Chalcogenide glass (ChG) is widely studied due to its wide infrared transmission window, low refractive index temperature coefficient, and low dispersion coefficient. Precision glass molding (PGM) and single-point diamond turning (SPDT) are representative high-efficiency and high-precision methods for ChG processing. However, the high softening degree of ChG under high-temperature conditions leads to abnormal gas release and severe mold adhesion which deteriorate surface quality. Although SPDT typically facilitates high-precision machining, it has limited efficacy in long-term, large-area, large-depth processing; this limitation causes severe tool wear due to the high hardness and brittleness of ChG material. A new process combining the advantages of PGM and SPDT technology is proposed to fabricate aspheric lenses on ChG (IRG202) by ultra-precision and high-efficiency machining. The pre-molding of ChG by PGM reduces cutting loss during aspheric lens machining by SPDT. The machined aspheric lenses have the high quality with a form error of PV 103.5 nm and surface roughness Ra of 8.3 nm. The processing efficiency of each single lens is increased by almost 8 times over the traditional method. The proposed ChG aspheric lens fabrication process maintains high precision even under mass production conditions.
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This work was financially supported by National Natural Science Foundation of China (Nos. 51775046, 51875043, 52005040), the China Postdoctoral Science Foundation (No. 2019M660480), and the Beijing Municipal Natural Science Foundation (JQ20014).
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Zhou, T., Zhang, C., He, Y. et al. Aspheric lens processing of chalcogenide glass via combined PGM-SPDT process. Int J Adv Manuf Technol 120, 5855–5864 (2022). https://doi.org/10.1007/s00170-022-09112-4