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Modeling and multiresponse optimization of cutting parameters in SPDT of a rigid contact lens polymer using RSM and desirability function

DOI:10.1007/s00170-018-3169-1 期刊:The International Journal of Advanced Manufacturing Technology 出版年份:2019 更新时间:2025-09-23 15:22:29
摘要: Amidst different conventional contact lens manufacturing techniques, single-point diamond turning (SPDT) is one of the recently developed ultra-high precision machining techniques employed in the fabrication of advanced contact lenses due to its capability of producing high optical surfaces of complex shapes and nanometric accuracy. SPDT is regarded as an effective process for the generation of high-quality functional surfaces in optical industries. However, despite advances in the ultra-high precision machining, it is not always easy to achieve a high-quality surface finish with maximum productivity. Machining parameters, namely cutting speed, feed rate, and depth of cut, play the lead role in determining the machine economics and quality of machining. The present study focuses on the determination of the optimum cutting conditions leading to minimum surface roughness as well as electrostatic charge and maximum productivity, in SPDT of the polymethyl methacrylate (PMMA) contact lens polymer using monocrystalline diamond cutting tool. The optimization is based on the response surface methodology (RSM) together with the desirability function approach. In addition, a mathematical model is developed for surface roughness (Ra), electrostatic charge (ESC), and material removal rate (MRR) using RSM regression analysis for a rigid contact lens polymer by the Design-Expert software. RSM allowed the optimization of the cutting conditions for minimal surface roughness, electrostatic charge, and maximal material removal rate which provides an effective knowledge base for process parameters, to make its enhancement of process performance in SPDT of contact lens polymer.
作者: Muhammad Mukhtar Liman,Khaled Abou-El-Hossein
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To determine the optimum cutting conditions leading to minimum surface roughness and electrostatic charge and maximum productivity in single-point diamond turning of PMMA contact lens polymer.

The study successfully modeled and optimized cutting parameters for SPDT of PMMA contact lens polymer. Cutting speed was the most significant factor for surface roughness, feed rate for material removal rate, and a combination of parameters for electrostatic charge. The optimal conditions (cutting speed = 3712.78 rpm, feed rate = 10.55 mm/min, depth of cut = 36.67 μm) achieved minimal surface roughness (1.699 nm), minimal electrostatic charge (0.009 kV), and maximal material removal rate (23.972 mm3/min) with high desirability (0.997).

The study is limited to PMMA contact lens polymer and specific machining parameters; results may not generalize to other materials or conditions. The models are empirical and based on laboratory experiments, which may not fully capture real-world variability.

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