Precision glass molding (PGM) technology provides a possibility of rapidly manufacturing optical lenses with large volume, high precision, and complex shapes. It is difficult to fabricate micrometer-level structures in common PGM mold materials like tungsten carbide (WC) using a grinding/polishing approach. But no literature has pointed out how to design the dimensional tolerance of molds to ensure the molding accuracy in the case of the molds working in a temperature range of several hundreds of degrees Celsius. In this paper, a theoretical model is established based on the general molds designed sizes. The finite element method (FEM) and the PGM experiments were carried out. The measuring results of the decenter and tilt of the molded lens indicated that the optimization was effective and could be applied to other PGM experiments.
The fabrication of high-precision mold core can make the optical elements of freeform surface be mass-produced by plastic injection or glass mold pressing. However, diamond tools cannot directly cut ferrous materials due to rapid wear of tool. Therefore, the technology of ultrasonic assisted diamond turning is proposed to process the freeform surface on the die steel in this paper. The characteristics of vibration servo machining are analyzed and discussed by theoretical modeling and digital simulating. After fabricating freeform surface on die steel by this technology, the value Ra of surface roughness can be achieve to 5.905nm.
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