Writing Problem and Hypothesis

Statements for Engineering Research(46)

/

http://www.chineseowl.idv.tw


Setting of work proposal :
? ?
Work problem :
?
Quantitative specification of problem :

?
Importance of problem :
,
?
Project need : ,
?

Work objective : ?
Methodology to achieve objective
: ?
Anticipated results :
?
Contribution to field :
?
()
The 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. 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.
Therefore, a modified FJP method must be developed 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.
()
A modified FJP method can be developed 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.
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.
()
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.
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. Therefore, an
injection molding method must be developed 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.
()
An injection molding method can be developed 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. 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.
Further details can be found at
http://www.chineseowl.idv.tw