Precision glass molding: Toward an optimal fabrication of optical lenses

doi:10.1007/s11465-017-0408-3

Front. Mech. Eng.

2017, Vol. 12

Issue (1) : 3-17 https://doi.org/10.1007/s11465-017-0408-3

REVIEW ARTICLE

Precision glass molding: Toward an optimal fabrication of optical lenses

Liangchi ZHANG(

),Weidong LIU

Laboratory for Precision and Nano Processing Technologies, School of Mechanical and Manufacturing Engineering, The University of New South Wales, Sydney NSW 2052, Australia

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Abstract

It is costly and time consuming to use machining processes, such as grinding, polishing and lapping, to produce optical glass lenses with complex features. Precision glass molding (PGM) has thus been developed to realize an efficient manufacture of such optical components in a single step. However, PGM faces various technical challenges. For example, a PGM process must be carried out within the super-cooled region of optical glass above its glass transition temperature, in which the material has an unstable non-equilibrium structure. Within a narrow window of allowable temperature variation, the glass viscosity can change from 10⁵ to 10¹² Pa·s due to the kinetic fragility of the super-cooled liquid. This makes a PGM process sensitive to its molding temperature. In addition, because of the structural relaxation in this temperature window, the atomic structure that governs the material properties is strongly dependent on time and thermal history. Such complexity often leads to residual stresses and shape distortion in a lens molded, causing unexpected changes in density and refractive index. This review will discuss some of the central issues in PGM processes and provide a method based on a manufacturing chain consideration from mold material selection, property and deformation characterization of optical glass to process optimization. The realization of such optimization is a necessary step for the Industry 4.0 of PGM.

Keywords precision glass molding optical lens constitutive modeling optimization manufacturing chain Industry 4.0

Corresponding Author(s): 张

Just Accepted Date: 23 November 2016 Online First Date: 26 December 2016 Issue Date: 21 March 2017

Cite this article:

Liangchi ZHANG,Weidong LIU. Precision glass molding: Toward an optimal fabrication of optical lenses[J]. Front. Mech. Eng., 2017, 12(1): 3-17.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-017-0408-3
https://academic.hep.com.cn/fme/EN/Y2017/V12/I1/3

Fig.1 A comparison of traditional machining process with PGM

Fig.2 Key factors in the manufacturing chain of a PGM process

Tab.1 Moldable glass defined by manufacturers [41]

Fig.3 Moldable optical glass available [33]

Fig.4 A typical processing cycle of PGM

Fig.5 A typical PGM process

Tab.2 Typical tolerances for a precision glass molded lens [41]

Tab.3 Selection of mold materials for different PGM processes [41]

Fig.6 Performance comparison of TiAlN, CrAlN and Pt/Ir coatings after 20 pressing steps [73]

Relationship	Equation
Stress and strain	$ε i j = e i j + t r (ε) δ i j / 3$ , $σ i j = S i j + t r (σ) δ i j / 3$
Volumetric relationship	$t r (ε) / 3 − α Δ T = t r (σ) / 9 K$
Deviatoric relationship	$(1 + G r G) e ˙ i j + G r η s e i j = S ˙ i j 2 G + S i j 2 η s$
Viscosity variation	$η s = η 0 exp (V c G ∞ (T) / k B T)$
Thermal expansion	$α = α G + (α L − α G) δ T f / δ T$
Structure relaxation description	$T f = T − ∫ ξ (T 0) ξ (T) M p (ξ − ξ') d T d ξ' d ξ'$ $ξ = ∫ 0 t 1 / τ p d t ′$ $M p (ξ) = exp [− (ξ / τ p r) β]$ $τ p = τ 0 exp [x Δ H / R T + (1 − x) Δ H / R T f]$

Tab.4 Modulus-based constitutive model for optical glass [40]

Fig.7 (a) The evolution of a lens shape in PGM; (b) the deviation with respect to the mold cavity geometry; (c) the relationship between H/R and r/R [40]

Fig.8 The distributions of residual (a) hydrostatic stress, and (b) von Mises stress [40]

Fig.9 (a) Variations of the von Mises stresses with time at different points in the lens; (b) the stress distributions along the central line through the lens thickness; (c) the variations of CTEs at different points with time [40]

Fig.10 The effect of cooling rate on the internal stresses with time: (a) Effect of cooling rates in the first cooling stage, and (b) effect of cooling rates in the second cooling stage [40]

Fig.11 A typical optimization process

Fig.12 Variation of PMDS during the simultaneous optimization of R, k and a

Fig.13 (a) The comparison of the shape deviations of the molded lens along its radial direction with and without mold optimization; (b) the evolution of the PMSD during PGM

Fig.14 Initial and optimized cooling curves [94]

Fig.15 (a) The optimization path, and (b) the corresponding residual stress

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