微小非球面玻璃镜片的超精密热压成型关键技术研究

On the hot pressing of micro lenses, there exist some problems, such as low machining efficiency, accuracy, service life and high cost on lens mold machining. It also result in the defects of high residual stress, lens warping, surface flaw, deformation, and eccentricity on lens pressing. Therefore, a new-type manufacturing theory and method of micro ultra-precision aspheric lens mold is proposed based on WC & Ni-P & Ni-Co & carbon series coating (or noble metal coating) composite material in this project. It will improve the machining efficiency, accuracy, service life and reduce the cost on mold manufacturing. Meanwhile, using developed mold and based on glass hot pressing tests, a new constitutive model and theory of thermal viscoelasticity on hot pressing is proposed, and a five stages simulation theory and method is also developed. It will optimize process parameters, reduce forming defects, and realize high accuracy and efficiency manufacturing of micro aspheric glass lens. This research will has important theoretical and engineering value for the improvement of technical progress and industry upgrading for our optical manufacturing industry.

针对热压成型技术中微小非球面镜片模具制造的加工效率、加工精度难以保证，模具使用寿命较短，加工成本较高，以及压制镜片残留应力过高、镜片翘曲、表面瑕疵、表面变形和偏心等缺陷，本项目提出一种基于硬质合金-镍磷-镍钴-碳系膜（或贵金属膜）复合层的新型微小非球面镜片超精密模具的制造理论与方法，提高模具的加工精度、效率与使用寿命；同时，采用所开发的模具，结合玻璃热压实验，建立新的热压成型过程的热粘弹性本构模型与理论，提出热压过程的五阶段仿真理论与方法，优化工艺参数，减少成型缺陷，以实现微小非球面镜片的高精、高效制造。本研究对我国光学制造业的技术进步和产业提升具有较为重要的指导意义与工程价值。

针对热压成型技术中微小非球面镜片模具制造的加工效率、加工精度难以保证，模具使用寿命较短，加工成本较高，以及压制镜片残留应力过高、镜片翘曲、表面瑕疵、表面变形和偏心等问题，本项目提出了一种基于模具钢-镍磷-钛-类金刚石复合层的新型微小非球面镜片超精密模具的制造理论与方法，可以大幅提高模具的加工精度和效率，同时延长模具的使用寿命；在热压成型方面，提出了热压过程的五阶段连续仿真（加热-高温浸润-加压-退火-冷却）理论与方法，真实逼近实际情况，结合玻璃热压实验，优化工艺参数，最大程度减少成型缺陷，实现高精度、高效率的镜片制造。本研究可实现微小非球面玻璃镜片的低成本、高效率、高精度的制造，对我国光学制造业的技术进步和产业提升具有较为重要的指导意义与工程价值。