Minimized process chain for polymer optics

Boerret, Rainer; Klingenmaier, Juergen; Berger, Uwe; Frick, Achim

doi:10.1117/12.793277

Cited by 6 publications

(4 citation statements)

References 2 publications

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“…This is due to the fact that the produced parts acquire the geometry of the respective mould. Most plastic injection moulding parts use a steel mould tool, which is usually still polished by hand [2]. For this reason the polishing process step accounts for up to 30% of the total costs in the mould manufacturing process.…”

Section: Introductionmentioning

confidence: 99%

Steel mould surface improvement by robot fluid jet polishing and robot pad polishing for polymer optic production

et al. 2019

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In order to improve the quality of injection-moulded polymer optic parts, it is necessary to improve the quality of the respective steel moulds. For this reason, it is not only necessary to improve the surface roughness of the mould, but also its geometrical shape. The material removal obtained from robot pad polishing is too low. This makes a shape correction after the milling step a very prolonged process. The aim of this work is to use a polishing chain to improve the surface quality of steel samples in terms of shape deviation and surface roughness. This correction polishing chain uses the robot fluid jet polishing for the geometrical shape correction and afterwards the robot pad polishing for the improvement of the surface roughness. Due to the high material removal rates of the fluid jet polishing, it is possible to correct the geometrical shape of steel moulds very fast up to a certain deviation. The pad polishing process improves the surface roughness of the steel samples. A correction of the shape deviation of more than 80% with a RMS of approximately 8 nm was obtained.

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Section: Introductionmentioning

confidence: 99%

Steel mould surface improvement by robot fluid jet polishing and robot pad polishing for polymer optic production

et al. 2019

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“…The polishing process is still responsible for 30% of the total mould price as mentioned by (Uddeholm, 2014). This is due to the fact that steel moulds are still polished by hand as stated by (Börret, Klingenmaier, Berger, & Frick, 2008). To reduce the costs of the polishing process on moulds production, robot polishing is now starting to be more used as it brings more stability and reproduction to the moulds (Speich, Börret, Harrison, & DeSilva, 2013).…”

Section: Introductionmentioning

confidence: 99%

Material removal simulation for steel mould polishing

Almeida

Börret

Rimkus

et al. 2017

Production & Manufacturing Research

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The surface finish of an injection mould influences the quality of the moulded polymer optic parts. In order to improve and control the surface finish of the mould it is important to be able to predict the material removal during the polishing process of this mould. The aim of this work is to predict the material removal during the polishing process, comparing the results obtained from polishing attempts on steel samples and the results obtained from a simulation model. A simulation model is developed with the abrasive wear Holm-Archard equation in ANSYS. This simulation model will help to eliminate the iterative trial and error polishing, therefore facilitating the steel mould production.

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“…In general, moulds for plastic injection moulding are polished by manual workers [4,5]. To achieve good results concerning surface roughness and shape deviation the workers have to be experts in polishing.…”

Section: Introductionmentioning

confidence: 99%