對(duì)模壓成型應(yīng)用的夾層玻璃毛胚是有規(guī)定的：
①壓型板前毛胚的表層一定要維持十分光潔和清理；
②呈適度的幾何圖形樣子；
③有一定的必須的容積。毛胚一般都采用球型、餅形形或曲面樣子，選用冷碾磨成形或壓合成形。
模具材料必須具有以下特點(diǎn)：
①表層無疵病，可以碾磨成無出氣孔、光潔的電子光學(xué)鏡面玻璃；
②在高溫自然環(huán)境標(biāo)準(zhǔn)下具備很高的耐空氣氧化特性，并且構(gòu)造等不產(chǎn)生變化，工藝性能平穩(wěn)，面型精密度和光滑度維持不會(huì)改變；
③不與夾層玻璃起反映、產(chǎn)生黏連狀況，出模特性好；
④在高溫標(biāo)準(zhǔn)下具備很高的強(qiáng)度和抗壓強(qiáng)度等。
如今現(xiàn)有許多 相關(guān)開發(fā)設(shè)計(jì)模具材料的專利權(quán)，最有象征性的模具材料是：以超硬鋁合金做基材，表層鍍有貴重金屬鋁合金和氮化鈦等塑膠薄膜；以碳碳復(fù)合材料和超硬鋁合金做基材，表層鍍有硬質(zhì)的碳、金鋼石狀碳等碳系塑膠薄膜；及其Cr2O-ZrO2-TiO2系新式瓷器。
夾層玻璃鏡片壓型板用的模具材料，一般全是硬脆原材料，要想把這種模具材料精密機(jī)械加工成磨具，必不可少應(yīng)用高剛度的、螢?zāi)唤馕龆饶茏龅?.01μm下列的高圖元超高精密電子電腦電腦控制生產(chǎn)加工數(shù)控車床，用金鋼石磨輪開展切削生產(chǎn)加工。切削生產(chǎn)加工可得到 所盼望的樣子精密度，但隨后還需再稍稍打磨拋光深度加工成電子光學(xué)鏡面玻璃才行。在開展高精密的非球面生產(chǎn)加工中，非球面面型的檢測(cè)與點(diǎn)評(píng)技術(shù)性是十分關(guān)鍵的。對(duì)小型鏡片壓型板用模的生產(chǎn)加工，規(guī)定更為嚴(yán)苛，必不可少進(jìn)一步提高精密度和緩解切削的印痕。
Requirements for Glass Blanks Used in Precision Molding
1. Surface Cleanliness:
The surface of the blank must be exceptionally smooth and clean before molding.
2. Geometric Shape:
The blank must have an appropriate geometric shape.
3. Volume:
The blank must have the necessary volume for the molding process.
Blanks are typically spherical, disk-shaped, or curved and are produced through cold grinding or pressing methods.
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Characteristics Required for Mold Materials
1. Surface Perfection:
The mold surface must be free of defects and capable of being polished to achieve a pore-free, smooth optical mirror finish.
2. High Temperature Stability:
The material must exhibit excellent resistance to oxidation in high-temperature environments, with stable structural and processing properties. Surface precision and smoothness should remain unaffected under these conditions.
3. Non-Reactive with Glass:
The mold material must not react with the glass or cause adhesion. It should facilitate easy demolding.
4. Strength and Hardness:
The material must possess high strength and hardness to withstand high temperatures and pressure conditions.
These requirements ensure the production of high-quality optical components with precision and durability.
Currently, there are numerous patents related to the development of mold materials for precision molding. The most representative mold materials include:
1. Super-Hard Aluminum Alloys:
o Used as a base material.
o Coated with precious metal alloys and titanium nitride thin films.
2. Carbon-Based Composite Materials:
o Super-hard aluminum alloys and carbon-carbon composites serve as the base materials.
o Coated with hard carbon or diamond-like carbon (DLC) thin films.
3. New Ceramic Materials:
o Compositions such as Cr?O?-ZrO?-TiO? are employed as innovative ceramic materials for molds.
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Mold Material Requirements for Glass Lens Precision Molding
Mold materials for precision molding of glass lenses are typically hard and brittle. To achieve high precision in manufacturing these molds, the following technologies and equipment are essential:
1. High-Stiffness CNC Machines:
o Ultra-high-precision computer-controlled CNC lathes are required.
o These machines must achieve resolutions below 0.01 μm to process the desired shape accurately.
2. Diamond Grinding Wheels:
o Cutting processes use diamond grinding wheels to achieve the required shape precision.
3. Polishing for Optical Mirror Finish:
o After cutting, the molds must be finely polished to achieve an optical mirror finish suitable for lens production.
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Challenges in Aspheric Surface Processing
1. Testing and Evaluation of Aspheric Shapes:
o Aspheric surface measurement and evaluation techniques are critical in achieving precise mold shapes.
2. High Precision for Small Lens Molds:
o Manufacturing molds for small lenses requires even stricter precision standards.
o Cutting marks must be minimized, and the processing accuracy further improved.
These advanced materials and processing techniques ensure the production of molds capable of meeting the stringent requirements of precision molding for optical glass lenses.
