全内反射透镜注射压缩成型过程仿真及工艺优化

摘要

随着太阳能发电技术的深入发展,人们对具有特殊光学性能的复杂结构元件的加工精度及效率的要求也在不断提升.依据全内反射透镜的结构特点以及Moldflow软件对有限元模型的要求,制定了一种复杂结构光学元件中性面网格的建立方法.应用Taguchi实验设计法,以翘曲变形为工艺参数的优化指标,将成型过程中的注射时间、模具温度、熔体温度、压缩距离、等待时间、压缩时间、压缩力、压缩速度8个工艺参数作为影响因素,设计了L27试验矩阵对全内反射透镜的注射压缩成型过程进行了仿真分析.计算仿真结果的信噪比,获得了最佳工艺参数组合,并完成各工艺参数对透镜成型质量的影响规律分析,从而对成型工艺实验具有指导意义.%With the development of solar energy generation technology,the demand for high machining accuracy and efficiency of optical components with special optical properties and complex structure was increasing.Based on the structural characteristic of the total internal reflection (TIR) lens and the requirement of simulation software Moldflow/MPI on the finite element model,the method of establishing midplane meshes of the optical components was determined.An optimization method of Taguchi experimental design was used to optimize the processing parameters of injection compression moulding to minimize the warpage of the total internal reflection lens.The injection-compression processing parameters including injection time,mould temperature,melt temperature,press open distance,press waiting time,press compression time,press compression force cap,and press compression speed were first considered as the parameters of experiment plan for the Taguchi L27 experiment table,then a series of CAE simulation experiments were proceeded to study the warpage variation.Finally,the signal-to-noise ratio (SNR) was utilized to obtain the best injection-compression process parameters,as well as the affection of the parameters on the warpage was discussed,which could conduct the processing experiments.