注塑成型光学制品折射率分层模拟与实验研究

doi:10.11949/0438-1157.20190171

化工学报 ›› 2019, Vol. 70 ›› Issue (7): 2503-2511.DOI: 10.11949/0438-1157.20190171

注塑成型光学制品折射率分层模拟与实验研究

黄明^1,²(),康俊阳¹,吴昕哲¹,石宪章¹(),刘永志¹,曹伟¹,刘春太¹

1. 郑州大学橡塑模具国家工程研究中心，河南郑州 450002
2. 大连理工大学工业装备结构分析国家重点实验室，辽宁大连 116023

收稿日期:2019-03-01 修回日期:2019-04-29 出版日期:2019-07-05 发布日期:2019-07-05
通讯作者: 石宪章
作者简介:黄明（1978—），男，博士，副教授，<email>huangming@zzu.edu.cn</email>
基金资助:
大连理工大学工业装备结构分析国家重点实验室开放基金项目(GZ18203);河南省自然科学基金项目(162300410246, 182300410272);河南省科技攻关项目(182102210008)

Layered simulation in thickness direction and experimental study on refractive index of injection molded optical products

Ming HUANG^1,²(),Junyang KANG¹,Xinzhe WU¹,Xianzhang SHI¹(),Yongzhi LIU¹,Wei CAO¹,Chuntai LIU¹

1. National Engineering Research Center for Advanced Polymer Processing Technology, Zhengzhou University, Zhengzhou 450002, Henan, China
2. State Key Laboratory of Structural Analysis for Industrial Equipment, Dalian University of Technology, Dalian 116023, Liaoning, China

Received:2019-03-01 Revised:2019-04-29 Online:2019-07-05 Published:2019-07-05
Contact: Xianzhang SHI

摘要/Abstract

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Z-Mold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。

关键词: 折射率, 预测, 光学制品, 注塑成型, 数值模拟, 聚合物加工

Abstract:

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 Z-Mold, 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.

Key words: refractive index, prediction, optical products, injection molding, numerical simulation, polymers processing

中图分类号:

黄明, 康俊阳, 吴昕哲, 石宪章, 刘永志, 曹伟, 刘春太. 注塑成型光学制品折射率分层模拟与实验研究[J]. 化工学报, 2019, 70(7): 2503-2511.

Ming HUANG, Junyang KANG, Xinzhe WU, Xianzhang SHI, Yongzhi LIU, Wei CAO, Chuntai LIU. Layered simulation in thickness direction and experimental study on refractive index of injection molded optical products[J]. CIESC Journal, 2019, 70(7): 2503-2511.

图/表 14

图1 中面网格与厚度分层

Fig.1 Midplane mesh and thickness layering

图2 制品厚度分层

Fig.2 Product layering in thickness direction

图3 PC透明件与网格

Fig.3 PC injection molded part and midplane mesh

表1 PC性能参数

Table 1 PC performance parameters

Density/(kg·m^-3)	Thermal conductivity /(W·m^-1·K^-1)	Specific heat /(J·kg^-1·K^-1)	Transition temperature/K
1045.6	0.23	1881	417

图4 厚度方向折射率分布

Fig.4 Refractive index distribution in thickness direction

图5 流动方向折射率分布

Fig.5 Refractive index distribution in flow direction

图6 折射率测量仪器

Fig.6 Measuring instrument of refractive index

表2 折射率测量值与模拟值对比

Table 2 Comparison of measured refractive index with simulated values

Distance from injection gate/mm	Brewster angle/(°)	Measured value	Simulated value
10	58.05	1.6034	1.6000
25	57.89	1.5935	1.5914
40	57.97	1.5985	1.5903
55	57.97	1.5985	1.5890
70	58.11	1.6072	1.5953

图7 宇航服面窗网格

Fig.7 Mesh of spacesuits mask

图8 不同层折射率预测值

Fig.8 Predicted value of refractive index in different layer

图9 折射率分层模拟结果

Fig.9 Layered simulation results of refractive index

图10 不同保压方式下折射率预测值

Fig.10 Predicted value of refractive index in different packing mode

图11 不同保压方式下折射率的分布

Fig.11 Refractive index distribution in different packing mode

图12 PC注塑宇航服面窗

Fig.12 PC injection molded spacesuits mask

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注塑成型光学制品折射率分层模拟与实验研究

Layered simulation in thickness direction and experimental study on refractive index of injection molded optical products

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