Kuo-Ming Tsai and He-Yi Wang, "Determination of injection molding process windows for optical lenses using response surface methodology," Appl. Opt. 53, 5264-5274 (2014)
This study focuses on injection molding process window determination for
obtaining optimal imaging optical properties, astigmatism, coma, and spherical
aberration using plastic lenses. The Taguchi experimental method was first used
to identify the optimized combination of parameters and significant factors
affecting the imaging optical properties of the lens. Full factorial experiments
were then implemented based on the significant factors to build the response
surface models. The injection molding process windows for lenses with optimized
optical properties were determined based on the surface models, and confirmation
experiments were performed to verify their validity. The results indicated that
the significant factors affecting the optical properties of lenses are mold
temperature, melt temperature, and cooling time. According to experimental data
for the significant factors, the oblique ovals for different optical properties
on the injection molding process windows based on melt temperature and cooling
time can be obtained using the curve fitting approach. The confirmation
experiments revealed that the average errors for astigmatism, coma, and
spherical aberration are 3.44%, 5.62%, and 5.69%, respectively. The results
indicated that the process windows proposed are highly reliable.
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