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研究生:顏伯諭
研究生(外文):Yen, Po-Yu
論文名稱:光學塑膠元件射出成型製程模流分析之多目標加工參數優化設計與驗證
論文名稱(外文):Multi-objective Processing Parameter Optimization Design and Verification of Plastic Optical Injection Molding using Mold Flow Analysis
指導教授:林肇民
指導教授(外文):Lin, Chao-Ming
口試委員:林肇民吳佳璟譚仲明
口試委員(外文):Lin, Chao-MingWu, Chia-ChinTan, Chung-Ming
口試日期:2023-07-24
學位類別:碩士
校院名稱:國立嘉義大學
系所名稱:機械與能源工程學系
學門:工程學門
學類:機械工程學類
論文種類:學術論文
論文出版年:2023
畢業學年度:111
語文別:中文
論文頁數:58
中文關鍵詞:塑膠光學像點圖畸變調製轉換函數灰色關聯分析多目標穩健品質法Alvarez 透鏡
外文關鍵詞:Plastic OpticsSpot DiagramDistortionMTFGRARMCOAlvarez Lens
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塑膠光學元件隨著消費性電子產品的蓬勃發展,其輕量化及批量生產的特性加強塑膠光學的進程。其中,數值模擬於模流分析與光學系統皆占據元件製造相當重要的地位,透過數值模擬能夠有效降低生產成本並節省能源。然而,先前對於塑膠光學元件射出製程之數值模擬研究,僅限於模流分析軟體取得幾何變形以及材料變異,無法確切描述光學性質的改善,需要透過高成本的實際光學實驗重複驗證。本研究完善塑膠射出製程模擬軟體與光學分析軟體間的轉換問題,以光學軟體的結果判讀,包括:像點圖(Spot Diagram)、畸變(Distortion)與調製轉換函數(Modulation Transfer Function, MTF),並使用灰色關聯分析(Grey Relational Analysis, GRA)與多目標穩健品質法(Robust Multi-Criteria Optimization, RMCO),對 Alvarez 透鏡的射出成型製程參數最佳化分析。結果顯示,GRA優化組平均改善所有目標的均方偏差 20.547%;RMCO 最佳組平均改善所有目標均方偏差55.182%。應用本研究提出製造端至光學驗證端的數值分析方法,可以跨越幾何變形與材料變異影響光學性質的黑箱效應,模擬製造誘發的元件缺陷,並使用光學軟體對此元件判讀光學性能,使製造後的光學塑膠元件獲得更精準的評價函數。
Due to the rapid development of consumer electronic products, significant progress has been made in terms of the lightweight nature and suitability for mass production of plastic optical components. This progress has been facilitated by the utilization of numerical simulation in mold flow analysis and optical system analysis, resulting in cost reduction and energy savings. However, previous numerical simulation studies on the injection process of plastic optical components have been limited to the capturing of geometric deformations and material variations using mold flow analysis software. As a result, accurate description of improvements in optical properties has not been achieved, necessitating costly optical experiments for validation. In this study, the transition barrier between plastic injection process simulation software and optical analysis software has been successfully addressed. The results obtained from optical software, including spot diagram, distortion, and modulation transfer function (MTF), have been interpreted. Furthermore, grey relational analysis (GRA) and robust multi-criteria optimization (RMCO) have been employed to optimize the injection molding process parameters for Alvarez lens. The results indicate that GRA optimization led to an average improvement of 20.547% in mean square deviation for all objectives, while the optimization group from RMCO achieved an average improvement of 55.182% in mean square deviation for all objectives. Through the utilization of the innovative result interpretation method proposed in this study, overcoming the 'black box' effect becomes possible. This effect stems from the influence of geometric deformations and material variations on optical properties, leading to the potential for developing more precise evaluation functions for optical plastic components.
摘要 I
Abstract II
誌謝 III
目錄 IV
圖目錄 VI
表目錄 VII
第一章 緒論 1
第二章 研究方法 3
一、最佳化方法 5
(一) 田口試驗方法 5
(二) 灰色關聯分析 7
(三) 多目標穩健優化法 7
二、離散點數據回歸 8
(一) 多項式回歸與多元回歸 9
(二) 類神經網路擬合 10
第三章 理論分析 12
一、射出製程 12
(一) 翹曲變形 13
(二) 折射率 14
(三) 製程因子 14
二、模流分析 15
(一) 牛頓流體 15
(二) 廣義牛頓流體 16
(三) 模型簡化 17
三、光學結果判讀 18
(一) 像點圖(Spot Diagram) 19
(二) 畸變(Distortion) 19
(三) 調製轉換函數(Modulation Transfer Function, MTF) 20
四、光與應力關係 22
(一) 晶體雙折射 22
(二) 殘留雙折射 23
(三) 應力光學定律 23
第四章 結果與討論 24
一、環境變數 24
二、光學判讀嘗試過程 24
(一) 變形的幾何元件光學分析前處理 24
(二) 近軸折射率變異 24
(三) 全域折射率場多元回歸 25
三、研究模型 25
四、權重與增幅的計算 27
五、誤差分析 27
(一) 模流分析之模型網格尺寸收斂性分析 28
(二) 折射率多項式回歸 28
(三) 變形網格擬合曲面收斂性分析 28
六、因子篩選試驗 30
七、多目標優化 34
(一) 灰色關聯分析多目標最佳化 35
(二) Robust Multi-Criteria Optimization 38
(三) GRA與RMCO的差異 44
第五章 結論與未來展望 45
一、結論 45
二、未來展望 45
附錄 46
References 55
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