Optimization of injection molding process parameters and axial surface compensation for producing an aspheric plastic lens with large diameter and center thickness

Xirui Lan; Chuang Li; Chao Yang; Changxi Xue

doi:10.1364/AO.58.000927

Applied Optics
Vol. 58,
Issue 4,
pp. 927-934
(2019)
•https://doi.org/10.1364/AO.58.000927

Optimization of injection molding process parameters and axial surface compensation for producing an aspheric plastic lens with large diameter and center thickness

Xirui Lan, Chuang Li, Chao Yang, and Changxi Xue

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Xirui Lan, Chuang Li, Chao Yang, and Changxi Xue, "Optimization of injection molding process parameters and axial surface compensation for producing an aspheric plastic lens with large diameter and center thickness," Appl. Opt. 58, 927-934 (2019)

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Abstract

Form accuracy is an important parameter to measure whether a plastic lens can be used in imaging optics. Form accuracy exhibited by an aspheric plastic lens produced by injection molding is affected by process parameters and mold core. This paper proposes to optimize the process parameters through two stages. Stage one: An initial selection of process parameters was conducted in a wide range of the Taguchi method, and the process parameters were determined based on the signal-to-noise ratio, which significantly affected the axial deformation. Then the initial process parameters were obtained. Stage two: The regression model of process parameters was established according to the response surface methodology, with the optimal process parameters finally determined. For reducing the form accuracy error of aspheric plastic lens caused by material shrinkage and machining error of the mold core, an axial deformation compensation model was established. The aspheric plastic lens with form accuracy of 1.013 μm was experimentally verified, which met the requirements of imaging optics.

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Control Factor	Level 1	Level 2	Level 3
A. Melt temperature (°C)	235	240	245
B. Injection speed (mm/s)	2	3	4
C. Packing pressure I (Mpa)	120	135	150
D. Packing pressure II (Mpa)	70	75	80
E. Packing time I (s)	15	20	25
F. Packing time II (s)	8	10	12
G. Mold temperature (°C)	80	85	90
H. Cooling time (s)	70	80	90

Control Factor	Level 1	Level 2	Level 3
A. Melt temperature (°C)	245
B. Injection speed (mm/s)	1.3	2	2.7
C. Packing pressure I (Mpa)	145	150	155
D. Packing pressure II (Mpa)	75
E. Packing time I (s)	17	20	23
F. Packing time II (s)	12
G. Mold temperature (°C)	87	90	93
H. Cooling time (s)	90

Control Factor									Form Accuracy
Run	A	B	C	D	E	F	G	H	P-V Valve	S/N Ratio
1	245	4	150	80	25	12	90	90	2.8	−8.9432
2	245	4	150	80	20	10	85	80	3.3	−10.3703
3	245	4	150	80	15	8	80	70	9.9	−19.9127
4	245	3	135	75	25	12	90	80	3.2	−10.1030
5	245	3	135	75	20	10	85	70	3.7	−11.3640
6	245	3	135	75	15	8	80	90	4.3	−12.6694
7	245	2	120	70	25	12	90	70	4.0	−12.0412
8	245	2	120	70	20	10	85	90	3.9	−11.8213
9	245	2	120	70	15	8	80	80	3.9	−11.8213
10	240	4	135	70	25	10	80	90	7.6	−17.6163
11	240	4	135	70	20	8	90	80	3.0	−9.5424
12	240	4	135	70	15	12	85	70	4.1	−12.2557
13	240	3	120	80	25	10	80	80	8.3	−18.3816
14	240	3	120	80	20	8	90	70	3.9	−11.8213
15	240	3	120	80	15	12	85	90	3.1	−9.8272
16	240	2	150	75	25	10	80	70	5.2	−14.3201
17	240	2	150	75	20	8	90	90	1.5	−3.5218
18	240	2	150	75	15	12	85	80	3.0	−9.5424
19	235	4	120	75	25	8	85	90	6.8	−16.6502
20	235	4	120	75	20	12	80	80	6.9	−16.7770
21	235	4	120	75	15	10	90	70	3.8	−11.5957
22	235	3	150	70	25	8	85	80	4.1	−12.2557
23	235	3	150	70	20	12	80	70	4.4	−12.8691
24	235	3	150	70	15	10	90	90	2.9	−9.2480
25	235	2	135	80	25	8	85	70	4.1	−12.2557
26	235	2	135	80	20	12	80	90	4.2	−12.4650
27	235	2	135	80	15	10	90	80	2.8	−8.9432

Factors	SS	DF	MS	F
A	4.689	2	2.3444	1.04
B	26.895	2	13.4477	5.98
C	34.002	2	17.0011	7.56
D	0.476	2	0.2381	0.11
E	35.394	2	17.6971	7.87
F	5.374	2	2.6872	1.20
G	118.644	2	59.3218	26.39
H	6.400	2	3.2002	1.42
Residuals	22.479	10	2.2479
Total	254.355	26

Run	B	C	E	G	P-V Value
1	2.0	150	20	84	−3.531
2	2.7	155	23	87	−2.632
3	1.3	155	17	87	−4.716
4	1.3	155	23	87	−3.121
5	1.3	145	23	87	−2.911
6	1.3	145	17	87	−5.421
7	2.7	145	23	87	−2.315
8	2.7	145	17	87	−5.841
9	2.7	155	17	87	−6.001
10	2.0	150	26	90	−3.105
11	2.0	150	20	90	−5.504
12	0.6	150	20	90	−4.329
13	2.0	140	20	90	−5.121
14	2.0	150	20	90	−5.508
15	2.0	150	20	90	−5.524
16	2.0	150	20	90	−5.503
17	3.4	150	20	90	−4.132
18	2.0	150	20	90	−5.512
19	2.0	150	14	90	−5.516
20	2.0	150	20	90	−5.515
21	2.0	150	20	90	−5.536
22	2.0	160	20	90	−6.410
23	1.3	145	17	93	−4.903
24	1.3	155	23	93	−6.800
25	2.7	145	17	93	−4.232
26	1.3	155	17	93	−5.825
27	2.7	155	17	93	−5.531
28	1.3	145	23	93	−5.202
29	2.7	145	23	93	−4.230
30	2.7	155	23	93	−5.631
31	2.0	150	20	96	−5.303

Coefficient	$β_{0}$	$β_{1}$	$β_{2}$	$β_{3}$	$β_{4}$	$β_{5}$	$β_{6}$	$β_{7}$
P-V value	−235.6	−11.79	2.8781779	7.52242	−0.851	0.6548	−0.0026703	0.03289
	$β_{8}$	$β_{9}$	$β_{10}$	$β_{11}$	$β_{12}$	$β_{13}$	$β_{14}$	$R^{2}$
	0.030097	−0.0214175	0.1190	0.1131	−0.00751	−0.02167	−0.08611	0.9873

InSpeed (mm/s)	PaPress A (Mpa)	PaTime A (s)	MoTemp (°C)	Predicted Value (μm)	Confidence Interval (95%)	Actual Value (μm)
3.2	147	25.7	85.3	1.933	(1.292, 2.574)	2.109
0.78	153	25.7	84.6	1.967	(1.266, 2.669)	2.217
3.3	144	25.7	85.7	1.900	(1.176, 2.621)	2.304

	Design
R	73.14
K	$- 2.44366 E + 1$
$A_{4}$	$2.192726720393 E - 6$
$A_{6}$	$3.42476259951 E - 9$
Aperture (mm)	37

Abstract

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Equations (5)

Applied Optics