注塑成型光学制品折射率分层模拟与实验研究
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摘要
与玻璃制造光学制品相比,高分子注塑光学制品具有质量轻、易加工、抗冲击性好等优点,在航空航天、精密透镜等高端领域得到广泛应用。然而受注塑过程复杂压力场、温度场的耦合作用,注塑透明制品折射率通常呈非均匀的分布,存在角偏差、光畸变等光学缺陷。因此,开展注塑工艺对其折射行为影响的模拟与实验研究,对实现折射率可控光学制品的成型具有重要意义。基于Hele Shaw注塑理论和Lorentz Lorenz物理光学理论,构建了注塑光学制品厚度方向折射行为分层预测模型,开发了相关模拟程序,基于自主研发的注塑模软件ZMold实现了注塑过程与折射率分布的一体化模拟。以聚碳酸酯注塑平板件为例,利用Brewster法对折射率模拟结果进行了验证。该方法成功应用到神舟系列航天舱外服面窗的研制。
Compared with glass-made optical products, polymer injection optical products have the advantages of light weight, easy processing, good impact resistance, and are widely used in high-end fields such as aerospace and precision lenses. However, due to the coupling effect of complex thermal fields and pressure fields in the forming process, injection molded transparent products usually have optical defects such as uneven refractive index distribution, angular deviation, optical distortion and so on. Therefore, the simulation and experimental investigation on the effect of injection molding process on the refractive behavior is of great guiding significance for the manufacture of transparent products with controllable refractive index. In this paper, the layered computational model for the refractive behavior in thickness direction of injection molded optical products was built based on the Hele Shaw injection molding theory and Lorentz Lorenz equation characterizing density and refractive index. The corresponding simulation program with VC++ was developed, and then was merged into the software system ZMold, a self-developed injection mould simulation software. Furthermore, the coupling analysis of injection molding filling, packing, cooling and refractive index distribution was successfully implemented based on Z-Mold. Taking the polycarbonate transparent square plate as an example, its refractive index distribution in thickness and flow direction was predicted and analyzed. According to Brewster's law, the refractive index values of square plate at different position were measured. The simulation results were in good agreement with the measured data, which proved that the prediction model for refractive index had high accuracy. This method had been successfully applied to the analysis of the "Shenzhou" extravehicular spacesuits mask.
Compared with glass-made optical products, polymer injection optical products have the advantages of light weight, easy processing, good impact resistance, and are widely used in high-end fields such as aerospace and precision lenses. However, due to the coupling effect of complex thermal fields and pressure fields in the forming process, injection molded transparent products usually have optical defects such as uneven refractive index distribution, angular deviation, optical distortion and so on. Therefore, the simulation and experimental investigation on the effect of injection molding process on the refractive behavior is of great guiding significance for the manufacture of transparent products with controllable refractive index. In this paper, the layered computational model for the refractive behavior in thickness direction of injection molded optical products was built based on the Hele Shaw injection molding theory and Lorentz Lorenz equation characterizing density and refractive index. The corresponding simulation program with VC++ was developed, and then was merged into the software system ZMold, a self-developed injection mould simulation software. Furthermore, the coupling analysis of injection molding filling, packing, cooling and refractive index distribution was successfully implemented based on Z-Mold. Taking the polycarbonate transparent square plate as an example, its refractive index distribution in thickness and flow direction was predicted and analyzed. According to Brewster's law, the refractive index values of square plate at different position were measured. The simulation results were in good agreement with the measured data, which proved that the prediction model for refractive index had high accuracy. This method had been successfully applied to the analysis of the "Shenzhou" extravehicular spacesuits mask.
引文
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[8]Wang C F,Huang M,Shen C Y,et al.Warpage prediction of the injection-molded strip-like plastic parts[J].Chinese Journal of Chemical Engineering,2016,24(5):665-670.
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[14]王鑫,李海梅,杜林芳.模具结构和熔体温度对PC透明制品性能的影响[J].工程塑料应用,2008,36(1):27-30.Wang X,Li H M,Du L F.Influence of mold structure and melt temperature on performance of PC transparent injection molded parts[J].Engineering Plastics Application,2008,36(1):27-30.
[15]曹国荣,王克俭.注塑工艺对聚碳酸酯曲面透光件光学角偏差的影响[J].中国塑料,2015,29(11):87-91.Cao G R,Wang K J.Effect of injection molding process on angular deviation of curved transparent polycarbonate parts[J].China Plastics,2015,29(11):87-91.
[16]陈宇宏,袁渊,张宜生,等.基于光学畸变要求的注射成型透明平板应力翘曲分析[J].航空材料学报,2008,28(6):82-87.Chen Y H,Yuan Y,Zhang Y S,et al.Residual stresses,warpage and shrinkage analysis of injection molded transparent panel based on optical distortion[J].Journal of Aeronautical Materials,2008,28(6):82-87.
[17]Avraam I I,Tsui-Hsun L.Frozen-in birefringence and anisotropic shrinkage in optical moldings(Ⅰ):Theory and simulation scheme[J].Polymer,2010,51(1):316-327.
[18]Avraam I I,Tsui-Hsun L,Keehae K.Frozen-in birefringence and anisotropic shrinkage in optical moldings(Ⅱ):Comparison of simulations with experiments on light-guide plates[J].Polymer,2010,51(23):5623-5639.
[19]Yang S S,Tai H K.A study of birefringence,residual stress and final shrinkage for precision injection molded parts[J].KoreaAustralia Rheology Journal,2007,19(4):191-199.
[20]Park K,Joo W.Numerical evaluation of a plastic lens by coupling injection molding analysis with optical simulation[J].Japanese Journal of Applied Physics,2008,47(11):8402-8407.
[21]Yang C,Su L J,Huang C N,et al.Effect of packing pressure on refractive index variation in injection molding of precision plastic optical lens[J].Advances in Polymer Technology,2011,30(1):51-61.
[22]Bensingh R J,Machavaram R,Boopathy S R,et al.Injection molding process optimization of a bi-aspheric lens using hybrid artificial neural networks(ANNs)and particle swarm optimization(PSO)[J].Measurement,2019,134:359-374.
[23]Li L,Raasch T W,Yi A Y.Simulation and measurement of optical aberrations of injection molded progressive addition lenses[J].Applied Optics,2013,52(24):6022-6029.
[24]Adhikari A,Bourgade T,Asundi A.Residual stress measurement for injection molded components[J].Theoretical and Applied Mechanics Letters,2016,6(4):152-156.
[25]李金仓.注射成型聚碳酸酯制品透光性能模拟与实验研究[D].河南:郑州大学,2016.Li J C.Simulation and experimental study on light transmittance of injection molded polycarbonate products[D].Henan:Zhengzhou University,2016.
[26]黄明,石宪章,刘春太,等.基于统一网格的塑件成型与模具结构一体化分析[J].化工学报,2012,63(8):2617-2622.Huang M,Shi X Z,Liu C T,et al.Integrated analysis of part molding and mold structural mechanics based on identical mesh[J].CIESC Journal,2012,63(8):2617-2622.
[27]王超房,黄明,石宪章,等.注塑成型Hele-Shaw流动模拟中热对流的异步长求解[J].化工学报,2016,67(7):3047-3054.Wang C F,Huang M,Shi X Z,et al.Thermal convection calculation with variable time step in Hele-Shaw flow simulation of injection molding[J].CIESC Journal,2016,67(7):3047-3054.
[28]Chiang H H,Hieber C A,Wang K K.A unified simulation of the filling and postfilling stages in injection molding(I):Formulation[J].Polymer Engineering&Science,1991,31(2):116-124.
[29]Krishnaswamy R K,Janzen J.Exploiting refractometry to estimate the density of polyethylene:the Lorentz-Lorenz approach revisited[J].Polymer Testing,2005,24(6):762-765.com.cn
[30]陈方平,祁铮.Brewster角的测量方法[J].物理实验,2012,32(11):41-43.Chen F P,Qi Z.Measurement method of Brewster angle[J].Physics Experimentation,2012,32(11):41-43.
[31]王中林.基于Brewster定律的分光仪测量玻璃折射率实验[J].大学物理实验,2012,25(3):55-57.Wang Z L.Spectrometer measuring the refractive index of glass experiment based on Brewster.s law[J].Physical Experiment of College,2012,25(3):55-57.
[2]朱勤勤,封麟先.光学用透明高分子材料[J].高分子材料科学与工程,1995,(5):1-6.Zhu Q Q,Feng L X.Optical transparent polymer materials[J].Polymer Materials Science and Engineering,1995,(5):1-6.
[3]官建国,袁润章.光学透明材料的现状和研究进展(Ⅰ):光学透明高分子材料[J].武汉工业大学学报,1998,(2):11-13.Guan J G,Yuan R Z.The present situation and development of optically transparent materials(I):Optically transparent polymers[J].Journal of Wuhan University of Technology,1998,(2):11-13.
[4]Michaeli W,Klaiber F,Forster J.Geometrical accuracy and optical performance of injection moulded and injectioncompression moulded plastic parts[J].Manufacturing Technology,2007,56(1):545-548.
[5]Jha G S,Seshadri G,Mohan A,et al.Development of high refractive index plastics[J].Polymers,2007,7:1384-1408.
[6]Pina-Estany J,García-Granadab A A,Corull-Massanaa E.Injection moulding of plastic parts with laser textured surfaces with optical applications[J].Optical Materials,2018,79:372-380.
[7]Yanagishita T,Masui M,Ikegawa N,et al.Fabrication of polymer antireflection structures by injection molding using ordered anodic porous alumina mold[J].Journal of Vacuum Science&Technology B,2014,32(2):021809-021809-5.
[8]Wang C F,Huang M,Shen C Y,et al.Warpage prediction of the injection-molded strip-like plastic parts[J].Chinese Journal of Chemical Engineering,2016,24(5):665-670.
[9]Spina R,Walach P,Schild J,et al.Analysis of lens manufacturing with injection molding[J].International Journal of Precision Engineering&Manufacturing,2012,13(11):2087-2095.
[10]Huang C.Investigation of injection molding process for high precision polymer lens manufacturing[D].Ohio:The Ohio State University,2008.
[11]Afzal M A F,Hachmann J.Benchmarking DFT approaches for the calculation of polarizability inputs for refractive index predictions in organic polymers[J].Physical Chemistry Chemical Physics,2019,21(8):4452-4460.
[12]Afzal M A F,Cheng C,Hachmann J.Combining first-principles and data modeling for the accurate prediction of the refractive index of organic polymers[J].Journal of Chemical Physics,2018,148(24):241712-241712-8.
[13]李海梅,姜坤,徐文莉,等.工艺条件对透明光学制品性能的影响[J].中国机械工程,2006,(S1):157-160.Li H M,Jiang K,Xu W L,et al.Effects of process parameters on optical properties of injection molded parts[J].China Mechanical Engineering,2006,(S1):157-160.
[14]王鑫,李海梅,杜林芳.模具结构和熔体温度对PC透明制品性能的影响[J].工程塑料应用,2008,36(1):27-30.Wang X,Li H M,Du L F.Influence of mold structure and melt temperature on performance of PC transparent injection molded parts[J].Engineering Plastics Application,2008,36(1):27-30.
[15]曹国荣,王克俭.注塑工艺对聚碳酸酯曲面透光件光学角偏差的影响[J].中国塑料,2015,29(11):87-91.Cao G R,Wang K J.Effect of injection molding process on angular deviation of curved transparent polycarbonate parts[J].China Plastics,2015,29(11):87-91.
[16]陈宇宏,袁渊,张宜生,等.基于光学畸变要求的注射成型透明平板应力翘曲分析[J].航空材料学报,2008,28(6):82-87.Chen Y H,Yuan Y,Zhang Y S,et al.Residual stresses,warpage and shrinkage analysis of injection molded transparent panel based on optical distortion[J].Journal of Aeronautical Materials,2008,28(6):82-87.
[17]Avraam I I,Tsui-Hsun L.Frozen-in birefringence and anisotropic shrinkage in optical moldings(Ⅰ):Theory and simulation scheme[J].Polymer,2010,51(1):316-327.
[18]Avraam I I,Tsui-Hsun L,Keehae K.Frozen-in birefringence and anisotropic shrinkage in optical moldings(Ⅱ):Comparison of simulations with experiments on light-guide plates[J].Polymer,2010,51(23):5623-5639.
[19]Yang S S,Tai H K.A study of birefringence,residual stress and final shrinkage for precision injection molded parts[J].KoreaAustralia Rheology Journal,2007,19(4):191-199.
[20]Park K,Joo W.Numerical evaluation of a plastic lens by coupling injection molding analysis with optical simulation[J].Japanese Journal of Applied Physics,2008,47(11):8402-8407.
[21]Yang C,Su L J,Huang C N,et al.Effect of packing pressure on refractive index variation in injection molding of precision plastic optical lens[J].Advances in Polymer Technology,2011,30(1):51-61.
[22]Bensingh R J,Machavaram R,Boopathy S R,et al.Injection molding process optimization of a bi-aspheric lens using hybrid artificial neural networks(ANNs)and particle swarm optimization(PSO)[J].Measurement,2019,134:359-374.
[23]Li L,Raasch T W,Yi A Y.Simulation and measurement of optical aberrations of injection molded progressive addition lenses[J].Applied Optics,2013,52(24):6022-6029.
[24]Adhikari A,Bourgade T,Asundi A.Residual stress measurement for injection molded components[J].Theoretical and Applied Mechanics Letters,2016,6(4):152-156.
[25]李金仓.注射成型聚碳酸酯制品透光性能模拟与实验研究[D].河南:郑州大学,2016.Li J C.Simulation and experimental study on light transmittance of injection molded polycarbonate products[D].Henan:Zhengzhou University,2016.
[26]黄明,石宪章,刘春太,等.基于统一网格的塑件成型与模具结构一体化分析[J].化工学报,2012,63(8):2617-2622.Huang M,Shi X Z,Liu C T,et al.Integrated analysis of part molding and mold structural mechanics based on identical mesh[J].CIESC Journal,2012,63(8):2617-2622.
[27]王超房,黄明,石宪章,等.注塑成型Hele-Shaw流动模拟中热对流的异步长求解[J].化工学报,2016,67(7):3047-3054.Wang C F,Huang M,Shi X Z,et al.Thermal convection calculation with variable time step in Hele-Shaw flow simulation of injection molding[J].CIESC Journal,2016,67(7):3047-3054.
[28]Chiang H H,Hieber C A,Wang K K.A unified simulation of the filling and postfilling stages in injection molding(I):Formulation[J].Polymer Engineering&Science,1991,31(2):116-124.
[29]Krishnaswamy R K,Janzen J.Exploiting refractometry to estimate the density of polyethylene:the Lorentz-Lorenz approach revisited[J].Polymer Testing,2005,24(6):762-765.com.cn
[30]陈方平,祁铮.Brewster角的测量方法[J].物理实验,2012,32(11):41-43.Chen F P,Qi Z.Measurement method of Brewster angle[J].Physics Experimentation,2012,32(11):41-43.
[31]王中林.基于Brewster定律的分光仪测量玻璃折射率实验[J].大学物理实验,2012,25(3):55-57.Wang Z L.Spectrometer measuring the refractive index of glass experiment based on Brewster.s law[J].Physical Experiment of College,2012,25(3):55-57.