US US11/318,707 patent/US7328638B2/en active Active
• 2006
  • 2006-12-21 KR KR1020087015502A patent/KR101397795B1/ko not_active Expired - Fee Related
  • 2006-12-21 CN CN2006800492584A patent/CN101346210B/zh active Active
  • 2006-12-21 WO PCT/US2006/048806 patent/WO2007075898A1/en not_active Ceased
  • 2006-12-21 JP JP2008548629A patent/JP5296550B2/ja active Active
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