Zinc sulfide (ZnS) is a widely used material in far-infrared and near-infrared imaging systems due to its exceptional optical transmittance properties. Through a hot isostatic compression process, during manufacturing, ZnS undergoes crystal structure modifications, resulting in increased transmittance across the visible and infrared spectra. However, ZnS exhibits low fracture toughness and irregular crystal orientations, making it prone to brittle fracture during the conventional cutting processes. Such brittleness often leads to surface defects that scatter light, diminishing optical transmittance. Therefore, understanding the conditions conducive to ductile processing is critical and necessitates a thorough brittle fracture analysis. This study introduces a novel quantitative analysis method to determine the occurrence of ductile processing and brittle fracture in ZnS materials after the turning process. To validate the efficacy of this approach, experimental machining was conducted through diamond turning and magnetorheological fluid polishing processes. Subsequently, a comprehensive quantitative assessment of brittle fracture was performed. Additionally, the relationship between brittle fracture and optical transmittance was explored using the proposed analysis method.
Here in, a high-quality automotive camera lens was developed based on an ultra-precision diamond turning core and cyclic olefin polymer (COP) injection molding process. To improve surface roughness and achieve the accuracy of plastic injection molding lens, systematic mold core machining process was developed and demonstrated using the diamond turning machine. The cutting tool path was generated by using NanoCAM 2D, and it was partly revised to prevent interference between the cutting tool and the workpiece. After the initial machining using the generated tool path, the compensation-cutting process was conducted based on the measured surface profile of an initially machined surface. After two times of compensation machining, the fabricated core mold showed a shape error of 100 nm between peak to valley (PV) and Arithmetic mean roughness (Ra) of 3.9 nm. The performance of the fabricated core was evaluated using an injection molding test. Injection molded aspheric plastic lens showed contrasts that were higher than 55% at 0.0 F, 30% at 0.3 F, and 20% at 0.7 F without any moiré phenomenon that meets the specification for automotive vision module with 1MP and 140° field of view.
Citations
Citations to this article as recorded by
Research progress on grinding contact theory of axisymmetric aspheric optical elements Wenzhang Yang, Bing Chen, Bing Guo, Qingliang Zhao, Juchuan Dai, Guangye Qing Precision Engineering.2026; 97: 24. CrossRef
Performance enhancement of material removal using a surface-refinement model based on spatial frequency–response characteristics in magnetorheological finishing Minwoo Jeon, Seok-Kyeong Jeong, Woo-Jong Yeo, Hwan-Jin Choi, Mincheol Kim, Min-Gab Bog, Wonkyun Lee The International Journal of Advanced Manufacturing Technology.2024; 135(11-12): 5391. CrossRef
Recently, interest in astronomy has increased internationally, and the technological development of lenses for large space telescopes is progressing. The multi-order diffractive engineered (MODE) lenses can make a large space telescope light and thin. However, because glass lenses are difficult to machine, we have adopted a method of molding at high temperature and high pressure. The STAVAX is commercially available chrome alloy stainless steel, and it is applied as various mold materials. The ultrasonic vibration cutting was adopted for ultra-precision machining because the tool wear is severe when cutting the STAVAX with a diamond tool. To achieve a flat surface for smooth ultrasonic vibration cutting, we performed a precise shape cutting using a CBN tool and confirmed and observed changes in the surface roughness and hardness depending on the cutting conditions. The ultrasonic vibration cutting was performed on the surface of the machine using a CBN tool, and the surface roughness was observed. It was confirmed that the surface roughness was impacted by the surface hardness. The specimens with low surface hardness showed the highest surface roughness at approximately 3 nm.
Citations
Citations to this article as recorded by
Study on Reduction of Pyrolysis Shrinkage in the Carbonization of Furan Precursor by Addition of Vitreous Carbon Powder Young Kyu Kim, Dong-in Hong, Hongmin Kim, Suho Ahn, Seok-Min Kim Journal of the Korean Society for Precision Engineering.2024; 41(2): 139. CrossRef
Fabrication and Characterization of Automotive Aspheric Camera Lens Mold based on Ultra-precision Diamond Turning Process Ji-Young Jeong, Hwan-Jin Choi, Jong Sung Park, Jong-Keun Sim, Young-Jae Kim, Eun-Ji Gwak, Doo-Sun Choi, Tae-Jin Je, Jun Sae Han Journal of the Korean Society for Precision Engineering.2024; 41(2): 101. CrossRef
Analysis of Environmental Factors Affecting the Machining Accuracy Young Bok Kim, Wee Sam Lee, June Park, Yeon Hwang, June Key Lee Journal of the Korean Society of Manufacturing Process Engineers.2021; 20(7): 15. CrossRef
Infrared (IR) optic lens can be fabricated by a single point diamond turning (SPDT) machine without subsequent polishing process. However, this machining process often leaves microcracks that deteriorate the surface quality. In this work, we propose an experimental design to remove micro-cracks on IR lens. The proposed design gathered data between cutting process condition and Rt surface roughness. This is of great importance because the scale of microcracks is a few micrometer. Rt surface roughness is suitable for analyzing maximum peak height signals of the profile. The experimental results indicate that feed per revolution variable is one of the most dominant variable, affecting the generation micro-cracks on IR lens surfaces.
The micro barrier rip array structures have been applied in a variety of areas including as privacy films, micro heat sinks, touch panel and optical waveguide. The increased aspect ratio (AR) of barrier rip array structures is required in order to increase the efficiency and performance of these products. There are several problems such as burr, defect of surface roughness and deformation and breakage of barrier rip structure with machining high-aspect ratio micro barrier rip array structure using orthogonal cutting method. It is essential to develop technological methods to solve these problems. The optimum machining conditions for machining micro barrier rip array structures having high-aspect ratio were determined according to lengths (200 μm and 600 μm) and shape angles (2.89° and 0°) of diamond tool, overlapped cutting depths (5 μm and 10 μm), feed rates (100 mm/s) and three machining processes. Based on the optimum machining conditions, micro barrier rib array structures having aspect ratio 30 was machined in this study.
Micro structures which are widely used at various fields are commonly fabricated by lithograph, etching and laser methods. Recently, with the emergence of micro tools and ultra-precision machine tools, fabrication of the micro structures obtained using end-milling are studied. However, there are some problems due to the diameter of the micro end-mill getting smaller below 100 μm. The micro run-out resulted from miniaturization of end-mills have influence seriously on accuracy of micro structures. The error of run-out with a tooling jig showed a decrease of about 9.3 μm. Furthermore, micro structures with width of 30 μm could be applied through experiments of slot machining obtained using 30 and 50 μm end-mill. Also, narrow angle structures with 30° angle could be applied through analysis of machining acute angle structures. Based on basic experiments, micro fluidics channels and spiral patterns for air bearing were machined.
First
Prev
