| 摘要: | 由於市場對小型或微型光學透鏡的需求隨著具攝影功能之電子商品的熱賣而持續攀升，這些透 鏡都講求精密、輕巧、方便、價廉，所使用材質幾乎全以模具射出成型製造之塑膠件。透鏡的光學 品質與表面輪廓、粗糙度及內部折射率有密切的關係，相較其它塑膠產品，光學透鏡的品質要求更 高。透鏡在冷卻成形過程會伴隨著體積收縮而有熱應力殘留，殘留應力造成的局部雙折射變異，嚴 重影響鏡片成像品質，因此，光學透鏡成敗的關鍵在模穴內動態均溫的控制，而高效率之冷卻水路 則是動態均溫的最佳方案。受限於CNC 之加工能力，傳統的冷卻水路大都是二維、平行式，其溫 控能力受限，很難滿足精密光學模具的需求。近年來，由於金屬積層製造技術的興起，使三維、高 效率異型水路的製造得以實現，然而，金屬積層製造技術也仍在萌芽階段，需有新的合金材料來滿 足光學級的精密模具製造之發展。 據此，本計畫擬結合中大材料所的研究資源、金屬積層製造及光學模具製造等廠商的標的產品 載具，及工研院材化所金屬粉末製造研究部門之氣噴粉設備，提出「雷射積層製造用鐵基金屬玻璃 合金材料開發及其在光學模具應用之研究」，希望開發金屬積層製造用之鐵基金屬玻璃粉體, 並以 模擬之異型水路精密模具之製造來驗證新材料之特性。此三年期計畫將逐年建立鐵基金屬玻璃合金 粉末之氣噴製程技術及小型試量產氣噴製程技術, 藉由雷射積層製程參數優化及雷射積層異型水 路精密模具成型之耐久測試，來建立高品質含異型水路光學透鏡模具之製造技術。 本計畫之成果預期可直接應用於兩項重要產業，一是建立自主之積製造用粉體原料產業，二是 協助光學鏡片產業建立含異型水路模仁之金屬積層製程技術，提升模具之耐用性及產業競爭力。同 時本計畫也期許能在精密光學模具與金屬積層製造兩領域為台灣持續培育專精人才。 ;With the constant blooming of photography-featured consumer electronics, the global demand in mini or micro-scale optical lenses is continuously growing. These lenses have to be precise in shape but lightweight and inexpensive. They are all plastic and made by injection-molding technique. The optical performance of the lens depends strongly on the lens’ surface morphology and the interior refractive index. The residual thermal stress, caused by uneven volume shrinkage during the cooling course of the injection-molding process, leads to a variation in birefringence and degradation of image quality. The key to a successful injection-molding forming is to keep an instant uniform temperature distribution in all molding cavities. Therefore, an efficient cooling is a must. Traditionally, the cooling channels are “two-dimensional,” parallel to the CNC’s machining axes such that the cooling capability is uncompromising and usually unable to meet the requirement for precision lens forming. With the recent advent of laser additive manufacturing (LAM), fabrication of three-dimensional cooling channels, conformal cooling, becomes realizable. However, manufacturing an optical-grade mold still presents challenges because the analysis and design for an effective conformal cooling is very complex, requiring detailed mold flow analyses. In addition, LAM is just at its early stage, as many crucial LAM-based techniques are under development. Therefore, it is necessary to develop a new alloy powder and combine the new LAM process to manufacture the precision mold with 3D cooling channels for the demand of optic lens industry. Accordingly, we combine the research resource of In statute of Materials Science and Engineering, National Central University, the company equipped with LAM machine, and the companies in the fields of optics mold manufacturing, as well as the R&D division for developing the atomization technology of metal powder at Materials Chemistry Laboratories, ITRI to proposal the project entitled “Development of Fe-based Metallic glass Material for Laser Additive Manufacturing Process and apply on the optics mold manufacturing ”. We hope to develop the powder fabrication process for Fe-based metallic glass alloy and apply this powder on the manufacturing of precision mold by LAM process. In regard to execution, this 3-year project will establish the basic atomization technology and the small-scale pilot process of atomization for Fe-based metallic glass alloy. Via the parameter optimization of LAM process and the durability test of simulated conformal-cooling based precision mold, the manufacturing technology of high quality conformal-cooling optical mold can be established Results from this study are expected applicable directly to the following two main industries: (1) Establish the industry of independent-supplied LAM alloy powder, (2) Help the optical lens manufacturing industry to establish the manufacturing technology of high quality and more durable conformal-cooling optical mold by LAM process. Meanwhile, it is expected that students’ capabilities in the areas of precision optical molds and LAM can be well incubated. |
