光学玻璃离心熔铸过程中成型热历史对反射镜的影响
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摘要
为了研究离心熔铸反射镜制造技术中热历史状态(成型温度及冷却速度)对成型效果的影响,采用有限元分析软件Abaqus对不同的成型温度及冷却速率进行仿真分析,确定成型温度为950℃、冷却速率为1℃/s时可以完成反射镜在模具中的充模和成型;之后进行离心熔铸试验并对成型结果进行测量。在冷却速度大于1℃/s时,反射镜由于冷却后局部残余应力过大,导致其发生碎裂。同时通过对仿真结果、理论计算结果以及试验结果的分析对比,得到反射镜边缘的轴向高度与理论值相差10.12 mm,具有较大的面型误差,产生面型误差的原因是由于在高温成型冷却后反射镜体积收缩导致面型发生变化。
This study investigates the influence of thermal history(molding temperature and cooling rate) on the mirror forming process for spin-cast aspheric mirrors. Abaqus finite element analysis software using different molding temperature and cooling rate of simulation analysis to determine the Spin-cast temperature is 950 ℃ and the cooling rate of mirror is 1 ℃/s which can be completed in the mold filling and mirror forming. The spin-cast experiment was executed, and the forming results were measured. When the cooling rate is more than 1 ℃/s, the mirror is fragmented owing to the excessive local residual stress after cooling. Additionally, the axial height of the mirror edge differs from the theoretical value by 10.12 mm, and there is a large surface figure error. This surface figure error is attributable to the volume change on cooling.
This study investigates the influence of thermal history(molding temperature and cooling rate) on the mirror forming process for spin-cast aspheric mirrors. Abaqus finite element analysis software using different molding temperature and cooling rate of simulation analysis to determine the Spin-cast temperature is 950 ℃ and the cooling rate of mirror is 1 ℃/s which can be completed in the mold filling and mirror forming. The spin-cast experiment was executed, and the forming results were measured. When the cooling rate is more than 1 ℃/s, the mirror is fragmented owing to the excessive local residual stress after cooling. Additionally, the axial height of the mirror edge differs from the theoretical value by 10.12 mm, and there is a large surface figure error. This surface figure error is attributable to the volume change on cooling.
引文
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[11] 李峰,刘尧龙. 浅析热历史在玻璃成型中的作用[J]. 中国玻璃, 2015(3):7-8.LI F, LIU Y L.A brief analysis of the role of thermal history in glass forming [J]. China Glass, 2015 (3): 7-8.(in Chinese)
[12] DAS A, MONDAL SC, THAKKAR J J, et al.. A methodology for modeling and monitoring of centrifugal casting process[J]. International Journal of Quality & Reliability Management, 2015, 32(7):718-735.
[13] BONA E F. Liquid mirrors[J]. Scientific American,2004,270(2):76-81.
[14] XU X L, ZHANG X M. Centrifugal processing on aspheric mirror blank of optical glass material[J]. Key Engineering Materials, 2017, 744(4): 404-408.
[15] YAN J, ZHOU T, MASUDA J, et al.. Modeling high-temperature glass molding process by coupling heat transfer and viscous deformation analysis[J]. Precision Engineering, 2009, 33(2):150-159.
[16] JAIN, ANURAG. Experimental study and numerical analysis of molding process for manufacturing precision aspherical glass lenses[J]. Journal of the American Ceramic Society, 2006, 13(2):65-69.
[17] ANANTHASAYANAM B. Computational modeling of precision molding of aspheric glass optics[J]. Dissertations & Theses - Gradworks, 2008:3349809.
[18] 周萘,曹艳丽,吴知方,等. 玻璃对耐火材料侵蚀机理研究[J]. 建筑材料学报, 2012, 5(1):99-102.ZHOU N, CAO Y L, WU ZH F, et al..Erosion mechanism of blast furnace slag glass on refractory [J].Journal of Building Materials, 2012, 5 (1): 99-102.(in Chinese)
[19] 苏英,贺行洋.石英玻璃的结构弛豫及其影响因素[J].材料导报, 2007, 21(8):11-14.SU Y, HE X Y. Structural relaxation of quartz glass and its influencing factors [J].Materials And Information, 2007, 21(8):11-14.(in Chinese)
[20] 张景超, 李贺光, 闰玺.玻璃退火的应力分析[J].燕山大学学报,2012,36(3):235-240.ZHANG J CH, LI H G, REN X.Stress analysis of glass annealing [J]. Journal of Yanshan University, 2012,36 (3): 235-240.(in Chinese)
[2] 姜波, 吴越豪, 戴世勋,等. 大口径硫系玻璃内部缺陷检测物镜设计及实验验证[J]. 红外与激光工程, 2016, 45(7):172-178.. JIANG B, WU Y H, DAI SH X, et al..Design and experimental verification of objective detection of large-caliber chalcogenide glass internal defects [J]. Infrared and Laser Engineering, 2016,45 (7): 172-178.(in Chinese)
[3] 辛企明.光学塑料非球面技术的发展趋势[J].激光与光电子学进展,2010,46(12):11-16.XIN Q M.Development trend of optical plastic aspheric technology [J]. Advances in Laser and Optoelectronics, 2010,46 (12):11-16.(in Chinese)
[4] 尹韶辉,曾宪良,范玉峰,等.ELID镜面磨削加工技术研究进展[J].中国机械工程学报,2010,21(6):750-755 YIN SH H, ZENG X L, FAN Y F, et al..Research progress on mirror grinding of ELID[J].Chinese Journal of Mechanical Engineering, 2010,21 (6): 750-755.(in Chinese)
[5] 王勤,余景池,胡祖元.非球面复制成型技术的研究[J].光学技术,2006, 32(1):121M-123WANG Q, YU J CH, HU Z Y. Study on aspheric copy molding technology[J]. Optics Technology, 2006, 32 (1):121-123.(in Chinese)
[6] 郭永祥, 李永强, 廖志波,等. 新型离轴三反射光学系统设计[J]. 红外与激光工程, 2014, 43(2):546-550.GUO Y X, LI Y Q, LIAO ZH B, et al..Design of a new off-axis three-reflection optical system [J]. Infrared and Laser Engineering, 2014, 43 (2): 546-550.(in Chinese)
[7] 徐乐,张春雷,代雷,等. 高精度非回转对称非球面加工方法研究[J].中国光学, 2016, 9(3):364-370.XU L, ZHANG CH L, DAI L, et al..High precision non-rotational symmetric aspheric processing method [J].Chinese Optics, 2016,9 (3): 364-370.(in Chinese)
[8] CHENG A Y S, ANGEL J R P. Steps toward 8M honeycomb mirrors VIII: design and demonstration of a system of thermal control[J]. Proceedings of SPIE - The International Society for Optical Engineering, 1986, 628:536-544.
[9] ANGEL J R P, HILL J M. Manufacture of large glass honeycomb mirrors[J]. Physica Scripta, 1982, 332(12):298-306.
[10] HILL J M, ANGEL J R P. Casting the first 8.4-m borosilicate honeycomb mirror for the large binocular telescope[J]. Proceedings of SPIE - The International Society for Optical Engineering, 1998, 3352.
[11] 李峰,刘尧龙. 浅析热历史在玻璃成型中的作用[J]. 中国玻璃, 2015(3):7-8.LI F, LIU Y L.A brief analysis of the role of thermal history in glass forming [J]. China Glass, 2015 (3): 7-8.(in Chinese)
[12] DAS A, MONDAL SC, THAKKAR J J, et al.. A methodology for modeling and monitoring of centrifugal casting process[J]. International Journal of Quality & Reliability Management, 2015, 32(7):718-735.
[13] BONA E F. Liquid mirrors[J]. Scientific American,2004,270(2):76-81.
[14] XU X L, ZHANG X M. Centrifugal processing on aspheric mirror blank of optical glass material[J]. Key Engineering Materials, 2017, 744(4): 404-408.
[15] YAN J, ZHOU T, MASUDA J, et al.. Modeling high-temperature glass molding process by coupling heat transfer and viscous deformation analysis[J]. Precision Engineering, 2009, 33(2):150-159.
[16] JAIN, ANURAG. Experimental study and numerical analysis of molding process for manufacturing precision aspherical glass lenses[J]. Journal of the American Ceramic Society, 2006, 13(2):65-69.
[17] ANANTHASAYANAM B. Computational modeling of precision molding of aspheric glass optics[J]. Dissertations & Theses - Gradworks, 2008:3349809.
[18] 周萘,曹艳丽,吴知方,等. 玻璃对耐火材料侵蚀机理研究[J]. 建筑材料学报, 2012, 5(1):99-102.ZHOU N, CAO Y L, WU ZH F, et al..Erosion mechanism of blast furnace slag glass on refractory [J].Journal of Building Materials, 2012, 5 (1): 99-102.(in Chinese)
[19] 苏英,贺行洋.石英玻璃的结构弛豫及其影响因素[J].材料导报, 2007, 21(8):11-14.SU Y, HE X Y. Structural relaxation of quartz glass and its influencing factors [J].Materials And Information, 2007, 21(8):11-14.(in Chinese)
[20] 张景超, 李贺光, 闰玺.玻璃退火的应力分析[J].燕山大学学报,2012,36(3):235-240.ZHANG J CH, LI H G, REN X.Stress analysis of glass annealing [J]. Journal of Yanshan University, 2012,36 (3): 235-240.(in Chinese)