Precision Grinding of Structured Tungsten Carbide Mold

2012 ◽  
Vol 497 ◽  
pp. 15-19 ◽  
Author(s):  
Hirofumi Suzuki ◽  
Tatsuya Furuki ◽  
Mutsumi Okada ◽  
Yutaka Yamagata ◽  
Shinya MORITA
Keyword(s):  
Tungsten Carbide ◽  
Power Efficiency ◽  
Fresnel Lens ◽  
Rare Metal ◽  
Diamond Wheel ◽  
Precision Grinding ◽  
Form Accuracy ◽  
Molding Method ◽  
Grinding Method ◽  
Glass Lens

Demands of glass Fresnel lens is increasing in solar panel in order to increase power efficiency. Glass lens is usually molded by glass molding method with tungsten carbide molds. In this study, large Fresnel lens molds made of tungsten carbide are tested to be ground by simultaneous 2-axis (Y, Z) controlled grinding method. The resinoid bonded diamond wheel was trued with a rare metal truer to improve the sharpness of the wheel edge. In the grinding test of the tungsten carbide mold, a form accuracy of less than 0.8 μm P-V and surface roughness of 18 nm Rz were obtained, and it is clarified that the proposed grinding method is useful for the Fresnel grinding.

High Precision Grinding of Large Fresnel Lens Mold

2012 ◽  
Vol 516 ◽  
pp. 629-633
Author(s):  
Tatsuya Furuki ◽  
Hirofumi Suzuki ◽  
Mutsumi Okada ◽  
Yutaka Yamagata ◽  
Shinya MORITA
Keyword(s):  
Tungsten Carbide ◽  
Power Efficiency ◽  
Fresnel Lens ◽  
Rare Metal ◽  
Diamond Wheel ◽  
Precision Grinding ◽  
Form Accuracy ◽  
Grinding Method ◽  
Fresnel Lenses ◽  
Glass Lenses

Demand for glass Fresnel lenses is increasing in solar panel manufacture in order to increase power efficiency. Glass lenses are usually moulded using a glass moulding method with tungsten carbide moulds. In this study, large Fresnel lens moulds made of tungsten carbide are tested to be ground by a simultaneous 2-axis (Y, Z) controlled grinding method. The resinoid bonded diamond wheel is trued with a rare metal truer to increase the sharpness of the wheel edge. In the grinding test of the tungsten carbide mould, a form accuracy of less than 0.8 μm P-V and surface roughness of 18 nm Rz are obtained, and it is clarified that the proposed grinding method is useful for Fresnel grinding.

Ultrasonic Vibration Assisted Grinding of Microstructures on Binderless Tungsten Carbide (WC)

2014 ◽  
Vol 625 ◽  
pp. 475-479 ◽  
Author(s):  
Bing Guo ◽  
Qing Liang Zhao ◽  
Yan Hou ◽  
Cheng Ge ◽  
Xin Yu
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
Ultrasonic Vibration ◽  
Ground Surface ◽  
Precision Grinding ◽  
Form Accuracy ◽  
Grinding Method ◽  
Edge Radius ◽  
Microstructured Surfaces ◽  
Ultrasonic Vibration Assisted Grinding

Microstructured optical elements made of glass are generally replicated by hot pressing with super-hard materials, such as binderless tungsten carbide (WC) and precision ceramic. However, in grinding of microstructures, problems frequently occur in terms of rough ground surface, chipping and rounding of micro-structures edges when compared to conventional grinding. In order to overcome these technological constraints, a promising precision grinding method for microstructured surfaces that applies ultrasonic vibration to improve the surface quality, and protect the edges and tips of microstructured surfaces is presented. The experimental investigation of ultrasonic vibration assisted grinding of microstructures on binderless WC is researched. The effects of ultrasonic vibration on surface roughness, form accuracy and edge radius were analyzed. The morphology of surface and array edges was examined with a scanning electron microscope (SEM), while the surface roughness was measured by a laser interferometer. And a contact probe profilometer was used to assess the form of array and radius of microstructured edges. Experimental results showed that the application of ultrasonic vibration leads to significant improvements of the surface roughness and edges of microstructures compared with traditional precision grinding processes. A micro cylinder lens array of binderless WC with surface roughness of 78nm and edge radius of less than 1μm was obtained. The novel grinding method is feasible and applicable in machining higher form accuracy microstructures.

scholarly journals Precision Grinding of Micro Fresnel Lens Molding Die. Feasibility Study on Precision Grinding of Tungsten Carbide.

1999 ◽  
Vol 65 (8) ◽  
pp. 1163-1168 ◽  
Author(s):  
Hirofumi SUZUKI ◽  
Toshiro HIGUCHI ◽  
Naoshi WAJIMA ◽  
Takayuki KITAJIMA ◽  
Shigeki OKUYAMA ◽  
...  
Keyword(s):  
Tungsten Carbide ◽  
Feasibility Study ◽  
Fresnel Lens ◽  
Precision Grinding ◽  
Lens Molding

Study on Precision Grinding Technique for Large Size Optical Aspheric Lens

2013 ◽  
Vol 395-396 ◽  
pp. 1015-1019 ◽  
Author(s):  
Xiao Long Ke ◽  
Jian Chun Liu ◽  
Hai Bin Huang
Keyword(s):  
Diamond Wheel ◽  
Surface Measurement ◽  
Machining Accuracy ◽  
Precision Grinding ◽  
Aspheric Lens ◽  
Grinding Method ◽  
Large Size ◽  
Grinding Technique ◽  
Measurement And Evaluation ◽  
Grinding Machine

Large size optical aspheric lens is an important component in optical engineering. Aiming at the demand of precision processing for optical aspheric lens, this paper develops a precision grinding technique for large size optical aspheric lens. Based on precision surface grinding machine (MGK7160), grating-type parallel grinding method is put forward to realize grinding paths planning for optical aspheric lens. An on-machine measurement system is built to obtain surface measurement and evaluation after grinding. In order to ensure machining precision and efficiency, a diamond truer which self-developed is adopted to precision dress for arc diamond wheel. Finally, the experiment of precision grinding and error compensation validates machining accuracy for large size optical aspheric lens.

Fabrication of Micro Aspheric Mould Integrated Ultra-Precision Grinding and Magnetorheological Finishing

2010 ◽  
Vol 135 ◽  
pp. 134-138 ◽  
Author(s):  
Shao Hui Yin ◽  
Heng Ning Tang ◽  
Jian Wu Yu ◽  
Kun Tang ◽  
Feng Jun Chen ◽  
...  
Keyword(s):  
Surface Quality ◽  
Magnetorheological Finishing ◽  
Precision Grinding ◽  
Form Accuracy ◽  
Ultra Precision ◽  
Glass Lens ◽  
Parallel Grinding

This paper deals with one-point parallel grinding and magnetorheological finishing (MRF) polishing of micro glass lens mould. Firstly,the analysis and experiment of one-point parallel grinding are conducted on micro-aspheric mould with 10mm in diameter , after grinding ,the results show that the form accuracy of the micro aspheric mould are 2.538 μm in PVand 0.645 μm in RMS, also the subsurface damages and residual grinding marks are left ;And then , the magnetorheological finishing experiment is counducted, the form accuracy achieves 0.892 μm in PV and 0.287 μm in RMS ,after finishing, the surface quality was improved.

Optical Properties of Aspheric Glass Lens Using DLC Coating Mold

2007 ◽  
Vol 345-346 ◽  
pp. 1577-1580 ◽  
Author(s):  
Hyun Uk Kim ◽  
Sang Hwa Jeong ◽  
Hye Jeong Kim ◽  
Jeong Ho Kim
Keyword(s):  
Precision Grinding ◽  
Camera Phone ◽  
Form Accuracy ◽  
Ion Plating ◽  
Dlc Coating ◽  
Aspheric Glass Lens ◽  
Before And After ◽  
Ultra Precision ◽  
Glass Lens ◽  
Coating Mold

In this research, the optimal grinding condition has been obtained by design of experiment(DOE) for the development of aspheric lens for the 3 Mega Pixel, 2.5x optical zoom camera-phone module. Also, the WC mold was processed by the method of ultra precision grinding under this optimal grinding condition. The influence of DLC coating on form accuracy (PV) and surface roughness(Ra) of the mold was evaluated through measurements after DCL coating using ion plating on the ground mold. Also, aspheric glass lens was molded by before and after the use of the mold of DLC coating, respectively. The optical characteristics of each sample, which were molded by the different mold, were compared with each other.

Dressing of Grinding Wheels for Ultra Precision Grinding of Diffractive Structures in Tungsten Carbide Molds

2014 ◽  
Vol 625 ◽  
pp. 161-166 ◽  
Author(s):  
Thomas Bletek ◽  
Fritz Klocke ◽  
Martin Hünten ◽  
Olaf Dambon
Keyword(s):  
Tungsten Carbide ◽  
Grinding Wheel ◽  
Geometric Features ◽  
Grinding Wheels ◽  
Precision Grinding ◽  
Form Accuracy ◽  
Fine Grained ◽  
Diffractive Structure ◽  
Ultra Precision ◽  
Diffractive Structures

The manufacturing of molds with diffractive structures requires new approaches in terms of grinding wheel geometry and preparation. To be able to manufacture small geometric features such as widths and depths in the micron range on the mold, ideally sharp edged grinding wheels should be used. This paper will present dressing procedures to create sharp edged grinding wheels by using metal alloy blocks. The results and achieved tip radii of the dressed resin bonded and metal bonded fine grained grinding wheels will be presented. Finally, grinding tests of a tungsten carbide mold with a diffractive structure are conducted and the results of the achieved form accuracy and surface roughness are presented.

Research on the 3-Axis CNC Ultra-Precision Grinding of Aspheric Mould

2009 ◽  
Vol 69-70 ◽  
pp. 39-43 ◽  
Author(s):  
Li Jun Li ◽  
Fei Hu Zhang ◽  
Shen Dong
Keyword(s):  
Influence Factors ◽  
Grinding Wheel ◽  
Aspheric Surface ◽  
Precision Grinding ◽  
Form Accuracy ◽  
Form Errors ◽  
Machining Test ◽  
Ultra Precision ◽  
Grinding System ◽  
Parallel Grinding

Parallel grinding is an effective method of aspheric moulds machining which is usually made of industrial ceramic such as silicon carbide (SiC) or tungsten carbide (WC), but if the spherical grinding wheel is not being with precision truing and dressing, the roughness and form accuracy of the ground aspheric surface should get worse, for this reason, in this paper, the influence factors of thoroughness and form accuracy induced by the wheel truing and dressing are studied firstly, and a new 3-axis CNC Ultra-precision grinding system which is based on the PMAC (Programmable Multi-axes Controller) is developed, through simultaneous motion of the controlled X, Z and B axis, the form errors which is induced by the grinding wheel can be improved theoretically, and the aspheric mould machining test shown that the surface roughness of Ra 0.025μm and the form accuracy of P-V 1.15μm are achieved.

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