Integrated Optimum Layout of Conformal Cooling Channels and Optimal Injection Molding Process Parameters for Optical Lenses

被引:30
作者
Chung, Chen-Yuan [1 ]
机构
[1] Natl Cent Univ, Dept Mech Engn, Taoyuan 32001, Taiwan
来源
APPLIED SCIENCES-BASEL | 2019年 / 9卷 / 20期
关键词
gradient-based algorithm; robust genetic algorithm; warpage; design of experiments; fringe pattern; birefringence; OPTIMIZATION; DESIGN; SYSTEM; BIREFRINGENCE;
D O I
10.3390/app9204341
中图分类号
O6 [化学];
学科分类号
0703 ;
摘要
Plastic lenses are light and can be mass-produced. Large-diameter aspheric plastic lenses play a substantial role in the optical industry. Injection molding is a popular technology for plastic optical manufacturing because it can achieve a high production rate. Highly efficient cooling channels are required for obtaining a uniform temperature distribution in mold cavities. With the recent advent of laser additive manufacturing, highly efficient three-dimensional spiral channels can be realized for conformal cooling technique. However, the design of conformal cooling channels is very complex and requires optimization analyses. In this study, finite element analysis is combined with a gradient-based algorithm and robust genetic algorithm to determine the optimum layout of cooling channels. According to the simulation results, the use of conformal cooling channels can reduce the surface temperature difference of the melt, ejection time, and warpage. Moreover, the optimal process parameters (such as melt temperature, mold temperature, filling time, and packing time) obtained from the design of experiments improved the fringe pattern and eliminated the local variation of birefringence. Thus, this study indicates how the optical properties of plastic lenses can be improved. The major contribution of present proposed methods can be applied to a mold core containing the conformal cooling channels by metal additive manufacturing.
引用
收藏
页数:17
相关论文
共 33 条
[1]   Finite element cooling simulations of conformal cooling hybrid injection molding tools manufactured by selective laser melting [J].
Abbes, Boussad ;
Abbes, Fazilay ;
Abdessalam, Hichem ;
Upganlawar, Aditya .
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY, 2019, 103 (5-8) :2515-2522
[2]  
AC Technology Inc, 1995, C MOLD DES GUID RES
[3]   Study on Injection Molding of Shell Mold for Aspheric Contact Lens Fabrication [J].
Chen, Chao-Chang A. ;
Vu, Lien T. ;
Qiu, Yu-Ting .
ADVANCES IN MATERIAL & PROCESSING TECHNOLOGIES CONFERENCE, 2017, 184 :344-349
[4]   Effects of Mold Design of Aspheric Projector Lens for Head Up Display [J].
Chen, Chao-Chang A. ;
Tang, Jyun-Cing ;
Teng, Lin-Ming .
POLYMER OPTICS DESIGN, FABRICATION, AND MATERIALS, 2010, 7788
[5]  
Chen DC., 2016, ADV TECHNOL INNOV, V1, P46
[6]   An approach for impact structure optimization using the robust genetic algorithm [J].
Chen, SY .
FINITE ELEMENTS IN ANALYSIS AND DESIGN, 2001, 37 (05) :431-446
[7]   Optimization of lightweight structure and supporting bipod flexure for a space mirror [J].
Chen, Yi-Cheng ;
Huang, Bo-Kai ;
You, Zhen-Ting ;
Chan, Chia-Yen ;
Huang, Ting-Ming .
APPLIED OPTICS, 2016, 55 (36) :10382-10391
[8]   Determination of poroelastic properties of cartilage using constrained optimization coupled with finite element analysis [J].
Chung, Chen-Yuan ;
Mansour, Joseph M. .
JOURNAL OF THE MECHANICAL BEHAVIOR OF BIOMEDICAL MATERIALS, 2015, 42 :10-18
[9]  
COMSOL Inc, APPL ID 12371 COLL I
[10]   Manufacture of production injection mould tooling incorporating conformal cooling channels via indirect selective laser sintering [J].
Dalgarno, KW ;
Stewart, TD .
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE, 2001, 215 (10) :1323-1332