Welcome at the Kugler Group

Transcription

1 Welcome at the Kugler Group Mission statement Kugler is among the leading companies in the development and manufacture of ultra-precision machines and related optical and mechanical precision parts. 1

2 Manufacturing of high-precision optical surfaces on steel molds without polishing Dr. Tobias Mangler Business development and research micro machining Kugler GmbH, Salem Precision Fair, Conference Centre Koningshof, Veldhoven 04. December

3 Outline Kugler GmbH Kugler machines Diamond machining technology for steel an carbides Machining examples Summary 3

4 Kugler GmbH Family-owned enterprise since 1983 Developer and producer of micromachining systems and ultra precision components Operating figures: Founder: Lothar Kugler Head office: Salem, Germany Management: Lothar Kugler, Till Kugler, Jörg Kugler Number of employees: 120 Percentage of graduates: > 25% Annual turnover: approx. 12 Mio. EUR Production area: >10000 m 2 Clean room: ISO 5 and ISO 4 Rate of export: 30 % Participation in R&D: 15 % Quality standard: DIN EN ISO 9001:2008 ROHS compliant 4

5 Kugler machines Flycutting milling center Aerostatic axis bearings Linear motors Vibration isolation and damping Aerostatic beared flycutting spindel with up to Ø 600mm Integrated measuring tools for in-process measurements on the machine (e.g. interferometer) Micromaster Up to 5-hydrostatic axis bearings Position accuracy ± 0,25µm Linear motors and digital servo amplifiers High speed control unit Delta Tau PowerPMAC Full 64 Bit floating point calculation Large program size: 1.5 GB in normal NC-program > 20 GB in rotary mode 5

6 Kugler machines Magnetic Measurement Bench Solid monolithic design Air bearing linear system High speed control unit Delta Tau PowerPMAC Hydrostatic drum turning machine Active air-damping system Linear motors and digital servo amplifiers Hydrostatic beared axis Optical drum setting system Optical tool setting system Balancing system High speed control unit Delta Tau PowerPMAC 6

7 Hydrostatic drum turning machine Functional films Micro lens diffusion film 3D decorative film Transparent conductive film Anti-reflective film Anti-spy film Others Fast tool servo (FTS) Spiral cut Plunge cut Randomized structure Micro lens structure Crossed and pyramidal structure Sine wave cut Pattern machining generator Micro lenses Light-guide pattern Bright enhancement film 7

8 Process capability of TDM functional films Mirror finish, Ra < 5 nm Spiral cut, pitch 50 µm Plunge cut (1H,7L ), pitch 52 µm Milled dot pattern, dot Ø 100 µm FTS structure, dot Ø 300 µm Cross grating (e.g. retro reflector) 8

9 Hydrostatic 5-axis machine 5-axis simultaneous operation Micro milling Micro grinding 3D diamond turning Ruling of non-rotationally symmetric surface Flycutting Turning Slow tool 9

10 Ultra-precision machining examples High precision micro milling Micro-milling structures Circumference flycutting or ruling High precision micro grinding Diffractive grating, pyramidal structure Air bearing cylinder 10

11 Ultra-precision machining examples High precision micro milling and ruling in one fixture, part Ø 3 mm By courtesy of the ESA (European Space Agency) LISA Pathfinder project, Tube mirror for the Ultraviolet light re-direction High precision machining combination; Micro milling and flycutting, AuPt cube, edge length 46 mm, ~ 2 kg A Gold-Platinum Testmass for the ESA (European Space Agency) LISA Pathfinder project, property of ASI (Agenzi Spaziale Italiana), machined by KUGLER for Carlo Gavazzi Space under contract from EADS Astrium Friedrichshafen 11

12 Technology need Well-suited Single point diamond machining of non-ferrous metals and NiP-plating Optical P-V and Ra values Milling of steel or carbides with VHM/CBN-Tools Good P-V and Ra values possible (no optical surface quality) Finish polishing required New technology for: Plane mirrors Machining of steel or carbides Optical P-V and Ra values High precision positioning of diamond machined surface in respect to reference surface Cost reduction: lower tooling costs and longer tool lifetime Shorter lead times 0,001 // 0,002 A Machining example A ,002 Kugler ambition: Diamond machining of steel in the same quality (P-V / Ra) as in nonferrous materials 12

13 Diamond machining of steel Demand: Well-defined surface Fully deterministic path of motion, not statistical (as grinding) Continuous single point diamond cutting Ultra pecision machine Demand: Reduced machining time for diamond tool Avoiding tool wear Avoiding chemical reactions between tool and part material Micromaster 5X Ultrasonic machining technology NOW available Discontinued cut Contact time between material and tool bit reduced by a factor of 5 Dedicated cutting process for a specific kind of material feasible (individual combination of longitudinal/transversal oscillation and tool geometry) UltraSonic Tool By courtesy of Taga Electric Co. 13

14 Working principle: Elliptical or linear ultrasonic oscillation 1 Start oscillation 2 Start cutting 3 Lowermost oscillation point Transversal Longitudinal 4 5 Start contact between tool cutting face and spoon Machining of optical surface 6 Friction reversal 7 End of cutting By courtesy of Taga Electric Co. Tool moving: elliptical oscillation 14

15 Video Diamond machining of a microstructured steel mirror channel: Kugler GmbH 15

16 Mold insert for a car light with micro structure Material: Stavax , 52HRC, roughness Ra < 5 nm Mold Insert for car head light 16

17 Diamond machining of stavax (1.2083, AISI 420) (52 HRC) Steel mirror, mold insert Interferometer measurement Chipping structure visible Mold Insert for mobile lense, Ø 1 mm Roughness analysis Ra ~ 3,8 nm Surface profile PV 100 nm Machining examples directly machined in steel, retroreflector, diffractive grating, convex sphere By courtesy of Taga Electric Co. and A.L.M.T. Co. 17

18 Diamond machining of tungsten carbide Machining results in WC: Material: WC500 (Co 0%) Tool: R 1,0 mm; 12 rpm Roughness: Ra: 3.61 nm Material: WC500 (Co 12%) Tool: R 1,0 mm; 12 rpm Roughness: Ra: 1.7 nm Machining example for an optical surface on tungsten carbide Concave tungsten carbide mold insert for hot embossing application Surface Quality depending on: Machine type Sample material Chipping method Tool material and geometry Machining process Ra: 3.6 nm Ra: 3 nm, PV ~ µm By courtesy of Taga Electric Co. and A.L.M.T. Co. 18

19 NiP plating vs. directly machining Past: Conventional machining of NiP plated steel mold Disadvantage: NiP-plating time (~2 weeks) Corrupt plating possible (cavities, ) Optical surface very sensitive (scratches, ) Optical surface difficult to clean Standard mold output Diamond machined steel mold Corrupt NiP-plating Cavities and plating release Today: Directly diamond machining of steel mold without plating Advantage: Roughing and finishing in one machining step Reduced tool wear Short lead time: no plating necessary Molding output 1000 x higher to NiP plated mold Resistant surface: ease of use for worker Optical surface easy to clean Sensor barrier in Kugler TDM-2000LS 19

20 Polishing vs. diamond steel machining Past: Conventional polishing of steel contact surface Disadvantage: Imprecise surface positioning (<= 10 µm) High machining divergence between batches Long machining time 0,001 // 0,002 A A Planarity and parallelism of resonator alignment surfaces is as important as alignment tool thickness ,002 Today: Diamond machining of steel contact surface Advantage: High precision surface positioning (<= 1 µm) Machining divergence negotiable Short machining time higher output Sample alignment easier and faster High precision diamond machining of a laser resonator in steel. REM measurement, material: M333 Diamond machined surface 20

21 Summary Advantage of new machining methode High precision machining of steel or carbides in optical quality Cost reduction Cheaper sample production Longer mold lifetime Shorter lead times No NiP-plating necessary PV 100 nm Ultra-precise molds for new applications fabricable Ultra-precise form in steel (PV ~ 0,5 µm) Surface quality for optical mold fabricable Optical roughness (Ra 5 nm) Ease of use for worker at molding machine High precision positioning of machined surface Ra ~ 3,8 nm 21

22 Many thanks for your attention! Vielen Dank für Ihre Aufmerksamkeit! Kugler GmbH Heiligenberger Strasse Salem Germany tel: +49 (0) fax: +49 (0)

23 Our commitment Quality and innovation When looking for a supplier of ultra-precision machines or high-precision parts, the choice is simple: Buy Kugler quality today get high-grade technology for tomorrow. 23