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1、哈尔滨工业大学工学硕士学位论文 - - I 摘 要 随着太阳能发电技术的深入发展，人们对 具有特殊光学性能的 复杂结构元件的加工精度及效率的要求也在不断提升。在其制备过程中，与传统材料去除加工方法相比，注 射压缩成型工艺在成型复杂结构光学元件方面具有突出优势。注射压缩成型工艺效率高、成型质量好且稳定以及成型复杂结构相对容易。本文以壁厚变化显著且具有尖锐齿形角的高倍聚光器组件全内反射透镜为研究对象，进行了注射压缩成型技术的相关研究。 首先，通过对注射压缩成型工艺过程的研究，分析了该过程中注射和压缩两个阶段的成形特点，概括了注射压缩成型数值模拟的基本原理，并对注射阶段及其压缩阶段的数学模型进行了相
2、关介绍。针对 Moldflow/MPI 软件对有限元模型的要求，制定了全内反射透镜有限元模型的建立方法，从中性面模型的建立 过程到网格划分、修复、细化规整有序化、赋予各单元厚度属性等过程对该方法进行了详细的描述与分析。 其次，完成了注射压缩模具的设计及优化。依据注射压缩成型特点，确定了透镜注射压缩模具的设计方案：成型零件部分按压缩模具标准设计，模架部分按注射模具标准设计。另外，对影响成型质量较大的浇注系统和冷却系统进行了仿真优化，确定了主流道型浇口的始端直径和半锥角以及冷却水道的排布位置。 最后，对注射压缩成型工艺参数进行了优化并完成了相关实验。利用Taguchi 正交实验矩阵并引入信噪比设计
3、并完成了透镜注射压缩过程的模拟实验，应 用极差法得到了以翘曲变形及残余拉、压应力为目标的优化工艺参数组合，据此进行了注射压缩成型实验和注射成型对照实验，并对成型透镜进行检测，结果表明注射压缩成型透镜在整体轮廓精度和尖角的尖锐程度等方面均优于注射成型。 关键词： 复杂结构光学元件；全内反射透镜；注射压缩成型；工艺优化 哈尔滨工业大学工学硕士学位论文 - - II Abstract With the deep development of solar energy generation technology, the demand for high machining accuracy and e
4、fficiency of optical components with special optical properties and complex structure is increasing. The injection-compression moulding (ICM) technology has many advantages compared with traditional removing processing methods, which Include high efficiency, high moulding quality with stable machini
5、ng accuracy and easy to manufacture complex structure. In this thesis, the ICM of the total internal reflection lens, which is a represent of the optical components with complex structure, was studied in order to produce the optical components with high efficiency and precision. This thesis introduc
6、ed the basic theory of ICM first. The forming characteristics of injection and compression stages were analyzed, and the mathematical models were summarized briefly. After that, for the requirement of simulation software Moldflow/MPI on the finite element model, the method of establishing midplane m
7、eshes of the optical components was determined. The structure of the injection-compression mould was designed and optimized. According to the feature of the two stages included in injection compression moulding, the scheme to design the structure of the mould was as follows: the principle to design
8、the moulding part followed the design standard of compression mould and that of the mould base followed the standard mould base of injection mould. In addition, this thesis obtained optimum structure by simulation including the style and size of the feed system as well as the positional distribution
9、 of cooling duct, as the feed system and the cooling system ware main factors which influenced the quality of the products significantly. At the end of the thesis, Taguchi experimental design method as well as SNR (signal-to-noise ratio) was used to design simulation experiments whose target was to
10、obtain optimum processing parameters of ICM. After the simulation experiments, range analysis method was used to analyze the experiment result. Then discussed the affection of the parameters on the warpage and residual stresses of the total internal reflection lens and gain optimum processing parame
11、ters whose simulation result performs stable quality as well as low value of warpage and residual stresses. In terms of the optimum processing parameters, the ICM experiments and injection moulding experiments ware compared, and the results indicated that the quality of the lens moulded by ICM was b
12、etter than that of the lens moulded by ICM, which was reflected by the Contour Accuracy and the sharpness of the tooth profile angle. 哈尔滨工业大学工学硕士学位论文 - - III Keywords： optical components with complex structure; total internal reflection lens; injection-compression moulding; processing optimization 哈
13、尔滨工业大学工学硕士学位论文 - - IV 目 录 摘 要 . I ABSTRACT . II 第 1 章 绪论 . 1 1.1 课题背景及研究意义 . 1 1.2 国内外的研究现状 . 2 1.2.1 工艺参数对元件光学性能影响程度的研究现状 . 2 1.2.2 材料属性对工艺过程影响规律的研究现状 . 4 1.2.3 注射压缩成型工艺过程的研究现状 . 4 1.2.4 注射压缩成型过程数学模型的发展现状 . 5 1.3 本文的研究内容 . 6 第 2 章 注射压缩成型数值模拟理论及有限元模型建立 . 8 2.1 注射压缩成型概述 . 8 2.2 注射压缩成型数值模拟的基本原理 . 9 2.2.1 注射阶段的基本数学模型 . 10 2.2.2 材料性质的数学模型 . 12 2.2.3 压缩阶段的数学模型 .
