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Acoustic emissions in the glass polishing process: a possible approach for process monitoring 玻璃抛光过程中的声发射:一种可能的过程监控方法
Pub Date : 2023-09-05 DOI: 10.1117/12.2676245
Michael F. Benisch, Hemlin Shaji, Werner Bogner, Oliver Faehnle
Acoustic emissions (AEs) are elastic stress waves in solids. They occur when irreversible changes take place in the internal structure (e. g. the formation of cracks) of a solid (material). The benefits of the measurement of AEs are well known, and their application has already been described for various use cases. They are, for example, used for monitoring bridges to detect rope cracks. We want to investigate the possibilities of using AEs in the polishing process of glass, a complicated manufacturing process with several overlapping, chemical and mechanical influences. We will present the results of preliminary studies which shall answer the following questions: • Is it possible to measure acoustic emission signals, even if an unhindered access to the place of origin under manufacturing situations can not be guaranteed? • How is the development of the signal during the polishing process? • How can acoustic emissions be used in the future to improve optics manufacturing? • Is the opportunity of an endpoint detection existing? Answering these questions will demonstrate the abilities AEs can offer for evaluating and monitoring manufacturing processes. In the future it should be possible to create a cyber-physical system (CPS). In such a system, AE signals can be merged with other sensor signals (e. g. power of the machine, pH value, · · ·).
声发射(ae)是固体中的弹性应力波。当固体(材料)的内部结构发生不可逆的变化(如裂纹的形成)时,就会发生裂纹。度量ae的好处是众所周知的,并且它们的应用已经针对各种用例进行了描述。例如,它们被用于监测桥梁以检测绳索裂缝。我们想研究在玻璃抛光过程中使用AEs的可能性,这是一个复杂的制造过程,有几个重叠的化学和机械影响。我们将展示初步研究的结果,这些结果将回答以下问题:•即使不能保证在制造情况下不受阻碍地进入原产地,是否有可能测量声发射信号?•在抛光过程中信号的发展情况如何?•未来如何利用声发射来改进光学制造?•是否存在端点检测的机会?回答这些问题将展示ae在评估和监控制造过程方面的能力。在未来,应该有可能创建一个网络物理系统(CPS)。在该系统中,声发射信号可以与其他传感器信号(如机器功率,pH值,···)合并。
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引用次数: 0
Conceptual considerations for the paperless production of ophthalmic lenses 眼科镜片无纸化生产的概念考虑
Pub Date : 2023-09-05 DOI: 10.1117/12.2678303
Andreas Kaufmann
In addition to reducing paper consumption, paperless production offers the possibility of automating further work steps and additionally gaining further process information in the production of ophthalmic lenes.
除了减少纸张消耗外,无纸化生产还提供了进一步自动化工作步骤的可能性,并在眼科镜片的生产中获得进一步的工艺信息。
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引用次数: 0
Superposition of cryogenic and ultrasonic assisted machining of Zerodur 低温与超声辅助零度加工的叠加
Pub Date : 2023-09-05 DOI: 10.1117/12.2678074
Christian Vogt, Helge Thiess, Jacqueline Blasl, Nico Hanenkamp, Klaus Lichtinger
Cryogenic machining is a cooling strategy that has recently been frequently found in research in machining processes for materials such as inconel or titanium. In particular it is reported that these processes are more efficient in terms of tool life and material removal rate compared to those with water-based cooling lubrication. An increase in efficiency and productivity has significant potential from a cost perspective, especially when grinding Ceramic Matrix Composite materials and similar. These processes are used, for example, in the lightweighting of telescope mirrors made of e.g. fiber-reinforced silicon carbide, or Zerodur. An increase in productivity would be clearly noticeable in the manufacturing costs due to normally long machining times. In the "KryoSonic" project, we investigated whether and to what extent the use of cryogenic machining affects the rough machining of Zerodur with and without ultrasonic support.
低温加工是近年来在铬镍铁合金或钛等材料的加工工艺研究中经常发现的一种冷却策略。特别是,据报道,与水基冷却润滑相比,这些工艺在刀具寿命和材料去除率方面更有效。从成本的角度来看,效率和生产率的提高具有巨大的潜力,特别是在磨削陶瓷基复合材料和类似材料时。例如,这些工艺被用于由纤维增强碳化硅或Zerodur制成的望远镜反射镜的轻量化。由于通常较长的加工时间,生产率的提高将在制造成本中明显可见。在“KryoSonic”项目中,我们研究了使用低温加工是否以及在多大程度上影响有和没有超声波支撑的Zerodur粗加工。
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引用次数: 0
Simulation of system transmission values for different angles of incidence 不同入射角下系统传输值的仿真
Pub Date : 2023-09-05 DOI: 10.1117/12.2676121
Michael Wagner
For the design of a new asphere measuring system, it is necessary to know transmission values for a system consisting of a source, an optional auxiliary filter and an optical filter, on which angle-tuning is performed. To generate these transmission values for different angles of incidence and polarizations a simulation program was created. Input data of the simulation were based on data provided by the manufacturers. Simulation results are presented for a sample of four systems. Simulation was deemed successful and accelerates the design process of the metrology system, since a large range of source and filter combinations can be evaluated swiftly. Limitations of the simulation are discussed as well.
在设计一种新的非球面测量系统时,需要知道由光源、可选辅助滤光片和光学滤光片组成的系统的透射值,并对其进行角度调谐。为了生成不同入射角和不同偏振角的透射值,编写了一个仿真程序。仿真输入数据以厂家提供的数据为基础。给出了四个系统的仿真结果。仿真被认为是成功的,并且加速了计量系统的设计过程,因为可以快速评估大范围的源和滤波器组合。本文还讨论了模拟的局限性。
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引用次数: 0
Ultrasonic-assisted drilling of preforms for fibre optics 光纤预制体的超声辅助钻孔
Pub Date : 2023-09-05 DOI: 10.1117/12.2676016
Christian Pflanz, Jens Ketelaer
Fibre optics for demanding applications in communications, metrology, laser technology and medicine play an important role in today’s world. Thus, efficient manufacturing technologies to machine silica preforms, being the predominant material, are required. Ultrasonic-assisted drilling using diamond grinding tools is a very efficient and highly economical machining technology. In addition to significantly lower process forces and a longer tool life, there is less surface damage to the glass fibre preform. Besides the pure drilling process, also the alignment of the channels to a core fibre using automated camera systems is important to improve the overall productivity. Present developments of ultrasonic-assisted machining processes for preforms will be presented. An overall overview on ultrasonic drilling processes also for other applications will be given.
光纤在通信、计量、激光技术和医学等领域的应用在当今世界发挥着重要作用。因此,需要高效的制造技术来加工作为主要材料的二氧化硅预制体。超声辅助钻削金刚石磨具是一种高效、经济的加工技术。除了显著降低工艺力和延长刀具寿命外,玻璃纤维预制体的表面损伤也更少。除了纯粹的钻井过程外,使用自动摄像系统将通道对准核心纤维对于提高整体生产率也很重要。介绍了超声辅助预成形加工工艺的最新进展。本文将对超声钻孔工艺及其在其他方面的应用作一综述。
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引用次数: 0
Fast, semi-automated geometric and functional characterization of miniaturized lenses using optical coherence tomography-based systems and wavefront sensors 使用光学相干层析成像系统和波前传感器对小型化透镜进行快速、半自动的几何和功能表征
Pub Date : 2023-09-05 DOI: 10.1117/12.2675885
Alfredo Velazquez Iturbide, Robert Schmitt
Miniaturized lenses are increasingly utilized in a range of applications, including medical devices, optical communication, and imaging systems. The characterization of these lenses is crucial as their performance is highly dependent on their geometrical and functional properties. However, the small size of these lenses coupled with the required short measurement times, presents a significant challenge for conventional measurement techniques. Recent advances in optical coherence tomography (OCT) and Shack Hartmann wavefront sensors (SHWS) have enabled rapid, semi-automated geometric and functional characterization of miniaturized lenses when appropriate hardware, software, and algorithms are integrated. OCT is a non-invasive imaging technique that can provide high-resolution cross-sectional images of the lens, allowing the accurate measurement of its central thickness, curvature, and other geometric parameters of both surfaces. Moreover, SHWS can be used to measure the transmitted wavefront error of the lens, which is directly related to its optical performance. In this paper, we demonstrate the use of OCT and SHWS to characterize polymer and glass lenses with diameters and thicknesses of a few millimeters with spherical and aspherical shapes. Our results show that OCT is capable of accurately measuring the central thickness and surface profile of the lenses, while SHWS provides information on their wavefront aberrations. By combining these two techniques, we were able to obtain a com-prehensive characterization of the lenses' geometrical and functional properties.
小型化透镜越来越多地应用于各种应用,包括医疗设备、光通信和成像系统。这些透镜的特性是至关重要的,因为它们的性能高度依赖于它们的几何和功能特性。然而,这些镜头的小尺寸加上所需的短测量时间,对传统的测量技术提出了重大挑战。光学相干层析成像(OCT)和Shack Hartmann波前传感器(SHWS)的最新进展,在集成适当的硬件、软件和算法时,可以快速、半自动地对小型化透镜进行几何和功能表征。OCT是一种非侵入性成像技术,可以提供透镜的高分辨率横截面图像,允许精确测量其中心厚度,曲率和两个表面的其他几何参数。此外,SHWS可以用来测量透镜的透射波前误差,这直接关系到透镜的光学性能。在本文中,我们展示了使用OCT和SHWS来表征直径和厚度为几毫米的球形和非球形聚合物和玻璃透镜。我们的研究结果表明,OCT能够准确测量透镜的中心厚度和表面轮廓,而SHWS提供了它们的波前像差信息。通过结合这两种技术,我们能够获得透镜几何和功能特性的全面表征。
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引用次数: 0
Plasma jet polishing of optical surfaces 光学表面的等离子射流抛光
Pub Date : 2023-09-05 DOI: 10.1117/12.2675793
Heike Müller, Thomas Arnold
Plasma jet polishing of ground freeform optics is presented. Accurate measurement of local maximum surface temperature and a closed-loop for temperature-based power control is necessary to achieve form-preserving uniform surface polishing. Microroughness can be significantly reduced in one step. The roughness after plasma jet polishing in higher spatial frequencies strongly depends on the extend of sub-surface damage and grinding marks.
介绍了地面自由曲面光学的等离子体射流抛光。精确测量局部最高表面温度和基于温度的闭环功率控制是实现保持形状均匀表面抛光的必要条件。微粗糙度可以在一步中显着降低。在较高空间频率下,等离子射流抛光后的粗糙度与亚表面损伤和磨痕的范围密切相关。
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引用次数: 0
Analysis of flexibility in precision glass molding (PGM) 精密玻璃模压柔性分析
Pub Date : 2023-09-05 DOI: 10.1117/12.2675998
Carlos Marin Tovar, M. Friedrichs, T. Grunwald, Thomas Bergs
The demand for precision glass optics with complex shapes has increased in recent years, primarily in sectors such as lighting technology, automotive, laser technology, and consumer electronics. This rising trend, combined with production costs, represents a major challenge for the industry as demand needs to be met in a cost-effective manner. To address this challenge, the industry had developed innovative solutions to remain competitive. Precision glass molding (PGM) has emerged as a promising solution for this purpose. PGM is a replicative manufacturing process that enables a cost-effective production of precise glass optics. In this process, a glass preform is heated up into a viscoelastic state and pressed between a pair of molding tools. However, the manufacturing process of the molding tools can be both time-consuming and expensive. Additionally, they are specifically manufactured to produce a certain lens design under a given set of molding parameters. During this investigation, we considered a molding tool pair used to produce a specific lens design. We varied the process parameters, such as pressing force and temperature, into several different combinations, and produced the lenses subsequently. The aim is to analyze the flexibility in the PGM process, and to determine whether different lens geometries can be produced with a pair of molding tools. The final shape of the molded lenses was measured using a profilometer, while the center thickness of the lenses was measured with an absolute digital measuring probe. Finally, the shapes obtained from the molded lenses were compared and analyzed. The pressing temperature and force have a considerable impact in the final shape, which can be tuned along with other process parameters to achieve a certain degree of flexibility in the molding process.
近年来,对复杂形状的精密玻璃光学器件的需求有所增加,主要是在照明技术、汽车、激光技术和消费电子等领域。这种上升趋势与生产成本相结合,对该行业来说是一个重大挑战,因为需要以具有成本效益的方式满足需求。为了应对这一挑战,油气行业开发了创新的解决方案来保持竞争力。精密玻璃模塑(PGM)已成为解决这一问题的一个很有前途的解决方案。PGM是一种复制制造工艺,可实现高精度玻璃光学器件的经济高效生产。在这个过程中,玻璃预制品被加热到粘弹性状态,并在一对成型工具之间压制。然而,模具的制造过程既费时又昂贵。此外,它们是专门制造的,在给定的一组成型参数下生产某种透镜设计。在这次调查中,我们考虑了一种用于生产特定透镜设计的模具对。我们改变工艺参数,如压制力和温度,成几种不同的组合,并随后生产透镜。目的是分析PGM工艺的灵活性,并确定是否可以用一对成型工具生产不同的透镜几何形状。用轮廓仪测量成型透镜的最终形状,用绝对数字测量探头测量透镜的中心厚度。最后,对成型透镜的形状进行了比较和分析。压制温度和压力对最终形状有相当大的影响,可以与其他工艺参数一起调整,以在成型过程中实现一定程度的灵活性。
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引用次数: 0
Experimental investigations on the manufacturing of fused silica freeform surfaces by means of fine and ultra-fine grinding 精磨和超精磨加工熔融硅自由曲面的实验研究
Pub Date : 2023-09-05 DOI: 10.1117/12.2677292
Sebastian Henkel, Christian Schulze, Samson Frank, J. Bliedtner, E. Rädlein
The manufacturing of optical freeform surfaces offers a high potential for optical approaches in the future, since they can make new optical systems lighter and more compact or even enable completely new functions, compared to conventional optics. However, the expanded possibilities go hand in hand with higher complexity in production of freeforms for precision optical applications. This leads to high prices and long delivery times. This paper shows an approach to improve manufacturing of freeforms in small batch sizes with a high degree of customization, by a process chain consisting of (ultrasonic-assisted) pre- and fine grinding combined with ultra-fine grinding using resin bond tools. The process chain is suited for efficient fabrication of optical surfaces. A main focus of the experiments is on reduction of low- and mid-spatial frequency surface deviations, as well as surface roughness. Several different influencing factors in a 5-axis CNC grinding process of fused silica freeforms are investigated and their effects on the resulting surface topography (from the low to the high frequency range of surface deviations) are observed using white light interferometry measurement principles. Various optimization approaches can be concluded.
光学自由曲面的制造为未来的光学方法提供了很高的潜力,因为与传统光学相比,它们可以使新的光学系统更轻、更紧凑,甚至可以实现全新的功能。然而,扩展的可能性与精密光学应用的自由曲面生产的更高复杂性齐头并进。这导致价格高,交货时间长。本文展示了一种通过(超声辅助)预磨和精磨结合使用树脂结合工具的超精磨组成的工艺链,以提高小批量、高度定制的自由曲面制造的方法。该工艺链适用于光学表面的高效制造。实验的主要重点是减少低、中空间频率的表面偏差,以及表面粗糙度。利用白光干涉测量原理,研究了熔融石英自由曲面五轴数控磨削过程中几个不同的影响因素,并观察了它们对表面形貌的影响(从表面偏差的低频到高频范围)。可以归纳出各种优化方法。
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引用次数: 0
Fully automated centering and bonding of lenses for high-quality objectives 全自动定心和粘接高品质物镜镜头
Pub Date : 2022-07-15 DOI: 10.1117/12.2631763
Lisa Kempa, P. Langehanenberg, C. Wilde
Modern high-performance optical systems require new technologies for alignment and joining processes. With the established OptiCentric® Bonding 5D TRIOPTICS offers a technology that provides high-precision lens mounting based on adhesive bonding. With innovative alignment bonding in 5 dimensions, the lens surfaces are aligned to the tube with accuracies below 1 μm in x, y, z direction and below 2 arcsec in Θx and Θy direction. This fine-adjustment method doesn’t dependent on mechanical tolerances because the lens can move freely in the frame. By using high-resolution autocollimators as well as tactile and optical distance sensors the accuracy of each lens is checked after each step of machining. This procedure facilitates the stacking of several lenses into one tube without further costly alignment steps of sub-cells. This reduces the process steps and makes the multilens mounting into a tube more efficient. Furthermore, glue bonded lenses without sub-cells save space and weight due to waiver of set-screws and shims. Integrated into the production line this technology allows a greater degree of accuracy of optical systems and new design opportunities for more compact and higher-quality lenses. The highly flexible OptiCentric® Bonding 5D can be quickly converted to other types of lenses. This technology is also suitable for clean room applications.
现代高性能光学系统需要新的对准和连接工艺技术。凭借已建立的OptiCentric®Bonding 5D TRIOPTICS提供了一种基于粘合剂粘合的高精度镜头安装技术。通过创新的5维对准键,透镜表面对准管,在x、y、z方向上精度低于1 μm,在Θx和Θy方向上精度低于2弧秒。这种微调方法不依赖于机械公差,因为镜头可以在框架内自由移动。利用高分辨率的自准直仪以及触觉和光学距离传感器,在加工的每一步后检查每个镜头的精度。这一过程便于将多个透镜堆叠到一个管中,而无需进一步进行昂贵的亚细胞校准步骤。这减少了工艺步骤,使多镜头安装到一个管更有效。此外,由于无需固定螺钉和垫片,没有亚单元的胶水粘合透镜节省了空间和重量。将该技术集成到生产线中,可以提高光学系统的精度,并为更紧凑、更高质量的镜头提供新的设计机会。高度灵活的OptiCentric®Bonding 5D可以快速转换为其他类型的镜头。该技术也适用于洁净室应用。
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引用次数: 1
期刊
Precision Optics Manufacturing
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