变厚度透镜注射压缩成型的三维数值模拟

基于有限元法、Arbitrary Lagrangian-Eulerian有限元网格变形法理论及White-Metzner粘弹性本构方程,采用Moldex软件进行了变厚度光学透镜成型的三维仿真分析。模拟表明,压缩阶段的挤压流存在显著三维流动特征,较常规注射,注射压缩能有效地降低注射压力、剪切率与流动残余应力及因此造成的翘曲和光程差。减小压缩速度使压缩阶段浇口压力升高较小、熔体剪切作用减弱;增大压缩距离,可以降低注射压力,减弱剪切作用。实际上这些变量在厚度和距离浇口不同位置的分布不同。     

注射压缩成型工艺参数对厚壁聚碳酸酯制件厚度的影响

考察了不同注射压缩成型工艺参数(两点间距、压缩速率和压缩行程)对聚碳酸酯(PC)平板制件厚度偏差及厚度分布的影响。结果表明,PC平板厚度随两点间距和压缩速率的增大而减小,两点间距和压缩速率是控制厚度精度的主导因素,而压缩行程对厚度影响较小。同时,研究结果表明,所有的PC平板均是上薄下厚的分布趋势,且不同的压缩工艺仅对厚度值大小有影响,而对PC制件的厚度分布趋势没有影响。     

钛及钛合金粉末的注射成形

介绍了钛及钛合金粉末注射成形技术的发展、应用现状及制备工艺.指出了钛及钛合金粉末注射成形技术研究方向和扩大应用的途径是:①使用价格低廉的氢化脱氢粉和气体雾化粉混合得到的钛及钛合金粉作为注射成形的原料粉末;②开发新型高效的钛及钛合金粉末注射成形用的粘结剂体系;③优化混炼工艺;④优化注射条件参数以消除注射缺陷;⑤开发先进的脱脂工艺,使脱脂时间进一步缩短并减少脱脂缺陷,以降低成本;⑥研究钛及钛合金烧结工艺以及超小型零件的注射成形工艺,控制产品尺寸精度,提高产品性能,扩大产品的尺寸.     

碳化硼微孔喷嘴的注射成形工艺及其表面质量

利用粉末注射成形工艺制备碳化硼微孔喷嘴。研究了注射、脱脂和烧结工艺对碳化硼微孔喷嘴的微观形貌和成形质量的影响。结果表明,当模具温度为60℃、注射压力为100MPa、注射温度为175℃的情况下,微孔喷嘴得到良好的填充。脱脂后制品未发现裂纹和翘曲。随着烧结温度的升高,微孔喷嘴的致密度和线性收缩先增加后减小,表面粗糙度先减小后增加,在1950℃烧结后,微孔喷嘴的烧结性能和力学性能最好,致密度、线性收缩、维氏硬度和表面粗糙度值分别为97.1%,18.7%,3580HV和6.17μm。     

陶瓷微结构件的注射成形工艺及其微观组织

采用粉末微注射成形技术制作了ZrO2陶瓷微结构件,分析了其注射成形工艺,包括喂料配制、注射工艺及烧结工艺对微观组织的影响.实验结果表明,粉末体积分数为55%的生坯注射成形后在1 500℃下烧结2 h,采用排水法测得其微结构相对密度高达98.5%,采用纳米硬度分析法得到其微结构的显微硬度值为13.75 GPa.扫描电子显微镜(SEM)结果表明,提高模具温度和注射压力,有利于微结构的填充,进而改善微结构件的微观组织;高的烧结温度可以增加零件的致密度,但容易导致晶粒的过度长大和尺寸不均匀.激光共聚焦光学显微镜观察结果表明,使用亚微米级陶瓷超细粉得到的微结构具有良好的表面质量,其烧结前、后的表面粗糙度值分别为0.33μm和0.28μm.此外,提高粉末含量可以减小零件收缩率,从而有利于微结构的尺寸精度控制.     

金属粉末注射成形的原理与发展趋势

金属粉末注射成形技术是一种高效的近净成形技术,适用于生产小型的、具有复杂形状的零部件。本文综述了金属粉末注射成形技术的发展历程;概述了金属粉末注射成形原理,包括粉末和粘结剂的选择、混炼,注射成形及后续的脱脂、烧结;并介绍了金属粉末微注射成形技术的技术特点、注射工艺和微注射成形的应用;分析了金属粉末注射成形技术的局限性;展望了金属粉末注射成形技术的发展趋势,认为预制复合粉末有助于解决混炼和注射造成的成分不均匀,减小烧结过程由于收缩不均匀导致的制件变形,且应开发新的粘结剂和脱脂工艺以减少脱脂后其在材料中的残留和碳化,开发少粘结剂注射成形工艺。     

聚碳酸酯光学制品注塑成型的残余应力EI北大核心CSCD

采用单一变量实验考察了不同注射工艺参数对光学制品双折射的分布规律,通过应力-光弹定律计算了对称轴上残余应力值。用Moldflow软件对制品成型过程中型腔内流场进行模拟,分析了厚度方向应力的变化。结果表明,沿熔体流动方向上,制品残余应力是逐渐减小的,浇口附近有应力集中;在合理工艺范围内,适当提高成型温度和模具温度,延长保压时间和冷却时间有助于减小制品的残余应力,保压压力和注塑速度应适中才能改善制品的成型质量。     

聚碳酸酯光学制品注塑成型的残余应力

采用单一变量实验考察了不同注射工艺参数对光学制品双折射的分布规律,通过应力-光弹定律计算了对称轴上残余应力值。用Moldflow软件对制品成型过程中型腔内流场进行模拟,分析了厚度方向应力的变化。结果表明,沿熔体流动方向上,制品残余应力是逐渐减小的,浇口附近有应力集中;在合理工艺范围内,适当提高成型温度和模具温度,延长保压时间和冷却时间有助于减小制品的残余应力,保压压力和注塑速度应适中才能改善制品的成型质量。     

粉末微注射成形ZrO_2微结构表面质量控制

采用粉末微注射成形技术制得了二氧化锆陶瓷微结构件,注射成形最小微结构尺寸为Φ300μm×250μm.分析了微注射成形工艺参数、模具抽真空及硅模具对微结构表面质量的影响.实验结果表明在模具温度和注射压力较低时,相同工艺参数下随着微型腔尺寸的减小微结构顶端的表面平整度逐渐下降,提高模具温度和注射压力以及注射前对模具进行抽真空可以改善微结构表面平整度.另外,注射前的模具抽真空有助于减少微结构的表面气孔.亚微米陶瓷超细粉的使用明显改善了烧结后微结构的表面质量,其表面粗糙度值由烧结前的0.33μm降低为约0.28μm.     

传统工艺之上的新变革——塑料注射-压缩成型技术的介绍与应用

注射-压缩成型技术是近几年随着塑料成型工艺的不断发展,在传统的注射工艺上发展而成的新型工艺。它是将注射成型和压缩成型两种技术结合起来,即在成型过程中首次合模时动模和定模是不完全闭合的,保留一定的压缩空间。在注射到一定量时,两个模具开始对熔体压缩,并且在模具完全闭合时终止注射,最后通过保压,冷却等一系列后续工艺后成型。注射-压缩成型技术与传统注射成型技术相比在技术、质量、效率．大规模生产上都有很明显的优点。目前已经广泛应用在高精度光学制品领域和航空,汽车等大尺寸透明件中。     

汽车车门把手气辅成型工艺CAE优化研究

目的 针对传统汽车车门把手成型工艺在实际应用中塑件收缩变形量大、无法有效控制等问题,开展汽车车门把手气辅成型工艺优化研究。方法 通过确定基于计算机辅助工程的塑件成型方式、设置改造后汽车车门把手塑件结构、优化注塑和注气参数,提出一种针对汽车车门把手气辅成型的工艺优化方案。结果 与优化前成型工艺相比,采用优化后成型工艺得到的汽车车门把手塑件的收缩变形量明显降低,汽车车门把手塑件的收缩变形量均能够控制在0.45%以下。结论 引入计算机辅助工程优化分析技术对实现汽车车门把手整体制件结构设计具有更高的实际应用价值,有利于提升汽车车门把手设计、生产和加工的效率。     

Rapid manufacturing of plastic aspheric optical lens

This paper presents a new process to rapid manufacture the plastic aspheric optical lens. A bridge tooling was developed for fabricating the mold inserts of an aspheric lens using silicone rubber materials. Epoxy‐based composites were used to fabricate mold inserts of an aspheric optical lens. Z‐axis shrinkage error was investigated after plastic injection molding and compensated to the designed aspheric lens. In comparison with conventional method for fabricating a pair of mold inserts of a new plastic lens, a cost reduction of 75.02% and a time saving of 77.78% can be achieved. The deformation improvement percentage is about 92.48%. This technology can be used to compensate the z‐axis deformation efficiently due to shrinkage error of plastics in molding aspheric lens. Aspheric optical lens can be produced rapidly and cost‐effectively.     

Optimization of injection molding process parameters using sequential simplex algorithm

In this study warpage and shrinkage as defects in injection molding of plastic parts have been undertaken. MoldFlow software package has been used to simulate the molding experiments numerically. Plastic part used is an automotive ventiduct grid. The process optimization to minimize the above defects is carried out by sequential simplex method. Process design parameters are mold temperature, melt temperature, pressure switch-over, pack/holding pressure, packing time, and coolant inlet temperature. The output parameters aside from warpage and shrinkage consist of part weight, residual stresses, cycle time, and maximum bulk temperature. Results are correlated and interpreted with recommendations to be considered in such processes.     

基于混沌粒子群的微齿轮注塑精密成形翘曲变形分析

目的 针对注塑加工生产的微齿轮运转一段时间后会出现严重变形的问题,对微齿轮注塑精密成形翘曲变形进行分析。方法 基于混沌粒子群建立微齿轮注塑CAE模型,获取曲面全局最优解,在此基础上,计算微齿轮注塑精密成形翘曲收缩率,得到翘曲变形量,同时优化微齿轮注塑精密成形工艺参数,分析微齿轮注塑精密成形翘曲变形情况。结果 将仿真结果与实际试验结果进行对比,得出该分析方法的预测结果与实际翘曲变化趋势完全一致。结论 微齿轮注塑中心位置的翘曲变形量最大,离中心位置越远,翘曲变形量越小。     

Reducing shrinkage in injection moldings via the Taguchi, ANOVA and neural network methods

Plastic injection molding is suitable for mass production articles since complex geometries can be obtained in a single production step. However, the difficulty in setting optimal process conditions may cause defects in parts, such as shrinkage. In this study, optimal injection molding conditions for minimum shrinkage were determined by the Taguchi, experimental design and the analysis of variance (ANOVA) methods. Polypropylene (PP) and polystyrene (PS) were injected in rectangular-shaped specimens under various processing parameters: melt temperature, injection pressure, packing pressure and packing time. S/N ratios were utilized for determining the optimal set of parameters. According to the results, 260 °C of melt temperature, 60 MPa of injection pressure, 50 MPa of packing pressure and 15 s of packing time gave minimum shrinkage of 0.937% for PP and 1.224% for PS. Statically the most significant parameters were found to be as packing pressure and melt temperature for the PP and PS moldings, respectively. Injection pressure had the least effect on the shrinkage of either material. After the degree of significance of the studied process parameters was determined, the neural network (NN) model was generated and was shown to be an efficient predictive tool for shrinkage.     

基于翘曲的注塑成型工艺参数优化组合

采用Taguchi方法设计注塑成型模拟实验,以注塑成型工艺参数混合优化模块方法确定工艺参数最优组合。先建立注塑成型工艺参数混合优化模块,按L9(34)正交表进行实验,得到熔体温度、保压压力、注射时间、成型周期时间等参数不同水平时的翘曲和收缩率数据,翘曲量和收缩率都属于望小特性,计算出S/N比,通过S/N比反应图分析得出较优工艺参数组合,再实验验证确定最优组合,最后说明注塑成型工艺参数混合优化模块方法可行。     

Transparent zero-birefringence copolymer and its optical properties

Birefringence is caused by both orientation of polymer chains and photoelasticity. These birefringences were compensated by random copolymerization of negative birefringent methyl methacrylate and positive birefringent benzyl methacrylate, but orientational and photoelastic zero birefringences were achieved with quite different compositions of the copolymers. Note that the birefringence of the copolymer that occurred in the process of injection molding was almost completely eliminated with a composition for orientational zero birefringence. The orientational and photoelastic zero-birefringence copolymers possessed enough transparency as optical materials that the total scattering losses were 30.4 and 19.5 dB/km, respectively, competing with the transparency of homopolymers.     

Near field imaging from multilayer lens

Multilayer superlens has been reported that it had advantages over the single metal layer superlens. In this work, single silver layer and Ag-SiO2 multilayer superlens devices working at wavelength of 365 nm were fabricated using standard photolithography method. Grating objects with line/space (190 nm/190 nm) resolution could be resolved through both kinds of lens structures with working distance up to 128 nm. However, Ag-SiO2 multilayer lens shows higher transmittance and image contrast than the single silver layer device, the experimental result proves the theoretical calculation.     

Design and fabrication of gypsum mold for injection molding

Traditionally, a mold made of gypsum can only be used in a low-pressure molding, e.g. casting, due to the weak strength of gypsum material. This study addresses the potential of gypsum as a candidate for rapid tooling used in injection molding. The ingredients for the gypsum mold were decided upon, and an additional compression with a vibration process was introduced to enhance the mechanical strength of the gypsum mold. Scanning electron microscope (SEM) results show that the amount of void inside the gypsum mold is reduced, and more interlocking of the microstructure of gypsum is formed by increasing the intensity of the compression with a vibration process. A higher degree of interlocking produces a significant enhancement of the compressive strength of the gypsum. Two samples were selected as master designs for testing the replication performance and lifetime of the gypsum mold. The dimensional replication accuracy of the molded part was over 99.9%. The maximum lifetime of the gypsum mold is about 210 cycles of injection shots. This work provides an alternative tooling for injection molding that can allow manufacturers to produce a small quantity of prototypes in an efficient and cost-effective way in the early stages of product development.     

注射压缩成型与常规注射成型的模腔压力对比分析

在自主开发的注射压缩模具上安装模腔压力传感器,从工艺角度出发,对常规注射成型和注射压缩成型的模腔压力进行了工艺相关性的对比与分析。结果表明,注射压缩可有效降低注射压力和模腔压力,使模腔压力场更加均匀。常规注射成型中模腔压力受模具温度的影响最大,其次为熔体温度、保压时间和保压压力,而注射压缩成型中压缩速率对模腔压力的影响最大,其次为熔体温度和模具温度,压缩行程最弱。低残余应力与低翘曲变形进一步验证了注射压缩的技术优势和压力场特征,表明了模腔压力具有重要的工艺性能指导作用。