微光器件生产中的注塑工艺比较【中文4900字】
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微光
器件
生产
出产
中的
注塑
工艺
比较
对比
中文
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微光器件生产中的注塑工艺比较【中文4900字】,微光,器件,生产,出产,中的,注塑,工艺,比较,对比,中文
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PROCEDIAENGINEERING69201412961305AVAILABLEONLINEATWWWSCIENCEDIRECTCOM187770582014THEAUTHORSPUBLISHEDBYELSEVIERLTDOPENACCESSUNDERCCBYNCNDLICENSESELECTIONANDPEERREVIEWUNDERRESPONSIBILITYOFDAAAMINTERNATIONALVIENNADOI101016/JPROENG201403122SCIENCEDIRECT24THDAAAMINTERNATIONALSYMPOSIUMONINTELLIGENTMANUFACTURINGANDAUTOMATION,2013COMPARISONOFINJECTIONMOLDINGTECHNOLOGIESFORTHEPRODUCTIONOFMICROOPTICALDEVICESMARCOSORTINO,GIOVANNITOTIS,ELSOKULJANICDIEGM,UNIVERSITYOFUDINE,VIADELLESCIENZE206,UDINEI33100,ITALYABSTRACTINJECTIONMOLDINGISACOMPLEXPROCESSREGULATEDBYMANYFACTORSINJECTIONSPEED,INJECTIONPRESSURE,MELTTEMPERATURE,MOLDTEMPERATURE,ANDOTHERSDESPITE,PROCESSCONTROLANDPARAMETEROPTIMIZATION,ITISOFTENDIFFICULTTOREPLICATETHERMOPLASTICCOMPONENTSWITHADEQUATEDIMENSIONALACCURACY,ESPECIALLYINTHECASEOFGEOMETRIESWITHHIGHASPECTRATIOSFORTHESEREASON,THEREISANEEDFORINNOVATIVEMOULDINGTECHNOLOGIESSUCHASINJECTIONCOMPRESSIONMOLDINGICMORVACUUMINJECTIONMOULDINGVIMINTHISPAPERCONVENTIONALINJECTIONMOLDINGIMISCOMPAREDTOICMANDVIMFORTHEREPLICATIONOFOPTICALTHERMOPLASTICMICROSCALEPRISMPATTERNSTYPICALOFFRESNELLENSESAFULLDESIGNOFEXPERIMENTSWASPERFORMEDINCLUDINGSEVERALMICROSTRUCTUREDPRISMGEOMETRIES,INJECTIONMOLDINGTECHNOLOGIESANDSPECIFICPROCESSPARAMETERSFORATOTALOF288TESTSDATAANALYSISEVIDENCEDTHEGREATERQUALITYOFWORKPIECESOBTAINEDBYICM,WHEREASVIMWASAMINORPROCESSIMPROVEMENT2014THEAUTHORSPUBLISHEDBYELSEVIERLTDSELECTIONANDPEERREVIEWUNDERRESPONSIBILITYOFDAAAMINTERNATIONALVIENNAKEYWORDSINJECTIONMOLDINGINJECTIONCOMPRESSIONMOLDINGVACUUMINJECTIONMOLDINGACCURACY1INTRODUCTIONTHERECENTINNOVATIONSINTELECOMMUNICATIONS,PHOTOVOLTAICTECHNOLOGY,MEDICALIMAGINGDIAGNOSTICS,SURVEILLANCESYSTEMSANDILLUMINATIONSYSTEMSSTRONGLYENHANCEDTHEINTERESTINMANUFACTURINGCOMPLEXSHAPEOPTICCOMPONENTSWHOSEDIMENSIONSAREINTHERANGEFROM10MTO100M,COMMONLYNAMEDMICROOPTICSORMESOOPTICSTHEMAINPROCESSESAVAILABLEFORMASSIVEPRODUCTIONOFMESOOPTICSAREHOTEMBOSSING,USEDTOPRODUCEMICROSTRUCTUREDPLASTICFILMSHOLOGRAMS,WEARABLEREFLEX,RETROREFLECTORSFORSTREETAPPLICATION,ANDOTHERS,ANDINJECTIONCORRESPONDINGAUTHORTEL390432558241FAX390432558251EMAILADDRESSSORTINOUNIUDIT2014THEAUTHORSPUBLISHEDBYELSEVIERLTDOPENACCESSUNDERCCBYNCNDLICENSESELECTIONANDPEERREVIEWUNDERRESPONSIBILITYOFDAAAMINTERNATIONALVIENNA1297MARCOSORTINOETAL/PROCEDIAENGINEERING69201412961305MOLDING,APPLIEDTOPRODUCETRIDIMENSIONALOPTICALCOMPONENTSCOMPACTOPTICSFORCCD,MICRODIFFUSERS,FRESNELLENSES,ANDOTHER1ATTHEPRESENTTIME,ONLYINJECTIONMOLDINGISECONOMICALFORMASSPRODUCTIONDUETOITSHIGHPRODUCTIVITY2THEEFFICIENCYOFTHESETECHNIQUESFORMANUFACTURINGMICROOPTICSISVERYLIMITEDANDTHEREISASTRONGNEEDFORINNOVATIVEINSTRUMENTATIONANDMANUFACTURINGMETHODOLOGIESMOREOVER,THEDIMENSIONALACCURACYREQUIREDBYOPTICALCOMPONENTSISHIGHANDITISOFTENDIFFICULTTOACHIEVETHEREQUIREDQUALITYSTANDARDSTHEINJECTIONMOLDINGPROCESSATMICROSCALEISVERYCOMPLEXANDTHEREAREMANYFACTORSWHICHINFLUENCETHEPROCESSSUCHASINJECTIONSPEED,INJECTIONPRESSURE,MELTTEMPERATURE,MOLDTEMPERATURE,ANDOTHERS3THEREARESTRONGINTERACTIONSAMONGPROCESSPARAMETERS,VARIATIONOFPROCESSCONDITIONSANDOTHERPOSSIBLEPHENOMENAFORINSTANCE,AIRTRAPSWHICHREDUCEPROCESSREPEATABILITYTHEREFORE,ADVANCEDTECHNOLOGIESEGADAPTIVEINJECTIONMOULDING,PULSEDCOOLINGTECHNOLOGY,ULTRAHIGHSPEEDINJECTIONMOULDING,ANDOTHERSHAVEBEENDEVELOPEDGENERALLY,ITISNOTALWAYSPOSSIBLETOIMPROVETHEPROCESSACCURACYSIMPLYBYREGULATINGPROCESSPARAMETERSORBYMINORMODIFICATIONSOFTHEMOULDOROFTHEPRODUCTIONSETUPTHESEASPECTSAREOFPARTICULARRELEVANCEWHENTHEMOLDEDCOMPONENTISANOPTICALDEVICE,WHICHREQUIRESBOTHHIGHDIMENSIONALACCURACYANDSURFACEQUALITYINTHISPAPER,CONVENTIONALINJECTIONMOLDINGIMISCOMPAREDTOTWOINNOVATIVEMETHODOLOGIESSUCHASINJECTIONCOMPRESSIONMOLDINGICMANDVACUUMINJECTIONMOLDINGVIMFORTHEREPLICATIONOFOPTICALTHERMOPLASTICMICROSCALEPRISMPATTERNSTYPICALOFFRESNELLENSESRECENTPUBLICATIONSDEALINGWITHTHISTOPICAREFIRSTDISCUSSED,THENTHEEXPERIMENTALPROCEDUREISDESCRIBEDINDETAILEVENTUALLY,THEEXPERIMENTALDATAISDISCUSSEDANDCONCLUSIONSAREDRAWN11STATEOFTHEARTINTABLE1,RECENTSCIENTIFICPUBLICATIONSDEALINGWITHINNOVATIVEINJECTIONMOLDINGTECHNIQUESANDINVESTIGATINGTHEEFFECTOFINJECTIONMOLDINGPARAMETERSAREGIVENTABLE1SUMMARYOFRECENTRESEARCHWORKSDEALINGWITHINJECTIONMOLDINGOFOPTICALCOMPONENTSPSPOLYSTYRENEPCPOLYCARBONATECOCCYCLICOLEFINCOPOLYMERPMMAPOLYMETHYLMETHACRYLATESANSTYRENEACRYLONITRILECOPOLYMERHFPTFEETHEXAFLUOROPROPYLENETETRAFLUOROETHYLENEETHYLENETERPOLYMERIMINJECTIONMOLDINGICMINJECTIONCOMPRESSIONMOLDINGVIMVACUUMINJECTIONMOULDINGHEHOTEMBOSSINGVARIOUSSHAPETYPEMATERIALTECHNOLOGYMAINASPECTSREFYEARDISCPART2DPSIM,ICMSIMULATIONOFINJECTIONMOLDINGPROCESS42000SAMPLEPART,PLATE2DPCIM,ICMOPTICALQUALITYOBTAINEDBYDIFFERENTINJECTIONMOLDINGPROCESSES52000MONOSPHERICALLENS,DISK2DPCIMEFFECTOFTHEMOLDINGCONDITIONSONSURFACECONTOURERRORS62001LIGHTGUIDEWEDGESHAPED2DPMMAIM,ICMINFLUENCEOFPROCESSPARAMETERSONSHRINKAGE72003OPTICALDISC2DPCICMSIMULATIONOFINJECTIONMOLDINGPROCESS82003PICKUPLENS3DPMMAICMSIMULATIONOFINJECTIONMOLDINGPROCESS92005PICKUPLENSWITHDIFFRACTIONGRATINGS3DPMMAIM,ICMCOMPARISONOFPROCESSESFORPRODUCTIONONDIFFRACTIONGRATING102005PLATEWITHVGROOVES5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ANIMANDICMCYCLESDUETOTHETIMEREQUIREDTOREACHVACUUMCONDITIONINSIDETHEMOULDCAVITYHOWEVER,THETIMECOULDBEEASILYREDUCEDUSINGLARGERVACUUMRESERVOIRSVERIFICATIONOFTHEDIMENSIONALCORRECTNESSOFTHEMAINMOULDGEOMETRIESSPRUE,GATE,COOLINGDUCTSANDSELECTIONOFSUITABLERANGESOFPROCESSPARAMETERSFOREACHINJECTIONMOULDINGMETHODOLOGYWEREBASEDONMOLDFLOWCAESOFTWARESIMULATIONSINACCORDANCETOTHERESULTSOFTHECAEANALYSIS,LITERATUREREVIEWANDEXPERIENCE,ADESIGNOFEXPERIMENTSWITHTHREEPROCESSPARAMETERSASFACTORSWASREALIZEDFOREACHINJECTIONMOLDINGMETHODOLOGY,ASSHOWNINTABLE3ANDTABLE4TABLE3DESIGNOFEXPERIMENTSOFPROCESSPARAMETERSTECHNOLOGYFACTOR1FACTOR2FACTOR3LOW1HIGH1LOW1HIGH1LOW1HIGH1IMMOULDTEMPERATURECHOLDINGPRESSUREBARINJECTIONSPEEDMM/SEC9010030010003070ICMINJECTIONPRESSUREBARHOLDINGPRESSUREBARCOMPRESSIONGAPMM50010005009000615VIMINJECTIONPRESSUREBARHOLDINGPRESSUREBARINJECTIONSPEEDMM/SEC60016003008003070TABLE4INVESTIGATEDPRISMGEOMETRIESFACTORLEVELSINJECTIONMOLDINGMETHODOLOGY3PRISMGEOMETRY6FACTOR12FACTOR22FACTOR32REPETITIONS2TOTALTESTS3X6X2X2X2X2288EACHSAMPLEWASINSPECTEDUSINGAVEECOSLOANDEKTAK3STCONTACTPROFILOMETERWITHSTYLUSTIPRADIUS2,5M,INSPECTIONLENGTH4500M,CONTACTFORCE30MG,POINTDENSITY0625M/POINT,FIGURE6AANEXAMPLEOFDIGITALPROFILEOBTAINEDFROMPROFILOMETERINSPECTIONISGIVENINFIGURE6BDIGITALIZEDPROFILESWEREELABORATEDINMATLABTODETERMINETHETRANSCRIPTIONRATIOTRFOREACHPEAKANDSTOREDINADATABASEFORSTATISTICALANALYSIS1302MARCOSORTINOETAL/PROCEDIAENGINEERING69201412961305FIG6APROFILOMETERANDMEASURINGCONFIGURATIONBEXAMPLEOFMOULDEDPARTMEASUREMENT3DATAANALYSISANDDISCUSSIONTHEBOXPLOTSOFTHETRANSCRIPTIONRATIOFORTHEINJECTIONMOULDINGMETHODOLOGIESANDFOREACHPRISMGEOMETRYAREGIVENINFIGURE7IDEALLY,THEAVERAGEPOINTREPRESENTEDBYTHEREDLINEINSIDETHEBOXPLOTSHOULDBEASCLOSEASPOSSIBLETO100FORACCURACYANDTHEVERTICALDIMENSIONOFTHEBOXWHICHISRELATEDTODISPERSION/PRECISIONSHOULDBESMALLFIG7BOXPLOTS,WHISKERSPLOTSANDOUTLIERSOFTRFORTHEINVESTIGATEDINJECTIONMOULDINGMETHODOLOGIESANDFORALLCONSIDEREDPRISMGEOMETRIESITCANBEOBSERVEDTHATTHEREISASIGNIFICANTSTATISTICALDIFFERENCEBETWEENTHETRANSCRIPTIONRATIOOFTHETHREEMETHODOLOGIESSPECIFICALLY,THEICMPROCESSOBTAINEDTHEHIGHESTAVERAGETRANSCRIPTIONRATIOANDTHELOWEST1303MARCOSORTINOETAL/PROCEDIAENGINEERING69201412961305DISPERSIONACCORDINGLY,ICMCANBERECOGNIZEDASTHEMOSTPRECISEANDREPEATABLEOFTHETHREEINJECTIONMOLDINGMETHODOLOGIESTHEAVERAGETRANSCRIPTIONRATIOOFTHEVIMMETHODOLOGYISLOWERTHANICMBUTHIGHERTHANIMFORALLPRISMGEOMETRIESTHEDIMENSIONOFTHEBOXOFTHEBOXPLOTOFVIMISINSEVERALCASESOFTHESAMESIZEOFIM,INOTHERCASESSLIGHTLYSMALLERTHISANALYSISEVIDENCESTHATVIMISAMINORIMPROVEMENTOFTHECONVENTIONALINJECTIONMOLDINGPROCESS,ANDITSEFFECTIVENESSDEPENDSONTHEAPPLICATIONINCASESP4,P5,P6,WHERETHEPRISMANGLEWAS30AND45,THETRANSCRIPTIONRATIOSWERESMALLERTHANOTHERPRISMGEOMETRIESFOREXAMPLE,CASESP3ANDP6HADTHESAMEPRISMHEIGHTHM250MANDTWODIFFERENTPRISMANGLES,45FORP3AND30FORP6TRANSCRIPTIONRATIOFORP3WASABOUT7580WHEREASFORP6ITWAS6070THEREFORE,THETRANSCRIPTIONRATIOWASLOWWHENTHEPRISMANGLEWASSMALL,WHICHCOULDBEREASONABLYEXPECTEDSIMILARLY,GEOMETRIESP4,P5ANDP6HADTHESAMEPRISMANGLE30ANDDECREASINGPRISMHEIGHTHMITCANBESEENTHATTHETRANSCRIPTIONRATIOINTHESECASESWASINTHERANGE6070ACCORDINGTOTHISOBSERVATION,THEPRISMHEIGHTHMDIDNOTHAVEASIGNIFICANTEFFECTONTHETRANSCRIPTIONRATIOFIG8AVERAGEEFFECTSOFTHEFACTORSANDSEMINSPECTIONOFPRISMSOBTAINEDWITHIMANDICMTHEAVERAGEEFFECTOFTHEFACTORSFOREACHINJECTIONMOULDINGMETHODOLOGYANDFOREACHPRISMGEOMETRYTOGETHERWITHANEXAMPLEOFTHEMOLDEDPRISMGEOMETRIESOBTAINEDWITHIMANDWITHICMARESHOWNINFIGURE8THEMOSTRELEVANTFACTORFORALLTHEINJECTIONMOLDINGPROCESSESWASTHEHOLDINGPRESSURE,WHICHCAUSEDAVARIATIONOFTRBETWEEN2AND9FORIM,0AND35FORICM,25AND55FORVIMFORIM,THESECONDMOSTRELEVANTFACTORWASTHEMOULDTEMPERATUREFORLARGERPRISMANGLESGEOMETRIESP1,P2ANDP3ANDINJECTIONSPEEDFORSMALLERPRISMANGLESGEOMETRIESP4,P5ANDP6THESEDATAWEREINACCORDANCEWITHPREVIOUSSTUDIESINTHECASEOFICM,THESECONDMOSTRELEVANTFACTORWASTHEINJECTIONPRESSUREWHICHPRODUCED1304MARCOSORTINOETAL/PROCEDIAENGINEERING69201412961305AVARIATIONOFTRAROUND1INJECTIONSPEEDWASBYFARTHESECONDMOSTRELEVANTFACTORINTHEVIMPROCESS,PRODUCINGAVARIATIONOFTRAROUND124CONCLUSIONTHEAPPLICATIONOFINNOVATIVEINJECTIONMOLDINGMETHODOLOGIESINJECTIONCOMPRESSIONMOLDINGICMANDVACUUMINJECTIONMOLDINGVIMFORTHEMASSREPLICATIONOFOPTICALMISCROSCALEPLASTICCOMPONENTSWASCOMPAREDTOCONVENTIONALINJECTIONMOLDINGINJECTIONCOMPRESSIONMOULDINGPROCESSCANBEPERFORMEDONLYONDEDICATEDMACHINES,WHEREASVACUUMINJECTIONMOULDINGPROCESSCANBEAPPLIEDTOCONVENTIONALINJECTIONMOULDINGMACHINEWITHMINORSETUPANDMOULDMODIFICATIONSVACUUMINJECTIONMOLDINGIMPLIESANINCREASEINCYCLETIMEDUETOTHETIMENEEDEDTOREACHTHEVACUUMCONDITIONINSIDETHECAVITYTHEANALYSISOFTHETRANSCRIPTIONRATIODATADERIVEDFROMEXPERIMENTSEVIDENCEDTHATICMISMOSTPRECISEANDREPEATABLEOFTHETHREEINJECTIONMOLDINGMETHODOLOGIES,WHEREASVIMISAMINORPROCESSIMPROVEMENTHOWEVERTHEMAXIMUMTRANSCRIPTIONRATIOWASSTRONGLYDEPENDENTONTHEOPTICALPRISMGEOMETRYSPECIFICALLY,HIGHLEVELSOFTRANSCRIPTIONRATIOWEREREACHEDONLYWHENTHEPRISMANGLEWASLARGETHEREWASNOEVIDENCEOFASTRONGEFFECTOFTHEHEIGHTOFTHEPRISMHMONTHETRANSCRIPTIONRATIOHOLDINGPRESSUREWASTHEMAINFACTORINFLUENCINGALLINJECTIONMOLDINGPROCESSESANDPRODUCINGVARIATIONSOFTHETRUPTO9FORIM,35FORICMAND55FORVIMTHETRANSCRIPTIONRATIOOBTAINEDBYIMWASALSOINFLUENCEDBYTHEMOULDTEMPERATUREANDINJECTIONSPEEDINJECTIONSPEEDWASALSOTHESECONDMOSTRELEVANTFACTORINFLUENCINGTHEVIMPROCESSITWOULDBEOFFURTHERINTERESTTOCONTINUETHERESEARCHONTHISTOPICBYCOMBININGTHEICMANDVIMMETHODOLOGIESANDEXTENDINGTHEINVESTIGATIONTOOTHERPRISMGEOMETRIESACKNOWLEDGEMENTSTHEAUTHORSWOULDLIKETOTHANKMICHELEPASCOLO,NICOLADELNEGROANDCENTRORICERCHEPLASTOPTICA,AMAROUD,ITALY,FORTHEIRSUPPORTTOTHISRESEARCHREFERENCES1ADAVIS,RCBUSH,JCHARVEY,MFFOLEY,FRESNELLENSESINREARPROJECTIONDISPLAYS,SIDDIGESTOFTECHNICALPAPERXXXIII,200895982MWORGUL,HOTEMBOSSINGTHEORYANDTECHNOLOGYOFMICROREPLICATION,2009,WILLLIAMANDREWPUBLICATION3DOKAZMER,DHATCH,TOWARDSCONTROLLABILITYOFINJECTIONMOLDING,PROCEEDINGSOFMATERIALPROCESSINGSYMPOSIUM1999ASMEINTERNATIONALMECHANICALENGINEERINGCONGRESSANDEXPOSITION,NASHVILLE,TENNESSEE19994SCCHEN,YCCHEN,HSPENG,SIMULATIONOFINJECTIONCOMPRESSINGMOLDINGPROCESSPARTIIINFLUENCEOFPROCESSCHARACTERISTICONPARTSHRINKAGE,JOURNALOFAPPLIEDPOLYMERSCIENCE,752000164016545WMICHAELI,MWIELPUETZ,OPTIMIZATIONOFTHEOPTICALPARTQUALITYOFPOLYMERGLASSESINTHEINJECTIONMOULDINGPROCESS,MACROMOLECULARMATERIALSANDENGINEERING,284/28520008
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