In order to quickly obtain the optimal bonding styles in the adhesive bonded mirror, the simulation and experimental study of the adhesive bonding assembly process for plane mirror were carried out. A single-factor experiment was designed to study the variation of the PV and RMS values of the surface-shape of optical plane mirror with the change of various factors. Then, an orthogonal experiment was designed to study the optimal parameters for the optimal bonding process by taking the PV and RMS of the surface-shape as comprehensive indexes. A finite element model named "Mirror-Adhesive -Frame" was developed using ANSYS Parametric Design Language (APDL) to calculate the PV and RMS values of the surface-shape of the mirror after bonding. In addition, a interference instrument named ZYGO is used to verify the correctness of the surface shape from simulation. The results show that the prediction results of the developed simulation model are in good agreement with the measurement results. The values of surface shape index PV and RMS increase with the increase of adhesive layer diameter and thickness, and gradually decrease with the increase of adhesive layer position in R direction and H direction. The orthogonal experiment with four factors and three levels revealed that the diameter of adhesive layer is the main factor to change the shape of the surface. The optimal process parameters are as follows: adhesive layer diameter of Φ4mm, adhesive layer thickness of 0.1 mm. adhesive layer position in R-direction of 40 mm and adhesive layer position in H-direction of 9.5mm.
In order to quickly obtain the effect of different bonding process on the surface-shape of the adhesive bonded mirror, the simulation and experimental study of the linear expansion micro-stress assembly process were carried out.The mathematical expression of the solidification micro-stress of the adhesive in plane mirror assembly is derived based on the volume shrinkage rate. The structural stiffness of the mirror and the frame is also taken into the mathematical expression of the micro-stress.A finite element model named "Mirror-Adhesive -Frame" was developed using ANSYS Parametric Design Language (APDL) and User Interface Design Language (UIDL) to calculate the PV and RMS values of the surface-shape of the mirror after bonding.The ZYGO interferometer is used to measure the PV and RMS values of the surface-shape index before and after the bonding of the mirror with a specification of Φ100mm-15mm. By comparing the experimental results and the simulation results, the correction value of the equivalent linear expansion parameter of the adhesive layer is obtained. Then, the corrected equivalent linear expansion coefficient of the adhesive layer is brought into the simulation model to predict the PV and RMS values. The results show that the prediction results of the developed simulation model are in good agreement with the measurement results. Moreover, it is found that when the circumference and back of the mirror are both bonded, the PV and RMS values of the surface-shape reach the maximum, and the PV and RMS values are 0.187λ and 0.044λ, respectively
In order to obtain the microstress bonding curing process and its properties of precision optical components, various curing process schemes of XM-31 adhesive were designed and tested. Firstly, a mirror group simulation structure and hardness testing tool were developed to study the effect of the amount of six vulcanizing agents on the solidification rate of XM-31 adhesive. Secondly, the XM-31 adhesive with the best amount of curing agent was solidified under different temperature conditions.Densitometer, stretch machine, hardness tester and microscope were used to test the material properties of XM-31 adhesive after curing, so as to obtain the bonding performance of XM-31 adhesive under different solidification temperature conditions.Finally, the optimized process is applied to the bonding of optical elements in a star - sensitive lens. The results show that the optimum ratio of matrix adhesive and vulcanizing agent of XM-31 adhesive is 100:3 ~ 100:4. The volume shrinkage rate of XM-31 adhesive under four curing temperatures were 1.82%, 1.75%, 1.63% and 1.43%, respectively. The curing temperature will significantly improve the adhesive process efficiency, but the adhesive strength and hardness will be reduced. The surface shape index PV and RMS value of a certain type of star sensitive lens can meet the design requirements, when using the preferred process of XM-31 adhesive assembly.
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