# US 7,793,403 B2 · Manufacturing method of optical component or molding die therefor

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- Number: US 7,793,403 B2
- Document ID: US7793403B2
- Status: Granted
- Kind: B2
- Application number: 11/645,420
- Filed: 2006-12-26
- Published: 2007-07-12
- Granted: 2010-09-14
- Earliest claimed: 2005-12-27
- Assignees: Konica Minolta Opto, Inc.
- Inventors: Yasuhiro Matsumoto
- Web page: https://patentgrep.com/patent/US7793403B2

## CPC

- B28D 1/22: by cutting, e.g. incising
- B23C 3/16: Working surfaces curved in two directions
- B24B 13/00: Machines or devices designed for grinding or polishing optical surfaces on lenses or surfaces of similar shape on other work; Accessories therefor (edging optical work, e.g. lenses, prisms B24B9/14)
- G05B 19/188: {characterised by special applications and not provided for in the relevant subclasses, (e.g. making dies, filament winding)}
- B23C 2226/31: Diamond
- G05B 2219/45157: Grind optical lens
- G05B 2219/45204: Die, mould making
- G05B 2219/49383: Using pick feed with non reciprocating machining direction
- Y10T 29/49996: Successive distinct removal operations
- Y10T 409/303752: Process
- Y10T 409/303808: including infeeding
- B28D: WORKING STONE OR STONE-LIKE MATERIALS
- B23C: MILLING (broaching B23D; broach-milling in making gears B23F; arrangement for copying or controlling B23Q)
- B24B: MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING (grinding of gear teeth B23F, of screw-threads B23G1/36; by electro-erosion B23H; abrasive or related blasting B24C; tools for grinding, buffing or sharpening B24D; polishing compositions C09G1/00; abrasives C09K3/14; electrolytic etching or polishing C25F3/00; grinding arrangements for use on assembled railway tracks E01B31/17); DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A method of manufacturing an optical component or a molding die for the optical component, the method comprising the steps of: cutting a surface of a work with a tool by rotating the tool around its axis with a cutting edge facing outward and moving in a circle to cut the work surface at a point of the circle while relatively moving the tool and the work in a line direction crossing to the axis of the tool at a predetermined feed speed; and cutting the work surface in a next line after relatively moving the tool and the work in a pitch direction perpendicular to the line direction by a pick feeding distance in such a condition that: tool rotation speed (S): 10000 to 30000 rpm; feed speed (F): 300 to 2000 mm/min; rotating radius (D) of a cutting edge of a tool: 5 to 15 mm; pick feeding distance (f): 0.01 to 0.04 mm; nose radius (r) of a cutting edge of a tool: 5 to 20 mm. The method allows to form a surface of a work into a free-form surface having a surface roughness of approximately 10 nm or less.

## Claims

### Claim 1

A method of manufacturing an optical component or a molding die for the optical component, the method comprising the steps of:
cutting a surface of a work with a tool by rotating the tool around its axis with a cutting edge facing outward and moving in a circle to cut the work surface at a point of the circle while relatively moving the tool and the work in a line direction crossing to the axis of the tool at a predetermined feed speed; and
cutting the work surface in a next line after relatively moving the tool and the work in a pitch direction perpendicular to the line direction by a pick feeding distance;
wherein the above steps are carried out under the following conditions:
10000≦S≦30000;
(F/S)2/8D≦10 nm;
f2/8r≦10 nm,
where
S: tool rotation speed (rpm);
F: feed speed (mm/min);
D: rotating radius of a cutting edge of a tool (mm);
f: pick feeding distance (mm);
r: nose radius of a cutting edge of a tool (mm).

### Claim 2 (depends on 1)

The manufacturing method of the optical component or the molding die of the optical component according to claim 1,
wherein the tool rotation speed S (rpm) is in a range of:
10000≦S≦20000.

### Claim 3 (depends on 1)

The manufacturing method of the optical component or the molding die of the optical component according to claim 1, comprising the step of:
polishing the worked surface after completion of the cutting steps.

### Claim 4 (depends on 1)

The manufacturing method of the optical component or the molding die of the optical component according to claim 1,
wherein the feed speed F (mm/min) is in a range of:
300≦F≦2000.

### Claim 5 (depends on 1)

The manufacturing method of the optical component or the molding die of the optical component according to claim 1,
wherein the rotation radius D (mm) of the cutting edge of the tool is in a range of:
5≦D≦15.

### Claim 6 (depends on 1)

The manufacturing method of the optical component or the molding die of the optical component according to claim 1,
wherein the pick feeding distance f (mm) is in a range of:
0.01=≦f≦0.04.

### Claim 7 (depends on 1)

The manufacturing method of the optical component or the molding die of the optical component according to claim 1,
wherein the nose radius r (mm) of the cutting edge of the tool is in a range of:
5≦r≦20.

### Claim 8 (depends on 1)

The manufacturing method of the optical component or the molding die of the optical component according to claim 1,
wherein the feed speed F (mm/min), the rotating radius D (mm) of the cutting edge of the tool, the pick feeding distance f (mm), the nose radius r (mm) of the tool are in ranges of:
300≦F≦2000;
5≦D≦15;
0.01≦f≦0.04;
5≦r≦20.

### Claim 9 (depends on 1)

The manufacturing method of the optical component or the molding die of the optical component according to claim 1,
wherein the cutting steps are performed reciprocally by moving the work forward and backward alternately in the line direction.

### Claim 10 (depends on 9)

The manufacturing method of the optical component or the molding die of the optical component according to claim 9,
wherein the cutting steps are performed under a condition that the feed speed F (mm/min) and the tool rotation speed S (rpm) are in a relation of:
F/S≦0.1 (mm/rev).

### Claim 11 (depends on 9)

The manufacturing method of the optical component or the molding die of the optical component according to claim 9,
wherein a cutting amount into the work by the tool is larger in a down line where a moving direction of the cutting edge of the tool in scraping off the work at a cutting point and a moving direction of the work by a line movement relative to a center of rotation of the tool are equal than in an up line, the reverse direction of the down line.

### Claim 12

A method of manufacturing an optical component or a molding die for the optical component, the method comprising the steps of:
cutting a surface of a work with a tool by rotating the tool around its axis with a cutting edge facing outward and moving in a circle to cut the work surface at a point of the circle while relatively moving the tool and the work in a line direction crossing to the axis of the tool at a predetermined feed speed; and
cutting the work surface in a next line after relatively moving the tool and the work in a pitch direction perpendicular to the line direction by a pick feeding distance;
wherein the above steps are carried out under the following conditions:
10000≦S≦50000;
(F/S)2/8D≦10 nm;
f2/8r≦10 nm,
where
S: tool rotation speed (rpm);
F: feed speed (mm/min);
D: rotating radius of a cutting edge of a tool (mm);
f: pick feeding distance (mm);
r: nose radius of a cutting edge of a tool (mm).

### Claim 13

A manufacturing method of an optical component or a molding die of the optical component comprising the steps of:
cutting a surface of a work with a tool by rotating the tool around its axis with a cutting edge facing outward and moving in a circle to cut the work surface at a point of the circle while relatively moving the tool and the work in a line direction crossing to the axis of the tool at a predetermined feed speed;
cutting the work surface by a next line after relatively moving the tool and the work in a pitch direction perpendicular to the line direction by a pick feeding distance; and
polishing a worked surface after completion of the cutting steps,
wherein the above cuttings are carried out under the following conditions:
10000≦S≦30000;
(F/S)2/8D≦40 nm;
f2/8r≦40 nm,
where
S: tool rotation speed (rpm);
F: feed speed (mm/min);
D: rotation radius of a cutting edge of a tool (mm);
f: pick feeding distance (mm);
r: nose radius of a cutting edge of a tool (mm).

### Claim 14 (depends on 13)

The manufacturing method of the optical component or the molding die of the optical component according to claim 13,
wherein the tool rotation speed S (rpm) in the cutting steps is in a range of:
10000≦S≦20000.

### Claim 15 (depends on 13)

The manufacturing method of the optical component or the molding die of the optical component according to claim 13,
wherein a surface roughness Ry of the worked surface is made 10 nm or less by the polishing step.

### Claim 16 (depends on 13)

The manufacturing method of the optical component or the molding die of the optical component according to claim 13,
wherein the feed speed F (mm/min) in the cutting steps is in a range of:
300≦F≦2000.

### Claim 17 (depends on 13)

The manufacturing method of the optical component or the molding die of the optical component according to claim 13,
wherein the rotating radius D (mm) of the cutting edge of the tool in the cutting steps is in a range of:
5≦D≦15.

### Claim 18 (depends on 13)

The manufacturing method of the optical component or the molding die of the optical component according to claim 13,
wherein the pick feeding distance f (mm) in the cutting steps is in a range of:
0.04≦f≦0.08.

### Claim 19 (depends on 13)

The manufacturing method of the optical component or the molding die of the optical component according to claim 13,
wherein the nose radius r (mm) of the cutting edge in the cutting steps is in a range of:
5≦r≦20.

### Claim 20 (depends on 13)

The manufacturing method of the optical component or the molding die of the optical component according to claim 13,
wherein the feed speed F (mm/min), the rotating radius D (mm) of the cutting edge of the tool, the pick feeding distance f (mm), the nose radius r (mm) of the cutting edge of the tool in the cutting steps are in ranges of:
300≦F≦2000;
5≦D≦15;
0.04≦f≦0.08;
5≦r≦20.