微透鏡陣列注塑成型技術(shù)外文文獻(xiàn)翻譯/注射塑料模具外文翻譯/中英文翻譯

編號： 畢業(yè)設(shè)計 (論文 )外文翻譯 （原文） 學(xué) 院： 專 業(yè)： 學(xué)生姓名： 學(xué) 號： 指導(dǎo)教師單位： 姓 名： 職 稱： *年 * 月 * 日 The technology of Microlens array injection molding Abstract Injection molding could be used as a mass production technology for microlens arrays. It is of importance, and thus of our concern in the present study, to understand the injection molding processing condition effects on the replicability of microlens array profile. Extensive experiments were performed by varyingprocessing conditions such as flow rate, packing pressure and packing time for three different polymeric materials (PS, PMMA and PC). The nickel mold insert of microlens arrays was made by electroplating a microstructure master fabricated by a modified LIGA process. Effects of processing conditions on the replicability were investigated with the help of the surface profile measurements. Experimental results showed that a packing pressure and a flow rate significantly affects a final surface profile of the injection molded product. Atomic force microscope measurement indicated that the averaged surface roughness value of injection molded microlens arrays is smaller than that of mold insert and is comparable with that of fine optical components in practical use. 1 Introduction Microoptical products such as microlenses or microlens arrays have been used widely in various fields of microoptics, optical data storages, bio-medical applications, display devices and so on. Microlenses and microlens arrays are essential elements not only for the practical applications but also for the fundamental studies in the microoptics. There have been several fabrication methods for microlenses or microlens arryas such as a modified LIGA process 1, photoresist reflow process 2, UV laser illumination 3, etc. And the replication techniques, such as injection molding, compression molding 4 and hot embossing 5, are getting more important for a mass production of microoptical products due to the cost-effectiveness. As long as the injection molding can replicate subtle microstructures well, it is surely the most cost-effective method in the mass production stage due to its excellent reproducibility and productivity. In this regard, it is of utmost importance to check the injection moldability and to determine the molding processing condition window for proper injection molding of microstructures. In this study, we investigated the effects of processing conditions on the replication of microlens arrays by the injection molding. The microlens arrays were fabricated by a modified LIGA process, which was previously reported in 6, 7. Injection molding experiments were performed with an electroplated nickel mold insert so as to investigate the effects of some processing conditions. The surface profiles of molded microlens arrays were measured, and were used to analyze effects of processing conditions. Finally, a surface roughness of microlens arrays was measured by an atomic force microscope (AFM). 2 Mold insert fabrication Microlens arrays having several different diameters were fabricated on a PMMA sheet by a modified LIGA process 6. This modified LIGA process is composed of an X-ray irradiation on the PMMA sheet and a subsequent thermal treatment. The X-ray irradiation causes the decrease of molecular weight of PMMA, which in turn decreases the glass transition temperature and consequently causes a net volume increase during the thermal cycle resulting in a swollen microlens 7. The shapes of microlenses fabricated by the modified LIGA process can be predicted by a method suggested in 7. The microlens arrays used in the experiments were composed of 500m -(a 2 2 array), 300m -(2 2) and 200m (5 5) diameter arrays, and their heights were 20.81, 17.21 and 8.06 m, respectively. Using the microlens arrays fabricated by the modified LIGA process as a master, a metallic mold insert was fabricated by a nickel electroplating for the injection molding. Typical materials used in a microfabrication process, such as silicon, photoresists or polymeric materials, cannot be directly used as the mold or the mold insert due to their weak strength or thermal properties. It is desirable to use metallic materials which have appropriate mechanical and thermal properties to endure both a high pressure and a large temperature variation during the replication process. Therefore, a metallic mold insert is being used rather than the PMMA master on silicon wafer for mass production with such replication techniques. Otherwise special techniques should be adopted as a replication method, e.g. a low pressure injection molding 8. The size of final electroplated mold insert was 30 30 3 mm. The electroplated nickel mold insert having microlens arrays is shown in Fig. 1. Fig.1.Moldinsert fabricated by a nickel electroplating (a) Real view of the mold insert (b) SEM image of 200 m diameter microlens array (c) SEM image of 300 mdiameter microlens array 3 Injection molding experiments A conventional injection molding machine (Allrounders 220 M, Arburg) was used in the experiments. A mold base for the injection molding was designed to fix the electroplated nickel mold insert firmly with the help of a frametype bolster plate (Fig. 2). Shape of aperture of the bolster plate (in this study, a rectangular one) defines the outer geometry of the molded part on which the profiles of microlens arrays are to be transcribed. The mold base itself has delivery systems such as sprue, runner and gate which lead the molten polymer to the cavity formed by the bolster plate, the mold insert and amoving mold surface. The mold base was designed such that mold insert replacement is simple and easy. Of course, one may introduce an appropriate bolster plate with a specific aperture shape. Fig. 2. Mold base and mold insert used in the injection molding experiment The injection molding experiments were carried out with three general polymeric materials PS (615APR, Dow Chemical), PMMA (IF870, LG MMA) and PC (Lexan 141R, GE Plastics). These materials are quite commonly used for optical applications. They have different refractive indices (1.600, 1.490 and 1.586 for PS, PMMA and PC, respectively), giving rise to different optical properties in final products, e.g. different foci with the same geometry. The injectionmolding experiments were performed for seven processing conditions by changing flow rate, packing pressure and packing time for each polymeric material. Furthermore, same experiments were repeated three times for checking the reproducibility. It may be mentioned that the mold temperature effect was not considered in this study since the temperature effect is relatively less important for these microlens arrays due to their large radius of curvature than other microstructures of high aspect ratio. For high aspect ratio microstructures, we are currently investigating the temperature effect more closely and plan to report separately in the future. Therefore, flow rate, packing pressure and packing time were varied to investigate their effects more thoroughly with the mold temperature unchanged in this study. Table 1 shows the detailed processing conditions for three polymeric materials. Other processing conditions were kept unchanged during the experiment. The mold temperatures were set to 80, 70 and 60 _C for PC, PMMA and PS, respectively. It might be mentioned that we carried out the experiments without a vacuum condition in the mold cavity considering that the large radius of curvature of the microlens arrays in the present study will not entrap air in the microlens cavity during the filling stage. Table 1. Detailed processing conditions used in the injection molding experiments Case Flow rate (cc/sec) Packing time (sec) Packing pressure(MPa) 1 12.0 5.0 10.0 2 12.0 5.0 15.0 3 12.0 5.0 20.0 PS 4 12.0 2.0 10.0 5 12.0 10.0 10.0 6 18.0 5.0 10.0 7 24.0 5.0 10.0 1 6.0 10.0 10.0 2 6.0 10.0 15.0 PMMA 3 6.0 10.0 20.0 4 6.0 5.0 10.0 5 6 7 6.0 9.0 12.0 15.0 10.0 10.0 10.0 10.0 10.0 PC 1 6.0 5.0 5.0 2 6.0 5.0 10.0 3 5 6.0 6.0 9.0 5.0 10.0 15.0 5.0 6 5.0 5.0 7 12.0 5.0 5.0 4 Results and discussion Before detailed discussion of the experimental results, it might be helpful to summarize why flow rate, packingpressure and packing time (which were chosen as processing conditions to be varied in this study) affect thereplication quality. As far as the flow rate is concerned, there may exist an optimal flow rate in the sense that too small flow rate makes too much cooling before a complete filling and thus possibly results in so-called short shot phenomena whereas too high flow rate increases pressure fields which is undesirable. The packing stage is generally required to compensate for the volume shrinkage of hot molten polymer whencooled down, so that enough material should flow into a mold cavity during this stage to control the dimensionalaccuracy. The higher the packing pressure, the longer the packing time, more material tends to flow in. However, too much packing pressure sometimes may cause uneven distribution of density, thereby resulting in poor opticalquality. And too long packing time does not help at all since gate will be frozen and prevent material from flowing into the cavity. In this regard, one needs to investigate the effects of packing pressure and packing time. 4.1 Surface profiles Figure 3 shows typical scanning electron microscope (SEM) images of the injection molded microlens arrays for different diameters for PMMA (a) and different materials (b). Cross-sectional surface profiles of the mold insert and all the injection molded microlens arrays were measured by a 3D profile measuring system (NH-3N, Mitaka). (a)Injection molded microlensarrays (PMMA) (b) Injectionmolded microlenses of 300 mdiameter for different materials Fig. 3. SEM images of theinjection molded microlensarrays and microlenses As a measure of replicability, we have defined a relative deviation of profile as the height difference between the molded one and the corresponding mold insert for each microlens divided by the mold insert one. The computed relative deviations for all the microlenses are listed in Table 2. Diameter( m) Relative deviation (%) 1 2 3 4 5 6 7 PS 200 300 500 -7.62 5.86 2.38 -7.59 2.03 -0.38 2.08 2.86 0.51 -5.56 5.61 1.47 -8.66 6016 1.47 -11.44 4.29 1.47 -9.47 5.73 1.95 PMMA 200 300 500 7.20 5.77 -0.66 1.31 5.60 -1.62 -3.88 6.45 3.98 -5.80 5.95 2.80 -0.97 5.95 -0.72 -8.53 6.68 -0.90 4.86 -2.62 -0.72 PC 200 300 500 23.02 6.20 -0.93 16.05 4.96 5.09 16.87 2.66 -1.86 19.66 4.53 1.88 33.97 4.78 6.96 18.67 1.79 2.43 -2.94 4.15 -1.55 It may be mentioned that the moldability of polymeric materials affects the replicability. Therefore, the overall relative deviation differs for three polymeric materials used in this study. It may be noted that PC is the most difficult material for injection molding amongst the three polymers. The largest relative deviation can be found in PC for the smallest diameter case, as expected. In that specific case, the largest value is corresponding to the low flow rate and low packing pressure. Packing time in this case does not significantly affect the deviation. The relative deviation for PS and PMMA with the smallest diameter is far better than PC case. Table 2 indicates that the larger the diameter, the smaller the relative deviation. The larger diameter microlens is, of course, easier to be filled than smaller diameter during the filling stage and packing stage. Microlenses of larger diameters were generally replicated well regardless of processing conditions and regardless of materials. The best replicability is found for the case of PS with 500 m diameter. Generally, PS has a good moldability in comparison with PMMA and PC. It may be mentioned that some negative values of relative deviation were observed mostly in the smallest diameter case for PS and PMMA according to Table 2. In these cases, however, the absolute deviation is an order of 0.1 m in height, which is within the measurement error of the system. Therefore, the negative values could be ignored in interpreting the experimental data of replicability. Surface profiles of microlens of 300 m diameter are shown in Figs. 4 and 5 for PC and PMMA, respectively. As shown in Fig. 4, the higher packing pressure or the higher flow rate results in the better replication of microlens for the case of PC, as mentioned above. Packing time has little effect on the replication for these cases. For the case of PMMA, the packing pressure and packing time have insignificant effect as shown in Fig. 5； however, flow rate has the similar effect to PC. It might be reminded that packing time does not affect the replicability if a gate is frozen since frozen gate prevents material from flowing into the cavity. Therefore, the effect of packing time disappears after a certain time depending on the processing conditions. Fig.4ac(leftside).Surfce profiles of microlens (PC with diameter (/) of 300 m). a effect of packing pressure, b effect of flow rate, c effectof packing time Fig.5ac.(rightside)Surface profiles of microlens (PMMA with diameter(/) of 300m). a effect of packing pressure, b effect of flow rate,c effect of packing time 4.2 Surface roughness Averaged surface roughness, Ra, values of 300 m diameter microlenses and the mold insert were measured by an atomic force microscope (Bioscope AFM, Digital Instruments). The measurements were performed around the top of each microlens and the measuring area was 5 m 5 m. Figure 6 shows AFM images and measured Ra values of microlenses. PMMA replicas of microlens have the lowest Ra value, 1.606 nm. It may be noted that AFM measurement indicated that Ra value of injection molded microlens arrays is smaller than the corresponding one of the mold insert. The reason for the improved surface roughness in the replicated microlens arrays is not clear at this moment, but might be attributed to the reflow caused by surface tension during a cooling process. It may be further noted that the Ra value of injection molded microlens arrays is comparable with that of fine optical components in practical use. a Nickel mold insert, b PS, c PMMA, d PC Fig. 6. AFM images and averaged surface roughness, Ra, values of the mold insert and injection molded 300 m diameter microlenses. 4.3 Focal length The focal length of lenses can be calculated by a wellknown equation as follows : 1 121 1 1( 1 ) ( )nf R R where f, nl, R1 and R2 are focal length, refractive index of lens material, two principal radii of curvature, respectively.For instance, focal lengths of the molded microlenses were approximately calculated as 1.065 mm (with R1 0.624 mm and R2 ￥ ) for 200 m diameter microlens, 1.130 mm (with R1= 0.662 mm and R2=) for 300 m microlens and 2.580 mm (with R1=1.512 mm and R2=) for 500 m microlens according to Eq. (1). These calculations were based on an assumption that microlenses are replicated with PC (nl= 1.586) and have the identical shape of the mold insert. It might be mentioned that the geometry of the molded microlens might be inversely deduced from an experimental measurement of the focal length. 5 Conclusion The replication of microlens arrays was carried out by the injection molding process with the nickel mold insert which was electroplated from the microlens arrays master fabricated via a modified LIGA process. The effects of processing conditions were investigated through extensive experiments conducted with various processing conditions. The results showed that the higher packing pressure or the higher flow rate is, the better replicability is achieved. In comparison, the packing time was found to have little effect on the replication of microlens arrays. The injection molded microlens arrays had a smaller averaged surface roughness values than the mold insert, which might be attributed to the reflow induced by surface tension during the cooling stage. And PMMA replicas of microlens arrays had the best surface quality (i.e. the lowest roughness value of Ra =1.606 nm). The surface roughness of injection molded microlens arrays is comparable with that of fine optical components in practical use. In this regard, injection molding might be a useful manufacturing tool for mass production of microlensarrays. Modern mold technology Introduction Along with the global economy development, the new technological revolution made the new progress and the breakthrough unceasingly, the technical leap development already becomes the important attribute which the impetus world economics grew. The market economy unceasing development, urges the industry product more and more to the multi- varieties, high grade, the low cost direction to develop, in order to maintain and strengthens the product in market competitive power, product development cycle, production cycle more and more short, thereupon to makes each kind of product the essential craft equipment mold request to be more and more harsh. On the one hand the enterprise for the pursue scale benefit, causes the mold to turn towards high speed, is precise, the long life direction develops； On the other hand enterprise in order to satisfy the multi- varieties, the product renewal quickly, wins the market the need, requests the mold to turn towards the manufacture cycle to be short, the cost low fast economy direction develops. The computer, the laser, electronic, the new material, the new technical development, causes the fast economical pattern making technology even more powerful, the application scope expands unceasingly, the type increases unceasingly, the creation economic efficiency and the social efficiency are more and more remarkable. 1.Injection mold design The injection molding application temperature dependence change material performance, through uses the mold to obtain the final shape separate part to complete or to complete the size close. In this kind of process of manufacture, the liquid material is compelled to fill, coagulates in the die space mold. first, must create a pattern mold to need a design model and carries the box. First, must create a pattern mold to need a design model and carries the box. The design model has represented the end product, but carries the box to represent the mold modules bulk volume. The injection mold design involves the mold structure and the function constituent widespread experience knowledge (heuristic knowledge). In the typical process molds the recent development to be possible to divide into four big stages: Product design, molds ability appraisal, part detailed design, insertion die space design and detailed mold design. in the initial stage, the product concept is in (usually is together a combination marketing and project) completes by several people. The initial stage main focal point is analyzes the market the opportunity and the adaptation strategy. In the first stage, the canonical correlation craft manufacture information is increased to the design, designs the geometry detail. The conceptual design use suitable manufacture information transforms as the goods which may make. In the second stage, the drawing of patterns direction and a minute hairs breadth buy for use examine molds ability. Otherwise, the components shape revises once more. In the third stage, the components geometry is uses for to establish the mold the core and the die space shape, the mold the core and the die space, will use for to form the components. Generally, the contraction and the expansion need to perform to consider, like this, in processes under the temperature, the formation will have the correct size and the shape. The runner, the flow channel, the cold slug well, the vent also need to perform to supplement. Between the geometry data and the minute mold informations relation in this point is very important. The fourth stage and the mold overall mechanism are related, the mold overall mechanism including connects the mold to arrive at the injection molding machine, the injection molding machine is uses in pouring, cooling, taking out the mechanism which assembles with the mold. Parts of the heat treatment process, in the parts of the access requirements of the hardness At the same time, internal stress control needed to ensure that spare parts processing of the stability of size, different materials were different approach. Tooling industry in recent years with the development of more types of materials used, in addition to Cr12, 40Cr, Cr12MoV, carbide, on the strength of some of the work, the harsh edge of the convex and concave die, the choice of a new powder alloy steel material , such as the V10, ASP23, such material with high thermal stability and good state of the organization. Cr12MoV response to the material parts, in the rough after quenching, after quenching a lot of the workpiece retention stress, or easily lead to finishing the work of cracking, spare parts should be quenched while it is hot temper, quenching eliminate stress. quenching the temperature controlled at 900-1020 , and then cooled to air-cooled 200-220 released, and then quickly melted down 220 temper, it is known as a hardening process, and the intensity will be high wear resistance, to wear Failure to form molds effective. Encountered in the production of some of the corner more complex shape of the workpiece and tempering is not enough to eliminate quenching stress, before finishing annealing is needed to stress or multiple-aging treatment, and fully release stress. Against V10, APS23 powder alloy steel, and other components can withstand high temperatures because of tempering, hardening available in the second hardening process ,1050-1080 quenching and tempering temperature reuse 490-520 and many times, can be more high impact toughness and stability to the collapsing edge as the main form of die failure is applicable. The higher cost of 1.1. Execution The fact indicated that the SolidWorks API connection has used the object-oriented method and the API function permission choice object language, for example: As programming language Visual C+. Using this method, under Windows NT, based on Windows injection mold three dimensional design application software through Visual C+ code and commercial software SolidWorks99 connection development. This divides into several stages using the mold design process, provides the mold designer to make the mold design reliable method. Figure 3 has outlined this frame. Each stage may regard as a stand-alone program module. Several units have succeeded use SolidWorks to develop. In them two template modules and the minute mold module as follows show. 1.2 based on pould frame designs mold based on the pould frame designs mold and all modules and the fitting, look like HASCO, DME, HOPPT, LKM and FUTABA may found the parametrization standard template automatically. The designer commonly used may with ease have custom-made templates this kind of pould frame. The main feature includes: Looks like the prop, the sprue bushing, two boards, the sampan such standard pould frame modules usability, as well as has custom-made the non-standard mold template. divides into four main parts based on the pould frame designs mold, namely the component storehouse (including standard and non-standard letter storehouse), designs in the table the size actuation function, the structural relation management. In here, SolidWorks has provided the size actuation function is, supports its application. Figure 1 the details introduced based on the pould frame design mold. (1) module storehouse to strengthen the mold designed capacity day by day in this competition intense world, reduces designed cost and the reduction production cycle, reduces the manpower, the automation and so on achieves this goal primary factor. In other words, uses the computer software is very essential. The computer software can found easily, the revision, analyzes the mold design the part, in the renewal change design model. In order to achieve this goal, the three dimensional component storehouse provides the storage standard and the non-standard spare part data, its size is stores up in Microsoft Excel. Through assigns the appropriate size, these modules may produce and insert the assembly structure. This storehouse is definitely may have custom-made with the designer can put in own part to join the module storehouse. Parts surface left behind in processing Daogen, worn stress concentration is where is the source of crack propagation, in the processing end, the need for spare parts for surface hardening, through fitter grinding, processing disposed of hidden dangers. Some of the workpiece edge, the acute angle, a orifice inverted blunt, R-. In general, processing, the surface will have about 6-10 m metamorphic hardened layer, the colors were gray, brittle and hardened layer with residual stress in the use prior to the full elimination of hardened layer, and methods for surface polishing, sanding to remove hardened layer.In the grinding, EDM process, the workpiece must be magnetized, a weak magnetic, and is very easy sorption some small things, in the assembly prior to the workpiece for Demagnetization treatment with acetic acid and B lipid cleaning surface. Assembly process, to see assembly, Huaqi all parts, and then shows the various parts of the equipment between the order of the list should pay attention to issues, and then proceed mold assembly, the assembly of the general first-loaded I. Introduction sets, and then loaded Die frame and punch and die, and then the entire space, in particular the punch and die space with a group adjustment, the assembly to be implemented after the completion of mold testing, write the whole report. The problems discovered, the reverse may be thinking, that is, after the process forward from the process, from the rough finishing each inspection, until they find the crux to solve the problem. (2) size actuation SolidWorks has provided the powerful size actuation function, supports the parametrization design. Stores up in Microsoft Excel the size and the geometry existence logical relation. When the size establishment and the corresponding thing geometric parameter establishment unifies, may obtain the accurate model. (3) designs the table The design table permits the designer in inserting Microsoft in the Excel scheduling through the concrete parameter establishment many kinds of spare part dispositions. The design table preservation in the components folder, is the size which uses for to save, stops the characteristic and the performance disposition, including in the material, module and in customer request components quantity. When increases the suitable size, the design table will contain all essential information, establishes a precise assembly model. (4) structural relation management This part narrated sets up between templates structural relation, can help the mold designer from the design table supplys certain parameter establishment to insert these unit assembling structure, therefore, a specific assembly template may produce automatically 1.3 point mold module Some minute mold algorithm before has reported. mold design is to improve the quality of Mould most important step, need to take into account many factors, including the mould material selection, mold structure can be used and the safety of mold parts machinability and Die maintenance convenience, these in the design should be considered the beginning of a more comprehensive. mould material choice it is necessary to meet customer requirements on product quality, and also taking into account the cost of materials and cycle in the intensity settings, and of course in accordance with the type of mold, the use of methods of work, processing speed, the major failure mode, etc. Selection factors. In this aspects development, is divided the mold to use for the processing core and the die space. In injection mold computer-aided design system, this is a most important module. Designs a mold model to need to have the design model, the work piece and the effective minute profile. The design pattern has manifested the end product, but loaded the box to manifest the mold modules total quantity. To divide into the work piece the core and the die space, the design model first removes from the work piece. Then molds with a minute modular surface the work piece half, Chang Zhixing core and die space. When the fusing plastic injection die space, mold oppositions both sides form the end product. After the coagulation, two halves mold along divides modular surface d and d puts aside separately. Then has obtained the actual part. Figure 5the demonstration is divided the mold design process (1) point norm to decision The core and the die space open the opposite two directions are divided the norm to approach, for the shape ingredient line, divides the norm to be supposed first to determine. Minute norm to influence minute line localization. A minute line has decided molds order of complexity. In the majority situations, divides the norm to is also decided by the geometry and the manufacture question. (2) recognition and patching perforation When in the product has the perforation, the designer must mark the hole the minute mold position, lives the ingredient profile inside these. In this paper, this is so-called the patch . The surface needs to use for the through hole which patches. Because on the mold and under the mold is connected in the through hole place. If does not have to patch the through hole beforehand, the mold cannot separate, the core and the die space cannot found automatically (3) true fate line and goes against the direction In formation, a group of components surface by core mold, but another group is molds by the die space. Divides the line is therefore two group of superficial lines of intersection which molds by the core and the die space. A minute line chooses the biggest edge line in the superficial group. From a minute line to the core or thedie space boundary, goes against the direction to go against in the process, will divide the line to follow. A minuteline is vertical in a minute norm approaches, is parallel to the mold work piece surface superficial normal (4) point profile production Divides the profile is the core and the die space match surface. A minute profile may divide into as the division plane the mold two halves. Two methods may use next life the ingredient profile. Rolls up like a mat the law: Divides the profile through to go against divides the line to outside the core and the die space the boundary formation. Stretch method: In SolidWorks, divides the modular surface to be possible to use the stretch to divide the mold line to assign the distance the method foundation, this distance must be big enough, big enough to may along extend to the work piece outside surface (5) work piece foundation The thing loads in the work piece, the work piece periphery exceptional space calculates with the computer. The work piece size by the thing geometry size, the mold intensity, the mold parameter decided. The mold parameter may define the mold assembly effectively. (6) core and die space production In order to produce the core and the die space, the work piece quilt divides into two halves. First, the design model takes out from the work piece. Obtains a spatial space in the work piece interior. Then, divides the modular surface and the patching surface is used divides into the work piece the core block and the die space block. Finally, after simulation mold opening process and between inspection mold modules disturbance, work piece two halves along divide the norm separately to d and d from the minute mod ular surface separation 2 fast economical pattern makings technologies type The fast economical pattern making technology and the traditional machine-finishing compares, has the pattern making cycle short, the cost is low, the precision and the life can satisfy in the production the operation requirements, is synthesizes an economic efficiency quite remarkable kind to make the mold the technology, summarizes below, has several types to leave. 2.1 fast prototypes manufactures technology The fast prototype manufacture technology is called RPM, is one kind of new manufacture technology which the 80s later period develops. US, Japan, England, Israel, Germany, China have all promoted own commercialization product, and has formed the new industry gradually. RPM is the computer, the laser, the optical scanning, the advanced new material, the computer-aided design (CAD), the computer assistance processing (CAM), the numerical control (CNC) synthesizes the application the high technology and new technology. In takes shape in the concept take the plane separate, piles up as the instruction, in the control take the computer and the numerical control as the foundation, take biggest flexibility as general goals. It has abandoned the traditional machine-finishing method, to the manufacturing industry transformation is a significant breakthrough, uses the RPM technology to be possible directly or indirectly the fast pattern making, this technology already by profession widespread application and so on automobile, aviation, electrical appliances, ships, medical service, mold. Under summarized already commercialization several kind of models fast to take shape at present the craft. 2.1.1 lasers three-dimensional photoetching technology (SLA) The SLA technology hands over the computer CAD modelling system to obtain the product the three-dimensional model, through the microcomputer control laser, according to the determination path, is carrying on to the liquid state photosensitive resin by the level scanning, causes layer upon layer to solidify by the scanned sector, is united as one body, forms the final three dimensional entity, after again passes through the related finally hardening to polish and so on place the quantity, forms the workpiece or the mold. The laser three-dimensional photoetching technology main characteristic is may take shape wilfully the complex shape, takes shape the precision high, simulation strong, material use factor high, performance reliable, the performance price quite is high. Suits the product outlook to appraise, the function experiment, fast makes the electrode and each kind of fast economical mold. But this technology uses equipment and photosensitive resin price expensive, causes its cost to be high. 2.1.2 pack of levels outlines manufacture technology (LOM) The LOM technology is through the computer three-dimensional model, the use laser selectively to its lamination slice, will obtain each section outline layer upon layer will cake, finally will fold the addition three dimensional entity product. Its craft characteristic is takes shape the speed quickly, takes shape the material small advantage, the cost lowly, because does not have changes, therefore does not have the thermal load, the contraction, the inflation, the warp and so on, therefore the shape is stable with an inch precision, after but takes shape the waste material block to strip takes time, specially the duplicate miscellaneous items interior waste material strips. This craft is suitable for the aviation, the automobile and so on and center the volume big workpiece manufacture. 2.1.3 lasers powder electoral district agglutinates takes shape the technology (SLS) The SLS technology is the computer three-dimensional model through the lamination software its lamination, under the computer control, causes the laser beam basis lamination the slice section information to the powder by the level scanning, scans to the powder agglutinates the solidification (polymerization, agglutinates, caking, chemical reaction and so on), layer upon layer superimposes, piles up the three dimensional entity workpiece. This technical most major characteristic is can at the same time use several kind of different materials (the polycarbonate, the polyethylene chloride, the paraffin wax, the nylon, ABS, The casting granulated substance makes components. 2.1.4 fuses the deposition to take shape the technology (FDM) The FDM technology is may squeeze out by the computer control fuses the condition material the spray nozzle, determines the geometry information according to the CAD product model lamination software, squeezes out half flow regime the heat to model the material deposition to solidify the precise actual workpiece thin layer, from bottow to top layer upon layer piles up a three dimensional entity, may make the mold or the product directly. 2.1.5 three dimensional printing take shape the technology (3D-P) The 3D-P technology controls with the microcomputer to spurt the ink printing head continuously, the basis lamination software selectively deposits the liquid cementing material by the level on the powder level, finally piles up a three dimensional entity by the smooth printing two-dimensionalleve Justs like does not use the laser the fast pattern making technology. This technical main application takes shape in advance in the cermet compound materials porous ceramics on, its goal is produces the mold or ? the manufacture directly by the CAD product model. 2.2 surfaces take shape the pattern making technology The surface takes shape the pattern making technology, mainly is the use spurts spreads, the electrolytic casting, chemistry corrosion and so on the new technique formation cavity surface and the fine pattern one kind of craft technology, in the practical application including following several kind of types. 2.2.1 electric arcs spurt spread take shape the pattern making technology The electric arc spurts spreads takes shape the technical principle is: Has the electric arc quantity of heat using between 2 circular telegrams tinsel to melt the tinsel, depends upon the compressed gas its full atomization, and gives the certain kinetic energy, high speed sprays in the type mold surface, layer upon layer mounts, forms a metal shell, namely the cavity internal surface, uses to fill the substrate material again (generally for metal silt and resin compound materials) performs to support the reinforcement, enhances its intensity and the rigidity, combines the mold together with the metal pattern frame. This kind of pattern making technology craft simple, cost low, manufacture cycle extremely short, the cavity surface takes shape only needs for several hours, saves the energy and the metal material, general cavity surface 2-3mm is only thick, simulation greatly strengthened, the pattern precision may achieve 0.5 mu m. At present this technology widely uses in superficial shape and so on airplane, automobile mold, electrical appliances, furniture, shoemaking, fine arts handicraft is complex and the pattern fine each kind of polyurethane product blow molding, attracts models, the PVC injection, PU becomes spongy and each kind of injection takes shape in the mold. 2.2.2 electrolytic castings take shape the technology The electrolytic casting takes shape the technical principle to be same with the galvanization, is according to model the mold (ready-made product or female mold which makes according to product blueprint) is the datum (negative pole), places in the electrolytic casting fluid (anode), causes in the electrolytic casting fluid the metallic ion to return to original state a latter place deposition on the type mold, forms the metal shell, after strips it, contacts the surface with the type mold namely for the mold the cavity internal surface. This technical main characteristic is saves material, the mold manufacture cycle short, electrolytic casting level degree of hardness may reach 40HRC, enhanced the resistance to wear and the life, roughness, the size precision is completely consistent with the type mold, is suitable for the injection, attracts models, the blow molding, keeps out models, mold cavity and the electric spark and so on bakelite mold, glass mold, compression casting mold takes shape the electrode manufacture. 2.2.3 cavities surfaces fine pattern takes shape etching technology The etching technology is optics, chemistry, the machining synthesis application one kind of technology, its basic principle is makes first the pattern design the film, then in has spread the film on pattern design duplication the photosensitive material on the mold cavity surface, process chemistry processing, the mold cavity surface does not form by the etching partial protectors, then acts according to the mold material quality, the choice corresponding etching craft, pattern design etching in mold internal surface. This technical main characteristic is the time short, the expense is low, patching damages the pattern design to be possible to achieve flawlessly. 2.3 sprinkle to cast into the type system mold technique Sprinkling to cast into technical and common characteristics of the type system mold is according to the kind piece for basis, sprinkle a convex and cave mold, a surface do not need the machine to process.Make physically to mainly have following several categories type in the mold. 2.3.1 tin metal alloy system mold technique The tin metal alloy makes the mold technique quickly is a basis through the kind piece, with total metal alloy of ( the orders 138 s, the bulge rate is thousand times it three) of the Bi- Sn( tin of ) two dollars for material, have the precise foundry of method at the same time a convex mold, cave mold, press a kind of technique of the side turn.Should the technical characteristics is to make the mold cost low, the metal alloy is re-usable, the manufacturing period is short, the size accuracy is high, the shape, size and the kind pieces agree with completely, a mold for casting life span can amount to 500-3000, very in keeping with new product development, craft verification, the sample manufacture on a trial basis and win small batch quantity peace. 2.3.2 zinc metal alloy system mold technique This is a kind of to take the kind piece( or the kind mold) as the basis, with the order for 380 s or so zinc metal alloys for material, sprinkle to note the convex and cave mold respectively, a surface does not carry on one kind system mold technique that the machine process in principle.The techniques characteristics is to make the mold cost low, the period is short, being applicable to create the lamella large pull to stretch the mold and hurtle to cut the mold and plastics molds. 2.3.3 resin compounds model the molding tool technique This is a kind of to take the kind mold( or the craft model) as the basis, taking resin or its compound materials as the fluid material, sprinkling the convex( cave) mold of outpouring first, again the convex( cave) mold of basis sticks up the wax slice( the cleft layer), sprinkling to note the convex( cave) mold.A surface that that technique model does not need the machine to process.The that technique and CAD/ CAMs combine together, the characteristics is the molding tool size accuracy high, the manufacturing period is short, the cost is low, is the new product manufacture on a trial basis, the small batch quantity produces the craft material of new path.Be applicable to the creation large overlay the piece to pull to stretch the mold( also can the part inset the steel), vacuum to absorb the and gather the ammonia ester hair bubble to model the mold, porcelain and ceramics mold and imitate the type to depend the mold and cast mold etc. 2.3.4 rubbers of system mold technique That technique take making a prototype or models as the basis, making into soft rubber of system piece, then depend the high pressure dint and models to fit together completely. 2.4 extrusions takes shape the technology 2.4.1 cold extrusions takes shape Using the berylliuim copper alloy good thermal conductivity and the stability, after the solid melt aging treatment of metal, use the swaging pressure to make the mold concave model cavity. Its characteristic is makes the cycle short, the cavity precision is high (the IT7 level), surface roughness Ra=0.025 mu m, The intensity is high, the life may reach 500,000 times, does not have the environmental pollution. 2.4.2 ultra models takes shape the pattern making technology This technology is using the metal material in the thin crystal grain, certainly takes shape the temperature, under the low distortion speed condition, when the material has the best superplasticity, toes attend to carry out raised mold which the initiative finishes, then may extrude the concave mold with the small strength one kind of fast economical pattern making technology. Ultra models takes shape material typical representative is Zn-22%AL. 2.5 does not have the mold multi- spots forming technology Does not have the mold multi- spots fast forming technology is by CAD/CAM/CAT The technology is the main method about, may adjust the base main body group highly using the computer control to form forms the surface, replaces the traditional mold to carry on the three dimensional curved surface forming to the sheet an modern advanced manufacture technology. This technology may change the distortion way and the stressful condition at will, enhances the material the formed limit, may form repeatedly, by this elimination material interior remaining stress, the realization does not have the snapping back forming 2.6 triumphant Uygur bright steel belt blanking falls the material pattern making technology The new steel belt blanking falls the material pattern making technology is one kind is different with has raised, the concave mold structure steel belt mold generally, it is with specially makes the new fast economical pattern making technology by the single edge steel belt which the backing strip is composed. This kind of mold weight is light, only then 200kg, the processing precision for 0.35-0.50mm, may suit each kind of black and the non-ferrous metal 0.5-0.65mm thick sheet processing generally. The life may achieve 5-25 ten thousand, the production cost is low. 2.7 molds semifinished materials fast manufacture technology solid casting Because the massive molds are belong to the single unit or the production, the mold semifinished materials manufacture quality and the cycle and the cost to the final mold quality and cyclical and the cost influence are very important. The modern mold semifinished materials widely have used the seeds casting technology, the so-called solid casting is (polystyrene PS either polymethacrylate PMMA) manufactures using the foam plastics replaces traditional the wooden mold or the metal pattern, after the modelling does not have to take out the model, then may the casting, under the foam plastics model high temperature liquid metal function, deflagrate the gasification but to vanish, the molten metal substitution original foam plastics model holds the position, after the condensation forms the casting. The solid casting has the following several kind of situations in the practical application. 2.7.1 dry sands solid casting Namely all does not do any cementing agent quartz sand modelling with 55-100 goal, spreads with EPS or the PMMA foam plastics manufacture model hangs the 0.2-1mm thick permeability good fireproof coating level, by enhances the casting superficially attractive fineness, prevented the fat sand or collapses the box. 2.7.2 negative compactions casting The negative compaction casting calls V law modelling. This technology is the use all does but does not have the cementing agent the quartz sand to make the molding sand, makes the model with EPS or the PMMA foam plastics, in under the plastic film seal condition, entire lets cast (vacuum degree 0.4-0.67MPa) carries on the liquid metal casting under the negative pressure condition, after the casting coagulates relieves the negative pressure then to obtain the superficial bright and clean casting. 2.7.3 resins granulated substance solid casting Makes the molding sand using the resin granulated substance, makes the model with EPS or the PMMA foam plastics, under the normal temperature, the atmospheric pressure carries on the liquid metal casting but to make takes the casting. uses the solid casting the tec hnical manufacture mold semifinished materials to have the size precision high (the ISO9 level), processing remainder small (generally about 5mm), does not need to pull out the mold ascent, does not need the making core and the sand core brace, saves the metal material, economical makes the wooden model the lumber, the manufacture cycle short, the cost is low. This technology suits large-scale, is complex, the single unit mold semifinished materials production. the ceramics fine cast, lose the cerotin to cast and so on the technology are increasing the mold semifinished materials precision, reduce the processing man-hour, reduce the manufacture cycle, reduce aspect and so on cost also demonstrate its unique superiority. 2.8 other aspects technologies in order to simplify the mold the structural design, reduces the mold cost, reduces the mold manufacture cycle, in domestic and foreign also successively appeared some other aspects new technology application, like trades the mold frame, the ramming unit, the cutting edge built-up welding quickly, inlays the block casting, the nitrogen spring and so on. 2.8.1 nitrogen springs on mold application The nitrogen spring is one kind of new elastic function part, replaces the spring, the rubber, the polyurethane or the air cushion with it side, it can accurately provide presses the strength, then may have the greatly initial ball pressure in the small space, does not need pre- tightly, is basically hit the pressure basically in the mold entire work process to be constant. The ball pressure size and the working point position may, accurate, conveniently adjust as necessary, simplifies the mold to stretch, nearby the pressure, ex-denning isostructuralism, simplifies the mold design, reduces the pattern making cycle, debugs the mold to be convenient, reduces the replacement mold time, enhances the production efficiency. 2.8.2 fast trades the mold technology Because product variety increasing, causes the mold in the production the transmutation extremely frequently, how thereupon reduces the ramming equipment the down time, enhances the production efficiency, fast traded the mold technology to receive peoples attention. At present developed industrial nation some big companies traded the mold speed to achieve astonishing degree, whether had fast trades the mold technology to become for an enterprise technology advancement sign. The always tendency is reduces the mold to install on the equipment, to be fixed, the adjustment time, this both must give in the equipme nt structural design to consider, and must in the mold structural design, the standardized aspect consider, machine on work as far as possible placing machine under will do. 2.8.3 ramming units combination technology The ramming unit combination technology is dies a resolve into each one simple unit the convention to die, according to the working procedure request, the arrangement combination, completes the many kinds of ramming working procedure when the identical inferior stroke the new craft equipment, the work the ramming unit not with the punch press slide joint, only needs the slide attack then to complete the ramming work. When independent employment it is 1 complete mold. It may use for to process the sheet or the molding punch holes, falls the material, cuts the angle, the grooving, shuts off and the shallow stretch and so on. Has the assembly strongly, the easy to operate, the versatility, the efficiency is quickly good and so on the characteristic, suits the multi- varieties specially, center the production. 2.8.4 cutting edges built-up weldings technology In dies in the manufacture, take the ordinary gray iron as the substrate, in the cutting edge spot built-up welding high degree of hardness alloy steel, by replaces the molding tool steel to inlay the block, this technology becomes one of world advanced crafts. This is an item saves the manufacture man-hour, saves the expensive mold steel products, reduces the mold manufacture cycle the fast economical pattern making technology. At present melts extremely the argon arc welding technology application, enhanced the cutting edge built-up welding speed and the quality greatly. This technology various countries mold profession has widely used, has obtained the good economic efficiency. 2.8.5 solid casting die the cutting edge to inlay the block technology This is one kind dies the cutting edge method with the solid casting technique manufacture, namely inlays the block with the alloy-steel castings to replace forges the alloy steel to inlay the block. At present because the casting craft and the heat treatment craft consummate and the enhancement unceasingly, the casting inlaid the block the intrinsic quality to have the guarantee, therefore its application scope was expanding unceasingly. This item by casts the new technical prominent characteristic which the generation hammers saves the precious mold steel products, simplifies the mold manufacture working procedure, because the processing remainder is small, has saved the massive machining man-hour, reduces the mold manufacture cycle, reduces the mold cost. 2.8.6 may process the plastic in mold manufacture application May process the plastic to be common in the developed industrial nation application, specially in manufacturing industry and so on automobile, airplane, mainly replaces the lumber or the metal manufacture automobile body host model, the profile, examines has and the casting model and so on. May process the plastic the main characteristic is has both the lumber and the metal fine workability, the manufacture craft simple and direct (may use compression molding, pour, spells sticks, method well and so on sculpture), the size stability, does not distort, bears moistly, anti-corrosive, is easy to repair, the easy modification, the weight light, the manufacture cycle short, the cost to be low. 3 concluding remark Fast economical pattern making technology type very many, its has the characteristic, the application scope are various, this article only can broadly make some simple introductions, each kind of technology still had many concrete technological processes, the craft parameter and its the technical characteristic in the concrete application and the implementation process. The mold is one of foundation industries, in the globalization market economy and under each kind of high technology and new technology swift and violent development situation, the fast economical mold has entrusted with the new mission and the brand-new connotation, the classification increases unceasingly, the fast economical pattern making material turns towards the multi- varieties seriation to make great strides forward, the craft has the new innovation and the breakthrough unceasingly, is published one after another with it supplementary equipment, the service domain in opens up unceasingly, the creation economic efficiency is more and more remarkable. Along with the commodity economy development, the intense market competition, the product renewal acceleration, is reducing the cycle to the fast economical pattern making technology, reduces the cost, will increase the precision and lengthens the life aspect the request to be able to be more and more high inevitably. Because it can cause the enterprise to win the market, creates the remarkable economic efficiency, more and more receives entrepreneurs favor and the concerned leader departments enormous attention and the policy fund support. Each kind of fast economical pattern making technology also can consummate mature and the development unceasingly in the promoted application process, as a result of the high technology and new technology development, each kind of technical bonding with the seepage, for the adaption production in different demand, surely will be able to form some, the frugal energy, the frugal material fast pattern making technology new from now on. 編號： 畢業(yè)設(shè)計 (論文 )外文翻譯 （ 譯 文） 學(xué) 院： 專 業(yè)： 學(xué)生姓名： 學(xué) 號： 指 導(dǎo)教師單位： 姓 名： 職 稱： *年 * 月 * 日 1 微透鏡陣列注塑成型技術(shù) 摘要 微透鏡陣列注塑成型，可作為一種非常重要的大量生產(chǎn)技術(shù)。因此我們在近來的研究中非常關(guān)注， 為了進(jìn)一步了解注塑成型在不同的加工條件下對可復(fù)制的微透鏡陣列剖面的影響，如流量、填料壓力和填料時間，對 3 種不同的高分子材料 (PS， PMMA 和PC)進(jìn)行了大量的 試驗。 鎳金屬模具嵌件微陣列就是利用改良的 LIGA 技術(shù)電鍍主裝配的顯微結(jié)構(gòu)制造的。在表面輪廓得到測量的前提下，研究工藝條件對可復(fù)制的微透鏡陣列的影響。實(shí)驗結(jié)果表明， 填料壓力和流速對注射模塑的終產(chǎn)品的表面輪廓有重要的影響。 原子力顯微鏡測量表明， 微透鏡陣列注塑成型的平均表面粗糙度值小于模具嵌件成型， 并在實(shí)際運(yùn)用中，能與精細(xì)的光學(xué)元件相媲美。 1 說明 微型光學(xué)產(chǎn)品，如微透鏡或微透鏡陣列已廣泛應(yīng)用于光學(xué)數(shù)據(jù)存儲、生物醫(yī)學(xué)、顯示裝置等各個光學(xué)領(lǐng)域。微透鏡和微透鏡陣列不僅在實(shí)踐應(yīng)用上，而且在微型光學(xué)的基礎(chǔ)研 究上都是非常重要的。有幾種微透鏡或微透鏡陣列的制作方法，如改良的 LIGA 技術(shù)，光阻回流進(jìn)程，紫外激光照射等。還有復(fù)制技術(shù)，如注塑模壓成型和熱壓技術(shù) ，這種方法對于減少大規(guī)模生產(chǎn)的微型光學(xué)產(chǎn)品的成本尤為重要。由于其優(yōu)越的生產(chǎn)和再生產(chǎn)能力，只要注塑成型過程中能很好的復(fù)制微觀結(jié)構(gòu)，那么肯定是最適合于降低大量生產(chǎn)成本的方法。 基于這點(diǎn)，檢查注塑成型能力并確定成型加工條件是注塑成型微觀結(jié)構(gòu)過程中最重要的步驟。在本次研究中，我們考察了工藝條件對可復(fù)制的微透鏡陣列的注射成型的影響。微透鏡陣列是用之前介紹過的改良的 LIGA 技術(shù)來編制的。注塑成型實(shí)驗采用的是一種鍍鎳金屬模具，來探討了幾種不同工藝條件對成型的影響。通過對微透鏡陣列的表面輪廓測量，用來分析工藝條件產(chǎn)生的影響。最后，利用原子力顯微鏡 (AFM)測量微透鏡的表面粗糙度值的大小。 2 2 模具嵌件的制造 利用改良的 LIGA技術(shù)， 在一個有機(jī)玻璃板上制造出具有幾種不同直徑微透鏡陣列。此種技術(shù)是先用 X 光照射有機(jī)玻璃板，然后再進(jìn)行熱處理兩部分構(gòu)成的。 X-射線照射引起有機(jī)玻璃分子質(zhì)量的減少，同時降低了玻璃化轉(zhuǎn)變溫度，并因此導(dǎo)致凈含量的增加，在熱循環(huán)的作用下，微透鏡發(fā)生微膨脹。利用中提 出的方法，結(jié)合改良的 LIGA 技術(shù)可以預(yù)測微透鏡形狀的變化過程。 在試驗中使用的微透鏡陣列，有 500m (22 陣列 )， 300m (22)和 200m (55)的直徑陣列，高分別是 20.81m， 17.21m和 8.06m。采用改良的 LIGA 技術(shù)制造微透鏡陣列作為一個主要的技術(shù)，用來制作鍍鎳的金屬模具的注塑成型。另一些特殊材料，因為它們的強(qiáng)度不夠或熱性能差而不能直接進(jìn)行微細(xì)加工，當(dāng)作模具或金屬模具使用，如硅、光阻劑或高分子材料。盡量使用具有良好機(jī)械性能和熱性能的金屬材料，因為它們能在可復(fù)型加工過程 中經(jīng)受高壓力和不斷變化的溫度。因此，為了利用這種復(fù)制技術(shù)進(jìn)行大批量生產(chǎn)，我們選擇使用金屬模具材料而不是有機(jī)玻璃硅晶體。一些特殊技術(shù)，如低壓注塑成型 8技術(shù)，應(yīng)該作為良好的復(fù)制加工方法被采納。 電鍍模具的最終大小為 30 mm30 mm3mm。鍍鎳金屬模具所具有的微透鏡陣列如圖 1 所示。 圖 1 鍍鎳模具嵌件的制造 （ a）直接觀察；（ b）直徑為 200 m 的微透鏡陣列電子顯微鏡圖像；（ c）直徑為 300 m的微透鏡陣列電子顯微鏡圖像 3 3 注塑成型實(shí)驗 傳統(tǒng)注塑機(jī) (Allrounders 220 M， Arburg)多用做實(shí)驗機(jī)。注塑模具設(shè)計的模架就是利用一塊框形支撐板固定鍍鎳模具 (如圖 2 所示 )。 圖 2 注塑模具實(shí)驗中使用的模架和嵌件 用修改的微透鏡陣列確定模具零件孔形加強(qiáng)板 (在這次實(shí)驗中，是一塊矩形板 )的外部形狀。模架本身已含有傳輸系統(tǒng)，如注射口，流道及澆口，通過支撐板、模具流道和滑動的模具表面將熔融聚合物引入模腔。用這種方法設(shè)計的模架，能夠使模具零件更換起來簡單容易。不過，有時 候也使用具有特定孔徑形狀的支撐板。 實(shí)驗主要用三種普通高分子材料， PS(615APR，陶氏化學(xué) )，有機(jī)玻璃 (IF870， LG MMA)和 PC(Lexan 141R)進(jìn)行注塑成型。這些高分子材料通常在光學(xué)元件上使用，它們有不同的折射率 (PS， PMMA 和 PC 的折射率分別為 1.600， 1.490 和 1.586)，能生產(chǎn)出具有不同的光學(xué)特性的產(chǎn)品，例如 :具有相同的幾何尺寸卻有不同的焦距的光學(xué)元件。 通過改變每個高分子材料的流速，充填壓力和充填時間獲得 7 種加工條件進(jìn)行注塑成型試驗。此外，為了檢查是否能可再生產(chǎn)，同一 實(shí)驗往往需要重復(fù)三次?？赡苡腥藭赋觯瑢?shí)驗中沒有考慮模具溫度的影響，這是因為溫度效應(yīng)相對來說不是主要因素，而且微透鏡陣列曲率半徑比其他微觀結(jié)構(gòu)的高寬縱橫比大。正是因為較大的微觀結(jié)構(gòu)高寬縱橫比，使我們目前研究的溫度效應(yīng)更加可靠，并計劃在將來實(shí)驗時進(jìn)行單獨(dú)報告。 因此，在這項研究中，我們保持模具溫度不變，而流速、充填壓力和充填的時間都變化的情況下，能更清楚的觀察其產(chǎn)生效果。表 1 詳細(xì)的列出了三種高分子材料 PC， PMMA和 PS 在其他加工條件都保持不變，將模具溫度分別設(shè)定為 80 ， 70 和 60 的情況下的實(shí)驗結(jié)果。 表 1 注塑模具實(shí)驗中詳細(xì)的工藝條件 序號 流 速 (cc/s) 充填時間 (/s) 充填壓 (MPa) 1 12.0 5.0 10.0 2 12.0 5.0 15.0 4 3 12.0 5.0 20.0 PS 4 12.0 2.0 10.0 5 12.0 10.0 10.0 6 18.0 5.0 10.0 7 24.0 5.0 10.0 PMMA 1 6.0 10.0 10.0 2 6.0 10.0 15.0 3 6.0 10.0 20.0 4 6.0 5.0 10.0 5 6 6.0 9.0 15.0 10.0 10.0 10.0 續(xù)表 1 序號 流 速 (cc/s) 充填時間 (/s) 充填壓力(MPa) 7 12.0 10.0 10.0 PC 1 6.0 5.0 5.0 2 6.0 5.0 10.0 3 5 6.0 6.0 9.0 5.0 10.0 15.0 5.0 6 5.0 5.0 7 12.0 5.0 5.0 可能有人會指出，我們的實(shí)驗沒有考慮型腔出現(xiàn)真空狀態(tài)時的情況，其實(shí)大可不必?fù)?dān)心，因為在本研究中的注 射階段，大曲率半徑的微透鏡陣列不會把空氣引入到型腔中。 4 討論和結(jié)果 在詳細(xì)討論實(shí)驗結(jié)果之前，認(rèn)真思考一下，可能有助于總結(jié)為什么流速、充填壓力和充填時間 (在這項研究中被選為不同的加工條件 )影響復(fù)制的質(zhì)量。就流速而言，可能存在一個最佳流速，而在完成充填之前，流速太小會使得熔融聚合物過冷卻，從而可能導(dǎo)致所謂的短暫的不連續(xù)現(xiàn)象，而過高的流速增大了壓力面積，這是不可取的。 充填階段是一般要求，是要在冷卻時能夠彌補(bǔ)熱熔融聚合物的體積收縮 。 因此，在這個階段應(yīng)有足夠的熔融聚合物流入型腔并控制產(chǎn)品的尺寸精度。 越高 的充填壓力，越長的充填時間，將使更多的材料持續(xù)不斷的流向型腔。然而， 過高的充填壓力，有 5 時可能造成不均勻的密度分布，從而產(chǎn)生劣質(zhì)的光學(xué)質(zhì)量。過長的充填時間，不利于在各自澆口處的冷凝，并且會阻止熔融聚合物流入型腔。因此，我們需要研究不同的充填壓力和充填時間所產(chǎn)生的影響。 4.1 表面輪廓 圖 3 所示的是用電子顯微鏡 (SEM) 掃描的不同注塑微透鏡的直徑的 PMMA 圖像 (a)以及不同 材料的圖像 (b)。代表性的模具表面輪廓以及所有注塑微陣列都是通過三維輪廓測量系統(tǒng) (NH-3N， Mitaka)測定的。 圖 3 注塑模具的微透鏡陣列和微透鏡的電子顯微鏡圖像 （ a） PMMA 微透鏡陣列 （ b）不同材料直徑為 300m微透鏡陣列的注塑模具 作為一個可復(fù)制陣列的測量工具，我們已經(jīng)確定了在模具與相應(yīng)的模具嵌件分開的微陣列之間輪廓的相對高度偏差，所有的微透鏡陣列相對偏差值列在表 2 中，具體見表所示： 表 2 表面輪廓相對偏差 直徑 (m) 相對偏差 (%) 1 2 3 4 5 6 7 PS 200 300 500 -7.62 5.86 2.38 -7.59 2.03 -0.38 2.08 2.86 0.51 -5.56 5.61 1.47 -8.66 60.16 1.47 -11.44 4.29 1.47 -9.47 5.73 1.95 PMMA 200 300 500 7.20 5.77 -0.66 1.31 5.60 -1.62 -3.88 6.45 3.98 -5.80 5.95 2.80 -0.97 5.95 -0.72 -8.53 6.68 -0.90 4.86 -2.62 -0.72 6 PC 200 300 500 23.02 6.20 -0.93 16.05 4.96 5.09 16.87 2.66 -1.86 19.66 4.53 1.88 33.97 4.78 6.96 18.67 1.79 2.43 -2.94 4.15 -1.55 值得一提的是，高分子材料的塑性會影響其重復(fù)使用性能。 因此在研究中，三種高分子材料總的相對誤差是各不相同的。 PC 是三種聚合物中最難注塑成型的材料。在直徑最小的例子中產(chǎn)生最大的相對偏差，那都是意料之中的事。 在這種特殊情況下，充填時間并不對偏差產(chǎn)生顯著影響，最好的解決方法是采用相對低 的流速和充填壓力。PS 和 PMMA 最小的直徑的相對偏差要比 PC 小的多。 從表 2 可以看出，直徑越大，相對偏差越小。當(dāng)然，在注射和保壓階段，直徑大的微透鏡陣列容易比直徑小的更容易填補(bǔ)，不管是在什么加工條件下和使用什么材料，大直徑的微透鏡陣列一般都能得到較好的復(fù)型。研究發(fā)現(xiàn)直徑 500m的 PS 最好復(fù)型，一般而言，與 PMMA 和 PC 相比較， PS 具有良好的成型性能。 根據(jù)表 2 的數(shù)據(jù)，在考察最 小的直徑的 PS 和 PMMA 的相對偏差時，可能會有人提出一些消極的觀點(diǎn)，認(rèn)為偏差過大，但是在這些數(shù)據(jù)中可以得到，高度上的絕對偏差在0.1m 左右，這是在測量系統(tǒng)誤差 范 圍以內(nèi)。 所以，在解讀復(fù)型實(shí)驗數(shù)據(jù)時可以忽略這些消極的觀點(diǎn)。 直徑為 300m的 PC 和 PMMA 微透鏡表面輪廓分別如圖 4 和圖 5 所 示。正如之前所述，在圖 4 所示的 PC 中，越高的充填壓力或越高流速復(fù)制微透鏡時效果越好，而充填時間在這些復(fù)型例子中只起一點(diǎn)作用。如圖所示， 對于 PMMA 來說，充填壓力和充填時間的作用微不足道；然而，流速對于 PC 也有類似的效果。 它可以提醒我們注意如果一個澆口凍結(jié)了，并阻止材料流入型腔時，充填時間并不影響復(fù)型。 因此，經(jīng)過一段時間后，充填時間的影響，主要取決 于加工條件。 7 圖 4 直徑為 300 m的 PC 微透鏡表面輪廓 a 充填壓力的影響 b 流速的影響 c 充填時間的影響 圖 5 直徑為 300 m的 PMMA 微透鏡表面輪廓 a 充填壓力的影響 b 流速的影響 c 充填時間的影響 4.2 表面粗糙度 直 徑 300m 的微透鏡和模具嵌件的平均表面粗糙度 Ra 的值，是用原子力顯微鏡(Bioscope AFM，數(shù)字 儀表 ) 測量的。測量了每個微透鏡頂點(diǎn)周圍面積為 5m5m區(qū)域， 8 圖 6 所示的是原子力顯微鏡圖象和所測量的微透鏡 Ra 的值。 PMMA 微透鏡復(fù)型具有最低的 Ra 值，為 1.606nm。 通過 AFM 的測量表明，注塑成型微透鏡陣列的 Ra 值 比相 對應(yīng)的模具嵌件要小。 因此，現(xiàn)在還不清楚如何改善可復(fù)制微透鏡陣列的表面粗糙度，也許可以從冷卻過程的回流而造成的表面張力入手，它可能會進(jìn)一步得出，在實(shí)際運(yùn)用中，微透鏡陣列注塑成型的平均表面粗糙度值能與精細(xì)的光學(xué)元件相媲美。 a 鍍鎳模具嵌件 ； b PS； c PMMA； d PC 圖 6 直徑為 300 m 的模具嵌件和注塑模具微透鏡的原子力顯微鏡 (AFM)圖像和平均表面粗糙度 Ra 值 4.3 焦距 焦距可以通過下面這個著名的等式計算得出： 1 121 1 1( 1 ) ( )nf R R 式中 f， nl， R1 和 R2 分別指焦距，透鏡材料的折射率，兩個主曲率半徑。比如，根據(jù)等式可以計算得出，直徑為 200 m 的模具微透鏡的焦距大約為 1.065mm(其中R1=0.624mm 和 R2= )，直徑 300的微透鏡大約為 1.130mm (其中 R1=0.662mm和 R2= )，直徑 500 m 的微透鏡大約為 2.580mm(其中 R1=1.512mm 和 R2= )。 (1)這些計算結(jié)果是基于假設(shè)與模具嵌件具有相同形狀的 PC(nl=1.586)可復(fù)型的微透鏡而得到的，所以由此推導(dǎo)出的幾何尺寸可能與實(shí)驗所測量的焦距相反。 9 5 總結(jié) 通過使用改良的 LIGA 技術(shù)電鍍鎳金屬模具嵌件，改變各種加工條件進(jìn)行大量的實(shí)驗，研究工藝條件對可復(fù)型的微透鏡的注塑成型過程的影響。結(jié)果顯示越高的充填壓力或越高流速，能得到越好的可復(fù)型效果。 相比之下，充填時間對微透鏡陣列復(fù)型的影響卻很小。 也許是因為冷卻階段回流的表面張力造成的，注射成型微透鏡陣列比模具嵌件有更小的平均表面粗糙度值， PMMA 復(fù)型的微透鏡陣列具有最好的表面質(zhì)量 (即最低粗糙度值 Ra=1.606 nm)。在實(shí)際應(yīng)用中，注塑成型微透鏡陣列的表面粗糙度能與精密的光學(xué)元件相媲美。就憑這一點(diǎn)，注塑成型將成為大規(guī)模生產(chǎn)微透鏡陣列的一個有用方法。 1 現(xiàn)代 模具 技術(shù) 引言 隨著全球經(jīng)濟(jì)的發(fā)展，新的技術(shù)革命不斷取得新的進(jìn)展和突破，技術(shù)的飛躍發(fā)展已經(jīng)成為推動世界經(jīng)濟(jì)增長的重要因素。市場經(jīng)濟(jì)的不斷發(fā)展，促使工業(yè)產(chǎn) 品越來越向多品種、小批量、高質(zhì)量 、低成本的方向發(fā)展，為了保持和加強(qiáng)產(chǎn)品在市場上的競爭力，產(chǎn)品的開發(fā)周期、生產(chǎn)周期越來越短，于是對制造各種產(chǎn)品的關(guān)鍵工藝裝備 模具的要求越來越苛刻。 一方面企業(yè)為追求規(guī)模效益，使得模具向著高速、精密、長壽命方向發(fā)展； 另一方面企業(yè)為了滿足多品種、小批量、產(chǎn)品更新?lián)Q代快、贏得市場的需要，要求模具向著制造周期短、成本低的快速經(jīng)濟(jì)的方向發(fā)展。計算機(jī)、激光、電子、新材料、新技術(shù)的發(fā)展，使得快速經(jīng)濟(jì)制模技術(shù)如虎添翼，應(yīng)用范圍不斷擴(kuò)大，類型不斷增多，創(chuàng)造的經(jīng)濟(jì)效益和社會效益越來越顯著。 1.注塑模具設(shè)計 注塑成型使用溫度依賴性改變材料性能，通過使用模具取得最后的形狀離散部件完成或接近完成尺寸。在這種制造過程中，液體材料是被迫填入，在型腔模具內(nèi)凝固。 首先，要創(chuàng)造一個模式塑造需要一個設(shè)計模型和一個載箱。 首先，要創(chuàng)造一個模式塑造需要一個設(shè)計模型和一個載箱。設(shè)計模型代表了成品，而載箱代表模具組件的總體積。注塑模具設(shè)計涉及模具結(jié)構(gòu)與功能的組成部分廣泛的經(jīng)驗知識 (啟發(fā)式知識 )。典型的過程中塑造新的發(fā)展可以分為四大階段 :產(chǎn)品設(shè)計，模具的能力評估，部件詳細(xì)設(shè)計，插入型腔設(shè)計和詳細(xì)的模具設(shè)計。 在開始階段，產(chǎn)品概念是在一 起由幾個人 (通常是一個組合營銷和工程 )完成。開始階段主要焦點(diǎn)是分析市場的機(jī)遇與適應(yīng)戰(zhàn)略。在第一階段，典型相關(guān)工藝制造信息被添加到設(shè)計中，設(shè)計出幾何細(xì)節(jié)。概念設(shè)計利用適當(dāng)?shù)闹圃煨畔⑥D(zhuǎn)化為可制造的物品。在第二階段，脫模方向和分型線位置用來檢測模具的能力。否則，零件形狀再次修改。在第三階段，零件幾何是用來建立模具的型芯和型腔形狀，模具的型芯和型腔，將用來形成零件。一般，收縮和擴(kuò)張需要加以考慮，這樣，在處理溫度下，成型將具有正確的尺寸和形狀。澆口、流道、冷料穴、通風(fēng)口也需要加以補(bǔ)充。幾何數(shù)據(jù)和分模信息之間的聯(lián)系在這 一點(diǎn)是至關(guān)重要的。第四階段與模具總體機(jī)械結(jié)構(gòu)相關(guān)，模具總體機(jī)械結(jié)構(gòu)包括連接模具到注塑機(jī)，注塑機(jī)是用于澆注、冷卻、取出和模具裝配的機(jī)械裝置。零件的熱處理工序，在使零件獲得要求的硬度的同時，還需對內(nèi)應(yīng)力進(jìn)行控制，保證零件加工 2 時尺寸的穩(wěn)定性，不同的材質(zhì)分別有不同的處理方式。隨著近年來模具工業(yè)的發(fā)展，使用的材料種類增多了，除了 Cr12、 40Cr、 Cr12MoV、硬質(zhì)合金外，對一些工作強(qiáng)度大，受力苛刻的凸、凹模，可選用新材料粉末合金鋼，如 V10、 ASP23 等，此類材質(zhì)具有較高的熱穩(wěn)定性和良好的組織狀態(tài)。針對以 Cr12MoV 為材質(zhì)的零件，在粗加工后進(jìn)行淬火處理，淬火后工件存在很大的存留應(yīng)力，容易導(dǎo)致精加工或工作中開裂，零件淬火后應(yīng)趁熱回火，消除淬火應(yīng)力。淬火溫度控制在 900-1020 ，然后冷卻至 200-220 出爐空冷，隨后迅速回爐 220 回火，這種方法稱為一次硬化工藝，可以獲得較高的強(qiáng)度及耐磨性，對于以磨損為主要失效形式的模具效果較好。生產(chǎn)中遇到一些拐角較多、形狀復(fù)雜的工件，回火還不足以消除淬火應(yīng)力，精加工前還需進(jìn)行去應(yīng)力退火或多次時效處理，充分釋放應(yīng)力。針對 V10、 APS23 等粉末合金鋼零件，因其能承受高溫回火，淬 火時可采用二次硬化工藝， 1050-1080 淬火，再用 490-520 高溫回火并進(jìn)行多次，可以獲得較高的沖擊韌性及穩(wěn)定性，對以崩刃為主要失效形式的模具很適用。粉末合金鋼的造價較高，但其性能好，正在形成一種廣泛運(yùn)用趨勢。 1.1.執(zhí)行 事實(shí)表明， SolidWorks 的 API 接口采用了面向?qū)ο蟮姆椒ê?API 函數(shù)允許選擇對象語言，例如 :作為編程語言的 Visual C+。利用這種方法，在 Windows NT下，基于 Windows的注塑模具三維設(shè)計的應(yīng)用軟件通過 Visual C+的代碼與商業(yè)軟件 SolidWorks99 接口開發(fā)。這個應(yīng)用模具設(shè)計過程分為幾個階段，提供模具設(shè)計者制造模具設(shè)計可靠方法。圖3 概述了這個框架。每一個階段可以視為一個獨(dú)立程序模塊。幾個單元已成功使用SolidWorks 開發(fā) .它們中的兩個模板模塊和分模模塊如下所示。 1.2 基于模架設(shè)計的模具 基于模架設(shè)計的模具與所有的組件和配件，像 HASCO， DME， HOPPT， LKM 和FUTABA 可自動創(chuàng)建參數(shù)化標(biāo)準(zhǔn)模板。設(shè)計師常用可以輕松地定制模板的這種模架。主要特點(diǎn)包括 :像支柱、澆道襯套、兩板，三板那樣的標(biāo)準(zhǔn)模架組件的實(shí)用性，以及定制非標(biāo)準(zhǔn)模具模板基于。 模架設(shè)計的模具分為四個主要部分，即構(gòu)件庫 (包括標(biāo)準(zhǔn)和非標(biāo)準(zhǔn)件庫 )，設(shè)計表中的尺寸驅(qū)動功能，結(jié)構(gòu)關(guān)系管理。在這里， SolidWorks 提供了尺寸驅(qū)動的功能是，以支持其申請。 （ 1）組件庫 為了在這競爭日益激烈的世界加強(qiáng)模具設(shè)計能力，降低設(shè)計成本和縮短生產(chǎn)周期，減少人力、自動化等是達(dá)到這一目的主要因素。換句話說，使用計算機(jī)軟件是非常必要的。 計算機(jī)軟件能夠容易地創(chuàng)建，修改，分析模具設(shè)計的部件，更新變化中的設(shè)計模型。為達(dá)到這個目標(biāo)，三維構(gòu)件庫提供儲存標(biāo)準(zhǔn)和非標(biāo)準(zhǔn)零部件的數(shù)據(jù)，其尺寸是儲存在 Microsoft Excel 中 。通過指定合適的尺寸，這些組件可以生成和插入裝配結(jié)構(gòu)。 這個庫是完全可定制和設(shè)計師能放入自己的部分加入組件庫。表面處理及組配 , 零件表面在加工時留下刀痕、磨痕是應(yīng)力集中的地方，是裂紋擴(kuò)展的源頭，因此在加工結(jié)束后， 3 需要對零件進(jìn)行表面強(qiáng)化，通過 鉗工 打磨，處理掉加工隱患。對工件的一些棱邊、銳角、孔口進(jìn)行倒鈍， R 化。一般地，電加工表面會產(chǎn)生 6-10m左右的變質(zhì)硬化層，顏色呈灰白色，硬化層脆而且?guī)в袣埩魬?yīng)力，在使 用之前要充分消除硬化層，方法為表面拋光，打磨去掉硬化層。在磨削加工、電加工過程中，工件會有一定磁化，具有微弱磁力，十分容易吸著一些小東西，因此在組裝之前，要對工件作退磁處理，并用乙酸乙脂清洗表面。組裝過程中，先參看裝配圖，找齊各零件，然后列出各零件相互之間的裝備順序，列出各項應(yīng)注意事項，然后著手裝配模具，裝配一般先裝導(dǎo)柱導(dǎo)套，然后裝模架和凸凹模，然后再對各處間隙，特別是凸凹模間隙進(jìn)行組配調(diào)整，裝配完成后要實(shí)施模具檢測，寫出整體情況報告。對發(fā)現(xiàn)的問題，可采用逆向思維法，即從后工序向前工序，從精加工到粗加工，逐 一檢查，直到找出癥結(jié)，解決問題。 （ 2）尺寸驅(qū)動 SolidWorks 提供了強(qiáng)有力的尺寸驅(qū)動功能，以支持參數(shù)化設(shè)計。儲存在 Microsoft Excel 中的尺寸和幾何存在邏輯關(guān)系。當(dāng)尺寸設(shè)置與相應(yīng)物件幾何參數(shù)設(shè)置相結(jié)合，可以獲得確切的模型。 （ 3）設(shè)計表 設(shè)計表允許設(shè)計師在嵌入的 Microsoft Exc