The Manufacturing of Horn Glasses Is a Perfect Combination of Traditional and Modern
Each pair of glasses needs to go through more than 200 processes and takes 20 to 30 days. It is a handicraft and a collection, so the manufacturing of ox horn glasses is a perfect combination of traditional handwork and modern precision processing.
The manufacturing of horn glasses is a perfect combination of traditional handicrafts and modern precision processing. The manufacturing of horn glasses does integrate traditional handicrafts and modern precision processing technology. This process not only retains the essence of traditional craftsmanship, but also improves the precision and quality of the products with the help of modern technology. This article describes the manufacturing of horn glasses from the perspective of a glasses manufacturer.
To make high-quality horn frame glasses, the first thing is to choose the horn material. Adult buffalo horns are selected. Most of these horns come from Asia and Africa, such as Tibet, India, Africa, etc. in China. The horns in these places are dense in texture, beautiful in texture and good in toughness. When selecting horns, remove horns with cracks, insect bites, calcification spots or internal cavities to ensure uniform color. Only high-quality horns can produce high-quality horn glasses.
After selecting the horns, they should be pre-treated and soaked in food-grade hydrogen peroxide or sodium hypochlorite solution with a concentration of about 3%-5% for 24 hours for sterilization and preservation. Then steam and soften them, and steam them at 80-90℃ for 2-3 hours to facilitate subsequent cutting.
Then cut the pre-treated horns. Use a band saw or CNC cutting machine to cut the horns longitudinally, preserving the complete texture direction. Pay attention to thickness control when cutting. According to the requirements of eyeglass components, cut out horn pieces with a thickness of 3-8mm (the frame needs to be thicker and the temples are slightly thinner).
Press the material and heat it. Place the horn pieces on a constant temperature press and heat them to 120-140℃. The main component of horns is keratin, with a glass transition temperature of about 130℃. After softening, press them to 10-15MPa for 30 minutes.
Use stainless steel molds to press to form a flat plate and eliminate the natural curvature.
After pressing, double-sided abrasives should be used to make the front and back sides very flat.
1. Rough grinding: 80-120 mesh belt sander to remove burrs and correct the plate thickness tolerance to ±0.2mm.
2. Fine grinding: 400-600 mesh sandpaper is used for manual grinding to eliminate scratches, and the surface roughness Ra≤0.8μm.
Then the inspectors will conduct a detailed inspection of each piece of horn plate, pick out any defective materials, and only leave those without any defects for making horn glasses. Through the above processes, a high-quality horn plate is made. The next step is the production of the front frame.
Production of the front frame of horn glasses.
CNC inner and outer ring finishing. The first is the choice of tool, generally using 0.5-2mm carbide milling cutter, spindle speed 8000-12000rpm, feed speed 800-1200mm/min. Inner ring fine carving: lens groove depth is accurate to ±0.05mm, base curve should be adapted to different lens curvatures. Outer ring fine carving: milling out the design outline according to the CAD drawing of horn glasses, such as square, round or cat's eye shape.
The pads and the head (i.e. the structure connecting the frame and the temples).
The pads are usually a composite structure of horn or metal (titanium alloy/stainless steel). If it is a horn nose pad, the horn plate of fixed size and thickness is pre-cut, and epoxy resin glue (temperature resistant -40℃ to 120℃) is used to stick it on the horn plate of the front frame, and then pressurized and cured for 24 hours.
If it is a metal pads, it usually has a pipe made of metal wire, and the transparent or horn leaf is installed on the pipe box. First, a groove must be cut on the inside of the horn frame, and then the metal pipe is embedded, and a small amount of glue is often used to fix it.
Roller polishing removes the surface texture and makes it smoother and brighter.
In a special container, ceramic triangle blocks and walnut shell particles (ratio 3:7) are used, and a small amount of paraffin is added for lubrication. The speed of the roller is generally 15-20rpm, which lasts for 6-8 hours to eliminate the micro stress caused by CNC processing and the uneven surface. The horn frame after the roller is smoother and brighter.
Ring bending (hot bending and shaping). The hot bending process is divided into two steps, local heating and bending shaping. The heating process generally uses infrared focusing heating or puts it in hot oil to heat and soften, and then bends and shapes it, puts it into an aluminum alloy bending mold, and applies pressure for 5 minutes to form an ergonomic nose pad curve.
Hinge assembly process.
The drilling accuracy uses a 0.8-1.2mm tungsten steel drill bit, and the drilling position error is ≤0.1mm.
Spring hinges (opening and closing times ≥20,000 times) or ordinary screw hinges, made of medical grade 316L stainless steel.
Grinding and polishing process.
800-grit sandpaper to remove machining marks.
1500-grit water sandpaper for wet grinding.
Cloth wheel + palm wax polishing, speed 2800rpm, temperature control ≤50℃ to prevent horn from scorching.
Temple production process.
For CNC carving, the shape is processed according to the shape of the CAD drawing. Four-axis or five-axis linkage processing can be used to carve the streamlined surface of the temple, such as the gradually thinning design, with a thickness of 1.2mm at the end to 2.5mm at the ear hook.
The temple is bent and the curvature of the leg is fixed. First, it is heated in sections. A special heating machine is used to heat the temple in three zones (60℃/80℃/60℃), corresponding to the bending points behind the ear, the temple, and the ear hook. Then a bending tool is used to keep the curvature fixed for more than 24 hours.
Temple hinge and polishing process. The process is the same as the front frame. Pay attention to the weight balance of the temple and the hinge to prevent it from slipping when worn.
Final assembly and post-processing
Computer CNC lathe.
Data input. Generate processing program according to the data of CAD drawings. The resin lens is turned by the diamond tool of the automatic lathe machine, with a surface accuracy of ≤0.02D and an edge thickness error of ±0.1mm.
Laser engraving.
The LOGO, printing or pattern on the temples generally uses laser technology. The laser parameters are generally fiber laser (wavelength 1064nm), power 20W, scanning speed 1200mm/s, depth 0.1-0.3mm.
Metal accessories assembly.
If a metal nose pad is used, the nose pad must be installed. The silicone nose pad is inserted into the embedded metal pile, and the torque test is ≥5N·m without falling off.
Screw tightening: Use a watch screwdriver, and the torque is controlled at 0.15-0.2N·m to avoid thread slippage.
Packing process
Packaging according to customer requirements. If the customer has no special requirements, the PE sleeve is usually installed first, then the right spleen is closed first, then the left spleen, and then put into the PE lock bag.
Generally, 8 to 10 pairs are placed in an environmentally friendly white box, and finally placed in a hard 7-layer environmentally friendly outer box.
Difficulties and innovations in the process of horn glasses frame.
Anti-crack treatment of horns. The surface of the finished horn glasses needs to be coated with BABY oil to prevent deformation or cracking caused by humidity changes.
Texture matching. Since horn materials are natural, the materials of each pair of horn glasses are taken from different horns and different parts, and the growth environment of each individual horn will be different, so when assembling the front frame and temples, they must be selected and classified first, and try to make the color of each pair symmetrical, coordinated and beautiful.
Environmental protection technology. Horn scraps are recycled into buttons or handicrafts to achieve zero waste production.
Each pair of glasses needs to go through more than 200 processes and takes 20 to 30 days to become high-quality buffalo horn glasses. A pair of high-end horn glasses can not only protect your eyes, but also be a handicraft and your collection. It can be said that the manufacture of horn glasses is a perfect combination of traditional handwork and modern precision processing.
The manufacturing of horn glasses is a perfect combination of traditional handicrafts and modern precision processing. The manufacturing of horn glasses does integrate traditional handicrafts and modern precision processing technology. This process not only retains the essence of traditional craftsmanship, but also improves the precision and quality of the products with the help of modern technology. This article describes the manufacturing of horn glasses from the perspective of a glasses manufacturer.
To make high-quality horn frame glasses, the first thing is to choose the horn material. Adult buffalo horns are selected. Most of these horns come from Asia and Africa, such as Tibet, India, Africa, etc. in China. The horns in these places are dense in texture, beautiful in texture and good in toughness. When selecting horns, remove horns with cracks, insect bites, calcification spots or internal cavities to ensure uniform color. Only high-quality horns can produce high-quality horn glasses.
After selecting the horns, they should be pre-treated and soaked in food-grade hydrogen peroxide or sodium hypochlorite solution with a concentration of about 3%-5% for 24 hours for sterilization and preservation. Then steam and soften them, and steam them at 80-90℃ for 2-3 hours to facilitate subsequent cutting.
Then cut the pre-treated horns. Use a band saw or CNC cutting machine to cut the horns longitudinally, preserving the complete texture direction. Pay attention to thickness control when cutting. According to the requirements of eyeglass components, cut out horn pieces with a thickness of 3-8mm (the frame needs to be thicker and the temples are slightly thinner).
Press the material and heat it. Place the horn pieces on a constant temperature press and heat them to 120-140℃. The main component of horns is keratin, with a glass transition temperature of about 130℃. After softening, press them to 10-15MPa for 30 minutes.
Use stainless steel molds to press to form a flat plate and eliminate the natural curvature.
After pressing, double-sided abrasives should be used to make the front and back sides very flat.
1. Rough grinding: 80-120 mesh belt sander to remove burrs and correct the plate thickness tolerance to ±0.2mm.
2. Fine grinding: 400-600 mesh sandpaper is used for manual grinding to eliminate scratches, and the surface roughness Ra≤0.8μm.
Then the inspectors will conduct a detailed inspection of each piece of horn plate, pick out any defective materials, and only leave those without any defects for making horn glasses. Through the above processes, a high-quality horn plate is made. The next step is the production of the front frame.
Production of the front frame of horn glasses.
CNC inner and outer ring finishing. The first is the choice of tool, generally using 0.5-2mm carbide milling cutter, spindle speed 8000-12000rpm, feed speed 800-1200mm/min. Inner ring fine carving: lens groove depth is accurate to ±0.05mm, base curve should be adapted to different lens curvatures. Outer ring fine carving: milling out the design outline according to the CAD drawing of horn glasses, such as square, round or cat's eye shape.
The pads and the head (i.e. the structure connecting the frame and the temples).
The pads are usually a composite structure of horn or metal (titanium alloy/stainless steel). If it is a horn nose pad, the horn plate of fixed size and thickness is pre-cut, and epoxy resin glue (temperature resistant -40℃ to 120℃) is used to stick it on the horn plate of the front frame, and then pressurized and cured for 24 hours.
If it is a metal pads, it usually has a pipe made of metal wire, and the transparent or horn leaf is installed on the pipe box. First, a groove must be cut on the inside of the horn frame, and then the metal pipe is embedded, and a small amount of glue is often used to fix it.
Roller polishing removes the surface texture and makes it smoother and brighter.
In a special container, ceramic triangle blocks and walnut shell particles (ratio 3:7) are used, and a small amount of paraffin is added for lubrication. The speed of the roller is generally 15-20rpm, which lasts for 6-8 hours to eliminate the micro stress caused by CNC processing and the uneven surface. The horn frame after the roller is smoother and brighter.
Ring bending (hot bending and shaping). The hot bending process is divided into two steps, local heating and bending shaping. The heating process generally uses infrared focusing heating or puts it in hot oil to heat and soften, and then bends and shapes it, puts it into an aluminum alloy bending mold, and applies pressure for 5 minutes to form an ergonomic nose pad curve.
Hinge assembly process.
The drilling accuracy uses a 0.8-1.2mm tungsten steel drill bit, and the drilling position error is ≤0.1mm.
Spring hinges (opening and closing times ≥20,000 times) or ordinary screw hinges, made of medical grade 316L stainless steel.
Grinding and polishing process.
800-grit sandpaper to remove machining marks.
1500-grit water sandpaper for wet grinding.
Cloth wheel + palm wax polishing, speed 2800rpm, temperature control ≤50℃ to prevent horn from scorching.
Temple production process.
For CNC carving, the shape is processed according to the shape of the CAD drawing. Four-axis or five-axis linkage processing can be used to carve the streamlined surface of the temple, such as the gradually thinning design, with a thickness of 1.2mm at the end to 2.5mm at the ear hook.
The temple is bent and the curvature of the leg is fixed. First, it is heated in sections. A special heating machine is used to heat the temple in three zones (60℃/80℃/60℃), corresponding to the bending points behind the ear, the temple, and the ear hook. Then a bending tool is used to keep the curvature fixed for more than 24 hours.
Temple hinge and polishing process. The process is the same as the front frame. Pay attention to the weight balance of the temple and the hinge to prevent it from slipping when worn.
Final assembly and post-processing
Computer CNC lathe.
Data input. Generate processing program according to the data of CAD drawings. The resin lens is turned by the diamond tool of the automatic lathe machine, with a surface accuracy of ≤0.02D and an edge thickness error of ±0.1mm.
Laser engraving.
The LOGO, printing or pattern on the temples generally uses laser technology. The laser parameters are generally fiber laser (wavelength 1064nm), power 20W, scanning speed 1200mm/s, depth 0.1-0.3mm.
Metal accessories assembly.
If a metal nose pad is used, the nose pad must be installed. The silicone nose pad is inserted into the embedded metal pile, and the torque test is ≥5N·m without falling off.
Screw tightening: Use a watch screwdriver, and the torque is controlled at 0.15-0.2N·m to avoid thread slippage.
Packing process
Packaging according to customer requirements. If the customer has no special requirements, the PE sleeve is usually installed first, then the right spleen is closed first, then the left spleen, and then put into the PE lock bag.
Generally, 8 to 10 pairs are placed in an environmentally friendly white box, and finally placed in a hard 7-layer environmentally friendly outer box.
Difficulties and innovations in the process of horn glasses frame.
Anti-crack treatment of horns. The surface of the finished horn glasses needs to be coated with BABY oil to prevent deformation or cracking caused by humidity changes.
Texture matching. Since horn materials are natural, the materials of each pair of horn glasses are taken from different horns and different parts, and the growth environment of each individual horn will be different, so when assembling the front frame and temples, they must be selected and classified first, and try to make the color of each pair symmetrical, coordinated and beautiful.
Environmental protection technology. Horn scraps are recycled into buttons or handicrafts to achieve zero waste production.
Each pair of glasses needs to go through more than 200 processes and takes 20 to 30 days to become high-quality buffalo horn glasses. A pair of high-end horn glasses can not only protect your eyes, but also be a handicraft and your collection. It can be said that the manufacture of horn glasses is a perfect combination of traditional handwork and modern precision processing.
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