光學塑膠鏡片使用射出成型製程製造出高精度的鏡片，其幾何形狀控制必須非常精確，翹曲量必須要控制在要求的公差內，避免在鏡頭組裝過程中，因鏡片翹曲過大而導致零件配合不良的問題。在業界常以成型參數設計進行對產品良率改善，主要是設定產品或製程參數的因子水準，使其對雜訊變數的敏感性變小。大多數工程師應用田口方法來優化參數設計，但是田口方法只能獲得離散的最優解，當參數值連續時，無法求得真正的最佳值。本研究目的在於找出光學鏡片模流分析製程參數設計最佳化，因此結合田口法與反應曲面法，以Moldex3D進行模流分析，利用田口方法減少實驗次數及達到離散的最優解，再運用反應曲面法優化參數設計，最後，探討製程參數對鏡片翹曲量的影響。本研究結果將可提供給工程師一套產品製程參數設計的最佳化流程。;Optical plastic lenses employed an injection molding process to produce high-precision lenses with precise geometry control. The warpage must be controlled within the required tolerance to avoid the problem of poor-fitting of the parts due to excessive lenses warpage during lenses assembled. In the industry, the improvement of product yield is often carried out by parameter design. Parameter design is critical to enhancement of a system’s robustness by identifying specific control factors and their levels that make the system less sensitive to noise. Most engineers employ Taguchi methods to optimize parameter design. However, Taguchi method can only obtain the discrete optimal solution, and can’t identify the real optimum when the parameter values are continuous. The purpose of this study is to optimize the design of the mold flow process parameters on optical lenses. We combined Taguchi method and response surface method for parameter optimization, and employ Moldex3D software for mold flow analysis. Taguchi method can reduce the number of experiments and obtain the discrete optimal solution, and response surface method for parameter optimization Finally, we discuss the impact of process parameters on lenses warpage. The results of this study can provide a process optimization on product parameter design to engineers.
