Abstract
The Taguchi robust design method is used to examine the effects of the processing conditions on the birefringence properties of a Fresnel lens fabricated using a plastic injection molding technique. The Computer Aided Engineering (CAE) simulation results show that the residual stress within the lens is determined (in descending order of influence) by the melt temperature, the filling time, the packing time and the mold temperature. In addition, it is shown that given an appropriate setting of the processing parameters, the average residual stress can be reduced by 75.1%; resulting in a reduction of 74.7% in the average birefringence. In general, the results presented in this study confirm the effectiveness of the integrated Taguchi/CAE approach in optimizing the performance of plastic Fresnel lenses for a variety of focusing applications.
Similar content being viewed by others
References
Aben H, Guillermet C (1993) Photoelasticity of Glass. Springer-Verlag, Berlin
Chen Y, Yi AY, Su L, Klocke F, Pongs G (2008) Numerical simulation and experimental study of residual stresses in compression molding of precision glass optical components. J Manufact Sci Eng 130(5):051012
Cosby RM (1977) The linear Fresnel lens solar concentrator: transverse tracking error effects. NASA CR-2889 National Aeronautics and Space Administration Washington. p 20546
Crawford RJ (1985) Plastics engineering. Pergamon, Oxford
Kumara V, Shrivastavaa RL, Untawaleb SP (2015) Fresnel lens A promising alternative of reflectors in concentrated. Renew Sus Energy Rev 44:376–390
Leutz R, Suzuki A (2001) Nonimaging Fresnel Lenses: Design and Performance of Solar Concentrators. Springer, NewYork
Lu X, Khim LS (2001) A statistical experimental study of the injection molding of optical lenses. J Mater Process Technol 113:189
Peace GS (1993) Taguchi methods. Addison-Wesley Publishing Company, Taipei
Rao RS, Prakasham RS, Prasad KK, Rajesham S, Sarma PN, Rao LV (2004) Xylitol production by Candida sp.: parameter optimization using Taguchi approach. Process Biochem 39:951
Rao RS, Kumar CG, Prakasham RS, Hobbs PJ (2008) The Taguchi methodology as a statistical tool for biotechnological applications: a critical appraisal. J Biotechnol 3:510
Rosa JL, Robin A, Silva MB, Baldan CA, Peres MP (2009) Electro deposition of copper on titanium wires: taguchi experimental design approach. J Mater Process Technol 209:1181
Rosato DV (1986) Injection Moulding Handbook. Van Nostrand Reinhold, New York
Wang W, Aichmayer L, Laumert B, Fransson T (2014) Design and validation of a low-cost high-flux solar simulator using Fresnel lens concentrators. Energy Procedia 49:2221–2230
Yeha Naichia, Yeh Pulin (2016) Analysis of point-focused, non-imaging Fresnel lenses’ concentration profile and manufacture parameters. Renew Energy 85:514–523
Acknowledgements
The authors gratefully acknowledge the financial support provided to this study by the Ministry of Science and Technology (MOST), ROC, under Grant Numbers 103-2815-C-415-005-E and 105-2221-E-415-004-. The technical support provided by Core Tech System Co., Ltd in performing the Moldex3D mold flow simulations is also much appreciated.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Lin, CM., Hsieh, HK. Processing optimization of Fresnel lenses manufacturing in the injection molding considering birefringence effect. Microsyst Technol 23, 5689–5695 (2017). https://doi.org/10.1007/s00542-017-3375-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00542-017-3375-z