微透镜阵列注塑成型技术外文文献翻译/注射塑料模具外文翻译/中英文翻译

编号： 毕业设计 (论文 )外文翻译 （原文） 学 院： 专 业： 学生姓名： 学 号： 指导教师单位： 姓 名： 职 称： *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. 编号： 毕业设计 (论文 )外文翻译 （ 译 文） 学 院： 专 业： 学生姓名： 学 号： 指 导教师单位： 姓 名： 职 称： *年 * 月 * 日 1 微透镜阵列注塑成型技术 摘要 微透镜阵列注塑成型，可作为一种非常重要的大量生产技术。因此我们在近来的研究中非常关注， 为了进一步了解注塑成型在不同的加工条件下对可复制的微透镜阵列剖面的影响，如流量、填料压力和填料时间，对 3 种不同的高分子材料 (PS， PMMA 和PC)进行了大量的 试验。 镍金属模具嵌件微阵列就是利用改良的 LIGA 技术电镀主装配的显微结构制造的。在表面轮廓得到测量的前提下，研究工艺条件对可复制的微透镜阵列的影响。实验结果表明， 填料压力和流速对注射模塑的终产品的表面轮廓有重要的影响。 原子力显微镜测量表明， 微透镜阵列注塑成型的平均表面粗糙度值小于模具嵌件成型， 并在实际运用中，能与精细的光学元件相媲美。 1 说明 微型光学产品，如微透镜或微透镜阵列已广泛应用于光学数据存储、生物医学、显示装置等各个光学领域。微透镜和微透镜阵列不仅在实践应用上，而且在微型光学的基础研 究上都是非常重要的。有几种微透镜或微透镜阵列的制作方法，如改良的 LIGA 技术，光阻回流进程，紫外激光照射等。还有复制技术，如注塑模压成型和热压技术 ，这种方法对于减少大规模生产的微型光学产品的成本尤为重要。由于其优越的生产和再生产能力，只要注塑成型过程中能很好的复制微观结构，那么肯定是最适合于降低大量生产成本的方法。 基于这点，检查注塑成型能力并确定成型加工条件是注塑成型微观结构过程中最重要的步骤。在本次研究中，我们考察了工艺条件对可复制的微透镜阵列的注射成型的影响。微透镜阵列是用之前介绍过的改良的 LIGA 技术来编制的。注塑成型实验采用的是一种镀镍金属模具，来探讨了几种不同工艺条件对成型的影响。通过对微透镜阵列的表面轮廓测量，用来分析工艺条件产生的影响。最后，利用原子力显微镜 (AFM)测量微透镜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技术， 在一个有机玻璃板上制造出具有几种不同直径微透镜阵列。此种技术是先用 X 光照射有机玻璃板，然后再进行热处理两部分构成的。 X-射线照射引起有机玻璃分子质量的减少，同时降低了玻璃化转变温度，并因此导致净含量的增加，在热循环的作用下，微透镜发生微膨胀。利用中提 出的方法，结合改良的 LIGA 技术可以预测微透镜形状的变化过程。 在试验中使用的微透镜阵列，有 500m (22 阵列 )， 300m (22)和 200m (55)的直径阵列，高分别是 20.81m， 17.21m和 8.06m。采用改良的 LIGA 技术制造微透镜阵列作为一个主要的技术，用来制作镀镍的金属模具的注塑成型。另一些特殊材料，因为它们的强度不够或热性能差而不能直接进行微细加工，当作模具或金属模具使用，如硅、光阻剂或高分子材料。尽量使用具有良好机械性能和热性能的金属材料，因为它们能在可复型加工过程 中经受高压力和不断变化的温度。因此，为了利用这种复制技术进行大批量生产，我们选择使用金属模具材料而不是有机玻璃硅晶体。一些特殊技术，如低压注塑成型 8技术，应该作为良好的复制加工方法被采纳。 电镀模具的最终大小为 30 mm30 mm3mm。镀镍金属模具所具有的微透镜阵列如图 1 所示。 图 1 镀镍模具嵌件的制造 （ a）直接观察；（ b）直径为 200 m 的微透镜阵列电子显微镜图像；（ c）直径为 300 m的微透镜阵列电子显微镜图像 3 3 注塑成型实验 传统注塑机 (Allrounders 220 M， Arburg)多用做实验机。注塑模具设计的模架就是利用一块框形支撑板固定镀镍模具 (如图 2 所示 )。 图 2 注塑模具实验中使用的模架和嵌件 用修改的微透镜阵列确定模具零件孔形加强板 (在这次实验中，是一块矩形板 )的外部形状。模架本身已含有传输系统，如注射口，流道及浇口，通过支撑板、模具流道和滑动的模具表面将熔融聚合物引入模腔。用这种方法设计的模架，能够使模具零件更换起来简单容易。不过，有时 候也使用具有特定孔径形状的支撑板。 实验主要用三种普通高分子材料， PS(615APR，陶氏化学 )，有机玻璃 (IF870， LG MMA)和 PC(Lexan 141R)进行注塑成型。这些高分子材料通常在光学元件上使用，它们有不同的折射率 (PS， PMMA 和 PC 的折射率分别为 1.600， 1.490 和 1.586)，能生产出具有不同的光学特性的产品，例如 :具有相同的几何尺寸却有不同的焦距的光学元件。 通过改变每个高分子材料的流速，充填压力和充填时间获得 7 种加工条件进行注塑成型试验。此外，为了检查是否能可再生产，同一 实验往往需要重复三次。可能有人会指出，实验中没有考虑模具温度的影响，这是因为温度效应相对来说不是主要因素，而且微透镜阵列曲率半径比其他微观结构的高宽纵横比大。正是因为较大的微观结构高宽纵横比，使我们目前研究的温度效应更加可靠，并计划在将来实验时进行单独报告。 因此，在这项研究中，我们保持模具温度不变，而流速、充填压力和充填的时间都变化的情况下，能更清楚的观察其产生效果。表 1 详细的列出了三种高分子材料 PC， PMMA和 PS 在其他加工条件都保持不变，将模具温度分别设定为 80 ， 70 和 60 的情况下的实验结果。 表 1 注塑模具实验中详细的工艺条件 序号 流 速 (cc/s) 充填时间 (/s) 充填压 (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 续表 1 序号 流 速 (cc/s) 充填时间 (/s) 充填压力(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 可能有人会指出，我们的实验没有考虑型腔出现真空状态时的情况，其实大可不必担心，因为在本研究中的注 射阶段，大曲率半径的微透镜阵列不会把空气引入到型腔中。 4 讨论和结果 在详细讨论实验结果之前，认真思考一下，可能有助于总结为什么流速、充填压力和充填时间 (在这项研究中被选为不同的加工条件 )影响复制的质量。就流速而言，可能存在一个最佳流速，而在完成充填之前，流速太小会使得熔融聚合物过冷却，从而可能导致所谓的短暂的不连续现象，而过高的流速增大了压力面积，这是不可取的。 充填阶段是一般要求，是要在冷却时能够弥补热熔融聚合物的体积收缩 。 因此，在这个阶段应有足够的熔融聚合物流入型腔并控制产品的尺寸精度。 越高 的充填压力，越长的充填时间，将使更多的材料持续不断的流向型腔。然而， 过高的充填压力，有 5 时可能造成不均匀的密度分布，从而产生劣质的光学质量。过长的充填时间，不利于在各自浇口处的冷凝，并且会阻止熔融聚合物流入型腔。因此，我们需要研究不同的充填压力和充填时间所产生的影响。 4.1 表面轮廓 图 3 所示的是用电子显微镜 (SEM) 扫描的不同注塑微透镜的直径的 PMMA 图像 (a)以及不同 材料的图像 (b)。代表性的模具表面轮廓以及所有注塑微阵列都是通过三维轮廓测量系统 (NH-3N， Mitaka)测定的。 图 3 注塑模具的微透镜阵列和微透镜的电子显微镜图像 （ a） PMMA 微透镜阵列 （ b）不同材料直径为 300m微透镜阵列的注塑模具 作为一个可复制阵列的测量工具，我们已经确定了在模具与相应的模具嵌件分开的微阵列之间轮廓的相对高度偏差，所有的微透镜阵列相对偏差值列在表 2 中，具体见表所示： 表 2 表面轮廓相对偏差 直径 (m) 相对偏差 (%) 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，高分子材料的塑性会影响其重复使用性能。 因此在研究中，三种高分子材料总的相对误差是各不相同的。 PC 是三种聚合物中最难注塑成型的材料。在直径最小的例子中产生最大的相对偏差，那都是意料之中的事。 在这种特殊情况下，充填时间并不对偏差产生显著影响，最好的解决方法是采用相对低 的流速和充填压力。PS 和 PMMA 最小的直径的相对偏差要比 PC 小的多。 从表 2 可以看出，直径越大，相对偏差越小。当然，在注射和保压阶段，直径大的微透镜阵列容易比直径小的更容易填补，不管是在什么加工条件下和使用什么材料，大直径的微透镜阵列一般都能得到较好的复型。研究发现直径 500m的 PS 最好复型，一般而言，与 PMMA 和 PC 相比较， PS 具有良好的成型性能。 根据表 2 的数据，在考察最 小的直径的 PS 和 PMMA 的相对偏差时，可能会有人提出一些消极的观点，认为偏差过大，但是在这些数据中可以得到，高度上的绝对偏差在0.1m 左右，这是在测量系统误差 范 围以内。 所以，在解读复型实验数据时可以忽略这些消极的观点。 直径为 300m的 PC 和 PMMA 微透镜表面轮廓分别如图 4 和图 5 所 示。正如之前所述，在图 4 所示的 PC 中，越高的充填压力或越高流速复制微透镜时效果越好，而充填时间在这些复型例子中只起一点作用。如图所示， 对于 PMMA 来说，充填压力和充填时间的作用微不足道；然而，流速对于 PC 也有类似的效果。 它可以提醒我们注意如果一个浇口冻结了，并阻止材料流入型腔时，充填时间并不影响复型。 因此，经过一段时间后，充填时间的影响，主要取决 于加工条件。 7 图 4 直径为 300 m的 PC 微透镜表面轮廓 a 充填压力的影响 b 流速的影响 c 充填时间的影响 图 5 直径为 300 m的 PMMA 微透镜表面轮廓 a 充填压力的影响 b 流速的影响 c 充填时间的影响 4.2 表面粗糙度 直 径 300m 的微透镜和模具嵌件的平均表面粗糙度 Ra 的值，是用原子力显微镜(Bioscope AFM，数字 仪表 ) 测量的。测量了每个微透镜顶点周围面积为 5m5m区域， 8 图 6 所示的是原子力显微镜图象和所测量的微透镜 Ra 的值。 PMMA 微透镜复型具有最低的 Ra 值，为 1.606nm。 通过 AFM 的测量表明，注塑成型微透镜阵列的 Ra 值 比相 对应的模具嵌件要小。 因此，现在还不清楚如何改善可复制微透镜阵列的表面粗糙度，也许可以从冷却过程的回流而造成的表面张力入手，它可能会进一步得出，在实际运用中，微透镜阵列注塑成型的平均表面粗糙度值能与精细的光学元件相媲美。 a 镀镍模具嵌件 ； b PS； c PMMA； d PC 图 6 直径为 300 m 的模具嵌件和注塑模具微透镜的原子力显微镜 (AFM)图像和平均表面粗糙度 Ra 值 4.3 焦距 焦距可以通过下面这个著名的等式计算得出： 1 121 1 1( 1 ) ( )nf R R 式中 f， nl， R1 和 R2 分别指焦距，透镜材料的折射率，两个主曲率半径。比如，根据等式可以计算得出，直径为 200 m 的模具微透镜的焦距大约为 1.065mm(其中R1=0.624mm 和 R2= )，直径 300的微透镜大约为 1.130mm (其中 R1=0.662mm和 R2= )，直径 500 m 的微透镜大约为 2.580mm(其中 R1=1.512mm 和 R2= )。 (1)这些计算结果是基于假设与模具嵌件具有相同形状的 PC(nl=1.586)可复型的微透镜而得到的，所以由此推导出的几何尺寸可能与实验所测量的焦距相反。 9 5 总结 通过使用改良的 LIGA 技术电镀镍金属模具嵌件，改变各种加工条件进行大量的实验，研究工艺条件对可复型的微透镜的注塑成型过程的影响。结果显示越高的充填压力或越高流速，能得到越好的可复型效果。 相比之下，充填时间对微透镜阵列复型的影响却很小。 也许是因为冷却阶段回流的表面张力造成的，注射成型微透镜阵列比模具嵌件有更小的平均表面粗糙度值， PMMA 复型的微透镜阵列具有最好的表面质量 (即最低粗糙度值 Ra=1.606 nm)。在实际应用中，注塑成型微透镜阵列的表面粗糙度能与精密的光学元件相媲美。就凭这一点，注塑成型将成为大规模生产微透镜阵列的一个有用方法。 1 现代 模具 技术 引言 随着全球经济的发展，新的技术革命不断取得新的进展和突破，技术的飞跃发展已经成为推动世界经济增长的重要因素。市场经济的不断发展，促使工业产 品越来越向多品种、小批量、高质量 、低成本的方向发展，为了保持和加强产品在市场上的竞争力，产品的开发周期、生产周期越来越短，于是对制造各种产品的关键工艺装备 模具的要求越来越苛刻。 一方面企业为追求规模效益，使得模具向着高速、精密、长寿命方向发展； 另一方面企业为了满足多品种、小批量、产品更新换代快、赢得市场的需要，要求模具向着制造周期短、成本低的快速经济的方向发展。计算机、激光、电子、新材料、新技术的发展，使得快速经济制模技术如虎添翼，应用范围不断扩大，类型不断增多，创造的经济效益和社会效益越来越显著。 1.注塑模具设计 注塑成型使用温度依赖性改变材料性能，通过使用模具取得最后的形状离散部件完成或接近完成尺寸。在这种制造过程中，液体材料是被迫填入，在型腔模具内凝固。 首先，要创造一个模式塑造需要一个设计模型和一个载箱。 首先，要创造一个模式塑造需要一个设计模型和一个载箱。设计模型代表了成品，而载箱代表模具组件的总体积。注塑模具设计涉及模具结构与功能的组成部分广泛的经验知识 (启发式知识 )。典型的过程中塑造新的发展可以分为四大阶段 :产品设计，模具的能力评估，部件详细设计，插入型腔设计和详细的模具设计。 在开始阶段，产品概念是在一 起由几个人 (通常是一个组合营销和工程 )完成。开始阶段主要焦点是分析市场的机遇与适应战略。在第一阶段，典型相关工艺制造信息被添加到设计中，设计出几何细节。概念设计利用适当的制造信息转化为可制造的物品。在第二阶段，脱模方向和分型线位置用来检测模具的能力。否则，零件形状再次修改。在第三阶段，零件几何是用来建立模具的型芯和型腔形状，模具的型芯和型腔，将用来形成零件。一般，收缩和扩张需要加以考虑，这样，在处理温度下，成型将具有正确的尺寸和形状。浇口、流道、冷料穴、通风口也需要加以补充。几何数据和分模信息之间的联系在这 一点是至关重要的。第四阶段与模具总体机械结构相关，模具总体机械结构包括连接模具到注塑机，注塑机是用于浇注、冷却、取出和模具装配的机械装置。零件的热处理工序，在使零件获得要求的硬度的同时，还需对内应力进行控制，保证零件加工 2 时尺寸的稳定性，不同的材质分别有不同的处理方式。随着近年来模具工业的发展，使用的材料种类增多了，除了 Cr12、 40Cr、 Cr12MoV、硬质合金外，对一些工作强度大，受力苛刻的凸、凹模，可选用新材料粉末合金钢，如 V10、 ASP23 等，此类材质具有较高的热稳定性和良好的组织状态。针对以 Cr12MoV 为材质的零件，在粗加工后进行淬火处理，淬火后工件存在很大的存留应力，容易导致精加工或工作中开裂，零件淬火后应趁热回火，消除淬火应力。淬火温度控制在 900-1020 ，然后冷却至 200-220 出炉空冷，随后迅速回炉 220 回火，这种方法称为一次硬化工艺，可以获得较高的强度及耐磨性，对于以磨损为主要失效形式的模具效果较好。生产中遇到一些拐角较多、形状复杂的工件，回火还不足以消除淬火应力，精加工前还需进行去应力退火或多次时效处理，充分释放应力。针对 V10、 APS23 等粉末合金钢零件，因其能承受高温回火，淬 火时可采用二次硬化工艺， 1050-1080 淬火，再用 490-520 高温回火并进行多次，可以获得较高的冲击韧性及稳定性，对以崩刃为主要失效形式的模具很适用。粉末合金钢的造价较高，但其性能好，正在形成一种广泛运用趋势。 1.1.执行 事实表明， SolidWorks 的 API 接口采用了面向对象的方法和 API 函数允许选择对象语言，例如 :作为编程语言的 Visual C+。利用这种方法，在 Windows NT下，基于 Windows的注塑模具三维设计的应用软件通过 Visual C+的代码与商业软件 SolidWorks99 接口开发。这个应用模具设计过程分为几个阶段，提供模具设计者制造模具设计可靠方法。图3 概述了这个框架。每一个阶段可以视为一个独立程序模块。几个单元已成功使用SolidWorks 开发 .它们中的两个模板模块和分模模块如下所示。 1.2 基于模架设计的模具 基于模架设计的模具与所有的组件和配件，像 HASCO， DME， HOPPT， LKM 和FUTABA 可自动创建参数化标准模板。设计师常用可以轻松地定制模板的这种模架。主要特点包括 :像支柱、浇道衬套、两板，三板那样的标准模架组件的实用性，以及定制非标准模具模板基于。 模架设计的模具分为四个主要部分，即构件库 (包括标准和非标准件库 )，设计表中的尺寸驱动功能，结构关系管理。在这里， SolidWorks 提供了尺寸驱动的功能是，以支持其申请。 （ 1）组件库 为了在这竞争日益激烈的世界加强模具设计能力，降低设计成本和缩短生产周期，减少人力、自动化等是达到这一目的主要因素。换句话说，使用计算机软件是非常必要的。 计算机软件能够容易地创建，修改，分析模具设计的部件，更新变化中的设计模型。为达到这个目标，三维构件库提供储存标准和非标准零部件的数据，其尺寸是储存在 Microsoft Excel 中 。通过指定合适的尺寸，这些组件可以生成和插入装配结构。 这个库是完全可定制和设计师能放入自己的部分加入组件库。表面处理及组配 , 零件表面在加工时留下刀痕、磨痕是应力集中的地方，是裂纹扩展的源头，因此在加工结束后， 3 需要对零件进行表面强化，通过 钳工 打磨，处理掉加工隐患。对工件的一些棱边、锐角、孔口进行倒钝， R 化。一般地，电加工表面会产生 6-10m左右的变质硬化层，颜色呈灰白色，硬化层脆而且带有残留应力，在使 用之前要充分消除硬化层，方法为表面抛光，打磨去掉硬化层。在磨削加工、电加工过程中，工件会有一定磁化，具有微弱磁力，十分容易吸着一些小东西，因此在组装之前，要对工件作退磁处理，并用乙酸乙脂清洗表面。组装过程中，先参看装配图，找齐各零件，然后列出各零件相互之间的装备顺序，列出各项应注意事项，然后着手装配模具，装配一般先装导柱导套，然后装模架和凸凹模，然后再对各处间隙，特别是凸凹模间隙进行组配调整，装配完成后要实施模具检测，写出整体情况报告。对发现的问题，可采用逆向思维法，即从后工序向前工序，从精加工到粗加工，逐 一检查，直到找出症结，解决问题。 （ 2）尺寸驱动 SolidWorks 提供了强有力的尺寸驱动功能，以支持参数化设计。储存在 Microsoft Excel 中的尺寸和几何存在逻辑关系。当尺寸设置与相应物件几何参数设置相结合，可以获得确切的模型。 （ 3）设计表 设计表允许设计师在嵌入的 Microsoft Exc