目的 针对注射成形制备高精密光学镜头产品过程中收缩、翘曲导致的质量不达标问题,提出了一种基于高精度仿真的非均匀补偿技术。方法 通过准确测量流变、材料、P-V-T等材料参数,以及设置传感器校准仿真软件中的工艺参数,实现高精准度的仿真。基于精准仿真获得的轮廓基准点收缩向量,计算获得模具型腔对应的基准点坐标,拟合获得模具型腔参数,通过对比径向和轴向的收缩差异计算模具轮廓上各点的补偿量,从而实现型腔非均匀补偿。结果 在多种工艺条件下验证了仿真方法精度,结果表明,仿真面型轮廓与实测值类似,面型仿真的平均误差可控制在10%以内。通过仿真验证了非均匀补偿方法效果,发现使用非均匀补偿方法的镜片模型两面的面型偏差为0.34 μm和0.46 μm,远小于不经过补偿的模型（19.89 μm和7.79 μm）和经过均匀补偿模型（4.58 μm和1.31 μm）。采用最终非均匀补偿系数制备的2块镜片模仁的面型偏差分别为1.210 0 μm/1.418 3 μm和1.363 1 μm/1.243 8 μm,达到镜片制造T0环节所要求的2 μm误差。结论 所提的仿真校准思路能有效提高仿真精度,结合仿真结果的非均匀补偿方法不仅在流程上节省了试模成本,而且精度远高于传统方法,能满足实际制造中的精度要求。
Abstract
The work aims to propose a non-uniform compensation method leveraging high-precision simulation to deal with challenges to the quality compliance of high-precision optical lenses caused by shrinkage and warpage during injection molding. High-precision simulation was achieved by accurately measuring material parameters such as rheology, material properties, and P-V-T (Pressure-Volume-Temperature), as well as calibrating the process settings in the simulation software through sensor deployment. Based on the shrinkage vectors of the contour reference points obtained from the precise simulation, the corresponding reference point coordinates of the mold cavity were calculated, and the cavity parameters were derived through fitting. The compensation amount for each point on the mold contour was computed by comparing the shrinkage differences in the radial and axial directions, thereby realizing non-uniform cavity compensation. The accuracy of the simulation method was verified under multiple process conditions. Results showed that the simulated surface contour was consistent with the measured values, and the average error of the surface simulation could be controlled within 10%. The effect of the non-uniform compensation method was verified via simulation: the surface deviations of the models using the non-uniform compensation method were 0.34 μm and 0.46 μm, which were significantly smaller than those of the uncompensated models (19.89 μm and 7.79 μm) and uniformly compensated models (4.58 μm and 1.31 μm). Two lens mold cores manufactured with the final non-uniform compensation coefficients exhibited surface deviations of 1.210 0 μm/1.418 3 μm and 1.363 1 μm/1.243 8 μm, respectively, meeting the 2 μm error requirement for the T0 phase of lens manufacturing. The results indicate that the proposed simulation calibration approach can effectively improve simulation accuracy. The non-uniform compensation method combined with simulation results not only reduces mold trial costs in the process but also achieves much higher precision than traditional methods, which can meet the accuracy requirements in practical manufacturing.
关键词
精密注射成形 /
光学镜头 /
仿真 /
收缩补偿 /
传感器
Key words
precision injection molding /
optical lens /
simulation /
shrinkage compensation /
sensor
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基金
武汉市自然科学基金（2024040701010043）
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