Effects of the injection compression process parameters on residual stress of plastic lenses

Simeng Chen; Baohua Li; Yajun Zhang; Zhiming Jin

doi:10.1364/AO.404024

Applied Optics
Vol. 59,
Issue 30,
pp. 9626-9632
(2020)
•https://doi.org/10.1364/AO.404024

Effects of the injection compression process parameters on residual stress of plastic lenses

Simeng Chen, Baohua Li, Yajun Zhang, and Zhiming Jin

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Simeng Chen, Baohua Li, Yajun Zhang, and Zhiming Jin, "Effects of the injection compression process parameters on residual stress of plastic lenses," Appl. Opt. 59, 9626-9632 (2020)

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Abstract

Residual stress affects significantly the quality of plastic lenses. In this paper, the influence of process parameters on the residual stress of injection compression molded plastic lenses was investigated by orthogonal simulation. The results show that the effect of compression delay time on residual stress was the most significant, followed by compression distance and compression speed, which are both related to the compression process. Then, the relationship between the residual stress obtained by simulations and the optical path difference measured by the experiment was compared by single factor experiments of four key injection compression molding process parameters. The change trends were similar, which proves that the numerical simulation has the potential to predict the residual stress of plastic lenses and optimize the process parameters, so as to improve their optical quality.

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Dimension Parameter			Value/mm
Main runner	Diameter of big end		8.14
	Diameter of small end		5
	Length		60
Branch runner	Diameter		9
	Length		20
Fan gate	Big end	Top width	9
		Bottom width	11
		Height	1
	Small end	Top width	6.4
		Bottom width	8.5
		Height	1.5

Category	Data
Density	$1.19 g / c m^{3}$
MFR	16 g/10 min
Hardness	M-84
Water absorption	0.3 %
Elongation	5 %
Impact strength	$2 k J / m^{2}$
Heat deflection temperature	90 °C
Injection pressure	800–1400 bar
Total optical transmittance	92 %
Tortuosity ratio	1.491

		Level
Factors		1	2	3
A	Compression distance/mm	1	1.5	2
B	Compression delay time/s	0	1	2
C	$C o m p r e s s i o n s p e e d / m m \cdot s^{- 1}$	30	70	110
D	Compression force/KN	150	250	350
E	Injection time/s	0.5	1	1.5
F	Melt temperature/°C	205	225	245
G	Mold temperature/°C	50	70	90

	Level
Factors	No.1	No.2	No.3	No.4	No.5	No.6	No.7	No.8	No.9	No.10	No.11	No.12	No.13	No.14	No.15	No.16	No.17	No.18
A Compression distance/mm	1	1	1	2	2	2	3	3	3	1	1	1	2	2	2	3	3	3
B Compression delay time/s	1	2	3	1	2	3	1	2	3	1	2	3	1	2	3	1	2	3
C $C o m p r e s s i o n s p e e d / m m \cdot s^{- 1}$	1	2	3	1	2	3	2	3	1	1	2	3	1	2	3	2	3	1
D Compression force/KN	1	2	3	2	3	1	1	2	3	1	2	3	2	3	1	1	2	3
E Injection time/s	1	2	3	2	3	1	3	1	2	1	2	3	2	3	1	3	1	2
F Melt temperature/°C	1	2	3	3	1	2	2	3	1	1	2	3	3	1	2	2	3	1
G Mold temperature/°C	1	2	3	3	1	2	3	1	2	1	2	3	3	1	2	3	1	2
Residual stress/Mpa	30.84	30.94	33.07	30.65	31.04	31.36	31.18	32.22	33.43	30.82	31.21	30.15	29.95	31.00	33.57	31.16	32.42	33.37

	Mean Residual Stress/Mpa			Max-Min (Range)
Factors	K1	K2	K3	Max-Min (Range)
A Compression Distance/mm	31.190	31.262	32.297	1.107
B Compression Delay Time/s	30.767	31.490	32.492	1.725
C Compression Speed $/ m m \cdot s^{- 1}$	32.038	31.105	31.605	0.933
D Compression Force/KN	31.512	31.448	31.788	0.340
E Injection Time/s	31.157	31.702	31.890	0.733
F Melt Temperature/°C	31.270	31.715	31.763	0.493
G Mold Temperature/°C	31.977	31.360	31.412	0.617

Factors		Sum of Squares	Degree of Freedom	F Value	F Critical Value	Prominence
A	Compression distance/mm	4.602	2	11.74	19	-
B	Compression delay time/s	9.004	2	22.969	19	*
C	$C o m p r e s s i o n s p e e d / m m \cdot s^{- 1}$	2.618	2	6.679	19	-
D	Compression force/KN	0.392	2	1	19	-
E	Injection time/s	1.741	2	4.441	19	-
F	Melt temperature/°C	0.887	2	2.263	19	-
G	Mold temperature/°C	1.404	2	3.582	19	-
Error		0.39	2

Basic Parameters	Value
Screw diameter	22 mm
Max injection pressure	287.1 MPa
Theoretical injection volume	$41.8 {c m}^{3}$
Max clamp force	550 KN
Screw length diameter ratio	20
Max screw speed	$30 s^{- 1}$

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Applied Optics