监控系统非球面反射镜注射成型工艺优化
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摘要
为了提高非球面反射镜面型精度,满足监控系统要求。以熔体温度、模具温度、保压压力、保压时间、注射时间为试验因素,以反射镜z轴翘曲总量及z轴有效区域翘曲量差值最小为优化目标,设计正交试验。根据极差分析结果,选取影响程度较大的熔体温度、保压压力、保压时间建模分析。基于响应面模型,结合多目标遗传算法对注塑工艺进行优化,得到合理注射成型工艺。优化后,成型工艺将反射镜有效区域z轴翘曲总量由90μm降低为1. 1μm,z轴翘曲差值由100μm降低为0. 6μm。经过试模验证,反射镜PV值达到2μm以下,优化后,成型工艺提高了反射镜面型精度,监控系统成像清晰,满足系统装配及使用要求。
In order to improve the accuracy of the aspherical mirror surface and meet the requirements of the monitoring system. The experimental factors of the orthogonal experiment were the melt temperature,the mold temperature,the holding pressure,the holding time,the injection time,and the optimization target of the orthogonal experiment were the minimum total z-axis warp of the mirror and the minimum difference in the amount of warpage in the effective area of the z-axis. According to the results of the range analysis,melt temperature,holding pressure and holding time modeling analysis were selected. Based on the response surface model,combined with multi-objective genetic algorithm,the injection molding process were optimized,a reasonable injection molding process was obtained. After optimization,the total warpage of the mirror was reduced from 90μm to 1. 1 μm,the warpage difference of the mirror was reduced from 100 μm to 0. 6 μm. After the test mode verification,the PV value of the mirror was below 2 μm,the molding process with optimized mirror surface accuracy was improved,the imaging effect of the monitoring system was clear,and the mirror quality met the system assembly and system requirements.
In order to improve the accuracy of the aspherical mirror surface and meet the requirements of the monitoring system. The experimental factors of the orthogonal experiment were the melt temperature,the mold temperature,the holding pressure,the holding time,the injection time,and the optimization target of the orthogonal experiment were the minimum total z-axis warp of the mirror and the minimum difference in the amount of warpage in the effective area of the z-axis. According to the results of the range analysis,melt temperature,holding pressure and holding time modeling analysis were selected. Based on the response surface model,combined with multi-objective genetic algorithm,the injection molding process were optimized,a reasonable injection molding process was obtained. After optimization,the total warpage of the mirror was reduced from 90μm to 1. 1 μm,the warpage difference of the mirror was reduced from 100 μm to 0. 6 μm. After the test mode verification,the PV value of the mirror was below 2 μm,the molding process with optimized mirror surface accuracy was improved,the imaging effect of the monitoring system was clear,and the mirror quality met the system assembly and system requirements.
引文
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[3]陈韬.塑料非球面光学镜片注塑成型数值模拟与工艺优化[D].武汉:武汉理工大学,2008:24-26.
[4]刘言.车载全景鱼眼镜头的设计与制造[D].江苏:江苏大学,2016.
[5]巩盾,王红.含有自由曲面的大视场低畸变同轴三反射光学系统设计[J].光学学报,2014,34(7):198-200.
[6] LAI H E,WANG P J. Study of process parameters on optical qualities for injection-molded Plastic lenses[J]. Applied optics,2008,47(12):2017-2027.
[7]宋美娴,金志明,李波.车用快插接头壳体注射成型工艺优化[J].塑料,2018,47(1):88-90.
[8]王梦寒,董晶晶,周杰,等.基于代理模型和改进遗传算法的注塑翘曲优化[J].材料科学与工艺,2013,21(2):96-100.
[9]郁道银,谈恒英.工程光学[M]. 2版.北京:机械工业出版社,2011.
[10]王文生,刘冬梅,向阳,等.应用光学[M].武汉:华中科技大学出版社,2010.
[11]庄怀港.非球面塑料光学镜片成型工艺仿真与优化[D].武汉:武汉理工大学,2006.
[12]王文生,牟达,陈宇,等.现代光学系统设计[M].北京:国防工业出版社,2016.
[13]毛文炜.现代光学镜头设计方法与实例[M]. 2版.北京:机械工业出版社,2017.
[14]任露泉.试验设计及其优化[M].北京:科学出版社,2009.
[15]吴真繁.基于响应面方法的注塑成型工艺优化和质量预测研究[D].宁波:宁波大学,2009.
[16]蔡厚道.正交设计与响应面法在空气滤清器盖注塑工艺优化中的应用和比较[J].中国塑料,2017,31(2):88-92.
[17]隋允康,宇慧平.响应面方法的改进及其对工程优化的应用[M].北京:科学出版社,2011.
[18]飞思科技产品研发中心. Matlab 6. 5辅助优化计算与设计[M].北京:电子工业出版社,2003.
[19]周香,文琳,王晓花,等.基于Kriging代理模型和遗传算法的注塑件翘曲优化[J].塑性工程学报,2015,22(2):142-146.
[20]黄立东,周小蓉. BP神经网络与GA算法相结合的空调风叶翘曲均匀性优化[J].中国塑料,2014,28(7):77-80.