变曲率ICM聚碳酸酯制品残余应力分布
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摘要
结合注射压缩成型(injection compression molding,ICM)工艺特点,运用平面偏振和数值仿真方法,对变曲率聚碳酸酯ICM制品残余应力的分布进行分析,研究不同压缩工艺下残余应力分布特点以及随曲率变化的规律。结果发现:除了浇口和末端小部分区域外,光弹应力条纹环绕制品形状分布;顺序式ICM残余应力条纹有较规整的对称分布结构,同步式ICM充填末端区域残余应力在厚度方向与传统注塑成型区别较为明显,呈现"压-拉"两层应力分布状态;同一平面内,变曲率ICM制品厚度方向残余应力随曲率的减小而递减。除平板制品外,其余四类不同曲率制品的平均残余应力与对应曲率均呈反比例变化关系。研究对优化变曲率透明聚合物制品的设计有一定指导意义。
Based on generating mechanism and mathematical model of residual stress in traditional injection process,plane polarization and numerical simulation method were used to research residual stress distribution of ICM(injection compression molding)products with variety curvature qualitatively and quantificationally.The investigation has shown that residual stress distributions followed the shape of part except gate and end of part region.Well geometric asymmetry of stress fringe were detected in ICM-seq molding,while two layers of stress distribution states at end of part were found in ICM-sim molding.The phenomenon was different from tradition injection molding.Within the same plane,maximum residual stress values were reduced as the decrease of curvature.Meanwhile,inversely proportional relationships between average residual stress and part curvature were obtained for all different type of part(except for plate shape).It makes sense for optimizing design of optical products with variable curvature.
Based on generating mechanism and mathematical model of residual stress in traditional injection process,plane polarization and numerical simulation method were used to research residual stress distribution of ICM(injection compression molding)products with variety curvature qualitatively and quantificationally.The investigation has shown that residual stress distributions followed the shape of part except gate and end of part region.Well geometric asymmetry of stress fringe were detected in ICM-seq molding,while two layers of stress distribution states at end of part were found in ICM-sim molding.The phenomenon was different from tradition injection molding.Within the same plane,maximum residual stress values were reduced as the decrease of curvature.Meanwhile,inversely proportional relationships between average residual stress and part curvature were obtained for all different type of part(except for plate shape).It makes sense for optimizing design of optical products with variable curvature.
引文
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[18]郑利凯.平面曲线曲率计算公式的探讨[J].河北北方学院学报(自然科学版),2012,28(5):20-21.ZHENG L K.On calculation formula of plane curve curvature[J].Journal of Hebei North University(Natural Science Edition),2012,28(5):20-21.
[19]ZOETELIEF W F,DOUVEN L F A,HOUSZ A J.Residual thermal stresses in injection molded products[J].Polymer Engineering&Science,1996,36(14):1886-1896.
[20]刘恒.注塑成型制品残余应力和模后收缩的数值模拟[D].郑州:郑州大学,2011.LIU H.Numerical simulation of residual stress and shrinkage after ejection for injection molded parts[D].Zhengzhou:Zhengzhou University,2011.
[21]WANG P J,LAI H E.Study of residual birefringence in injection molded lenses[J].Annual Technical Conference-ANTEC,Conference Proceedings,2007,(4):2480-2484.
[22]GUENETTE R,FORTIN M.FORTIN,M.A new mixed finite element method for computing viscoelastic flows[J].Journal of Non-Newtonian Fluid Mechanics,1995,60(1):27-52.
[23]CAO W,MIN Z,ZHANG S X,et al.Numerical simulation for flow-induced stress in injection/compression molding[J].Polymer Engineering&Science,2016,56(3):287-298.
[24]徐文莉.透明注塑件残余应力与光学性能的研究[D].郑州:郑州大学,2006.XU W L.Research on residual stress and optical performance of transparent injection molded parts[D].Zhengzhou:Zhengzhou University,2006.
[25]NUGAY I I,CAKMAK M.Instrumented film-insert injection compression molding for lens encapsulation of liquid crystal displays[J].Displays,2015,38:20-31.
[26]GUAN W S,HUANG H X,WANG B.Poiseuille/squeeze flow-induced crystallization in microinjection-compression molded isotactic polypropylene[J].Journal of Polymer Science,Part B:Polymer Physics,2013,51(5):358-367.
[27]JANSEN K M B,TITOMANLIO G.Effect of pressure history on shrinkage and residual stress-injection molding with constrained shrinkage[J].Polymer Engineering&Science,1996,36(15):2029-2040.
[28]POSTAWA P,KWIATKOWSKI D.Residual stress distribution in injection molded parts[J].Journal of Achievements in Materials&Manufacturing Engineering,2006,18(1/2):349-356.
[29]KATMER S,KARATAS C.Effect of injection molding conditions on residual stress in HDPE and PP parts[J].Journal of the Faculty of Engineering&Architecture of Gazi University,2015,30(3):319-327.
[30]HEYDE C C,HALL P.Index-martingale limit theory and its application[J].Martingale Limit Theory&Its Application,1980:301-308.
[2]WU C H,CHEN W S.Injection molding and injection compression molding of three-beam grating of DVD pickup lens[J].Sensors&Actuators A Physical,2006,125(2):367-375.
[3]MASATO D,SORGATO M,LUCCHETTA G.Characterization of the micro injection-compression molding process for the replication of high aspect ratio micro-structured surfaces[J].Microsystem Technologies,2016:1-10.
[4]NAGATO K.Injection compression molding of replica molds for nanoimprint lithography[J].Polymers,2014,6(3):604-612.
[5]YOUNG W B.Effect of process parameters on injection compression molding of pickup lens[J].Applied Mathematical Modelling,2005,29(10):955-971.
[6]GUAN W S,HUANG H X,WU Z.Manipulation and online monitoring of micro-replication quality during injection-compression molding[J].Journal of Micromechanics&Microengineering,2012,22(11):115003.
[7]陈宇宏,袁渊,刘小艳,等.注射成型和注射压缩成型透明件的光学性能对比与分析[J].航空材料学报,2011,31(2):55-60.CHEN Y H,YUAN Y,LIU X Y,et al.Comparison on optical properties of injection molded and injection compression molded transparencies[J].Journal of Aeronautical Materials,2011,31(2):55-60.
[8]谢春稳,王克俭.变厚度透镜注射压缩成型的三维数值模拟[J].高分子材料科学与工程,2013,29(9):169-174.XIE C W,WANG K J.3D numerical simulation of injection compression molding optical lens with variable thickness[J].Polymer Materials Science&Engineering,2013,29(9):169-174.
[9]蒋晶,王小峰,侯建华,等.注射压缩成型聚碳酸酯制品的低温拉伸力学性能[J].化工学报,2015,66(10):4268-4274.JIANG J,WANG X F,HOU J H,et al.Tensile properties of ICM polycarbonate part under low temperature[J].CIESC Journal,2015,66(10):4268-4274.
[10]LIU Z Q,CUNHA A M,YI X.Key properties to understand the performance of polycarbonate reprocessed by injection molding[J].Journal of Applied Polymer Science,2015,77:1393-1400.
[11]LANG J L,WANG T,GE Y,et al.Residual stress analysis in cross section of injection-molded polycarbonate[J].Acta Polymerica Sinica,2016,(6):1-9.
[12]WANG C Y,WANG P J.Analysis of optical properties in injection-molded and compression-molded optical lenses.[J].Applied Optics,2014,53(11):2523-31.
[13]孔玲佩,肖作良,段友顺,等.聚碳酸酯注塑工艺条件研究[J].工程塑料应用,2015,(5):54-57.KONG L P,XIAO Z L,DUAN Y S,et al.Study on injection molding technology of polycarbonate[J].Engineering Plastics Application,2015,(5):54-57.
[14]韩珍.ICM成型充填过程数值模拟[D].郑州:郑州大学,2007.HAN Z.Numerieal simulation of the filling stage of injection compression molding[D].Zhengzhou:Zhengzhou University,2007.
[15]KABANEMI K K,CROCHET M J.Thermoviscoelastic calculation of residual stresses and residual shape[J].International Polymer Processing Journal of the Polymer Processing Society,2013,7(1):60-70.
[16]奚国栋,周华民,李德群.注塑工艺参数对制品残余应力和收缩的影响[J].化工学报,2007,58(1):248-254.XI G D,ZHOU H M,LI D Q.Effect of processing conditions on residual stress and shrinkage in injection molding[J].Journal of Chemical Industry and Engineering(China),2007,58(1):248-254.
[17]陈己明,彭响方,赖鹏.基于Midplane网格单元Hypermesh与Moldflow的网格前处理[J].塑料科技,2007,35(3):66-69.CHEN J M,PENG X F,LAI P.Mesh preprocessing between hypermesh and moldflow based on midplane[J].Plastics Science and Technology,2007,35(3):66-69.
[18]郑利凯.平面曲线曲率计算公式的探讨[J].河北北方学院学报(自然科学版),2012,28(5):20-21.ZHENG L K.On calculation formula of plane curve curvature[J].Journal of Hebei North University(Natural Science Edition),2012,28(5):20-21.
[19]ZOETELIEF W F,DOUVEN L F A,HOUSZ A J.Residual thermal stresses in injection molded products[J].Polymer Engineering&Science,1996,36(14):1886-1896.
[20]刘恒.注塑成型制品残余应力和模后收缩的数值模拟[D].郑州:郑州大学,2011.LIU H.Numerical simulation of residual stress and shrinkage after ejection for injection molded parts[D].Zhengzhou:Zhengzhou University,2011.
[21]WANG P J,LAI H E.Study of residual birefringence in injection molded lenses[J].Annual Technical Conference-ANTEC,Conference Proceedings,2007,(4):2480-2484.
[22]GUENETTE R,FORTIN M.FORTIN,M.A new mixed finite element method for computing viscoelastic flows[J].Journal of Non-Newtonian Fluid Mechanics,1995,60(1):27-52.
[23]CAO W,MIN Z,ZHANG S X,et al.Numerical simulation for flow-induced stress in injection/compression molding[J].Polymer Engineering&Science,2016,56(3):287-298.
[24]徐文莉.透明注塑件残余应力与光学性能的研究[D].郑州:郑州大学,2006.XU W L.Research on residual stress and optical performance of transparent injection molded parts[D].Zhengzhou:Zhengzhou University,2006.
[25]NUGAY I I,CAKMAK M.Instrumented film-insert injection compression molding for lens encapsulation of liquid crystal displays[J].Displays,2015,38:20-31.
[26]GUAN W S,HUANG H X,WANG B.Poiseuille/squeeze flow-induced crystallization in microinjection-compression molded isotactic polypropylene[J].Journal of Polymer Science,Part B:Polymer Physics,2013,51(5):358-367.
[27]JANSEN K M B,TITOMANLIO G.Effect of pressure history on shrinkage and residual stress-injection molding with constrained shrinkage[J].Polymer Engineering&Science,1996,36(15):2029-2040.
[28]POSTAWA P,KWIATKOWSKI D.Residual stress distribution in injection molded parts[J].Journal of Achievements in Materials&Manufacturing Engineering,2006,18(1/2):349-356.
[29]KATMER S,KARATAS C.Effect of injection molding conditions on residual stress in HDPE and PP parts[J].Journal of the Faculty of Engineering&Architecture of Gazi University,2015,30(3):319-327.
[30]HEYDE C C,HALL P.Index-martingale limit theory and its application[J].Martingale Limit Theory&Its Application,1980:301-308.