微结构模芯的精密磨削及其在微注塑成形中应用

Precision Grinding of Micro-structured Mould Cores and Its Application in Micro Injection Molding

针对微结构聚合物元器件的批量化生产与制造效率低等问题,采用精密修整成V形尖端的金刚石砂轮,在自润滑性和脱模性良好的钛硅碳陶瓷模芯表面加工制造出形状精度可控的V沟槽阵列结构,然后利用微注塑成形工艺将模芯表面的V沟槽阵列结构一次成形复制到聚合物表面,高效注塑成形制造出倒V形阵列结构的聚合物工件。分析了微模芯的表面加工质量与形状精度,研究了熔体温度、注射速度、保压压力、保压时间等微注塑成形工艺参数对微结构聚合物注塑成形角度偏差和填充率的影响。实验结果表明:通过微细磨削加工技术和微注塑成形工艺可以高效率、高精度地制造出规则整齐的微结构注塑工件,注射速度对微成形角度偏差的影响最大,保压压力对微成形填充率的影响最大,微结构模芯的微细磨削形状精度值为4.05μm,微成形的最小角度偏差和最大填充率分别为1.47°和99.30%。

For low efficient mass production and manufacture of the micro-structured polymer components,a precision trued V-tip diamond grinding wheel was used to grind V-groove array structures with controllable form accuracy on the surfaces of titanium silicon carbide(Ti3SiC2)ceramic mould cores with good self-lubricity and demoulding,then the micro injection molding technology was employed to replicate micro-ground V-groove array structures on mould core surfaces to efficiently injection mold the polymer workpieces with inverted V-shaped array structures.The surface machining quality and form accuracy of the micro-structured mould cores were analyzed.The influences of micro injection molding parameters,including melt temperature,injection speed,holding pressure and holding time on injection molding angle deviation and filling rate of micro-structured polymers were investigated.The experimental results show that the micro injection molded parts with regular and integrated micro-array structures may be high efficiently and precisely fabricated through micro grinding processes and micro injection molding technology.The injection speed has the greatest influence on the micro-molding angle deviation and the holding pressure has the greatest impact on micro-molding filling rate.The micro-ground form accuracy value of micro-structured mould cores is as 4.05μm.The smallest angle deviation and the highest filling rate of micro-molding are as 1.47°and 99.30%,respectively.