Experimental Research And Simulation Analysis On Ultrasonic Vibration-assisted Molding Press For Optical Microstructures

Glass Molding Process(GMP)have created a new era of mass and high efficiency manufacturing of optical glass components because it can fabricate precise optical glass components once time,however,there will be some defects in filling performance,shape precision and molding pressure while molding of components including complex geometry,small size and large number of units,in order to solve the limitations of GMP and provide a support for the selection of GMP parameters,MSC.Marc was used to simulate filling performance and molding pressure of optical components with Vgrooves,then the difference between simulation results of the ultrasonic-assisted glass molding process(UGMP)and GMP was analyzed;the simulation results were verified by using self-developed molding machine.The main contents are as follows:(1)In order to improve the accuracy of optical glass components and reduce the mold pressure,the array model of multiple V-grooves structures was taken as the research object,and the effect of molding depth,speed and temperature on the filling performance and molding pressure were analyzed by MSC.Marc.At the same time,the comprehensive impact of various molding factors on the molding process was discussed,and the influence degree of each factor and the optimal parameters corresponding to different test indexes were obtained.(2)In order to study the effects of ultrasonic vibration on the molding pressure and filling performance,the stress distribution,molding pressure,and filling performance in UGMP and GMP were comparatively analyzed.It was found that the maximum stress of the formed glass was obviously reduced and the stress distribution was effectively homogenized in UGMP.Meanwhile,the maximum molding pressure of glass was 4.05 kN in GMP and only 3.07 kN in UGMP with a decrease of 24.5%.Additionally,the average filling rate of the formed glass was increased from 93.51% in GMP to 96.59% in UGMP.Therefore,the overall formalbility of the glass was enhanced in UGMP.(3)The simulation results of the glass molding process were experimentally verified.It was found that the filling effect of the glass was improved with the increase of molding depth,but the maximum molding pressure was also increased.It was noted that the maximum molding pressure tended to decrease with the increased molding temperature within a certain temperature range.On the other hand,the filling depth was increased,and a better filling performance was achieved.