Study On Injection-compression Moulding Of Optical Componets With Complex Structure

With the deep development of solar energy generation technology, the demandfor high machining accuracy and efficiency of optical components with specialoptical properties and complex structure is increasing. The injection-compressionmoulding (ICM) technology has many advantages compared with traditionalremoving processing methods, which Include high efficiency, high moulding qualitywith stable machining accuracy and easy to manufacture complex structure. In thisthesis, the ICM of the total internal reflection lens, which is a represent of theoptical components with complex structure, was studied in order to produce theoptical components with high efficiency and precision.This thesis introduced the basic theory of ICM first. The formingcharacteristics of injection and compression stages were analyzed, and themathematical models were summarized briefly. After that, for the requirement ofsimulation software Moldflow/MPI on the finite element model, the method ofestablishing midplane meshes of the optical components was determined.The structure of the injection-compression mould was designed and optimized.According to the feature of the two stages included in injection compressionmoulding, the scheme to design the structure of the mould was as follows: theprinciple to design the moulding part followed the design standard of compressionmould and that of the mould base followed the standard mould base of injectionmould. In addition, this thesis obtained optimum structure by simulation includingthe style and size of the feed system as well as the positional distribution of coolingduct, as the feed system and the cooling system ware main factors which influencedthe quality of the products significantly.At the end of the thesis, Taguchi experimental design method as well as SNR(signal-to-noise ratio) was used to design simulation experiments whose target wasto obtain optimum processing parameters of ICM. After the simulation experiments,range analysis method was used to analyze the experiment result. Then discussedthe affection of the parameters on the warpage and residual stresses of the totalinternal reflection lens and gain optimum processing parameters whose simulationresult performs stable quality as well as low value of warpage and residual stresses.In terms of the optimum processing parameters, the ICM experiments and injectionmoulding experiments ware compared, and the results indicated that the quality ofthe lens moulded by ICM was better than that of the lens moulded by ICM, whichwas reflected by the Contour Accuracy and the sharpness of the tooth profile angle.