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Study on the tool path generation of an automotive headlamp reflector in ultra-precision raster milling

  • Sandy To*
  • , Hao Wang
  • , Bing Li
  • , Chi Fai Cheung
  • , Su Juan Wang
  • *Corresponding author for this work
  • Hong Kong Polytechnic University
  • Harbin Institute of Technology Shenzhen

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

Abstract

Nowadays faceted reflector design has become popular in automotive illumination systems. The advantage of a compound surface enables it to achieve the required hot spot intensity by directing more than 60% of the generated light towards the road, thereby largely illuminate the area through the aperture. The research is oriented to fabricating the mold insert on ultra-precision raster milling (Freeform 705G). In this paper, the tool path generation method for automotive headlamp reflectors is studied, and a practical gouging detection and avoidance algorithm is proposed. The surface roughness and form accuracy (peak-to-valley height) are then calculated theoretically using mathematical formulae. Through the tool path generation of a small but representative surface patch with a gap, a possible way is finally found to generate the tool path for such a class of freeform surface with special equipment.

Original languageEnglish
Title of host publicationAdvances in Materials Manufacturing Science and Technology II - Selected Papers from the 12th International Manufacturing Conference in China
EditorsChengyu Jiang, Geng Liu, Dinghua Zhang, Xipeng Xu
PublisherTrans Tech Publications Ltd
Pages673-676
Number of pages4
ISBN (Print)0878494219, 9780878494217
DOIs
StatePublished - 2006
Externally publishedYes
Event12th International Manufacturing Conference in China, IMCC2006 - Xi'an, China
Duration: 21 Sep 200623 Sep 2006

Publication series

NameMaterials Science Forum
Volume532-533
ISSN (Print)0255-5476
ISSN (Electronic)1662-9752

Conference

Conference12th International Manufacturing Conference in China, IMCC2006
Country/TerritoryChina
CityXi'an
Period21/09/0623/09/06

Keywords

  • Automotive headlamp reflector
  • Gouge-free tool path
  • Ultra-precision raster milling

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