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Precision glass molding: Toward an optimal fabrication of optical lenses

Liangchi ZHANG,Weidong LIU

《机械工程前沿（英文）》 2017年第12卷第1期页码 3-17 doi: 10.1007/s11465-017-0408-3

摘要：

It is costly and time consuming to use machining processes, such as grinding, polishing and lapping, to produce optical glass lenses with complex features. Precision glass molding (PGM) has thus been developed to realize an efficient manufacture of such optical components in a single step. However, PGM faces various technical challenges. For example, a PGM process must be carried out within the super-cooled region of optical glass above its glass transition temperature, in which the material has an unstable non-equilibrium structure. Within a narrow window of allowable temperature variation, the glass viscosity can change from 10⁵ to 10¹² Pa·s due to the kinetic fragility of the super-cooled liquid. This makes a PGM process sensitive to its molding temperature. In addition, because of the structural relaxation in this temperature window, the atomic structure that governs the material properties is strongly dependent on time and thermal history. Such complexity often leads to residual stresses and shape distortion in a lens molded, causing unexpected changes in density and refractive index. This review will discuss some of the central issues in PGM processes and provide a method based on a manufacturing chain consideration from mold material selection, property and deformation characterization of optical glass to process optimization. The realization of such optimization is a necessary step for the Industry 4.0 of PGM.

关键词： precision glass molding optical lens constitutive modeling optimization manufacturing chain Industry 4.0

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Recent advancements in optical microstructure fabrication through glass molding process

Tianfeng ZHOU,Xiaohua LIU,Zhiqiang LIANG,Yang LIU,Jiaqing XIE,Xibin WANG

《机械工程前沿（英文）》 2017年第12卷第1期页码 46-65 doi: 10.1007/s11465-017-0425-2

摘要：

Optical microstructures are increasingly applied in several fields, such as optical systems, precision measurement, and microfluid chips. Microstructures include microgrooves, microprisms, and microlenses. This paper presents an overview of optical microstructure fabrication through glass molding and highlights the applications of optical microstructures in mold fabrication and glass molding. The glass-mold interface friction and adhesion are also discussed. Moreover, the latest advancements in glass molding technologies are detailed, including new mold materials and their fabrication methods, viscoelastic constitutive modeling of glass, and microstructure molding process, as well as ultrasonic vibration-assisted molding technology.

关键词： optical microstructure microgroove microlens glass molding process single-point diamond cutting

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Micro-optical fabrication by ultraprecision diamond machining and precision molding

Hui LI, Likai LI, Neil J. NAPLES, Jeffrey W. ROBLEE, Allen Y. YI

《机械工程前沿（英文）》 2017年第12卷第2期页码 181-192 doi: 10.1007/s11465-017-0444-z

摘要：

Ultraprecision diamond machining and high volume molding for affordable high precision high performance optical elements are becoming a viable process in optical industry for low cost high quality microoptical component manufacturing. In this process, first high precision microoptical molds are fabricated using ultraprecision single point diamond machining followed by high volume production methods such as compression or injection molding. In the last two decades, there have been steady improvements in ultraprecision machine design and performance, particularly with the introduction of both slow tool and fast tool servo. Today optical molds, including freeform surfaces and microlens arrays, are routinely diamond machined to final finish without post machining polishing. For consumers, compression molding or injection molding provide efficient and high quality optics at extremely low cost. In this paper, first ultraprecision machine design and machining processes such as slow tool and fast too servo are described then both compression molding and injection molding of polymer optics are discussed. To implement precision optical manufacturing by molding, numerical modeling can be included in the future as a critical part of the manufacturing process to ensure high product quality.

关键词： ultraprecision machining slow tool servo fast tool servo compression molding injection molding microlens arrays optical fabrication

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成像光学工程面临的光学问题

潘君骅

《中国工程科学》 2000年第2卷第3期页码 32-35

摘要：

文章简单论述了现代成像光学主要领域的情况，指出非球面反射系统是发展的必然趋势。讨论了加工与检验方面的基本情况及应着重深人研究的问题。对镜坯材料也提了一点看法。

关键词：成像光学非球面反射镜光学设计光学加工与检验

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高端光学元件超精密加工技术与装备发展研究

蒋庄德, 李常胜, 孙林, 段端志, 康城玮, 陈杉杉, 林启敬, 杨树明

《中国工程科学》 2023年第25卷第1期页码 131-141 doi: 10.15302/J-SSCAE-2023.07.003

摘要：

高端光学元件是决定高端装备性能水平的核心零件，研究高端光学元件超精密加工技术与装备发展，对于实施制造强国战略、满足高端装备产业需求具有积极意义。本文剖析了光学元件超精密加工方法与装备、高性能基础部件、超精密光学加工中的测量方法与装备等的发展情况，凝练了精度与尺寸极端化、形状与性能一体化、加工工艺复合化、加工与检测一体化、装备与工艺智能化等发展趋势。通过广泛的行业调研和研讨，从需求、目标、产品、关键技术、应用示范、支撑保障等层次着手，形成了面向2035 年我国高端光学元件超精密制造技术路线图。针对性提出了优化创新体系设置、组织优势资源成立技术联盟，加大资源保障力度、布局基础研究和技术攻关计划，加强人才培育、构建梯队并扩大队伍规模，筑牢产业发展基础、培育龙头企业和专精特新“小巨人”企业等发展建议，以期促进高端光学元件加工产业提升与高质量发展。

关键词：光学元件；精密制造；超精密机床；超精密加工；光学加工

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Mesoscale fabrication of a complex surface for integral impeller blades

Xibin WANG,Tianfeng ZHOU,Lijing XIE,Li JIAO,Zhibing LIU,Zhiqiang LIANG,Pei YAN

《机械工程前沿（英文）》 2017年第12卷第1期页码 116-131 doi: 10.1007/s11465-017-0426-1

摘要：

Integral impeller is the most important component of a mini-engine. However, the machining of a mesoscale impeller with a complex integral surface is difficult because of its compact size and high accuracy requirement. A mesoscale component is usually manufactured by milling. However, a conventional milling tool cannot meet the machining requirements because of its size and stiffness. For the fabrication of a complex integral impeller, a micro-ball-end mill is designed in accordance with the non-instantaneous-pole envelope principle and manufactured by grinding based on the profile model of the helical groove and the mathematical model of the cutting edge curve. Subsequently, fractal theory is applied to characterize the surface quality of the integral impeller. The fractal theory-based characterization shows that the completed mesoscale integral impeller exhibits a favorable performance in terms of mechanical properties and morphological accuracy.

关键词： mesoscale fabrication micro-milling tool mesoscale milling impeller blade

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Development of surface reconstruction algorithms for optical interferometric measurement

Dongxu WU, Fengzhou FANG

《机械工程前沿（英文）》 2021年第16卷第1期页码 1-31 doi: 10.1007/s11465-020-0602-6

摘要： Optical interferometry is a powerful tool for measuring and characterizing areal surface topography in precision manufacturing. A variety of instruments based on optical interferometry have been developed to meet the measurement needs in various applications, but the existing techniques are simply not enough to meet the ever-increasing requirements in terms of accuracy, speed, robustness, and dynamic range, especially in on-line or on-machine conditions. This paper provides an in-depth perspective of surface topography reconstruction for optical interferometric measurements. Principles, configurations, and applications of typical optical interferometers with different capabilities and limitations are presented. Theoretical background and recent advances of fringe analysis algorithms, including coherence peak sensing and phase-shifting algorithm, are summarized. The new developments in measurement accuracy and repeatability, noise resistance, self-calibration ability, and computational efficiency are discussed. This paper also presents the new challenges that optical interferometry techniques are facing in surface topography measurement. To address these challenges, advanced techniques in image stitching, on-machine measurement, intelligent sampling, parallel computing, and deep learning are explored to improve the functional performance of optical interferometry in future manufacturing metrology.

关键词： surface topography measurement optical interferometry coherence envelope phase-shifting algorithm

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国外光纤光纤带和带状光缆技术的最新发展

刘良炎

《中国工程科学》 2001年第3卷第9期页码 86-94

摘要：

综合介绍了近年国外关于低衰耗的色散补偿光纤，非零色散位移光纤，用于恶劣环境的碳涂覆和氮化硅涂覆光纤的研究；光纤带制造技术包括光纤带的结构、涂层、性能、生产工艺，大芯数光纤带状光缆包括层绞式松管、中心松管式、骨架式、干缆芯带状光缆的设计制造技术的最新进展。

关键词：光纤通信低衰耗光纤光纤带光纤带状光缆

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Effects of critical geometric parameters on the optical performance of a conical cavity receiver

Hu XIAO, Yanping ZHANG, Cong YOU, Chongzhe ZOU, Quentin FALCOZ

《能源前沿（英文）》 2019年第13卷第4期页码 673-683 doi: 10.1007/s11708-019-0630-2

摘要： The optical performance of a receiver has a great influence on the efficiency and stability of a solar thermal power system. Most of the literature focuses on the optical performance of receivers with different geometric shapes, but less research is conducted on the effects of critical geometric parameters. In this paper, the commercial software TracePro was used to investigate the effects of some factors on a conical cavity receiver, such as the conical angle, the number of loops of the helical tube, and the distance between the focal point of the collector and the aperture. These factors affect the optical efficiency, the maximum heat flux density, and the light distribution in the conical cavity. The optical performance of the conical receiver was studied and analyzed using the Monte Carlo ray tracing method. To make a reliable simulation, the helical tube was attached to the inner wall of the cavity in the proposed model. The results showed that the amount of light rays reaching the helical tube increases with the increasing of the conical angle, while the optical efficiency decreases and the maximum heat flux density increases. The increase in the number of loops contributed to an increase in the optical efficiency and a uniform light distribution. The conical cavity receiver had an optimal optical performance when the focal point of the collector was near the aperture.

关键词： parabolic collector conical cavity receiver critical geometric parameters optical performance

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A multi-probe micro-fabrication apparatus based on the friction-induced fabrication method

Zhijiang WU, Chenfei SONG, Jian GUO, Bingjun YU, Linmao QIAN

《机械工程前沿（英文）》 2013年第8卷第4期页码 333-339 doi: 10.1007/s11465-013-0276-4

摘要：

A novel multi-probe micro-fabrication apparatus was developed based on the friction-induced fabrication method. The main parts of the apparatus include actuating device, loading system, and control system. With a motorized linear stage, the maximum fabrication area of 50 mm × 50 mm can be achieved, and the maximum sliding speed of probes can be as high as 10 mm/s. Through locating steel micro balls into indents array, the preparation of multi-probe array can be realized by a simple and low-cost way. The cantilever was designed as a structure of deformable parallelogram with two beams, by which the fabrication force can be precisely controlled. Combining the friction-induced scanning with selective etching in KOH solution, various micro-patterns were fabricated on Si(100) surface without any masks or exposure. As a low-cost and high efficiency fabrication device, the multi-probe micro-fabrication apparatus may encourage the development of friction-induced fabrication method and shed new light on the texture engineering.

关键词： friction-induced fabrication silicon surface texture friction multi-probe

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真空光镊技术综述 Special Feature on Precision Measurement and Inst

Nan LI, Xun-min ZHU, Wen-qiang LI, Zhen-hai FU, Meng-zhu HU, Hui-zhu HU

《信息与电子工程前沿（英文）》 2019年第20卷第5期页码 655-673 doi: 10.1631/FITEE.1900095

摘要：光镊技术自上世纪七十年代由阿瑟·阿什金开创以来，作为捕获和操纵中性粒子的通用工具，已在分子生物学、纳米技术和实验物理学等领域得到广泛研究和应用。基于光镊技术的传感与精密测量系统，通过激光束悬浮传感单元，而非与装置固连，相比传统固态传感器，无机械耗散。此外，与液体或空气介质中的光镊系统不同，在真空中运作的光镊系统可实现传感单元与环境的完全隔离。基于上述优势，基础物理学和应用物理学领域科学家对真空光镊开展了大量研究。本文回顾了真空光镊技术的基本概念和发展历史，帮助读者全面了解该领域。

关键词：光镊；真空光阱；激光冷却

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光传送网中光监控通道信号Q值在线监测技术

唐勇,孙小菡,张明德,丁东

《中国工程科学》 2001年第3卷第12期页码 71-75

摘要：

提出了一种带有光监控通道（OSC）子系统的光传送网（OTN）分层结构模型，分析了OSC中的信号特点，指出OSC信号质量决定了运行、管理和维护（OAM）信号的可靠性。依据Q值与误码率（BER）的一一对应关系，提出了一种可在线监测OSC信号Q值的方案，并基于数字信号处理芯片（DSP）技术设计了监测模块，实现了OSC信号在线Q值监测。

关键词：光传送网（OTN）光监控通道（OSC）运行、管理和维护（OAM） Q值监测

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New computational treatment of optical wave propagation in lossywaveguides

Jian-xin ZHU,Guan-jie WANG

《信息与电子工程前沿（英文）》 2015年第16卷第8期页码 646-653 doi: 10.1631/FITEE.1400406

摘要： In this paper, the optical wave propagation in lossy waveguides is described by the Helmholtz equation with the complex refractive-index, and the Chebyshev pseudospectral method is used to discretize the transverse operator of the equation. Meanwhile, an operator marching method, a one-way re-formulation based on the Dirichletto-Neumann (DtN) map, is improved to solve the equation. Numerical examples show that our treatment is more efficient.

关键词： Adjoint operator Orthogonal Chebyshev Pseudospectral method Dirichlet-to-Neumann map

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光纤通信技术发展现状与展望

谈仲纬,吕超

《中国工程科学》 2020年第22卷第3期页码 100-107 doi: 10.15302/J-SSCAE-2020.03.016

摘要：

作为激光技术的重要应用，光纤通信技术是搭建现代通信网络的重要桥梁。随着物联网、大数据、云计算、虚拟现实和人工智能等新兴技术的涌现，信息传递需求与日俱增，这对光纤通信技术的发展提出了更高要求。本文在系统梳理光纤通信技术国内外发展现状的基础上，分析了在具体场景应用中面临的问题与挑战，研判了未来光纤通信技术发展的方向。经研究分析，激光通信技术在超大容量光纤通信系统中面临的挑战可从发射功率增加、光放大器带宽增加、低传输损耗光纤以及空分复用相关技术研究等方面入手探讨解决思路；同时结合现实应用情况，本文对面向其他场景的光纤通信系统成本困境的解决进行了思考。总体而言，光纤通信技术将朝着超大容量、智能化、集成化的方向不断演进，未来期望可以实现智能化网络参数监测和超长距离、超大容量信息传输，并且随着集成技术和光通信器件的不断进步，必将推动整个光纤通信行业的高性能、低成本发展。

关键词：光纤通信光网络超大容量集成智能化

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Smart optical-fiber structure monitoring based on granular computing

Guan LU, Dakai LIANG,

《机械工程前沿（英文）》 2009年第4卷第4期页码 462-465 doi: 10.1007/s11465-009-0073-2

摘要： Using an optic fiber self-diagnosing system in health monitoring has become an important direction of smart materials and structure research. The buried optic fiber sensor can be used to test the parameters of the composite material. The granular computing method can reach the requirement of damage detection by analyzing digital signals and character signals of the smart structure at the same time. The paper investigates an optic fiber smart layer and presents a method for realizing optic fiber smart structure monitoring and damage detection by using granular computing. After the analysis, it is presumed that optic fiber smart structure monitoring based on granular computation can identify the damage from complex signals.

关键词： smart material and structure GrC optical fiber sensor rough set clustering algorithm