Organizing Engineering

Research Papers (46)

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The fluid jet polishing (FJP) method originated from
the demand for miniaturized optical elements in recent years and
the inability of the conventional polishing method can not satisfy
the fabrication requirements of those elements. The FJP method
facilitates the removal of nanometer deep material, subsequently
correcting errors in the optical elements.
However, the FJP method fails to comply with the
requirement of a higher pressure, i.e. >6 bar, to pump the slurry
in order to remove the material of elements. Additionally, the
shape that the FJP produces on the surface is not the Gaussian
distribution, thus making it extremely difficult to more accurately
control form correction.
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For instance, the FJP method has
difficult in satisfying the requirement of form error
/10 for small optical elements.
The inability to optimize the
design of an optical system owing to limitations of
the FJP method makes it impossible to achieve
high precision in product manufacturing.
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Based on the above, we should develop a
modified FJP method to ensure not only that the shape is
close to Gaussian distribution with a low pressure air source,
but also that the resolution of material removal should be
small and stable.
To do so, slurry can be carried with low air
pressure, based on use of siphonic and laminar flow theories.
The Gaussian shape can then be achieved by using a nozzle
different from the conventional one, in which both air and
slurry can pass through simultaneously. Next, fine resolution
of material removal can be obtained by optimization of the
slurry concentration and air pressure.
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As anticipated, the modified FJP
method can produce stable material removal less
then 50 nm deep by using 1~2 bar air pressure
source and the new nozzle. Via the modified FJP
method, small optical elements can be fabricated
using accurate material removal.
Moreover, the enhanced capability of
material removal can fabricate precise optical
elements, ultimately improving the performance of
an optical system.
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Extensively adopted in the opto-electronics industry
for producing polymer optical elements such as condenser lens,
light pipe, lens array, and Fresnel lens for mobile devices,
injection molding technology varies the temperature and
pressure in a polymer-based mold to reduce the number of
shrinkage defects in products.
The conventional means of optimizing process
parameters is inaccurate owing to its reliance on the subjective
experience of an operator to eliminate shrinkage defects in
products. Shrinkage can vary based on the polymer material,
geometrical configuration of the part, subsequently explaining
the complexity of the shrinkage phenomenon and the difficulty in
eliminating shrinkage faults.
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For instance, the conventional approach fails to
reduce shrinkage defects in products to less than 2%. Injection molding
is an extensively adopted polymer process in which molten polymer
flows into a closed chamber for solidification. The final dimensions and
geometrical configuration of the product is of priority concern in terms
of manufacturing quality. Shrinkage refers to the deviation between the
dimension of the cavity and final part. Therefore, as minimization of the
shrinkage is anticipated, an operator can increase the holding pressure
and mold temperature to eliminate shrinkage faults during the injection
molding process. However the operator can not determine the
appropriate values of process parameters immediately.
Moreover, in addition to lacking a pre-compensated
mold cavity, the conventional injection molding process also
manufactures the mold first, making a high yield rate for products
impossible and ultimately increasing fabrication costs. The inability to
reduce shrinkage defects in products to less than 2% makes it
impossible to comply with assembly specifications and increases
overhead manufacturing costs.

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Based on the above, we should develop an injection
molding method that can accurately estimate shrinkage defects
during product manufacturing by estimating the shrinkage rate of
a product part and pre-compensation of the mold cavity via
simulation, ultimately reducing shrinkage defects in products and
streamlining the manufacturing process.
To do so, shrinkage of wafer products can be
reduced based on mold shrinkage compensation. The shrinkage
compensation rates for various materials can then be
determined via computer-aided engineering (CAE) simulation.
Next, compensation dimensions of shrinkage and injection
molding process parameters can be optimized by performing
CAE simulations repeatedly. Additionally, design can be
simplified and manufacturing time significantly lowered by using
those compensation rates, which are stored in a database made
available for engineers.
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As anticipated, the proposed injection
molding method can streamline product design by
decreasing the shrinkage rate of defective
products to less than 2%.
Importantly, the proposed method can
ensure pre-compensation of the mold part,
ultimately ensuring high precision in the
manufacturing of exterior injection mold parts.
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