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    NachhaltigAngewandte Naturwissenschaften und WirtschaftsingenieurwesenIPH Teisnach

    Beitrag (Sammelband oder Tagungsband)

    Simon Killinger, Johannes Liebl, Rolf Rascher

    First steps towards an automated polishing process chain using one robot

    Proceedings of SPIE 11478 (Seventh European Seminar on Precision Optics Manufacturing [8 July 2020; Teisnach]), Bellingham, WA, USA

    2020

    DOI: 10.1117/12.2564840

    Abstract anzeigen

    Manufacturing precision optics is a complex process chain, which requires many operations on different machines. This is combined with operator-dependent steps such as manual cleaning, loading and measuring. In order to realize this process chain on a smaller shop area and to achieve a higher level of automation we build an operator-independent polishing cell. In this cell, an ABB robot serves as the actuator handling the workpiece. We positioned the robot in the center of the polishing cell to operate several workstations, so the whole process chain works with one single actuator. This arrangement allows a smaller and cheaper system, since no additional handling is required.

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    Beitrag (Sammelband oder Tagungsband)

    Michael Benisch, O. Fähnle, Rolf Rascher, Werner Bogner

    Force and pressure analysis during overarm polishing

    Proceedings of SPIE 11478 (Seventh European Seminar on Precision Optics Manufacturing [8 July 2020; Teisnach]), Bellingham, WA, USA

    2020

    DOI: 10.1117/12.2564903

    Abstract anzeigen

    The Preston-equation implies, that, besides the relative speed υrel and a specific constant KP, the pressure p plays a significant role for the removal rate when polishing an optical component. This paper demonstrates a possibility for a qualitative evaluation of the pressure distribution before the polishing process. A pressure-sensitive foil is used as a gauge for pressure measurement. The effectiveness of this measuring method is explained. Specific weaknesses and limitations in the use of these foils are discussed. A method for an integrated evaluation of the pressure on different spots of the polishing pad is proposed at the end of the paper.

    NachhaltigAngewandte Naturwissenschaften und WirtschaftsingenieurwesenIPH Teisnach

    Beitrag (Sammelband oder Tagungsband)

    M. Pohl, R. Börret, Olga Kukso, Rolf Rascher

    Mid spatial frequency error prevention strategies for the grinding process

    Proceedings of SPIE 11478 (Seventh European Seminar on Precision Optics Manufacturing [8 July 2020; Teisnach]), Bellingham, WA, USA

    2020

    DOI: 10.1117/12.2565261

    Abstract anzeigen

    This research is focused on the link between manufacturing parameters and the resulting mid-spatial frequency error in the manufacturing process of precision optics. The goal is to understand the generation mechanisms of mid-spatial frequency errors and avoid their appearance in the manufacturing process. Also, a simulation which is able to predict the resulting mid spatial frequency error from a manufacturing process is desired.

    NachhaltigAngewandte Naturwissenschaften und WirtschaftsingenieurwesenIPH Teisnach

    Beitrag (Sammelband oder Tagungsband)

    Jessica Stelzl, Christine Wünsche, S. Höfer

    Influencing factors for a continuous wave UV-laser component

    Proceedings of SPIE 11478 (Seventh European Seminar on Precision Optics Manufacturing [8 July 2020; Teisnach]), Bellingham, WA, USA

    2020

    DOI: 10.1117/12.2564916

    Abstract anzeigen

    During the development of an optical system, one comes to the point where you have to build the optically active element into a mechanical device that becomes part of the system. At this point you come across the well-known question that it is not only necessary to consider and ensure the quality of the individual element. It is also important to look at the entire component in order to identify potential influencing factors on the performance of the optical system. At the beginning of a two-year project at Technologiecampus Teisnach the polishing process of a nonlinear crystal as the crucial component of the optical system was being explored. This system is designed to create continuous wave laser beams in the deep UV range. The crystal has to be embedded between two prisms. Roughness and shape of the crystal is ensured via the polishing process which alone has many influencing factors and was examined at the beginning of the project. The quality of the crystal can be as good as it can be, but if the contacting prisms do not fit, the whole prism-coupled device will become unusable in the overall optical laser system. The performance of the laser can only be achieved by harmonizing all elements of the PCD and the PCD itself into the laser set-up. In the current phase of the project this question will be dealt with. The prism-coupled device is split up into its individual parts, which are the nonlinear crystal, the prisms as optical auxiliary components, micro screws and mechanical support. Going through the requirements to the properties of the crystal and their limitations, the influence of the PCD on the optical performance of the crystal is presented. Here, the main focus is placed on the mode of fixing the crystal between the prisms and on putting the stack of crystal and prisms in the laser beam. The influencing factors between the crystal, the prisms and the method of fixing the PCD are described.

    NachhaltigAngewandte Naturwissenschaften und WirtschaftsingenieurwesenIPH Teisnach

    Beitrag (Sammelband oder Tagungsband)

    Michael Wagner, Gerald Fütterer

    Computer-aided beam path generation and assessment for Stevick-Paul telescopes

    Proceedings of SPIE 11478 (Seventh European Seminar on Precision Optics Manufacturing [8 July 2020; Teisnach]), Bellingham, WA, USA

    2020

    DOI: 10.1117/12.2564852

    Abstract anzeigen

    At Deggendorf Institute of Technology a student project is currently under way to build a Stevick-Paul telescope for astrophotography. An important step in the overall development procedure of each telescope is the design of a beam-path and ensuring its suitability under optical and engineering aspects. The students performed this process in a sequential manner by using several different computer programs (e.g. MATLAB, Zemax, Creo Parametric). To accelerate the beam path design process, a Python program to automate the major part of the design process with minimum human supervision was created. The input data of the python program consists of ranges of the desired characteristics of the Stevick-Paul telescope, such as focal lengths, primary mirror diameters and tilts etc., mirror thickness and mount geometries, as well as the specific type of camera. After setting the input, the program creates 2D cross-sections of beam paths according to the formulas of D. Stevick and may introduce a flat fold mirror to reduce the overall system size as well as improve the accessibility of the focus plane. The subsequent assessment routine checks against the susceptibility for stray light and performs a complex analysis of the available installation space to ensure sufficient mechanical tolerances. In this way, collisions between mirrors, mounts and cameras are avoided and obstructions of the beam path are prevented. At any stage, the program can produce graphical representations of the beam paths. In this paper the computer-aided design of a telescope beam path with a focal length of 2400 mm is demonstrated. During development of the software, a subset of folded Stevick-Paul telescopes, in which certain components are parallel, was found. This subset may be useful to simplify the alignment procedure. In conclusion, further refinement of the software is necessary, although the program is already a useful aid for certain aspects when creating a beam path design.

    NachhaltigAngewandte Naturwissenschaften und WirtschaftsingenieurwesenIPH Teisnach

    Beitrag (Sammelband oder Tagungsband)

    Olga Kukso, Rolf Rascher, M. Pohl, R. Börret

    On the metrology and analysis of MSF error

    Proceedings of SPIE 11478 (Seventh European Seminar on Precision Optics Manufacturing [8 July 2020; Teisnach]), Bellingham, WA, USA

    2020

    DOI: 10.1117/12.2566251

    Abstract anzeigen

    The aim of our research was to study middle spatial frequency errors (MSFE) on optical surfaces. We investigate the surfaces after manufacturing processes to find out the main affecting factors and to choose the proper processing parameters to minimize the size of the errors. To find an appropriate parameter window we have to be able not only to define the factors, which lead to MSFE, but also to analyze the change of the error after next following production steps.

    NachhaltigAngewandte Naturwissenschaften und WirtschaftsingenieurwesenIPH Teisnach

    Beitrag (Sammelband oder Tagungsband)

    M. Jung, Christian J. Trum, Beate Schmidbauer, E. Willenborg, Rolf Rascher

    Non-ablative removal of sub surface damages in ground optical glass substrates by controlled melting of thin surface layers using CO2-laser radiation

    Proceedings of SPIE 11478 (Seventh European Seminar on Precision Optics Manufacturing [8 July 2020; Teisnach]), Bellingham, WA, USA

    2020

    DOI: 10.1117/12.2564801

    Abstract anzeigen

    The form generation of optical surfaces by grinding and mechanical polishing results in small sub surface damages in the form of micro cracks that conventionally have to be removed by further removal of the damaged surface layers. In order to reduce process time and material cost non-ablative methods for removal of micro cracks are desired. Utilising the low optical penetration depths of less than 10 μm for CO2-laser radiation in glass, the laser energy can be used to heat up and melt thin surface layers. Using a 1.5 kW CO2-laser, a quasi-line focus formed by a scanner unit and a constant feed speed, it is possible to close all micro cracks present in the rough grinded test surfaces (max. SSD-depth ~ 63 μm), while achieving a process time of less than 2 seconds for a Ø 30 mm N-BK7 lens, respectively 7.5 seconds for fused silica. With a Sa as low as 50 nm and low distortion from the original shape the surfaces can directly be conventionally polished, further reducing the process chain complexity.

    NachhaltigAngewandte Naturwissenschaften und WirtschaftsingenieurwesenIPH Teisnach

    Beitrag (Sammelband oder Tagungsband)

    Sebastian Sitzberger, Johannes Liebl, Christian J. Trum, Rolf Rascher

    Concept of a two-part clamping system for lenses in optical metrology

    Proceedings of SPIE 11478 (Seventh European Seminar on Precision Optics Manufacturing [8 July 2020; Teisnach]), Bellingham, WA, USA

    2020

    DOI: 10.1117/12.2566547

    Abstract anzeigen

    The developed concept represents a universally applicable clamping system designed to fit in any measuring machine with any measuring principle. The design ensures that, as long as the lens remains clamped, the measurement results are reproducible. Form errors due to tension remain constant across all measuring and processing steps. The version presented in this paper was developed especially for small lenses in the diameter range up to 40 mm. On the one hand, the design allows for fast measurement of loose lenses. On the other hand, the device can also be used for measurement comparisons, since lenses can also be mounted permanently. In the following, the concept and first results of measurement tests are presented.

    NachhaltigAngewandte Naturwissenschaften und WirtschaftsingenieurwesenIPH Teisnach

    Beitrag (Sammelband oder Tagungsband)

    Armin Reif, Sebastian Sitzberger, Rolf Rascher

    Cutting high-performance materials with ultrasonically modulated cutting speed

    Proceedings of SPIE 11478 (Seventh European Seminar on Precision Optics Manufacturing [8 July 2020; Teisnach]), Bellingham, WA, USA

    2020

    DOI: 10.1117/12.2565757

    Abstract anzeigen

    The continuing trend towards lightweight construction and the associated machining rates of up to 95 % lead to an increased use of high-performance materials. The ever growing demands on the strength and quality of components and the associated use of materials which are hard to machine require the further development of new, economical machining techniques. In ultrasonic-assisted machining, an additional high-frequency vibration is superimposed on the conventional machining process. The vibration of the tool is usually excited axially or longitudinally to the workpiece, i.e. vertical to the cutting direction. An additional vibration overlay around the rotation axis (torsional) of the tool is also possible. This generates a vibration overlay in the cutting direction. The vibration initiation causes vibration amplitudes in the range of a few micrometers at the tool cutting edge. This leads in turn to a high-frequency change in the cutting speed or feed rate. Overall, an additional torsional vibration overlap can further reduce cutting forces, increase tool life and improve workpiece quality. In order for a grinding tool to generate a torsional vibration, a special tool was required that had to be designed by simulation. The formation of a torsional vibration was achieved by helical slots in the sonotrode. Depending on the angle of rotation and the length of the slots, a part of the axial vibration is converted into a torsional vibration by an axial excitation of the sonotrode. The aim in designing the slots was to achieve the highest possible vibration amplitude. Following the simulation, the slots were inserted into the tool in the corresponding optimum geometric position. Afterwards, the specially designed grinding tool was validated by machining the brittle-hard glass-ceramic material Zerodur. The first test results with the torsionally vibrating tool are presented in the following.

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    Zeitschriftenartikel

    Armin Reif, P. Rinck, Sebastian Sitzberger, Rolf Rascher, M. Zäh

    Zerspanung von Hochleistungswerkstoffen mit ultrasonisch modulierter Schnittgeschwindigkeit

    ZWF - Zeitschrift für wirtschaftlichen Fabrikbetrieb, vol. 115, no. 3, pp. 2-5

    2020

    DOI: 10.3139/104.112255

    Abstract anzeigen

    Die steigenden Anforderungen an die Festigkeit und die Qualität von Bauteilen und die damit verbundene Verwendung hochfester Materialien erfordert die Weiterentwicklung neuer wirtschaftlicher Zerspanungstechniken. Durch eine werkzeugseitige Schwingungsüberlagerung können bei der Bearbeitung von schwer zerspanbaren Werkstoffen die Zerspankräfte und der Werkzeugverschleiß reduziert sowie die Oberflächenqualität verbessert werden.

    NachhaltigAngewandte Naturwissenschaften und Wirtschaftsingenieurwesen

    Vortrag

    David Scholz, Thomas Stirner

    Hartree-Fock simulation of hematite surfaces with a posteriori calculation of correlation energy

    Preisträgervortrag zur Verleihung des Georg-Simon-Ohm-Preises der Deutschen Physikalischen Gesellschaft an David Scholz

    DPG-Frühjahrstagung, Dresden (abgesagt wegen Covid-19, gehalten an THD), Dresden

    2020

    NachhaltigAngewandte Naturwissenschaften und Wirtschaftsingenieurwesen

    Zeitschriftenartikel

    Thomas Stirner, David Scholz, J. Sun

    Convergence of surface energy calculations for various methods: (001), (012), (100) hematite and the applicability of the standard approach

    Journal of Physics: Condensed Matter, vol. 32, no. 18

    2020

    DOI: 10.1088/1361-648X/ab6f88

    Abstract anzeigen

    Three different methods for the calculation of the surface energy, namely the standard approach, the Boettger relation and the linear-fit method, are applied to the (0 0 1), (0 1 2) and (1 0 0) hematite surfaces. The standard approach was previously shown to suffer from a divergence problem, and the Boettger relation was shown to exhibit quantum size effects. While the linear-fit method, in general, leads to a good convergence behavior of the surface energy, the questions arise whether the relative order of the calculated surface energies depends on the chosen calculation method, and whether there is any merit at all in employing the standard approach. The present work investigates these questions with hematite as a benchmark material system. The simulations show that, for the surface facets and slab thicknesses studied here, the relative order of the surface energies is unaffected by the chosen calculation method. A regime is found where the three methods are in reasonably good agreement with respect to the obtained surface energies. Finally, a procedure is put forward to extract meaningful surface energy values from the standard approach.

    NachhaltigAngewandte Naturwissenschaften und WirtschaftsingenieurwesenIPH Teisnach

    Patent

    Christian J. Trum, Sebastian Sitzberger

    Akkubetriebene Ultraschall-Handbohrmaschine sowie Verfahren zum Betreiben einer solchen Ultraschall-Handbohrmaschine

    2019

    NachhaltigAngewandte Naturwissenschaften und WirtschaftsingenieurwesenIPH Teisnach

    Patent

    Sebastian Sitzberger, Christian J. Trum, Michael Benisch

    Ultraschall-Handbohrmaschine und Verfahren zum Betreiben einer Ultraschall-Handbohrmaschine

    2019

    NachhaltigAngewandte Naturwissenschaften und WirtschaftsingenieurwesenIPH Teisnach

    Vortrag

    Simon Killinger, Alexander Haberl, Rolf Rascher

    Analysis of residual errors during computer controlled polishing

    EOS Optical Technologies: Conference on Manufacturing, Tolerancing and Testing of Optical Systems (MOS) – Session 7: Plenary Session, München

    2019

    Abstract anzeigen

    In computer controlled subapertur polishing the formation of mid spatial frequency errors (MSFE) needs special attention. In this work the formation of MSFE in feed direction is investigated using the ADAPT tool from Satisloh.

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    Vortrag

    Sebastian Sitzberger, P. Rinck, A. Gueray, Rolf Rascher

    Ultraschallunterstützte Zerspanung von Advanced Materials

    3. Wissenschaftliches Forum zur ULTRASONIC-Bearbeitung, Jena

    2019

    NachhaltigAngewandte Naturwissenschaften und WirtschaftsingenieurwesenIPH Teisnach

    Vortrag

    Sebastian Sitzberger, Jakob Reitberger, Rolf Rascher

    Clamping system for optical components for adaptation in optical production

    10th HLEM 2019 - High Level Expert Meeting Asphere Metrology on Joint Investigations, Braunschweig

    2019

    NachhaltigAngewandte Naturwissenschaften und WirtschaftsingenieurwesenTAZ Spiegelau

    Zeitschriftenartikel

    Benedikt Scharfe, S. Lehmann, Thorsten Gerdes, D. Brüggemann

    Optical and Mechanical Properties of Highly Transparent Glass-Flake Composites

    Journal of Composites Science, vol. 3, no. 101, pp. 1-17

    2019

    DOI: 10.3390/jcs3040101

    Abstract anzeigen

    In this paper, the dynamic mechanic and optical properties of composites made of Polyvinyl Butyral (PVB) and Micro Glass Flakes (MGF) with matching refractive indices (RIs) are investigated. The composite is produced by a slurry-based process using additional blade casting and lamination. It can be shown that a high degree of ordering of the MGF in the polymer matrix can be achieved with this method. This ordering, combined with the platelet-like structure of the MGF, leads to very efficient strengthening of the PVB with increasing content of the MGF. By carefully adjusting the RIs of the polymer, it is shown that haze is reduced to below 2%, which has not been achieved with irregular fillers or glass fibers.

    NachhaltigAngewandte Naturwissenschaften und WirtschaftsingenieurwesenTAZ Spiegelau

    Zeitschriftenartikel

    L. Schwinger, S. Lehmann, L. Zielbauer, Benedikt Scharfe, Thorsten Gerdes

    Aluminum Coated Micro Glass Spheres to Increase the Infrared Reflectance

    Coatings (Special Issue "Current Research in Thin Film Deposition: Applications, Theory, Processing, and Characterisation"), vol. 9, no. 3

    2019

    DOI: 10.3390/coatings9030187

    Abstract anzeigen

    The reflective properties of micro glass spheres (MGS) such as Solid Micro Glass Spheres (SMGS, “glass beads”) and Micro Hollow Glass Spheres (MHGS, “glass bubbles”) are utilized in various applications, for example, as retro-reflector for traffic road stripe paints or facade paints. The reflection behavior of the spheres can be further adapted by coating the surfaces of the spheres, e.g., by titanium dioxide or a metallic coating. Such coated spheres can be employed as, e.g., mid infrared (MIR)-reflective additives in wall paints to increase the thermal comfort in rooms. As a result, the demand of heating energy can be reduced. In this paper, the increase of the MIR-reflectance by applying an aluminum coating on MGS is discussed. Aluminum coatings are normally produced via the well-known Physical Vapor Deposition (PVD) or Chemical Vapor Deposition (CVD). In our work, the Liquid Phase Deposition (LPD) method, as a new, non-vacuum method for aluminum coating on spherical spheres, is investigated as an alternative, scalable, and simple coating process. The LPD-coating is characterized by X-ray diffraction (XRD), energy dispersive X-ray spectroscopy (EDX), scanning electron microscopy (SEM), and reflection measurements. The results are compared to a reference PVD-coating. It is shown that both sphere types, SMGS and MHGS, can be homogeneously coated with metallic aluminum using the LPD method but the surface morphology plays an important role concerning the reflection properties. With the SMGS, a smooth surface morphology and a reflectance increase to a value of 30% can be obtained. Due to a structured surface morphology, a reflection of only 5% could be achieved with the MHGS. However, post-treatments showed that a further increase is possible.