本研究係以Moldex3D模擬不同冷卻水路在相同的成型條件與模具配置下，因冷卻水路外觀走向不同所造成的溫度分佈、熱位移、冷卻時間、模具溫度差等結果；並且透過不同加工參數的變化調整，藉以改善塑膠光學鏡片之光學性質，達到良好的折射率並消除殘留應力與局部雙折射變異。 ;Plastic lenses possess both light and mass-producing advantages, so the large diameter aspheric plastic lens plays an important role in the optical industry. Injection molding process is the popular technology in the plastic optical manufactures. High efficient cooling channel is the key factor of making a uniform temperature distribution in mold cavities. With the recent advent of laser additive manufacturing, fabrication of three-dimensional cooling channels, conformal cooling, becomes realizable. Still, the design of conformal cooling channels is very complex and requiring optimized analyses. This study combines the finite element analysis with four algorithms such as FDM, RCFDM, SMDS and RGA for searching the optimal parameters of cooling channel arrangement.
According to the results of simulation, using FDM optimized analyses can shorten 3.92% of ejection time and decrease 13.4% of surface temperature difference. Using RCFDM optimized analyses can shorten 9.14% of ejection time and decrease 34.08% of surface temperature difference. Using SMDS optimized analyses can shorten 8.01% of ejection time and decrease 32.28% of surface temperature difference. Using RGA optimized analyses can shorten 21.77% of ejection time and decrease 45.5% of surface temperature difference. It shows the present study have considerable benefits on reducing the lens processing period and improving the lens manufacturing quality.
This study simulates the temperature distribution, thermal displacement, cooling time and mold temperature difference of the different conformal cooling channels under the same processing conditions and mold configuration by Moldex3D. In order to achieve an acceptable refractive index; and eliminate the residual stress well as the local birefringence variation, the processing parameters will be adjusted to improve the optical properties of plastic optical lenses.
