8-外殼注塑模具設(shè)計(jì)

8-外殼注塑模具設(shè)計(jì),外殼,注塑,模具設(shè)計(jì) 微透鏡陣列注塑成型技術(shù)摘要微透鏡陣列注塑成型，可作為一種非常重要的大量生產(chǎn)技術(shù)。因此我們?cè)诮鼇?lái)的研究中非常關(guān)注， 為了進(jìn)一步了解注塑成型在不同的加工條件下對(duì)可復(fù)制的微透鏡陣列剖面的影響，如流量、填料壓力和填料時(shí)間，對(duì)3種不同的高分子材料(PS，PMMA和PC)進(jìn)行了大量的試驗(yàn)。 鎳金屬模具嵌件微陣列就是利用改良的LIGA技術(shù)電鍍主裝配的顯微結(jié)構(gòu)制造的。在表面輪廓得到測(cè)量的前提下，研究工藝條件對(duì)可復(fù)制的微透鏡陣列的影響。實(shí)驗(yàn)結(jié)果表明， 填料壓力和流速對(duì)注射模塑的終產(chǎn)品的表面輪廓有重要的影響。 原子力顯微鏡測(cè)量表明， 微透鏡陣列注塑成型的平均表面粗糙度值小于模具嵌件成型， 并在實(shí)際運(yùn)用中，能與精細(xì)的光學(xué)元件相媲美。1 說(shuō)明微型光學(xué)產(chǎn)品，如微透鏡或微透鏡陣列已廣泛應(yīng)用于光學(xué)數(shù)據(jù)存儲(chǔ)、生物醫(yī)學(xué)、顯示裝置等各個(gè)光學(xué)領(lǐng)域。微透鏡和微透鏡陣列不僅在實(shí)踐應(yīng)用上，而且在微型光學(xué)的基礎(chǔ)研究上都是非常重要的。有幾種微透鏡或微透鏡陣列的制作方法，如改良的LIGA技術(shù)，光阻回流進(jìn)程，紫外激光照射等。還有復(fù)制技術(shù)，如注塑模壓成型和熱壓技術(shù) ，這種方法對(duì)于減少大規(guī)模生產(chǎn)的微型光學(xué)產(chǎn)品的成本尤為重要。由于其優(yōu)越的生產(chǎn)和再生產(chǎn)能力，只要注塑成型過程中能很好的復(fù)制微觀結(jié)構(gòu)，那么肯定是最適合于降低大量生產(chǎn)成本的方法?；谶@點(diǎn)，檢查注塑成型能力并確定成型加工條件是注塑成型微觀結(jié)構(gòu)過程中最重要的步驟。在本次研究中，我們考察了工藝條件對(duì)可復(fù)制的微透鏡陣列的注射成型的影響。微透鏡陣列是用之前介紹過的改良的LIGA技術(shù)來(lái)編制的。注塑成型實(shí)驗(yàn)采用的是一種鍍鎳金屬模具，來(lái)探討了幾種不同工藝條件對(duì)成型的影響。通過對(duì)微透鏡陣列的表面輪廓測(cè)量，用來(lái)分析工藝條件產(chǎn)生的影響。最后，利用原子力顯微鏡(AFM)測(cè)量微透鏡的表面粗糙度值的大小。2 模具嵌件的制造利用改良的LIGA技術(shù)，在一個(gè)有機(jī)玻璃板上制造出具有幾種不同直徑微透鏡陣列。此種技術(shù)是先用X光照射有機(jī)玻璃板，然后再進(jìn)行熱處理兩部分構(gòu)成的。X-射線照射引起有機(jī)玻璃分子質(zhì)量的減少，同時(shí)降低了玻璃化轉(zhuǎn)變溫度，并因此導(dǎo)致凈含量的增加，在熱循環(huán)的作用下，微透鏡發(fā)生微膨脹。利用中提出的方法，結(jié)合改良的LIGA技術(shù)可以預(yù)測(cè)微透鏡形狀的變化過程。 在試驗(yàn)中使用的微透鏡陣列，有500m (22陣列)，300m (22)和200m (55)的直徑陣列，高分別是20.81m，17.21m和8.06m。采用改良的LIGA技術(shù)制造微透鏡陣列作為一個(gè)主要的技術(shù)，用來(lái)制作鍍鎳的金屬模具的注塑成型。另一些特殊材料，因?yàn)樗鼈兊膹?qiáng)度不夠或熱性能差而不能直接進(jìn)行微細(xì)加工，當(dāng)作模具或金屬模具使用，如硅、光阻劑或高分子材料。盡量使用具有良好機(jī)械性能和熱性能的金屬材料，因?yàn)樗鼈兡茉诳蓮?fù)型加工過程中經(jīng)受高壓力和不斷變化的溫度。因此，為了利用這種復(fù)制技術(shù)進(jìn)行大批量生產(chǎn)，我們選擇使用金屬模具材料而不是有機(jī)玻璃硅晶體。一些特殊技術(shù)，如低壓注塑成型8技術(shù)，應(yīng)該作為良好的復(fù)制加工方法被采納。電鍍模具的最終大小為30 mm30 mm3mm。鍍鎳金屬模具所具有的微透鏡陣列如圖1所示。 圖1 鍍鎳模具嵌件的制造 （a）直接觀察；（b）直徑為200m的微透鏡陣列電子顯微鏡圖像；（c）直徑為300m的微透鏡陣列電子顯微鏡圖像3 注塑成型實(shí)驗(yàn) 傳統(tǒng)注塑機(jī)(Allrounders 220 M，Arburg)多用做實(shí)驗(yàn)機(jī)。注塑模具設(shè)計(jì)的模架就是利用一塊框形支撐板固定鍍鎳模具(如圖2所示)。 圖2 注塑模具實(shí)驗(yàn)中使用的模架和嵌件用修改的微透鏡陣列確定模具零件孔形加強(qiáng)板(在這次實(shí)驗(yàn)中，是一塊矩形板)的外部形狀。模架本身已含有傳輸系統(tǒng)，如注射口，流道及澆口，通過支撐板、模具流道和滑動(dòng)的模具表面將熔融聚合物引入模腔。用這種方法設(shè)計(jì)的模架，能夠使模具零件更換起來(lái)簡(jiǎn)單容易。不過，有時(shí)候也使用具有特定孔徑形狀的支撐板。 實(shí)驗(yàn)主要用三種普通高分子材料，PS(615APR，陶氏化學(xué))，有機(jī)玻璃(IF870， LG MMA)和PC(Lexan 141R)進(jìn)行注塑成型。這些高分子材料通常在光學(xué)元件上使用，它們有不同的折射率(PS，PMMA和PC的折射率分別為1.600，1.490和1.586)，能生產(chǎn)出具有不同的光學(xué)特性的產(chǎn)品，例如:具有相同的幾何尺寸卻有不同的焦距的光學(xué)元件。通過改變每個(gè)高分子材料的流速，充填壓力和充填時(shí)間獲得7種加工條件進(jìn)行注塑成型試驗(yàn)。此外，為了檢查是否能可再生產(chǎn)，同一實(shí)驗(yàn)往往需要重復(fù)三次?？赡苡腥藭?huì)指出，實(shí)驗(yàn)中沒有考慮模具溫度的影響，這是因?yàn)闇囟刃?yīng)相對(duì)來(lái)說(shuō)不是主要因素，而且微透鏡陣列曲率半徑比其他微觀結(jié)構(gòu)的高寬縱橫比大。正是因?yàn)檩^大的微觀結(jié)構(gòu)高寬縱橫比，使我們目前研究的溫度效應(yīng)更加可靠，并計(jì)劃在將來(lái)實(shí)驗(yàn)時(shí)進(jìn)行單獨(dú)報(bào)告。 因此，在這項(xiàng)研究中，我們保持模具溫度不變，而流速、充填壓力和充填的時(shí)間都變化的情況下，能更清楚的觀察其產(chǎn)生效果。表1詳細(xì)的列出了三種高分子材料PC，PMMA和PS在其他加工條件都保持不變，將模具溫度分別設(shè)定為80，70和60的情況下的實(shí)驗(yàn)結(jié)果。表1注塑模具實(shí)驗(yàn)中詳細(xì)的工藝條件序號(hào)流 速 (cc/s)充填時(shí)間 (/s)充填壓(MPa)112.05.010.0212.05.015.0312.05.020.0PS412.02.010.0512.010.010.0618.05.010.0724.05.010.0PMMA16.010.010.026.010.015.036.010.020.046.05.010.0566.09.015.010.010.010.0續(xù)表1序號(hào)流 速 (cc/s)充填時(shí)間 (/s)充填壓力(MPa)712.010.010.0PC 16.05.05.026.05.010.0356.06.09.05.010.015.05.065.05.0712.05.05.0可能有人會(huì)指出，我們的實(shí)驗(yàn)沒有考慮型腔出現(xiàn)真空狀態(tài)時(shí)的情況，其實(shí)大可不必?fù)?dān)心，因?yàn)樵诒狙芯恐械淖⑸潆A段，大曲率半徑的微透鏡陣列不會(huì)把空氣引入到型腔中。4 討論和結(jié)果在詳細(xì)討論實(shí)驗(yàn)結(jié)果之前，認(rèn)真思考一下，可能有助于總結(jié)為什么流速、充填壓力和充填時(shí)間(在這項(xiàng)研究中被選為不同的加工條件)影響復(fù)制的質(zhì)量。就流速而言，可能存在一個(gè)最佳流速，而在完成充填之前，流速太小會(huì)使得熔融聚合物過冷卻，從而可能導(dǎo)致所謂的短暫的不連續(xù)現(xiàn)象，而過高的流速增大了壓力面積，這是不可取的。充填階段是一般要求，是要在冷卻時(shí)能夠彌補(bǔ)熱熔融聚合物的體積收縮 。 因此，在這個(gè)階段應(yīng)有足夠的熔融聚合物流入型腔并控制產(chǎn)品的尺寸精度。 越高的充填壓力，越長(zhǎng)的充填時(shí)間，將使更多的材料持續(xù)不斷的流向型腔。然而， 過高的充填壓力，有時(shí)可能造成不均勻的密度分布，從而產(chǎn)生劣質(zhì)的光學(xué)質(zhì)量。過長(zhǎng)的充填時(shí)間，不利于在各自澆口處的冷凝，并且會(huì)阻止熔融聚合物流入型腔。因此，我們需要研究不同的充填壓力和充填時(shí)間所產(chǎn)生的影響。4.1 表面輪廓圖3所示的是用電子顯微鏡(SEM) 掃描的不同注塑微透鏡的直徑的PMMA圖像(a)以及不同 材料的圖像(b)。代表性的模具表面輪廓以及所有注塑微陣列都是通過三維輪廓測(cè)量系統(tǒng)(NH-3N， Mitaka)測(cè)定的。圖3 注塑模具的微透鏡陣列和微透鏡的電子顯微鏡圖像（a）PMMA微透鏡陣列 （b）不同材料直徑為300m微透鏡陣列的注塑模具作為一個(gè)可復(fù)制陣列的測(cè)量工具，我們已經(jīng)確定了在模具與相應(yīng)的模具嵌件分開的微陣列之間輪廓的相對(duì)高度偏差，所有的微透鏡陣列相對(duì)偏差值列在表2中，具體見表所示： 表2 表面輪廓相對(duì)偏差直徑 (m)相對(duì)偏差(%)1234567PS200300500-7.625.862.38-7.592.03-0.382.082.860.51-5.565.611.47-8.6660.161.47-11.444.291.47-9.475.731.95PMMA2003005007.205.77-0.661.315.60-1.62-3.886.453.98-5.805.952.80-0.975.95-0.72-8.536.68-0.904.86-2.62-0.72PC20030050023.026.20-0.9316.054.965.0916.872.66-1.8619.664.531.8833.974.786.9618.671.792.43-2.944.15-1.55值得一提的是，高分子材料的塑性會(huì)影響其重復(fù)使用性能。 因此在研究中，三種高分子材料總的相對(duì)誤差是各不相同的。PC是三種聚合物中最難注塑成型的材料。在直徑最小的例子中產(chǎn)生最大的相對(duì)偏差，那都是意料之中的事。 在這種特殊情況下，充填時(shí)間并不對(duì)偏差產(chǎn)生顯著影響，最好的解決方法是采用相對(duì)低的流速和充填壓力。PS和PMMA最小的直徑的相對(duì)偏差要比PC小的多。 從表2可以看出，直徑越大，相對(duì)偏差越小。當(dāng)然，在注射和保壓階段，直徑大的微透鏡陣列容易比直徑小的更容易填補(bǔ)，不管是在什么加工條件下和使用什么材料，大直徑的微透鏡陣列一般都能得到較好的復(fù)型。研究發(fā)現(xiàn)直徑500m的PS最好復(fù)型，一般而言，與PMMA和PC相比較，PS具有良好的成型性能。根據(jù)表2的數(shù)據(jù)，在考察最小的直徑的PS和PMMA的相對(duì)偏差時(shí)，可能會(huì)有人提出一些消極的觀點(diǎn)，認(rèn)為偏差過大，但是在這些數(shù)據(jù)中可以得到，高度上的絕對(duì)偏差在0.1m左右，這是在測(cè)量系統(tǒng)誤差范圍以內(nèi)。 所以，在解讀復(fù)型實(shí)驗(yàn)數(shù)據(jù)時(shí)可以忽略這些消極的觀點(diǎn)。 直徑為300m的PC和PMMA微透鏡表面輪廓分別如圖4和圖5所示。正如之前所述，在圖4所示的PC中，越高的充填壓力或越高流速?gòu)?fù)制微透鏡時(shí)效果越好，而充填時(shí)間在這些復(fù)型例子中只起一點(diǎn)作用。如圖所示，對(duì)于PMMA來(lái)說(shuō)，充填壓力和充填時(shí)間的作用微不足道；然而，流速對(duì)于PC也有類似的效果。 它可以提醒我們注意如果一個(gè)澆口凍結(jié)了，并阻止材料流入型腔時(shí)，充填時(shí)間并不影響復(fù)型。 因此，經(jīng)過一段時(shí)間后，充填時(shí)間的影響，主要取決于加工條件。 圖4 直徑為300m的PC微透鏡表面輪廓 a 充填壓力的影響 b 流速的影響c 充填時(shí)間的影響 圖5 直徑為300m的PMMA微透鏡表面輪廓a 充填壓力的影響 b 流速的影響 c 充填時(shí)間的影響4.2 表面粗糙度直徑300m的微透鏡和模具嵌件的平均表面粗糙度Ra的值，是用原子力顯微鏡(Bioscope AFM，數(shù)字儀表) 測(cè)量的。測(cè)量了每個(gè)微透鏡頂點(diǎn)周圍面積為5m5m區(qū)域， 圖6所示的是原子力顯微鏡圖象和所測(cè)量的微透鏡Ra的值。PMMA微透鏡復(fù)型具有最低的Ra值，為1.606nm。通過AFM的測(cè)量表明，注塑成型微透鏡陣列的Ra值比相對(duì)應(yīng)的模具嵌件要小。 因此，現(xiàn)在還不清楚如何改善可復(fù)制微透鏡陣列的表面粗糙度，也許可以從冷卻過程的回流而造成的表面張力入手，它可能會(huì)進(jìn)一步得出，在實(shí)際運(yùn)用中，微透鏡陣列注塑成型的平均表面粗糙度值能與精細(xì)的光學(xué)元件相媲美。a 鍍鎳模具嵌件; b PS; c PMMA; d PC圖6 直徑為300m的模具嵌件和注塑模具微透鏡的原子力顯微鏡(AFM)圖像和平均表面粗糙度Ra值 4.3 焦距 焦距可以通過下面這個(gè)著名的等式計(jì)算得出： 式中f，nl， R1和R2分別指焦距，透鏡材料的折射率，兩個(gè)主曲率半徑。比如，根據(jù)等式可以計(jì)算得出，直徑為200m的模具微透鏡的焦距大約為1.065mm(其中R1=0.624mm和R2=)，直徑300的微透鏡大約為1.130mm (其中R1=0.662mm和R2=)，直徑500m的微透鏡大約為2.580mm(其中R1=1.512mm和R2=)。 (1)這些計(jì)算結(jié)果是基于假設(shè)與模具嵌件具有相同形狀的PC(nl=1.586)可復(fù)型的微透鏡而得到的，所以由此推導(dǎo)出的幾何尺寸可能與實(shí)驗(yàn)所測(cè)量的焦距相反。5 總結(jié) 通過使用改良的LIGA技術(shù)電鍍鎳金屬模具嵌件，改變各種加工條件進(jìn)行大量的實(shí)驗(yàn)，研究工藝條件對(duì)可復(fù)型的微透鏡的注塑成型過程的影響。結(jié)果顯示越高的充填壓力或越高流速，能得到越好的可復(fù)型效果。 相比之下，充填時(shí)間對(duì)微透鏡陣列復(fù)型的影響卻很小。也許是因?yàn)槔鋮s階段回流的表面張力造成的，注射成型微透鏡陣列比模具嵌件有更小的平均表面粗糙度值，PMMA復(fù)型的微透鏡陣列具有最好的表面質(zhì)量(即最低粗糙度值Ra=1.606 nm)。在實(shí)際應(yīng)用中，注塑成型微透鏡陣列的表面粗糙度能與精密的光學(xué)元件相媲美。就憑這一點(diǎn)，注塑成型將成為大規(guī)模生產(chǎn)微透鏡陣列的一個(gè)有用方法。11現(xiàn)代模具技術(shù)引言隨著全球經(jīng)濟(jì)的發(fā)展，新的技術(shù)革命不斷取得新的進(jìn)展和突破，技術(shù)的飛躍發(fā)展已經(jīng)成為推動(dòng)世界經(jīng)濟(jì)增長(zhǎng)的重要因素。市場(chǎng)經(jīng)濟(jì)的不斷發(fā)展，促使工業(yè)產(chǎn) 品越來(lái)越向多品種、小批量、高質(zhì)量、低成本的方向發(fā)展，為了保持和加強(qiáng)產(chǎn)品在市場(chǎng)上的競(jìng)爭(zhēng)力，產(chǎn)品的開發(fā)周期、生產(chǎn)周期越來(lái)越短，于是對(duì)制造各種產(chǎn)品的關(guān)鍵工藝裝備模具的要求越來(lái)越苛刻。 一方面企業(yè)為追求規(guī)模效益，使得模具向著高速、精密、長(zhǎng)壽命方向發(fā)展； 另一方面企業(yè)為了滿足多品種、小批量、產(chǎn)品更新?lián)Q代快、贏得市場(chǎng)的需要，要求模具向著制造周期短、成本低的快速經(jīng)濟(jì)的方向發(fā)展。計(jì)算機(jī)、激光、電子、新材料、新技術(shù)的發(fā)展，使得快速經(jīng)濟(jì)制模技術(shù)如虎添翼，應(yīng)用范圍不斷擴(kuò)大，類型不斷增多，創(chuàng)造的經(jīng)濟(jì)效益和社會(huì)效益越來(lái)越顯著。1.注塑模具設(shè)計(jì)注塑成型使用溫度依賴性改變材料性能，通過使用模具取得最后的形狀離散部件完成或接近完成尺寸。在這種制造過程中，液體材料是被迫填入，在型腔模具內(nèi)凝固。首先，要?jiǎng)?chuàng)造一個(gè)模式塑造需要一個(gè)設(shè)計(jì)模型和一個(gè)載箱。 首先，要?jiǎng)?chuàng)造一個(gè)模式塑造需要一個(gè)設(shè)計(jì)模型和一個(gè)載箱。設(shè)計(jì)模型代表了成品，而載箱代表模具組件的總體積。注塑模具設(shè)計(jì)涉及模具結(jié)構(gòu)與功能的組成部分廣泛的經(jīng)驗(yàn)知識(shí)(啟發(fā)式知識(shí))。典型的過程中塑造新的發(fā)展可以分為四大階段:產(chǎn)品設(shè)計(jì)，模具的能力評(píng)估，部件詳細(xì)設(shè)計(jì)，插入型腔設(shè)計(jì)和詳細(xì)的模具設(shè)計(jì)。在開始階段，產(chǎn)品概念是在一起由幾個(gè)人(通常是一個(gè)組合營(yíng)銷和工程)完成。開始階段主要焦點(diǎn)是分析市場(chǎng)的機(jī)遇與適應(yīng)戰(zhàn)略。在第一階段，典型相關(guān)工藝制造信息被添加到設(shè)計(jì)中，設(shè)計(jì)出幾何細(xì)節(jié)。概念設(shè)計(jì)利用適當(dāng)?shù)闹圃煨畔⑥D(zhuǎn)化為可制造的物品。在第二階段，脫模方向和分型線位置用來(lái)檢測(cè)模具的能力。否則，零件形狀再次修改。在第三階段，零件幾何是用來(lái)建立模具的型芯和型腔形狀，模具的型芯和型腔，將用來(lái)形成零件。一般，收縮和擴(kuò)張需要加以考慮，這樣，在處理溫度下，成型將具有正確的尺寸和形狀。澆口、流道、冷料穴、通風(fēng)口也需要加以補(bǔ)充。幾何數(shù)據(jù)和分模信息之間的聯(lián)系在這一點(diǎn)是至關(guān)重要的。第四階段與模具總體機(jī)械結(jié)構(gòu)相關(guān)，模具總體機(jī)械結(jié)構(gòu)包括連接模具到注塑機(jī)，注塑機(jī)是用于澆注、冷卻、取出和模具裝配的機(jī)械裝置。零件的熱處理工序，在使零件獲得要求的硬度的同時(shí)，還需對(duì)內(nèi)應(yīng)力進(jìn)行控制，保證零件加工時(shí)尺寸的穩(wěn)定性，不同的材質(zhì)分別有不同的處理方式。隨著近年來(lái)模具工業(yè)的發(fā)展，使用的材料種類增多了，除了Cr12、40Cr、Cr12MoV、硬質(zhì)合金外，對(duì)一些工作強(qiáng)度大，受力苛刻的凸、凹模，可選用新材料粉末合金鋼，如V10、ASP23等，此類材質(zhì)具有較高的熱穩(wěn)定性和良好的組織狀態(tài)。針對(duì)以Cr12MoV為材質(zhì)的零件，在粗加工后進(jìn)行淬火處理，淬火后工件存在很大的存留應(yīng)力，容易導(dǎo)致精加工或工作中開裂，零件淬火后應(yīng)趁熱回火，消除淬火應(yīng)力。淬火溫度控制在900-1020，然后冷卻至200-220出爐空冷，隨后迅速回爐220回火，這種方法稱為一次硬化工藝，可以獲得較高的強(qiáng)度及耐磨性，對(duì)于以磨損為主要失效形式的模具效果較好。生產(chǎn)中遇到一些拐角較多、形狀復(fù)雜的工件，回火還不足以消除淬火應(yīng)力，精加工前還需進(jìn)行去應(yīng)力退火或多次時(shí)效處理，充分釋放應(yīng)力。針對(duì)V10、APS23等粉末合金鋼零件，因其能承受高溫回火，淬火時(shí)可采用二次硬化工藝，1050-1080淬火，再用490-520高溫回火并進(jìn)行多次，可以獲得較高的沖擊韌性及穩(wěn)定性，對(duì)以崩刃為主要失效形式的模具很適用。粉末合金鋼的造價(jià)較高，但其性能好，正在形成一種廣泛運(yùn)用趨勢(shì)。1.1.執(zhí)行事實(shí)表明，SolidWorks的API接口采用了面向?qū)ο蟮姆椒ê虯PI函數(shù)允許選擇對(duì)象語(yǔ)言，例如:作為編程語(yǔ)言的Visual C+。利用這種方法，在Windows NT下，基于Windows的注塑模具三維設(shè)計(jì)的應(yīng)用軟件通過Visual C+的代碼與商業(yè)軟件SolidWorks99接口開發(fā)。這個(gè)應(yīng)用模具設(shè)計(jì)過程分為幾個(gè)階段，提供模具設(shè)計(jì)者制造模具設(shè)計(jì)可靠方法。圖3概述了這個(gè)框架。每一個(gè)階段可以視為一個(gè)獨(dú)立程序模塊。幾個(gè)單元已成功使用SolidWorks開發(fā).它們中的兩個(gè)模板模塊和分模模塊如下所示。1.2 基于模架設(shè)計(jì)的模具基于模架設(shè)計(jì)的模具與所有的組件和配件，像HASCO，DME，HOPPT，LKM和FUTABA可自動(dòng)創(chuàng)建參數(shù)化標(biāo)準(zhǔn)模板。設(shè)計(jì)師常用可以輕松地定制模板的這種模架。主要特點(diǎn)包括:像支柱、澆道襯套、兩板，三板那樣的標(biāo)準(zhǔn)模架組件的實(shí)用性，以及定制非標(biāo)準(zhǔn)模具模板基于。模架設(shè)計(jì)的模具分為四個(gè)主要部分，即構(gòu)件庫(kù)(包括標(biāo)準(zhǔn)和非標(biāo)準(zhǔn)件庫(kù))，設(shè)計(jì)表中的尺寸驅(qū)動(dòng)功能，結(jié)構(gòu)關(guān)系管理。在這里，SolidWorks提供了尺寸驅(qū)動(dòng)的功能是，以支持其申請(qǐng)。（1）組件庫(kù)為了在這競(jìng)爭(zhēng)日益激烈的世界加強(qiáng)模具設(shè)計(jì)能力，降低設(shè)計(jì)成本和縮短生產(chǎn)周期，減少人力、自動(dòng)化等是達(dá)到這一目的主要因素。換句話說(shuō)，使用計(jì)算機(jī)軟件是非常必要的。 計(jì)算機(jī)軟件能夠容易地創(chuàng)建，修改，分析模具設(shè)計(jì)的部件，更新變化中的設(shè)計(jì)模型。為達(dá)到這個(gè)目標(biāo)，三維構(gòu)件庫(kù)提供儲(chǔ)存標(biāo)準(zhǔn)和非標(biāo)準(zhǔn)零部件的數(shù)據(jù)，其尺寸是儲(chǔ)存在Microsoft Excel中 。通過指定合適的尺寸，這些組件可以生成和插入裝配結(jié)構(gòu)。 這個(gè)庫(kù)是完全可定制和設(shè)計(jì)師能放入自己的部分加入組件庫(kù)。表面處理及組配, 零件表面在加工時(shí)留下刀痕、磨痕是應(yīng)力集中的地方，是裂紋擴(kuò)展的源頭，因此在加工結(jié)束后，需要對(duì)零件進(jìn)行表面強(qiáng)化，通過鉗工打磨，處理掉加工隱患。對(duì)工件的一些棱邊、銳角、孔口進(jìn)行倒鈍，R化。一般地，電加工表面會(huì)產(chǎn)生6-10m左右的變質(zhì)硬化層，顏色呈灰白色，硬化層脆而且?guī)в袣埩魬?yīng)力，在使用之前要充分消除硬化層，方法為表面拋光，打磨去掉硬化層。在磨削加工、電加工過程中，工件會(huì)有一定磁化，具有微弱磁力，十分容易吸著一些小東西，因此在組裝之前，要對(duì)工件作退磁處理，并用乙酸乙脂清洗表面。組裝過程中，先參看裝配圖，找齊各零件，然后列出各零件相互之間的裝備順序，列出各項(xiàng)應(yīng)注意事項(xiàng)，然后著手裝配模具，裝配一般先裝導(dǎo)柱導(dǎo)套，然后裝模架和凸凹模，然后再對(duì)各處間隙，特別是凸凹模間隙進(jìn)行組配調(diào)整，裝配完成后要實(shí)施模具檢測(cè)，寫出整體情況報(bào)告。對(duì)發(fā)現(xiàn)的問題，可采用逆向思維法，即從后工序向前工序，從精加工到粗加工，逐一檢查，直到找出癥結(jié)，解決問題。（2）尺寸驅(qū)動(dòng)SolidWorks提供了強(qiáng)有力的尺寸驅(qū)動(dòng)功能，以支持參數(shù)化設(shè)計(jì)。儲(chǔ)存在Microsoft Excel中的尺寸和幾何存在邏輯關(guān)系。當(dāng)尺寸設(shè)置與相應(yīng)物件幾何參數(shù)設(shè)置相結(jié)合，可以獲得確切的模型。（3）設(shè)計(jì)表設(shè)計(jì)表允許設(shè)計(jì)師在嵌入的Microsoft Excel 制表中通過具體參數(shù)建立多種零部件配置。設(shè)計(jì)表保存在零件文件夾，是用來(lái)存儲(chǔ)的尺寸， 制止特點(diǎn)和性能配置， 其中包括在材料，組件和客戶的要求中的零件數(shù)量。 當(dāng)增加適當(dāng)?shù)某叽纾O(shè)計(jì)表將包含所有必要的信息，以建立一個(gè)精確的裝配模型。（4）結(jié)構(gòu)關(guān)系管理本部分講述了組建模板之間的結(jié)構(gòu)關(guān)系，從設(shè)計(jì)表供應(yīng)的某些參數(shù)設(shè)置能幫助模具設(shè)計(jì)師插入這些部件裝配結(jié)構(gòu)， 因此，一個(gè)特定的裝配模板就可以自動(dòng)生成。1.3 分模模塊一些分模算法以前就報(bào)導(dǎo)過。在這方面的發(fā)展，分模用來(lái)處理型芯和型腔。在注塑模具計(jì)算機(jī)輔助設(shè)計(jì)系統(tǒng)中，這是一個(gè)最重要的模塊。設(shè)計(jì)一個(gè)模具模型需要有設(shè)計(jì)模型， 工件和有效分型面。設(shè)計(jì)模式體現(xiàn)了成品，而裝載箱體現(xiàn)了模具組件的總量。為了把工件分成型芯和型腔，設(shè)計(jì)模型首先從工件中去除。然后用分模面把工件塑造成半，常指型芯和型腔。當(dāng)熔融塑料射入型腔，模具對(duì)立的兩面形成成品。凝固后，兩半模子沿分模面d和d分別移開。然后獲得了實(shí)際部分。(1) 分模方向決定型芯和型腔打開的相反兩個(gè)方向就是分模方向，為了形成分型線，分模方向應(yīng)首先確定。 分模方向影響分型線定位。分型線決定了模具的復(fù)雜度。 在大多數(shù)情況下， 分模方向是由幾何和制造問題同時(shí)決定。(2) 識(shí)別和修補(bǔ)穿孔當(dāng)產(chǎn)品中有穿孔，設(shè)計(jì)者必須標(biāo)明孔的分模位置，在這些孔里邊生成分型面。在這篇論文中，這就是所謂的補(bǔ)丁。表面都需要用來(lái)修補(bǔ)的通孔。 由于上模具和下模具在通孔處相連。如果沒有事先修補(bǔ)通孔，模具是不能分開，型芯和型腔不能自動(dòng)創(chuàng)建(見圖6b)。(3) 確定分型線和頂出方向在成型中，模具的設(shè)計(jì)是提高模具質(zhì)量的最重要的一步，需要考慮到很多因素，包括模具材料的選用，模具結(jié)構(gòu)的可使用性及安全性，模具零件的可加工性及模具維修的方便性，這些在設(shè)計(jì)之初應(yīng)盡量考慮得周全些。模具材料的選用既要滿足客戶對(duì)產(chǎn)品質(zhì)量的要求，還需考慮到材料的成本及其在設(shè)定周期內(nèi)的強(qiáng)度，當(dāng)然還要根據(jù)模具的類型、使用工作方式、加工速度、主要失效形式等因素來(lái)選材.一組零件的表面由型芯塑造，而另一組是由型腔塑造。分型線因此是由型芯和型腔塑造的兩組表面的相交線。分型線在表面組選擇最大邊緣線。從分型線到型芯或型腔邊界，頂出方向在頂出過程中，分型線將會(huì)跟隨。分型線是垂直于分模方向，平行于模具工件面的表面法線(見圖 6c) 圖（6）(4) 分型面生成分型面是型芯和型腔的匹配面。分型面可以作為分裂面把模具分成兩半。兩種方法可以用來(lái)生成分型面。席卷法：分型面通過頂出分型線到型芯和型腔外邊界形成。拉伸方法：在SolidWorks中，分模面可以使用拉伸分模線到指定距離的方法創(chuàng)建，這個(gè)距離要足夠大，大到可以沿伸到工件的外表面。(見圖6e)(5) 工件的創(chuàng)建物件裝入工件中，工件外圍額外空間用計(jì)算機(jī)計(jì)算。工件大小由物件的幾何大小、模具強(qiáng)度、模具參數(shù)決定。模具參數(shù)可以有效定義模具裝配。(6) 型芯和型腔的生成為了生成型芯和型腔，工件被子分成兩半。首先，設(shè)計(jì)模型從工件中取出。在工件內(nèi)部獲得一個(gè)空的空間。然后，分模面和修補(bǔ)面被使用把工件分成型芯塊和型腔塊。最后，在模擬模具開啟過程和檢查模具組件之間的干擾后，工件兩半分別沿分模方向d和d從分模面分離(圖6g)。2快速經(jīng)濟(jì)制模技術(shù)類型快速經(jīng)濟(jì)制模技術(shù)與傳統(tǒng)的機(jī)械加工相比，具有制模周期短、成本低、精度與壽命又能滿足生產(chǎn)上的使用要求，是綜合經(jīng)濟(jì)效益比較顯著的一類制造模具的技術(shù)，概括起來(lái)，有以下幾種類別。2.1快速原型制造技術(shù)快速原型制造技術(shù)簡(jiǎn)稱RPM，是80年代后期發(fā)展起來(lái)的一種新型制造技術(shù)。美國(guó)、日本、英國(guó)、以色列、德國(guó)、中國(guó)都推出了自己的商業(yè)化產(chǎn)品，并逐漸形成了新型產(chǎn)業(yè)。RPM是電腦、激光、光學(xué)掃描、先進(jìn)的新型材料、計(jì)算機(jī)輔助設(shè)計(jì)(CAD)、計(jì)算機(jī)輔助加工(CAM)、數(shù)控(CNC)綜合應(yīng)用的高新技術(shù)。在成型概念上以平面離散、堆積為指導(dǎo)，在控制上以計(jì)算機(jī)和數(shù)控為基礎(chǔ)，以最大柔性為總體目標(biāo)。它摒棄了傳統(tǒng)的機(jī)械加工方法，對(duì)制造業(yè)的變革是一個(gè)重大的突破，利用RPM技術(shù)可以直接或間接地快速制模，該技術(shù)已被汽車、航空、家電、船舶、醫(yī)療、模具等行業(yè)廣泛應(yīng)用。下面簡(jiǎn)述一下目前已經(jīng)商業(yè)化的幾種典型快速成型工藝。2.1.1激光立體光刻技術(shù)(SLA)SLA技術(shù)是交計(jì)算機(jī)CAD造型系統(tǒng)獲得制品的三維模型，通過微機(jī)控制激光，按著確定的軌跡，對(duì)液態(tài)的光敏樹脂進(jìn)行逐層掃描，使被掃描區(qū)層層固化，連成一體，形成最終的三維實(shí)體，再經(jīng)過有關(guān)的最終硬化打光等后處量，形成制件或模具。激光立體光刻技術(shù)主要特點(diǎn)是可成型任意復(fù)雜形狀，成型精度高，仿真性強(qiáng)，材料利用率高，性能可靠，性能價(jià)格比較高。適合產(chǎn)品外型評(píng)估、功能實(shí)驗(yàn)、快速制造電極和各種快速經(jīng)濟(jì)模具。但該技術(shù)所用的設(shè)備和光敏樹脂價(jià)格昂貴，使其成本較高。2.1.2疊層輪廓制造技術(shù)(LOM)LOM技術(shù)是通過計(jì)算機(jī)的三維模型，利用激光選擇性地對(duì)其分層切片，將得到的各層截面輪廓層層粘結(jié)，最終疊加成三維實(shí)體產(chǎn)品。其工藝特點(diǎn)是成型速度快，成型材料便宜、成本低，因無(wú)相變，故無(wú)熱應(yīng)力、收縮、膨脹，翹曲等，所以形狀與盡寸精度穩(wěn)定，但成型后廢料塊剝離較費(fèi)事，特別是復(fù)雜件內(nèi)部的廢料剝離。該工藝適用于航空、汽車等和中體積較大制件的制作。2.1.3激光粉末選區(qū)燒結(jié)成型技術(shù)(SLS)SLS技術(shù)是將計(jì)算機(jī)的三維模型通過分層軟件將其分層，在計(jì)算機(jī)控制下，使激光束依據(jù)分層的切片截面信息對(duì)粉末逐層掃描，掃描到的粉末燒結(jié)固化(聚合、燒結(jié)、粘結(jié)、化學(xué)反應(yīng)等)，層層疊加，堆積成三維實(shí)體制件。該技術(shù)最大特點(diǎn)是能同時(shí)用幾種不同材料(聚碳酸脂、聚乙烯氯化物、石蠟、尼龍、ABS、鑄造砂)制造一個(gè)零件。2.1.4熔融沉積成型技術(shù)(FDM)FDM技術(shù)是由計(jì)算機(jī)控制可擠出熔融狀態(tài)材料的噴嘴，根據(jù)CAD產(chǎn)品模型分層軟件確定的幾何信息，擠出半流動(dòng)狀態(tài)的熱塑材料沉積固化成精確的實(shí)際制件薄層 ，自下而上層層堆積成一個(gè)三維實(shí)體，可直接做模具或產(chǎn)品。2.1.5三維印刷成型技術(shù)(3D-P)3D-P技術(shù)用微機(jī)控制一個(gè)連續(xù)噴墨印刷頭，依據(jù)分層軟件逐層選擇性地在粉末層上沉積液體粘結(jié)材料，最終由順序印刷的二維層堆積成一個(gè)三維實(shí)體，猶如不使用激光的快速制模技術(shù)。該技術(shù)主要應(yīng)用在金屬陶瓷復(fù)合材料的多孔陶瓷預(yù)成型件上，其目標(biāo)是由CAD產(chǎn)品模型直接生產(chǎn)模具或功能性制作。2.2表面成型制模技術(shù)表面成型制模技術(shù)，主要是利用噴涂、電鑄、化學(xué)腐蝕等新的工藝方法形成型腔表面及精細(xì)花紋的一種工藝技術(shù)，實(shí)際應(yīng)用中包括以下幾種類型。2.2.1電弧噴涂成型制模技術(shù)電弧噴涂成型技術(shù)的原理是：利用2根通電的金屬絲之間產(chǎn)生電弧的熱量將金屬絲熔化，依靠高壓氣體將其充分霧化，并給予一定的動(dòng)能，高速噴射在樣模表面，層層鑲嵌，形成一金屬殼體，即型腔的內(nèi)表面，再用充填基體材料(一般為金屬粉粒與樹脂的復(fù)合材料)加以支撐加固，提高其強(qiáng)度和剛性，連同金屬模架組合成模具。這種制模技術(shù)工藝簡(jiǎn)單、成本低，制造周期非常短，型腔表面的成型僅需幾個(gè)小時(shí)，節(jié)省能源和金屬材料，一般型腔表面僅2-3mm厚，仿真性極強(qiáng)，花紋精度可達(dá)到0.5m。目前該技術(shù)被廣泛地用于飛機(jī)、汽車的內(nèi)飾件模具、家電、家俱、制鞋、美術(shù)工藝品等表面形狀復(fù)雜及花紋精細(xì)的各種聚氨酯制品的吹塑、吸塑、PVC注射、PU發(fā)泡及各類注射成型模具中。2.2.2電鑄成型技術(shù)電鑄成型技術(shù)的原理同電鍍一樣，是依樣模(現(xiàn)成制品或按制品圖紙制成的母模)為基準(zhǔn)(陰極)，置放在電鑄液中(陽(yáng)極)，使電鑄液中的金屬離子還原后一層一層地沉積在樣模上，形成金屬殼體，將其剝離后，與樣模接觸的表面即為模具的型腔內(nèi)表面。該技術(shù)主要特點(diǎn)是節(jié)省材料、模具制造周期短，電鑄層硬度可達(dá)40HRC，提高了耐磨性和壽命，粗糙度、尺寸精度與樣模完全一致，適用于注射、吸塑、吹塑、搪塑、膠木模、玻璃模、壓鑄模等模具型腔及電火花成型電極的制造。2.2.3型腔表面精細(xì)花紋成型的蝕刻技術(shù)蝕刻技術(shù)是光學(xué)、化學(xué)、機(jī)加工綜合應(yīng)用的一種技術(shù)，它的基本原理是先把花紋圖案制成膠片，再把膠片上的花紋圖案復(fù)制在已涂上光敏材料的模具型腔表面上，經(jīng)過化學(xué)處理，模具型腔表面形成不被蝕刻部分的保護(hù)層，再根據(jù)模具材質(zhì)，選擇相應(yīng)蝕刻工藝，將花紋圖案蝕刻在模具內(nèi)表面上。該技術(shù)的主要特點(diǎn)是時(shí)間短、費(fèi)用低，修補(bǔ)破損花紋圖案可做到天衣無(wú)縫。2.3澆鑄成型制模技術(shù)澆鑄成型制模技術(shù)的共同特點(diǎn)是依樣件為基準(zhǔn)，澆鑄出凸、凹模，型腔表面不需要機(jī)械加工。實(shí)際制模中主要有以下幾種類型。2.3.1鉍錫合金制模技術(shù)鉍錫合金快速制模技術(shù)是經(jīng)樣件為基準(zhǔn)，以Bi-Sn(鉍錫)二元共晶合金(熔點(diǎn)138，脹縮率萬(wàn)分之三)為材料，有精密鑄造的方法同時(shí)鑄出凸模、凹模、壓邊圈的一種技術(shù)。該技術(shù)的特點(diǎn)是制模成本低，合金可重復(fù)使用，制造周期短，尺寸精度高，形狀、尺寸與樣件完全相符，一次鑄模壽命可達(dá)500-3000件，非常適合新產(chǎn)品開發(fā)、工藝驗(yàn)證、樣品試制及中小批量和平。2.3.2鋅基合金制模技術(shù)這是一種以樣件(或樣模)為基準(zhǔn)，以熔點(diǎn)為380左右的鋅基合金為材料，分別澆注凸、凹模，原則上型腔表面不進(jìn)行機(jī)械加工的一種制模技術(shù)。該技術(shù)特點(diǎn)是制模成本低、周期短，適用于制作薄板大型拉伸模、沖裁模及塑料模。2.3.3樹脂復(fù)合成型模具技術(shù)這是一種以樣模(或工藝模型)為基準(zhǔn)，以樹脂或其復(fù)合材料為流體材料，先澆注出凸(凹)模，再依據(jù)凸(凹)模貼上蠟片(間隙層)，澆注凸(凹)模。該技術(shù)成型的型腔表面不需機(jī)械加工。該技術(shù)與CAD/CAM相結(jié)合，特點(diǎn)是模具尺寸精度高、制造周期短、成本低，是新產(chǎn)品試制、小批量生產(chǎn)工藝裝備的新途徑。適用于制作大型覆蓋件拉伸模(也可局部鑲鋼)、真空吸塑、聚氨酯發(fā)泡成型模、陶瓷模、仿型靠模、鑄造模等。2.3.4硅橡膠制模技術(shù)該技術(shù)以制件原型或模型為基準(zhǔn)，將柔態(tài)硅橡膠制做成塊，再靠高壓力與模型完全吻合。2.4擠壓成型技術(shù)2.4.1冷擠壓成型利用鈹銅合金的良好的導(dǎo)熱性和穩(wěn)定性，經(jīng)固熔時(shí)效處理后，采用冷擠壓制造模具凹模型腔。其特點(diǎn)是制造周期短，型腔精度高(IT7級(jí))，表面粗糙度Ra=0.025m,強(qiáng)度高，壽命可達(dá)50萬(wàn)次，無(wú)環(huán)境污染。2.4.2超塑成型制模技術(shù)該技術(shù)是利用金屬材料在細(xì)化晶粒、一定成型溫度、低變形速率條件下，材料具有最佳超塑性時(shí)，將事先制作好的凸模，用較小的力便可擠壓出凹模的一種快速經(jīng)濟(jì)制模技術(shù)。超塑成型材料的典型代表是Zn-22%AL。2.5無(wú)模多點(diǎn)成形技術(shù)無(wú)模多點(diǎn)快速成形技術(shù)是以CAD/CAM/CAT技術(shù)為主要手段，利用計(jì)算機(jī)控制高度可調(diào)基本體群形成上下成形面，代替?zhèn)鹘y(tǒng)模具對(duì)板料進(jìn)行三維曲面成形的又一現(xiàn)代先進(jìn)制造技術(shù)。此項(xiàng)技術(shù)可以隨意改變變形路徑與受力狀態(tài)，提高材料的成形極限，可反復(fù)成形，以此消除材料內(nèi)部的殘余應(yīng)力，實(shí)現(xiàn)無(wú)回彈成形。2.6凱維朗(KEVRON)鋼帶沖裁落料制模技術(shù)新型鋼帶沖裁落料制模技術(shù)是一種不同于一般具有凸、凹模結(jié)構(gòu)的鋼帶模，它是由單刃鋼帶與特制墊板組成的新型快速經(jīng)濟(jì)制模技術(shù)。這種模具重量輕，一般只有200kg，加工精度為0.35-0.50mm，可適合各種黑色和有色金屬的0.5-0.65mm厚的板料加工。壽命可達(dá)到5-25萬(wàn)次，制造成本低。2.7模具毛坯的快速制造技術(shù)實(shí)型鑄造由于大量的模具是屬于單件或小批量生產(chǎn)，模具毛坯的制造質(zhì)量和周期及成本對(duì)最終的模具質(zhì)量和周期及成本的影響是至關(guān)重要的?，F(xiàn)代模具毛坯已廣泛地采用子實(shí)型鑄造技術(shù)，所謂實(shí)型鑄造就是利用泡沫塑料(聚苯乙烯PS或聚甲基丙烯酸酯PMMA)制作代替?zhèn)鹘y(tǒng)的木?；蚪饘倌?，造型后不需取出模型，便可以澆鑄，泡沫塑料模型的高溫液體金屬作用下，迅速燃燒氣化而消失，金屬液取代原來(lái)泡沫塑料模型所占有的位置，冷凝后形成鑄件。實(shí)型鑄造在實(shí)際應(yīng)用中有下列幾種情況。2.7.1干砂實(shí)型鑄造即用55-100目的全干沒有任何粘結(jié)劑的石英砂造型，用EPS或PMMA泡沫塑料制作的模型涂掛0.2-1mm厚透氣性良好的耐火涂料層，以提高鑄件表面光潔度，防止粘砂或塌箱。2.7.2負(fù)壓實(shí)型鑄造負(fù)壓實(shí)型鑄造又稱V法造型。該技術(shù)是使用全干而無(wú)粘結(jié)劑的石英砂做型砂，用EPS或PMMA泡沫塑料做模型，在塑料薄膜的密封條件下，讓整個(gè)鑄型在負(fù)壓條件下(真空度0.4-0.67MPa)進(jìn)行液體金屬澆鑄，鑄件凝固后解除負(fù)壓即可得到表面光潔的鑄件。2.7.3樹脂砂實(shí)型鑄造利用樹脂砂做型砂，用EPS或PMMA泡沫塑料做模型，在常溫、常壓下進(jìn)行液體金屬澆鑄而制取鑄件。利用實(shí)型鑄造的技術(shù)制造模具毛坯具有尺寸精度高(ISO9級(jí))，加工余量小(一般在5mm左右)，不需要拔模斜度，不需要制型芯與泥芯撐，節(jié)省金屬材料，節(jié)省做木模型的木材，制造周期短，成本低。該技術(shù)適合大型、復(fù)雜、單件模具毛坯的生產(chǎn)。陶瓷型精鑄、失蠟精鑄等技術(shù)在提高模具毛坯精度、降低加工工時(shí)、縮短制造周期、降低成本等方面也顯示出其特有的優(yōu)越性。2.8其它方面技術(shù)為了簡(jiǎn)化模具的結(jié)構(gòu)設(shè)計(jì)，降低模具成本，縮短模具制造周期，在國(guó)內(nèi)外也先后出現(xiàn)了一些其它方面新技術(shù)的應(yīng)用，如快換模架、沖壓?jiǎn)卧?、刃口堆焊、鑲塊鑄造、氮?dú)鈴椈傻取?.8.1氮?dú)鈴椈稍谀＞呱系膽?yīng)用氮?dú)鈴椈墒且环N新型彈性功能部件，用它代替彈簧、橡膠、聚氨酯或者氣墊，它能夠準(zhǔn)確地提供壓邊力，在較小空間便可產(chǎn)生較大初始彈壓力，不需預(yù)緊，在模具整個(gè)工作過程中彈壓力基本恒定。彈壓力大小及受力點(diǎn)位置可隨時(shí)、準(zhǔn)確、方便地調(diào)整，簡(jiǎn)化模具拉伸、壓邊、卸料等結(jié)構(gòu)，簡(jiǎn)化模具設(shè)計(jì)，縮短制模周期，調(diào)試模具方便，縮短更換模具時(shí)間，提高生產(chǎn)效率。2.8.2快速換模技術(shù)由于產(chǎn)品品種的增多，使模具在生產(chǎn)中更換變得十分頻繁，于是如何縮短沖壓設(shè)備的停機(jī)時(shí)間，提高生產(chǎn)效率，快速換模技術(shù)受到了人們的關(guān)注。目前發(fā)達(dá)工業(yè)國(guó)家的一些大公司換模速度達(dá)到了驚人的程度，是否具有快速換模技術(shù)已成為企業(yè)技術(shù)進(jìn)步的一項(xiàng)標(biāo)志。總的趨勢(shì)就是減少模具在設(shè)備上安裝、固定、調(diào)整的時(shí)間，這既要在設(shè)備結(jié)構(gòu)設(shè)計(jì)上予以考慮，又要在模具的結(jié)構(gòu)設(shè)計(jì)、標(biāo)準(zhǔn)化方面予以考慮，將機(jī)上的作業(yè)盡可能地放在機(jī)下做。2.8.3沖壓?jiǎn)卧M合技術(shù)沖壓?jiǎn)卧M合技術(shù)是將常規(guī)的沖模分解為一個(gè)個(gè)簡(jiǎn)單的單元沖模，根據(jù)工序件的要求，排列組合，在同一次沖程內(nèi)完成多種沖壓工序的新型工藝裝備，工作時(shí)沖壓?jiǎn)卧慌c沖床滑塊聯(lián)接，只需滑塊打擊即可完成沖壓工作。單獨(dú)使用時(shí)它就是1副完整模具。它可以用來(lái)加工板料或型材的沖孔、落料、切角、切槽、切斷及淺拉伸等。具有組裝快捷、使用方便、通用性強(qiáng)、經(jīng)濟(jì)性好等特點(diǎn)，特別適合多品種、中小批量生產(chǎn)。2.8.4刃口堆焊技術(shù)在沖模制造中，以普通灰鑄鐵為基體，在刃口部位堆焊高硬度的合金鋼，以代替模具鋼鑲塊，這一技術(shù)成為世界先進(jìn)工藝之一。這是一項(xiàng)節(jié)省制造工時(shí)，節(jié)省昂貴的模具鋼材，縮短模具制造周期的快速經(jīng)濟(jì)制模技術(shù)。目前熔化極氬弧焊技術(shù)的應(yīng)用，大大地提高了刃口堆焊的速度和質(zhì)量。這項(xiàng)技術(shù)世界各國(guó)模具行業(yè)已廣泛采用，取得了良好的經(jīng)濟(jì)效益。2.8.5實(shí)型鑄造沖模刃口鑲塊技術(shù)這是一種用實(shí)型鑄造的工藝方法制造沖模刃口的方法，即用合金鋼鑄件鑲塊代替鍛造合金鋼鑲塊。目前由于鑄造工藝和熱處理工藝不斷完善和提高，鑄造鑲塊的內(nèi)在質(zhì)量有了保證，故其應(yīng)用范圍在不斷擴(kuò)大。這項(xiàng)以鑄代鍛的新技術(shù)的突出特點(diǎn)是節(jié)省貴重模具鋼材，簡(jiǎn)化模具制造工序，由于加工余量小，節(jié)省了大量機(jī)加工工時(shí)，縮短模具制造周期，降低模具成本。2.8.6可加工塑料在模具制造中的應(yīng)用可加工塑料在發(fā)達(dá)的工業(yè)國(guó)家應(yīng)用較普遍，特別是在汽車、飛機(jī)等制造業(yè)中，主要代替木材或金屬制作汽車車身主模型、靠模、檢具和鑄造模型等?？杉庸に芰系闹饕攸c(diǎn)是兼?zhèn)淠静暮徒饘俚膬?yōu)良加工性能，制作工藝簡(jiǎn)捷(可采用模塑、澆注、拼粘、雕塑等方法)、尺寸穩(wěn)定性好、不變形、耐潮濕、耐腐蝕、易修復(fù)、易改型、重量輕、制作周期短、成本低。3結(jié)束語(yǔ)快速經(jīng)濟(jì)制模技術(shù)種類很多，其所具有的特點(diǎn)、應(yīng)用范圍各不相同，本文僅能概括地做一些簡(jiǎn)單介紹，每種技術(shù)在具體應(yīng)用和實(shí)施過程中尚有許多具體的工藝過程、工藝參數(shù)及其技術(shù)特性。模具是基礎(chǔ)工業(yè)之一，在全球化市場(chǎng)經(jīng)濟(jì)和各種高新技術(shù)的迅猛發(fā)展形勢(shì)下，快速經(jīng)濟(jì)模具賦予了新的使命和全新的內(nèi)涵，分類不斷增加，快速經(jīng)濟(jì)制模材料向著多品種系列化邁進(jìn)，工藝不斷有新的創(chuàng)新和突破，與之配套設(shè)備相繼問世，服務(wù)領(lǐng)域在不斷地拓寬，創(chuàng)造的經(jīng)濟(jì)效益越來(lái)越顯著。隨著商品經(jīng)濟(jì)的發(fā)展，激烈的市場(chǎng)競(jìng)爭(zhēng)，產(chǎn)品更新?lián)Q代的加速，對(duì)快速經(jīng)濟(jì)制模技術(shù)在縮短周期、降低成本，提高精度和延長(zhǎng)壽命方面的要求勢(shì)必會(huì)越來(lái)越高。由于它能使企業(yè)贏得市場(chǎng)，創(chuàng)造顯著的經(jīng)濟(jì)效益，越來(lái)越受到企業(yè)家的青睞和有關(guān)領(lǐng)導(dǎo)部門的極大關(guān)注與政策資金的支持。各種快速經(jīng)濟(jì)制模技術(shù)在推廣應(yīng)用過程中也會(huì)不斷完善成熟和發(fā)展，由于高新技術(shù)的發(fā)展，各種技術(shù)的復(fù)合與滲透，為適應(yīng)生產(chǎn)中的不同需求，今后必定會(huì)形成一些新型、節(jié)約能源、節(jié)約材料的快速制模技術(shù)。The technology of Microlens array injection moldingAbstract Injection molding could be used as a mass production technology for microlens arrays. It is of importance, and thus of our concern in the present study, to understand the injection molding processing condition effects on the replicability of microlens array profile. Extensive experiments were performed by varyingprocessing conditions such as flow rate, packing pressure and packing time for three different polymeric materials (PS, PMMA and PC). The nickel mold insert of microlens arrays was made by electroplating a microstructure master fabricated by a modified LIGA process. Effects of processing conditions on the replicability were investigated with the help of the surface profile measurements. Experimental results showed that a packing pressure and a flow rate significantly affects a final surface profile of the injection molded product. Atomic force microscope measurement indicated that the averaged surface roughness value of injection molded microlens arrays is smaller than that of mold insert and is comparable with that of fine optical components in practical use.1 Introduction Microoptical products such as microlenses or microlens arrays have been used widely in various fields of microoptics, optical data storages, bio-medical applications, display devices and so on. Microlenses and microlens arrays are essential elements not only for the practical applications but also for the fundamental studies in the microoptics. There have been several fabrication methods for microlenses or microlens arryas such as a modified LIGA process 1, photoresist reflow process 2, UV laser illumination 3, etc. And the replication techniques, such as injection molding, compression molding 4 and hot embossing 5, are getting more important for a mass production of microoptical products due to the cost-effectiveness. As long as the injection molding can replicate subtle microstructures well, it is surely the most cost-effective method in the mass production stage due to its excellent reproducibility and productivity. In this regard, it is of utmost importance to check the injection moldability and to determine the molding processing condition window for proper injection molding of microstructures. In this study, we investigated the effects of processing conditions on the replication of microlens arrays by the injection molding. The microlens arrays were fabricated by a modified LIGA process, which was previously reported in 6, 7. Injection molding experiments were performed with an electroplated nickel mold insert so as to investigate the effects of some processing conditions. The surface profiles of molded microlens arrays were measured, and were used to analyze effects of processing conditions. Finally, a surface roughness of microlens arrays was measured by an atomic force microscope (AFM).2 Mold insert fabricationMicrolens arrays having several different diameters were fabricated on a PMMA sheet by a modified LIGA process 6. This modified LIGA process is composed of an X-ray irradiation on the PMMA sheet and a subsequent thermal treatment. The X-ray irradiation causes the decrease of molecular weight of PMMA, which in turn decreases the glass transition temperature and consequently causes a net volume increase during the thermal cycle resulting in a swollen microlens 7. The shapes of microlenses fabricated by the modified LIGA process can be predicted by a method suggested in 7.The microlens arrays used in the experiments were composed of 500m -(a 2 2 array), 300m -(2 2) and 200m (5 5) diameter arrays, and their heights were 20.81, 17.21 and 8.06 m, respectively. Using the microlens arrays fabricated by the modified LIGA process as a master, a metallic mold insert was fabricated by a nickel electroplating for the injection molding. Typical materials used in a microfabrication process, such as silicon, photoresists or polymeric materials, cannot be directly used as the mold or the mold insert due to their weak strength or thermal properties. It is desirable to use metallic materials which have appropriate mechanical and thermal properties to endure both a high pressure and a large temperature variation during the replication process. Therefore, a metallic mold insert is being used rather than the PMMA master on silicon wafer for mass production with such replication techniques. Otherwise special techniques should be adopted as a replication method, e.g. a low pressure injection molding 8.The size of final electroplated mold insert was 30 30 3 mm. The electroplated nickel mold insert having microlens arrays is shown in Fig. 1.Fig.1.Moldinsert fabricated by a nickel electroplating (a) Real view of the mold insert (b) SEM image of 200 m diameter microlens array (c) SEM image of 300 mdiameter microlens array3 Injection molding experimentsA conventional injection molding machine (Allrounders 220 M, Arburg) was used in the experiments. A mold base for the injection molding was designed to fix the electroplated nickel mold insert firmly with the help of a frametype bolster plate (Fig. 2). Shape of aperture of the bolster plate (in this study, a rectangular one) defines the outer geometry of the molded part on which the profiles of microlens arrays are to be transcribed. The mold base itself has delivery systems such as sprue, runner and gate which lead the molten polymer to the cavity formed by the bolster plate, the mold insert and amoving mold surface. The mold base was designed such that mold insert replacement is simple and easy. Of course, one may introduce an appropriate bolster plate with a specific aperture shape. Fig. 2. Mold base and mold insert used in the injection molding experimentThe injection molding experiments were carried out with three general polymeric materials PS (615APR, Dow Chemical), PMMA (IF870, LG MMA) and PC (Lexan 141R, GE Plastics). These materials are quite commonly used for optical applications. They have different refractive indices (1.600, 1.490 and 1.586 for PS, PMMA and PC, respectively), giving rise to different optical properties in final products, e.g. different foci with the same geometry. The injectionmolding experiments were performed for seven processing conditions by changing flow rate, packing pressure and packing time for each polymeric material. Furthermore, same experiments were repeated three times for checking the reproducibility. It may be mentioned that the mold temperature effect was not considered in this study since the temperature effect is relatively less important for these microlens arrays due to their large radius of curvature than other microstructures of high aspect ratio. For high aspect ratio microstructures, we are currently investigating the temperature effect more closely and plan to report separately in the future. Therefore, flow rate, packing pressure and packing time were varied to investigate their effects more thoroughly with the mold temperature unchanged in this study. Table 1 shows the detailed processing conditions for three polymeric materials. Other processing conditions were kept unchanged during the experiment. The mold temperatures were set to 80, 70 and 60 _C for PC, PMMA and PS, respectively.It might be mentioned that we carried out the experiments without a vacuum condition in the mold cavity considering that the large radius of curvature of the microlens arrays in the present study will not entrap air in the microlens cavity during the filling stage.Table 1. Detailed processing conditions used in the injection molding experimentsCaseFlow rate (cc/sec)Packing time (sec)Packing pressure(MPa)112.05.010.0212.05.015.0312.05.020.0PS412.02.010.0512.010.010.0618.05.010.0724.05.010.0PMMA16.010.010.026.010.015.036.010.020.046.05.010.05676.09.012.015.010.010.010.010.010.0PC 16.05.05.026.05.010.0356.06.09.05.010.015.05.065.05.0712.05.05.04 Results and discussionBefore detailed discussion of the experimental results, it might be helpful to summarize why flow rate, packingpressure and packing time (which were chosen as processing conditions to be varied in this study) affect thereplication quality. As far as the flow rate is concerned, there may exist an optimal flow rate in the sense that too small flow rate makes too much cooling before a complete filling and thus possibly results in so-called short shot phenomena whereas too high flow rate increases pressure fields which is undesirable.The packing stage is generally required to compensate for the volume shrinkage of hot molten polymer whencooled down, so that enough material should flow into a mold cavity during this stage to control the dimensionalaccuracy. The higher the packing pressure, the longer the packing time, more material tends to flow in. However, too much packing pressure sometimes may cause uneven distribution of density, thereby resulting in poor opticalquality. And too long packing time does not help at all since gate will be frozen and prevent material from flowing into the cavity. In this regard, one needs to investigate the effects of packing pressure and packing time.4.1 Surface profilesFigure 3 shows typical scanning electron microscope (SEM) images of the injection molded microlens arrays for different diameters for PMMA (a) and different materials (b). Cross-sectional surface profiles of the mold insert and all the injection molded microlens arrays were measured by a 3D profile measuring system (NH-3N, Mitaka).(a)Injection molded microlensarrays (PMMA) (b) Injectionmolded microlenses of 300 mdiameter for different materialsFig. 3. SEM images of theinjection molded microlensarrays and microlensesAs a measure of replicability, we have defined a relative deviation of profile as the height difference between the molded one and the corresponding mold insert for each microlens divided by the mold insert one. The computed relative deviations for all the microlenses are listed in Table 2.Diameter( m)Relative deviation (%)1234567PS200300500-7.625.862.38-7.592.03-0.382.082.860.51-5.565.611.47-8.6660161.47-11.444.291.47-9.475.731.95PMMA2003005007.205.77-0.661.315.60-1.62-3.886.453.98-5.805.952.80-0.975.95-0.72-8.536.68-0.904.86-2.62-0.72PC20030050023.026.20-0.9316.054.965.0916.872.66-1.8619.664.531.8833.974.786.9618.671.792.43-2.944.15-1.55It may be mentioned that the moldability of polymeric materials affects the replicability. Therefore, the overall relative deviation differs for three polymeric materials used in this study. It may be noted that PC is the most difficult material for injection molding amongst the three polymers. The largest relative deviation can be found in PC for the smallest diameter case, as expected. In that specific case, the largest value is corresponding to the low flow rate and low packing pressure. Packing time in this case does not significantly affect the deviation. The relative deviation for PS and PMMA with the smallest diameter is far better than PC case.Table 2 indicates that the larger the diameter, the smaller the relative deviation. The larger diameter microlens is, of course, easier to be filled than smaller diameter during the filling stage and packing stage. Microlenses of larger diameters were generally replicated well regardless of processing conditions and regardless of materials. The best replicability is found for the case of PS with 500 m diameter. Generally, PS has a good moldability in comparison with PMMA and PC.It may be mentioned that some negative values of relative deviation were observed mostly in the smallest diameter case for PS and PMMA according to Table 2. In these cases, however, the absolute deviation is an order of 0.1 m in height, which is within the measurement error of the system. Therefore, the negative values could be ignored in interpreting the experimental data of replicability. Surface profiles of microlens of 300 m diameter are shown in Figs. 4 and 5 for PC and PMMA, respectively. As shown in Fig. 4, the higher packing pressure or the higher flow rate results in the better replication of microlens for the case of PC, as mentioned above. Packing time has little effect on the replication for these cases. For the case of PMMA, the packing pressure and packing time have insignificant effect as shown in Fig. 5; however, flow rate has the similar effect to PC. It might be reminded that packing time does not affect the replicability if a gate is frozen since frozen gate prevents material from flowinginto the cavity. Therefore, the effect of packing time disappears after a certain time depending on the processing conditions.Fig.4ac(leftside).Surfce profiles of microlens (PC with diameter (/) of 300 m). a effect of packing pressure, b effect of flow rate, c effectof packing timeFig.5ac.(rightside)Surface profiles of microlens (PMMA with diameter(/) of 300m). a effect of packing pressure, b effect of flow rate,c effect of packing time4.2 Surface roughnessAveraged surface roughness, Ra, values of 300 m diameter microlenses and the mold insert were measured by an atomic force microscope (Bioscope AFM, Digital Instruments). The measurements were performed around the top of each microlens and the measuring area was 5 m 5 m. Figure 6 shows AFM images and measured Ra values of microlenses. PMMA replicas of microlens have the lowest Ra value, 1.606 nm. It may be noted that AFM measurement indicated that Ra value of injection molded microlens arrays is smaller than the corresponding one of the mold insert. The reason for the improved surface roughness in the replicated microlens arrays is not clear at this moment, but might be attributed to the reflow caused by surface tension during a cooling process. It may be further noted that the Ra value of injection molded microlens arrays is comparable with that of fine optical components in practical use.a Nickel mold insert, b PS, c PMMA, d PCFig. 6. AFM images and averaged surface roughness, Ra, values of the mold insert and injection molded 300 m diameter microlenses.4.3 Focal lengthThe focal length of lenses can be calculated by a wellknown equation as follows:where f, nl, R1 and R2 are focal length, refractive index of lens material, two principal radii of curvature, respectively.For instance, focal lengths of the molded microlenses were approximately calculated as 1.065 mm (with R1 0.624 mm and R2 ￥) for 200 m diameter microlens, 1.130 mm (with R1= 0.662 mm and R2=) for 300 m microlens and 2.580 mm (with R1=1.512 mm and R2=) for 500 m microlens according to Eq. (1). These calculations were based on an assumption that microlenses are replicated with PC (nl= 1.586) and have the identical shape of the mold insert. It might be mentioned that the geometry of the molded microlens might be inversely deduced from an experimental measurement of the focal length.5 ConclusionThe replication of microlens arrays was carried out by the injection molding process with the nickel mold insert which was electroplated from the microlens arrays master fabricated via a modified LIGA process.The effects of processing conditions were investigated through extensive experiments conducted with various processing conditions. The results showed that the higher packing pressure or the higher flow rate is, the better replicability is achieved. In comparison, the packing time was found to have little effect on the replication of microlens arrays.The injection molded microlens arrays had a smaller averaged surface roughness values than the mold insert, which might be attributed to the reflow induced by surface tension during the cooling stage. And PMMA replicas of microlens arrays had the best surface quality (i.e. the lowest roughness value of Ra =1.606 nm). The surface roughness of injection molded microlens arrays is comparable with that of fine optical components in practical use. In this regard, injection molding might be a useful manufacturing tool for mass production of microlensarrays.Modern mold technologyIntroductionAlong with the global economy development, the new technological revolution made the new progress and the breakthrough unceasingly, the technical leap development already becomes the important attribute which the impetus world economics grew. The market economy unceasing development, urges the industry product more and more to the multi- varieties, high grade, the low cost direction to develop, in order to maintain and strengthens the product in market competitive power, product development cycle, production cycle more and more short, thereupon to makes each kind of product the essential craft equipment mold request to be more and more harsh. On the one hand the enterprise for the pursue scale benefit, causes the mold to turn towards high speed, is precise, the long life direction develops; On the other hand enterprise in order to satisfy the multi- varieties, the product renewal quickly, wins the market the need, requests the mold to turn towards the manufacture cycle to be short, the cost low fast economy direction develops. The computer, the laser, electronic, the new material, the new technical development, causes the fast economical pattern making technology even more powerful, the application scope expands unceasingly, the type increases unceasingly, the creation economic efficiency and the social efficiency are more and more remarkable. 1.Injection mold designThe injection molding application temperature dependence change material performance, through uses the mold to obtain the final shape separate part to complete or to complete the size close. In this kind of process of manufacture, the liquid material is compelled to fill, coagulates in the die space mold. first, must create a pattern mold to need a design model and carries the box. First, must create a pattern mold to need a design model and carries the box. The design model has represented the end product, but carries the box to represent the mold modules bulk volume. The injection mold design involves the mold structure and the function constituent widespread experience knowledge (heuristic knowledge). In the typical process molds the recent development to be possible to divide into four big stages: Product design, molds ability appraisal, part detailed design, insertion die space design and detailed mold design. in the initial stage, the product concept is in (usually is together a combination marketing and project) completes by several people. The initial stage main focal point is analyzes the market the opportunity and the adaptation strategy. In the first stage, the canonical correlation craft manufacture information is increased to the design, designs the geometry detail. The conceptual design use suitable manufacture information transforms as the goods which may make. In the second stage, the drawing of patterns direction and a minute hairs breadth buy for use examine molds ability. Otherwise, the components shape revises once more. In the third stage, the components geometry is uses for to establish the mold the core and the die space shape, the mold the core and the die space, will use for to form the components. Generally, the contraction and the expansion need to perform to consider, like this, in processes under the temperature, the formation will have the correct size and the shape. Th