光學鏡片模具之模流分析與成品誤差檢測

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姓名

溫曜有(Yao-yu Wen) 查詢紙本館藏

畢業系所

機械工程學系

論文名稱

光學鏡片模具之模流分析與成品誤差檢測

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摘要(中)

目前光學透鏡主要生產方式以射出成型工法為主，精密的光學元件需要高精度的要求，想要製作高品質的光學透鏡的製程條件也必須以高規格的要求。本研究為整合模流分析及逆向工程的技術來進行光學透鏡的射出成型及誤差分析的研究，並且討論模流分析與逆向工程應用於射出成型中的優點。傳統上生產射出成型產品依賴工程師的經驗，而研究中利用模流分析進行射出成型過程中的參數研究，以提高成品零件的品質，透過逆向工程進行驗證判斷成品誤差來源，提供模具的修改指引，並且以實際的模具設計及製造探討一項光學產品經由射出成型製造的可行性。

摘要(英)

Currently, injection molding is the primacy method for the manufacture of plastic optical lens. Precise optical components require high accuracy in both geometry and optical specifications. Thus, high quality of the manufacturing process should be provided for producing high-quality optical lenses. This study integrates techniques of mold flow analysis and reverse engineering, and uses these techniques to perform injection molding simulation and error analysis of optical lenses. Also, the advantages of mold flow analysis and reverse engineering are investigated. Traditionally, engineer’s experience is very important in injection molding. This study employs mold flow analysis to analysis parameters of injection molding for improving the quality of the finished parts, and applied reverse engineering to judge the error source for providing the guidance for part improvement. Finally, this study employs actual mold design and manufacturing to demonstrate the manufacturing feasibility of producing optical lenses.

關鍵字(中)

★ 光學透鏡
★ 射出成型
★ 模流分析
★ 逆向工程

關鍵字(英)

★ Optical lenses
★ Injection molding
★ Mold flow analysis
★ Reverse engineering

論文目次

摘要 I
Abstract II
誌謝 III
目錄 IV
圖目錄 VI
表目錄 VIII
第一章緒論 1
1.1前言 1
1.2文獻回顧 2
1.3研究目的與方法 5
1.3.1研究目的 5
1.3.2 研究方法 9
1.4論文架構 13
第二章逆向工程與模流分析技術 14
2.1前言 14
2.2逆向工程技術 14
2.2.1 CAD逆向重建 16
2.2.2誤差分析 19
2.3模流分析技術 22
2.3.1 CAD模型Mesh建立 24
2.3.2模流分析流程 26
2.3.3模流分析結果判斷方法 28
第三章模流分析成型參數設計 35
3.1前言 35
3.2充填相關參數設定 35
3.3保壓相關參數設定 44
3.4冷卻相關參數設定 48
第四章案例製作分析及問題討論 52
4.1前言 52
4.2微小光學透鏡模具製作 52
4.3案例分析改善 53
4.3.1縫合線問題產生 57
4.3.2成型透鏡單邊收縮問題 60
4.4案例問題討論 62
4.4.1模流分析與射出透鏡形貌差距 62
4.4.2逆向技術模型應用問題 63
4.4.3實務與模流參數設定差異 63
第五章結論與未來展望 64
5.1結論 64
5.2未來展望 65
參考文獻 66

參考文獻

[1] J. W. Bozzelli, J. Cardinal and B. Fierens “Pressure Loss in Thin Wall Molding” Spe/Antec, Vol. 1, pp. 425-428, 1997.

[2] K. M. B. Jansen, D. J. V. Dijk and M. H. Husselman, “Effect of Processing Conditions on Shrinkage in Injection Molding”, Polymer Engineering and Science, Vol. 38, No. 5, pp. 838-846, 1998.

[3] X. Lu and L. S. Khin, “A Statistical Experimental Study of the Injection Molding of Optical Lenses”, Journal of Materials Processing Technology, Vol. 113, pp.189-195, 2001.

[4] B. H. Min, “A Study on Quality Monitoring of Injection-molded Parts”, Journal of Materials Processing Technology, Vol. 136, pp. 1-6, 2003.

[5] M. C. Huang and C. C. Tai, “The Effective Factors in the Warpage Problem of an Injection-molded Part with a Thin Shell”, Journal of Materials Processing Technology, Vol. 110, pp. 1-9, 2001.

[6] T. S. Kwak, T. Suzuki, W. B. Bae, Y. Uehara and H. Ohmori, “Application of Neural Network and Computer Simulation to Improve Surface Profile of Injection Molding Optic Lens”, Journal of Materials Processing Technology, Vol. 170, pp. 24-31, 2005.

[7] S. W. Kim and L. S. Turng, “Three-dimensional Numerical Simulation of Injection Molding Filling of Optical Lens and Multiscale Geometry Using Finite Element Method”, Polymer Engineering and Science, Vol. 46, pp. 1263-1274, 2006.

[8] T. Erzurumlu and B. Ozcelik, “Minimization of Warpage and Sink Index in Injection-molded Thermoplastic Parts Using Taguchi Optimization Method” Materials & Design, Vol. 27, pp. 853-861, 2006.

[9] C. Yang, L. J. Su, C. N. Huang, H. X. Huang, J. M. Castro and A.Y. Yi, “Effect of Packing Pressure on Refractive Index Variation in Injection Molding of Precision Plastic Optical Lens”, Advances in Polymer Technology, Vol. 30, No. 1, pp. 51-61, 2011.

[10] R. S. Chen, H. H. Lee and C. Y. Yu ,”Application of Taguchi’s Method on the Optimal Process Design of an Injection Molded PC/PBT Automobile Bumper”, Composite Structures, Vol. 39, pp. 209-214, 1997.

[11] T. C. Chang and E. Faison “Shrinkage Behavior and Optimization of Injection Molded Parts Studied by the Taguchi Method”, Polymer Engineering and Science, Vol. 41, No. 5, pp. 703-710, 2001.

[12] S. H. Tang, Y. J. Tan, S. M. Sapuan, S. Sulaiman, N. Ismail and R. Samin “The Use of Taguchi Method in the Design of Plastic Injection Mould for Reducing Warpage”, Journal of Materials Processing Technology, Vol. 182, pp. 418-426, 2007.

[13] K. M. Tsai, C. Y Hsieh and W. C. Lo “A Study of the Effects of Process Parameters for Injection Molding on Surface Quality of Optical Lenses”, Journal of Materials Processing Technology, Vol. 209, pp. 3469-3477, 2009.

[14] Moldex3D, Website: http://www.moldex3d.com/, Accessed 6 July 2015.

[15] Rhinoceros, Website: http://www.rhino3d.com/, Accessed 6 July 2015.

指導教授

賴景義(Jiing-yih Lai)

審核日期

2015-7-30

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