Acta Optica Sinica, Volume. 43, Issue 8, 0822011(2023)

Precision Molding for Glass Optical Components

Guangyu Liu and Fengzhou Fang*
Author Affiliations
  • State Key Laboratory of Precision Measuring Technology & Instruments, Laboratory of Micro/Nano Manufacturing Technology (MNMT), Tianjin University, Tianjin 300072, China
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    Figures & Tables(40)
    Schematic diagram of precision glass molding
    Comparison of volume,enthalpy change,and entropy change of glass with that of crystal during cooling[6]
    Typical viscosity-temperature curve for soda-lime-silicate glass[29]
    Viscoelastic response[87]. (a) Creep; (b) stress relaxation
    Glass constitutive models[35]. (a) Maxwell model; (b) Kelvin model; (c) Burgers model
    Generalized Maxwell model[15]
    Minimal uniaxial creep testing (MUCT) method[54]
    Thermo-rheologically simple (TRS) behavior of glass[6]
    Ultra precision grinding tungsten carbide mold[65]
    NiP micropyramid array machined by micro-groove cutting[92]. (a) Residual burrs after cutting; (b) SEM diagram of surface morphology
    Axial-feed fly cutting[104]
    Laser assisted cutting[109]. (a) In-process-heat laser assisted turning (In-LAT); (b) finished surface of WC mold
    Ultrasonic elliptical vibration cutting process[112]
    Molds machined by ultrasonic elliptical vibration cutting[111]
    SEM diagrams of GC mold and molded glass surface[116]. (a)(b) Mold surface; (c)(d) glass surface
    Appearance of contact angle of glass and mold[40]
    Pt-Ir film degradation model[42]
    Boundary conditions of different molding stages[152]
    Temperature distributions of WC mold and heat-resistant stainless steel mold after heating for 180 s[153]. (a) WC mold; (b) heat-resistant stainless steel mold
    Influence of near contact gap on temperature distribution[152]. (a) No near contact; (b) contact gap of 0.1 mm; (c) contact gap of 0.2 mm
    Predicted residual stress distributions inside molded lens for different molding velocities[155]. (a) 0.005 mm/s; (b) 0.01 mm/s; (c) 0.05 mm/s
    Residual tangential stress inside glass wafer[43]
    Predicted residual stress distributions[73]. (a) Equivalent stress on lens surface; (b) shear stress σyz in cross section
    Results of ring compression test for different interfacial conditions[156]
    Comparison of friction calibration curves from simulations with experimental data for L-BAL35 glass[156]
    Simulation results of glass cylinder compression[157]
    Influence of glass stress relaxation parameters on surface profile[159]
    Accuracy of predicted position of glass wafer lens [162]
    Predicted refractive index distribution in molded lens[163]
    Schematic diagram of basic structure of molding machine[29]
    Ultrasonic vibration assisted glass molding machine[168]
    Ultrasonic vibration assisted glass molding machine with pre-adjusted horn[169]
    Molded total internal reflection lens[173]
    Molded chalcogenide freeform lenses[17]
    Molded glass diffractive structure[181]. (a) Contraction between mold and glass; (b) glass surface quality; (c) profile deviation
    Wafer level glass lens molding[184]
    • Table 1. Comparison of mold material properties

      View table

      Table 1. Comparison of mold material properties

      MaterialElastic modulus /GPaHardness /HVThermal expansion /(10-6 ℃)Thermal conductivity /(W·m-1·℃-1Maximum molding temperature /℃
      Silicon(Si)16811502.6148~700
      Silicon carbide(SiC)35021003.748~850
      Tungsten carbide(WC)57026004.963~730
      Glassy carbon(GC)32.42302.15.8~1360
      NiP alloy(NiP)150.1769.2128~790
    • Table 2. Comparison of typical film materials

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      Table 2. Comparison of typical film materials

      MaterialSubstrateDeposition techniqueMolding temperature /℃CostOxidation resistanceLife time
      DLC(Ta-C)WCFiltered cathodic vacuum arc deposition~450LowLowShort
      Pt-IrWCMagnetron sputtering~700HighHighLong
      CrWNSi,WCIon beam assisted deposition~600HighModerateModerate
    • Table 3. Comparison of Marc and Abaqus[151]

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      Table 3. Comparison of Marc and Abaqus[151]

      PropertyAbaqusMarc
      Capability to reach overall dimension
      Capability to reach desired curvature
      Capability to predict residual stress
      Capability to introduce material properties×
      Calculation time×
      Visualization capability×
      Being user-friendly×
    • Table 4. Comparison of commercial glass molding machine

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      Table 4. Comparison of commercial glass molding machine

      ManufacturerModelMachineFeature
      Toshiba(Japan)[85]GMP-311V•Single-workstation;•Infrared heating,nitrogen gas controlled cooling;•Maximum mold size:65-110 mm;•Ultimate vacuum molding:0.6 Pa or less than 0.6 Pa;•Large diameter lens and multi-layout molding
      Nanotech(USA)[164]Nanotech 170GPM•Single-workstation;•Infrared heating,nitrogen gas controlled cooling;•Chamber size:φ170 mm;•Ultimate vacuum molding:0.6 Pa;•Controller & Software for industrial reliability
      Toshiba(Japan)[85]GMP-54-7S•Multi-workstations:2 heating stations,2 press stations,2 gradual cooling stations,1 steep cooling station;•Infrared heating,temperature preservative plate cooling;•Mass production for small/medium diameter lens
      KingDing(China)[165]MD8-65•Multi-workstations:8;•Mold size:diameter of 20-65 mm,height of 15-45 mm;•Maximum working temperature:700 ℃
      AIX-TECH(China)[166]ATM-ASP-11S•Multi-workstations:11;•Maximum mold size:φ65 mm;•Maximum working temperature:750 ℃;•Maximum pressure:7060.788 N;•Thermal parallelism:≤30''
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    Guangyu Liu, Fengzhou Fang. Precision Molding for Glass Optical Components[J]. Acta Optica Sinica, 2023, 43(8): 0822011

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    Paper Information

    Category: Optical Design and Fabrication

    Received: Oct. 31, 2022

    Accepted: Feb. 26, 2023

    Published Online: Apr. 6, 2023

    The Author Email: Fengzhou Fang (fzfang@tju.edu.cn)

    DOI:10.3788/AOS221906

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