Study Of Injection Molding Process For Aspherical Components In Look-around Monitoring System

As people's needs continue to increase for the field of view of the surveillance system,the panoramic monitoring system is applied in various fields because of its large field of view.The surround vision monitoring system based on the principle of catadioptric imaging has the advantages of small size,good real-time performance and easy integration of portable,It has become a research hotspot in China and abroad in recent years.The large curvature aspheric reflection mirror is the key component for the system to achieve lightweight and look-around effects.An aspherical component was developed in this paper in order to meet the requirements of the use of the look-around monitoring system and achieve mass production.Before the actual injection molding,the molding process was simulated by the mold flow analysis software in order to improve the production efficiency of the aspherical components with large curvature and reduce the blind injection molding experimental consumables.Firstly,by studying the principle of injection molding technology,the mechanism of process parameters and the characteristics of optical plastic materials,the characteristics and technical indexes of aspherical components were analyzed,and the initial molding scheme and molding materials of aspherical components were determined;Based on the mathematical model in the injection molding process,the Moldflow mold flow analysis software was used to simulate the injection molding process of the aspherical component;The orthogonal experimental method was used to optimize the forming process plan,and the influence trend and importance of each forming process parameter on the optimization index were studied based on the optimization result of the range analysis method.Secondly,the optimization results of orthogonal experiments could not meet the technical requirements of aspheric components,and the three process parameters with greater influence degree were selected based on the results of range analysis.By establishing a response model between injection molding process parameters and optimization indexes and using statistical indicators to evaluate the model prediction ability,the variation rules of optimization indicators when two parameters are combined and the interaction between processes were analyzed.Based on the response model combined with multi-objective genetic algorithm,the injection molding process scheme was iteratively optimized.The aspheric component optimization indicators before and after optimization were compared and analyzed based on the simulation results,and the effectiveness of the optimization scheme was evaluated.Finally,based on the simulation optimization scheme,the actual injection molding experiment was carried out,and the error between simulation and experiment is analyzed.The aspherical components satisfying the technical requirements were developed and the validity and feasibility of the simulation optimization results are verified.By studying the characteristics of the reflective material in the visible band,the coating system of the high-reflection film on the surface of the aspherical surface was designed,the aspherical reflection mirror was prepared and the preparation process was improved according to the reflection effect,and the aspherical reflection mirror was applied to the look-around monitoring system.The PV value of the aspherical element developed in this paper reaches 1.8376?m,and the average reflectivity of the front surface high reflection film at 420~650nm reached 97.63%.When the aspherical reflection mirror was applied to the look-around monitoring system,the system had clear imaging and good look-around effect and realized the real-time and portability requirements of the system.