微透镜阵列注射压缩成型的残余应力
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摘要
利用Autodesk Moldflow Insight软件,通过正交实验仿真分析熔体温度、模具温度、压缩速度、压缩距离、压缩压力和压缩延迟时间这6个因素的工艺特性,并进行极差分析。按照压缩框主轴压缩的方式制作注射压缩模具,采用单因素实验设计研究熔体温度、模具温度、压缩速度这3个主要因素的工艺特性,运用应力-光学定律,根据测量所得光程差间接得到平均残余应力。研究结果表明:模具温度对残余应力的影响最大,其次是压缩延迟时间和熔体温度;残余应力随模具温度的升高而降低,随熔体温度的升高先减小后增大,随压缩延迟时间的增加而上升。
Melt temperature, mold temperature, compression speed, compression distance, compression pressure and compression delay time were studied to simulate the process properties by the orthogonal experimental design using the Autodesk Moldflow Insight software. Range analysis was conducted, and the injection compression mold was designed using the compression frame driven by spindle to experimentally study the effect of the melt temperature, mold temperature and compression speed on the residual force of microlens array(MLA).Injection compression experiments were made with single factor experiment method. Stress-optic law was used to switch the optical path difference on residual stress. The results show that mold temperature is more significant than any other parameters, followed by compression delay time and melt temperature. With the increase of mold temperature, the residual stress of the microlens array tends to decrease. The residual stress decreases at first and increases later with the increase of melt temperature. The residual stress increases with the increase of compression delay time.
Melt temperature, mold temperature, compression speed, compression distance, compression pressure and compression delay time were studied to simulate the process properties by the orthogonal experimental design using the Autodesk Moldflow Insight software. Range analysis was conducted, and the injection compression mold was designed using the compression frame driven by spindle to experimentally study the effect of the melt temperature, mold temperature and compression speed on the residual force of microlens array(MLA).Injection compression experiments were made with single factor experiment method. Stress-optic law was used to switch the optical path difference on residual stress. The results show that mold temperature is more significant than any other parameters, followed by compression delay time and melt temperature. With the increase of mold temperature, the residual stress of the microlens array tends to decrease. The residual stress decreases at first and increases later with the increase of melt temperature. The residual stress increases with the increase of compression delay time.
引文
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[15]李沙.注射-压缩成型的制品收缩率均匀度以及双折射与可视化研究[D].广州:华南理工大学机电工程学院,2007:53-59.LI Sha.The study of shrinkage rate uniformity and birefringence and visualization in injection compression molding[D].Guangzhou:South China University of Technology.School of Mechanical and Electrical Engineering,2007:53-59.
[2]LEE B K,KIM D S,KWON T H.Replication of microlens arrays by injection molding[J].Microsystem Technologies,2004,10(6/7):531-535.
[3]齐斌,朱建毅,尹清珍.光盘注射压缩模设计[J].模具工业,2010,36(7):46-48.QI Bin,ZHU Jianyi,YIN Qingzhen.Design of CD injection compression mold[J].Die&Mold Industry,2010,36(7):46-48.
[4]费春红,张长春,李达,等.塑料光学制件精密成型技术的现状[J].橡塑技术与装备,2004,30(11):11-16.FEI Chunhong,ZHANG Changchun,LI Da,et al.Current situation of plastic optical component precision molding technology[J].China Rubber/Plastics Technology&Equipment,2004,30(11):11-16.
[5]蒋丰泽,刘义伦,陈磊,等.工艺参数对注射压缩成型微透镜阵列基板双折射率的影响[J].中南大学学报(自然科学版),2014,45(8):2610-2616.JIANG Fengze,LIU Yilun,CHEN Lei,et al.Effects of compression parameters on birefringence of injection compression molded microlens array substrate[J].Journal of Central South University(Science and Technology),2014,45(8):2610-2616.
[6]SHEN Y K.A novel fabrication method for mold insert of injection molded microlens array[C]//Materials Science Forum.Switzerland:Trans Tech Publication Ltd,2006:665-668.
[7]CHEN L,KIRCHBERG S,JIANG B Y,et al.Fabrication of long-focal-length plano-convex microlens array by combining the micro-milling and injection molding processes[J].Appl Opt,2014,53(31):7369-7380.
[8]李沙,黄汉雄.注射-压缩精密成型制品收缩率均匀度的研究[J].塑料,2007,36(5):54-58.LI Sha,HUANG Hanxiong.Shrinkage uniformity of injection-compression molded part[J].Plastics,2007,36(5):54-58.
[9]陈燕春,何文翰,区仲荣.注射压缩成型技术在塑料光学透镜生产中的应用[J].模具技术,2010(2):159-161.CHEN Yanchun,HE Wenhan,QU Zhongrong.The application of injection compression shaping technology in the production of plastic opticas lens[J].Moulds&Dies,2010(2):159-161.
[10]戴亚春,董芳.注射压缩成型新方法[J].模具工业,2006,32(3):53-56.DAI Yachun,DONG Fang.New method of injection and compression molding[J].Die&Mold Industry,2006,32(3):53-56.
[11]邱庆军,蒋炳炎,陈磊,等.薄壁塑件注射压缩成型热残余应力仿真研究[J].塑料工业,2012,40(7):35-39.QIU Qingjun,JIANG Bingyan,CHEN Lei,et al.Study on thermal residual stress of injection compression molded thin-walled plastic part by simulation[J].China Plastics Industry,2012,40(7):35-39.
[12]蒋丰泽.微透镜阵列注射压缩工艺与模具技术研究[D].长沙:中南大学机电工程学院,2014:42-60.JIANG Fengze.Research on parameters and mold technology of microlens array by injection compression molding[D].Changsha:Central South University.School of Mechanical and Electrical Engineering,2014:42-60.
[13]MICHAELI W.Injection-compression moulding of high precision optical lenses[C]//4M/ICOMM 2009.Kahsruhe,Germany:the Global Conference on Micro Manufacture,2009:407-410.
[14]KIM I H,PARK S J,CHUNG S T,et al.Numerical modeling of injection/compression molding for center-gated disk:Part II.Effect of compression stage[J].Polym Eng Sci,1999,39(10):1943-1951.
[15]李沙.注射-压缩成型的制品收缩率均匀度以及双折射与可视化研究[D].广州:华南理工大学机电工程学院,2007:53-59.LI Sha.The study of shrinkage rate uniformity and birefringence and visualization in injection compression molding[D].Guangzhou:South China University of Technology.School of Mechanical and Electrical Engineering,2007:53-59.