透镜注射成型工艺的稳健设计与正交设计对比

Comparison of Steady Design and Orthogonal Design in Injection Molding Process for Lens

采用稳健设计与正交设计,以LED非球面透镜的翘曲变形、折射指数变化、体积收缩率为实验目标,注射时间、V/P转换、保压时间、熔体温度、冷却时间、保压压力、模具温度为实验因素,对透镜的注射成型过程采用Moldflow2015软件进行模拟分析与对比。结果表明:稳健设计的信噪比法最佳工艺参数组合为A2B3C3D1E2F3G2,正交设计的方差法最佳工艺参数组合为A1B3C2D3E2F3G1,信噪比法与方差法得到的各因素影响权重排序相同,采用稳健设计透镜的最大翘曲变形量为0.0166 mm、最大折射指数变化0.0186、最大体积收缩率为10.49%、最高温度为215℃,采用正交设计透镜的最大翘曲变形量为0.0299 mm、最大折射指数变化为0.0327、最大体积收缩率为13.98%、最高温度为255℃,稳健设计得到的透镜最佳工艺参数组合要比传统的正交设计优越,可以更有效地提高LED非球面透镜的光学性能和成型质量。

Using steady design,orthogonal design,warpage deformation, refractive index variation and volume shrinkage of LED aspherie lens as experiment objective, injection time, V/P transition, holding time, melting temperature, cooling time, holding pressure and mold temperature as experiment factor, injection molding process for lens was simulated and compared through Moldflow 2015 software. The results showed that optimum processing parameter with signal-to-noise ratio method of steady design was A2B3C3D1E2F3G2, and optimum processing parameter with variance method of orthogonal design was A1B3C2D3E2F3G1. Each factor influence on weight order was same whether signal-to-noise ratio method or variance method. Using steady design for lens, maximum warpage deformation was 0. 0166 mm, maximum refractive index variation was 0. 0186, maximum volume shrinkage was 10.49% and maximum temperature was 215 ℃. Using orthogonal design for lens, maximum warpage deformation was 0. 0299 mm, maximum refractive index variation was 0. 0327, maximum volume shrinkage was 13.98% and maximum temperature was 255 ℃. Optimum processing parameter for lens obtained by steady design was superior to traditional orthogonal design, and improved optical performance and processing quality of LED aspheric lens.