Table 1
Process Parameters and Levels for the Screening Experiments
Factor Level 1 2 3 A. Melt temperature (
°
C
) 220 230 B. Filling-to-packing switchover point (%) 94 96 98 C. Injection speed (
mm
/
s
) 50 70 90 D. Injection pressure (MPa) 90 100 110 E. Packing pressure (MPa) 110 120 130 F. Packing time (s) 3 4 5 G. Mold temperature (
°
C
) 60 70 80 H. Cooling time (s) 10 15 20
Table 2
Experimental Results for
L
18
(
2
1
×
3
7
)
Screening Experiments based on the Procedure of Design of Experiment
No. A B C D E F G H Wav.(AVG.) Spher.(AVG.) Coma (AVG.) Astig. (AVG.) Illum. (Lux) Wav. (S/N) Spher. (S/N) Coma (S/N) Astig. (S/N) Illum. (S/N) Just Exp. 1 1 1 1 1 1 1 1 1 1.9080
−
0.5348
0.7164 0.8042 186.2056
−
5.6116
5.4362 2.8969 1.8927 45.3999 2 1 1 2 2 2 2 2 2 1.7574
−
0.7345
0.4182 1.1118 186.5864
−
4.8974
2.6802 7.5723
−
0.9205
45.4176 3 1 1 3 3 3 3 3 3 1.9282
−
2.0856
0.8048 1.0830 186.8644
−
5.7030
−
6.3846
1.8862
−
0.6926
45.4305 4 1 2 1 1 2 2 3 3 2.3506 0.4308 2.0220 1.1765 186.5680
−
7.4236
7.3145
−
6.1156
−
1.4118
45.4167 5 1 2 2 2 3 3 1 1 1.7066
−
0.9726
0.6086 0.9942 187.4215
−
4.6426
0.2413 4.3134 0.0505 45.4564 6 1 2 3 3 1 1 2 2 2.4782
−
0.5310
0.8446 1.4392 183.1020
−
7.8827
5.4981 1.4670
−
3.1624
45.2539 7 1 3 1 2 1 3 2 3 2.2422
−
0.5706
0.9484 1.0093 186.6510
−
7.0135
4.8734 0.4602
−
0.0804
45.4206 8 1 3 2 3 2 1 3 1 2.1362
−
3.0400
0.7070 1.2226 184.2870
−
6.5928
−
9.6575
3.0116
−
1.7457
45.3099 9 1 3 3 1 3 2 1 2 1.6716
−
1.0278
0.7386 0.9036 186.7562
−
4.4626
−
0.2382
2.6318 0.8805 45.4255 10 2 1 1 3 3 2 2 1 1.6530
−
1.1862
0.5506 1.3070 186.4251
−
4.3655
−
1.4832
5.1833
−
2.3255
45.4101 11 2 1 2 1 1 3 3 2 2.2452
−
0.1924
0.9816 0.8848 186.7531
−
7.0251
14.3159 0.1613 1.0631 45.4254 12 2 1 3 2 2 1 1 3 1.4832
−
0.9238
0.5708 0.8150 185.0054
−
3.4240
0.6884 4.8703 1.7768 45.3437 13 2 2 1 2 3 1 3 2 2.5912
−
0.2814
2.1508 1.7066 183.6572
−
8.2700
11.0135
−
6.6520
−
4.6426
45.2802 14 2 2 2 3 1 2 1 3 2.0892
−
0.7942
0.6580 1.6944 186.7462
−
6.3996
2.0014 3.6355
−
4.5803
45.4250 15 2 2 3 1 2 3 2 1 2.0380
−
0.6244
0.3866 0.8750 186.9005
−
6.1841
4.0907 8.2548 1.1598 45.4322 16 2 3 1 3 2 3 1 2 1.8274
−
1.3970
0.4786 1.3328 186.6860
−
5.2367
−
2.9039
6.4005
−
2.4953
45.4222 17 2 3 2 1 3 1 2 3 1.4668
−
0.9286
0.3004 0.5230 182.3428
−
3.3274
0.6434 10.4460 5.6300 45.2178 18 2 3 3 2 1 2 3 1 2.6140
−
0.4268
2.3648 1.6926 185.4820
−
8.3461
7.3955
−
7.4759
−
4.5711
45.3660 Six Months Later 1 1 1 1 1 1 1 1 1 2.1614
−
0.8950
0.9874 0.9020
−
6.6950
0.9635 0.1101 0.8959 2 1 1 2 2 2 2 2 2 2.0382
−
0.7336
0.5738 1.1870
−
6.1850
2.6910 4.8250
−
1.4890
3 1 1 3 3 3 3 3 3 2.1788
−
2.1528
0.6710 1.1518
−
6.7640
−
6.6600
3.4660
−
1.2280
4 1 2 1 1 2 2 3 3 2.4586
−
5.0210
1.1182 1.1130
−
7.8140
−
14.0200
−
0.9704
−
0.9299
5 1 2 2 2 3 3 1 1 1.9160
−
1.2666
0.7102 1.2000
−
5.6480
−
2.0530
2.9720
−
1.5840
6 1 2 3 3 1 1 2 2 2.2160
−
0.8516
0.9594 1.3010
−
6.9110
1.3950 0.3600
−
2.2860
7 1 3 1 2 1 3 2 3 2.5216
−
0.8606
1.0596 1.3278
−
8.0340
1.3040
−
0.5028
−
2.4630
8 1 3 2 3 2 1 3 1 1.9926
−
1.5700
0.6078 1.0848
−
5.9880
−
3.9180
4.3250
−
0.7070
9 1 3 3 1 3 2 1 2 1.8840
−
1.4790
0.9654 1.0474
−
5.5020
−
3.3990
0.3059
−
0.4023
10 2 1 1 3 3 2 2 1 2.0754
−
1.6548
0.6414 1.5038
−
6.3420
−
4.3750
3.8570
−
3.5440
11 2 1 2 1 1 3 3 2 2.2954
−
0.1196
2.1946 0.7772
−
7.2170
18.4500
−
6.8270
2.1890 12 2 1 3 2 2 1 1 3 1.8864
−
1.4072
0.8176 1.2576
−
5.5130
−
2.9670
1.7490
−
1.9910
13 2 2 1 2 3 1 3 2 2.5772
−
0.3594
2.1808 1.5364
−
8.2230
8.8880
−
6.7720
−
3.7300
14 2 2 2 3 1 2 1 3 2.1160
−
0.8594
0.7096 1.4602
−
6.5100
1.3160 2.9800
−
3.2880
15 2 2 3 1 2 3 2 1 2.3240
−
0.9738
0.4994 1.3672
−
7.3250
0.2306 6.0310
−
2.7170
16 2 3 1 3 2 3 1 2 2.2230
−
1.4052
0.5808 1.7230
−
6.9390
−
2.9550
4.7190
−
4.7260
17 2 3 2 1 3 1 2 3 2.0190
−
1.2434
0.4120 1.0568
−
6.1030
−
1.8920
7.7020
−
0.4799
18 2 3 3 2 1 2 3 1 2.5060
−
0.2368
2.2904 1.3108
−
7.9800
12.5100
−
7.1980
−
2.3510
Table 3
Analysis of Variance for the Contour Precision of the Lens
Just Experiment Six Months Later Df SS MS F Value Pr(F)
a
Df SS MS F Value Pr(F)
a
A 1 0.1515 - - - A 1 0.3787 0.3787 1.4483 0.3519 B 2 8.0614 - - - B 2 1.1502 0.5751 2.1992 0.3126 C 2 2.1534 - - - C 2 3.4901 1.7451 6.6733 0.1303 D 2 0.6292 - - - D 2 0.3798 0.1899 0.7262 0.5793 E※ 2 11.8855 5.9427 5.8212 0.01566 E 2 2.0522 1.0261 3.9240 0.2031 F 2 0.0618 - - - F 2 0.5317 0.2659 1.0167 0.4959 G※ 2 16.3093 8.1546 7.9879 0.0055 G 2 4.3230 2.1615 8.2659 0.1079 H 2 1.6800 - - - H 2 0.0907 0.0454 0.1734 0.8522 Residuals 2 0.5342 - Residuals 2 0.5230 0.2615 (Residuals) 13 (13.2714) (1.0208) Total 17 12.9195 Total 17 41.4661
a
When Pr(F)
<
0.05
, this indicates that the effect is significant at
α
=
0.05
.
Table 4
Analysis of Variance for the Spherical Aberration of the Lens
Just Experiment Six Months Later Df SS MS F Value Pr(F)
a
Df SS MS F Value Pr(F)
a
A 1 37.5506 - - - A※ 1 155.4796 155.4796 4.9140 0.0437 B 2 75.2357 - - - B 2 12.7105 - - - C 2 20.6478 - - - C 2 51.3379 - - - D※ 2 199.2866 99.6433 5.6629 0.0170 D 2 106.0004 - - - E※ 2 148.3834 74.1917 4.2164 0.0388 E* 2 301.6591 150.8296 4.7670 0.0264 F 2 1.5875 - - - F 2 15.4990 - - - G 2 29.6838 - - - G 2 50.9289 - - - H 2 58.4962 - - - H 2 192.4909 - - - Residuals 2 5.5451 - Residuals 2 13.9982 - (Residuals) 13 (28.7468) (7.5959) (Residuals) 14 (442.9658) (31.6404) Total 17 576.4167 Total 17 900.1044
a
When Pr(F)
<
0.05
, this indicates that the effect is significant at
α
=
0.05
.
Table 5
Analysis of Variance for the Coma of the Lens
Just Experiment Six Months Later Df SS MS F Value Pr (F)
a
Df SS MS F Value Pr (F)
a
A 1 2.4939 - - - A 1 4.1566 4.1566 0.7244 0.4844 B 2 26.3463 - - - B 2 1.8852 0.9426 0.1643 0.8589 C 2 62.3985 - - - C 2 21.4715 10.7357 1.8709 0.3483 D 2 32.427 - - - D 2 50.6885 25.3443 4.4167 0.1846 E 2 46.556 - - - E 2 89.0718 44.5359 7.7612 0.1141 F 2 22.1965 - - - F 2 3.1052 1.5526 0.2706 0.7870 G※ 2 223.7803 111.8902 8.4087 0.0036 G 2 117.8838 58.9419 10.2718 0.0887 H 2 1.9536 - - - H 2 28.7721 14.3860 2.5070 0.2851 Residuals 2 5.2259 - Residuals 2 11.4765 5.7382 (Residuals) 15 (199.5976) (13.3065) Total 17 328.5112 Total 17 423.3780
a
When Pr(F)
<
0.05
, this indicates that the effect is significant at
α
=
0.05
.
Table 6
Analysis of Variance for the Astigmatism of the Lens
Just Experiment Six Months Later Df SS MS F Value Pr (F)
a
Df SS MS F Value Pr (F)
a
A 1 0.8003 - - - A 1 6.0605 - - - B 2 16.2928 - - - B 2 7.4945 - - - C 2 6.1095 - - - C 2 7.0806 - - - D※ 2 52.2215 26.1108 5.6158 0.0151 D※ 2 19.8977 9.9488 5.2065 0.0192 E 2 6.0906 - - - E 2 2.4222 - - - F 2 16.8715 - - - F 2 1.1605 - - - G 2 13.8764 - - - G 2 3.3935 - - - H 2 8.3645 - - - H 2 0.0186 - - - Residuals 2 1.3370 - Residuals 2 1.0324 - (Residuals) 15 (69.7426) (4.6495) (Residuals) 15 (28.6629) (1.9108) Total 17 121.9641 Total 17 48.5606
a
When Pr(F)
<
0.05
, this indicates that the effect is significant at
α
=
0.05
.
Table 7
Analysis of Variance for the Illuminance of the Lens
Df SS MS F Value Pr (F)
a
A 1 0.0024 - - - B 2 0.0060 - - - C 2 0.0011 - - - D 2 0.0004 - - - E 2 0.0012 - - - F※ 2 0.0587 0.0294 17.8859 0.0001 G 2 0.0093 - - - H 2 0.0021 - - - Residual 2 0.0021 - (Residuals) 15 (0.0246) (0.0016) Total 17 0.0833
a
When Pr(F)
<
0.05
, this indicates that the effect is significant at
α
=
0.05
.
Table 8
Result of Contour Precision and Optical Properties of the Lens in the Confirmation Experiments
Contour Prec. Spherical Ab. Coma Astigm. Illum. Opt. factors
A
2
B
1
C
2
D
1
E
3
F
1
G
1
H
3
A
2
B
2
C
1
D
1
E
1
F
2
G
3
H
2
A
2
B
1
C
2
D
3
E
2
F
3
G
2
H
1
A
1
B
1
C
2
D
1
E
3
F
1
G
2
H
3
A
1
B
1
C
1
D
1
E
2
F
3
G
1
H
1
Pred.
1.6139
μ
m
0.3421
μ
m
0.5270
μ
m
0.8379
μ
m
186.88 Lux S/N
−
4.1576
±
1.5092
(
dB
)
(
−
5.6668
∼
−
2.6484
)
9.3179
±
4.1168
(
dB
)
(
5.2011
∼
13.4347
)
5.5639
±
4.7065
(
dB
)
(
0.8574
∼
10.2704
)
1.5357
±
2.7821
(
dB
)
(
−
1.2464
∼
4.3178
)
45.4312
±
0.0516
(
dB
)
(
45.3796
∼
45.4828
)
Exp. 1.488, 1.464, 1.506, 1.447, 1.439 0.278, 0.313, 0.333, 0.358, 0.345 0.632, 0.569, 0.663, 0.688, 0.582 0.873, 0.914, 0.827, 0.944, 1.114 186.235, 186.769, 187.135, 186.683, 187.565 S/N
−
3.452
,
−
3.311
,
−
3.557
,
−
3.209
,
−
3.161
11.119, 10.089, 9.551, 8.922, 9.244 3.986, 4.898, 3.570, 3.248, 4.702 1.180, 0.781, 1.650, 0.501,
−
0.938
45.401, 45.426, 45.443, 45.422, 45.463
Summary of Significant and Optimized Processing Factors Property of Lens Just Experiment Six Months Later Contour precision Sequential significant factors mold temperature, packing pressure without factor Optimized processing factors
A
2
B
1
C
2
D
1
E
3
F
1
G
1
H
3
A
1
B
1
C
2
D
3
E
3
F
1
G
1
H
1
Spherical aberration Sequential significant factors injection pressure, packing pressure melt temperature, packing pressure Optimized processing factors
A
2
B
2
C
1
D
1
E
1
F
2
G
3
H
2
A
2
B
1
C
2
D
2
E
1
F
3
G
3
H
2
Coma Sequential significant factors mold temperature without factor Optimized processing factors
A
2
B
1
C
2
D
3
E
2
F
3
G
2
H
1
A
1
B
3
C
2
D
3
E
2
F
3
G
2
H
3
Astigmatism Sequential significant factors injection pressure injection pressure Optimized processing factors
A
1
B
1
C
2
D
1
E
3
F
1
G
2
H
3
A
1
B
1
C
2
D
1
E
1
F
1
G
3
H
1
Illuminance Sequential significant factors packing time - Optimized processing factors
A
1
B
1
C
1
D
1
E
3
F
3
G
1
H
1
-