Simulation On Micro-injection Moulding Of Aspherical Lens

The development and use of aspheric lenses in optical systems has led to thesteady growth of demand for polymer material aspheric lenses. As one of the coretechnologies for manufacturing polymer material devices, micro-injection mouldingprogram has become more and more important due to its numerous advantages, suchas low cost, short manufacturing period, simple molding technology, as well as highquality of structures. However, it has only been a few decades since micro-injectionmoulding program was used in manufacturing micro devices, and there is yet to forma perfect theory on polymer micro-injection moulding. Therefore the actualprocessing of micro-injection moulding lacks theoretical guidance, and processparameters could only be obtained through repeated experimentation.As computer aided engineering develops, using computer simulation to study theprocess of micro-injection moulding has become a feasible method. In order to studythe influential factors during the process of the micro-injection of aspheric lenses andmethods of manufacturing aspheric lenses, a theoretical model of the polymer melt inthe micro-injection is studied adequately in this paper, based on the in-depth researchon the theory of the flow of polymer melt in micro cavity. Besides, based on thistheory, this paper did further research on the process parameters and actual process ofinjection moulding of aspheric lenses using computer simulation. Optimizationanalysis is performed on the cavity of the aspheric lenses, The effects of variousthickness of base and shape of the gate on the quality of the injection moulding areanalyzed. And the optimal design for the thickness of base and shape of gate of theaspherical lens cavity is determined.Experimentation is carried out to study the process parameters of the cavity，andoptimal process parameters are obtained through orthogonal tests. By the simulationof the filling process of the injection moulding, the form that the polymer melt flow inthe mold cavity is analyzed. And based on this theory, the production reason of thecavitation and weld linesis discussed. In addition, further analysis is made on thecoherence between filling process and quality of molding. The research conducted in this paper is of theoretical support and reference to micro-injection moulding ofaspheric lenses.