Microlens elements are widely applied in various beam processing applications. However, due to the geometric limitations of the cutting tool and the degrees of freedom of the machine tool, the traditional cutting strategy cannot be employed to fabricate high quality large-vector height microlens. In this paper, a method based on the tool swing cutting and stitching processing is presented. The interference situation and the relationship between the tool parameters and microlens vector height are analyzed. The analysis shows that this method can improve the microlens vector height by about 2 times compared to the slow tool servo. Then the influence of tool setting error on stitching accuracy is studied, and an accurate tool setting method combining CCD tool setting and trial cutting is proposed. Finally, the microlens are experimentally machined to reveal that this method is possible to fabricate microlens with large-vector height and high surface quality.
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