Week 3 Challenge

ABOUT LENS

• Lens is an optical material that controls the light emitted from a light source and allows it to distribute in a certain angle and density.
• Lenses provide precision control over light angle.
• Lenses can be made of plastic, silicon or glass material in various shapes and sizes.

MATERIAL USED FOR LENS LIGHTING

polycarbonates

WHY PC(polycarbonates)

• COST EFFECTIVE
• LOW MELTING POINT
• HIGH IMPACT STRENGTH
• GOOD SURFACE FINISH
• TRANSPARENT

COMPARISION OF MATERIAL TO CHOOSE FOR LIGHTING LENS

Polycarbonate vs ABS
Polycarbonate is an amorphous polymer made by melt polycondensation of bisphenol A and diphenyl carbonate.	ABS is a thermoplastic resins made by blending three types of monomers: acrylonitrile, butadiene, and styrene.
Properties
Polycarbonate has excellent creep resistance, very good dimensional stability, good electrical characteristics, self-extinguishing properties, excellent impact, and flexural properties.	ABS has impact resistance, good processability, good mechanical properties, high heat distortion temperature, and gloss property.
Applications
Polycarbonate is used for the manufacture of lenses, windshields, containers, light fittings, compact discs (CD), pump impellers, helmets, small, appliances and trays.	ABS is used for the manufacture of piping and fittings, instrument and appliance housings, components of office automation equipment, inner door cabinets of refrigerators, bathtubs, and door covers.
Hardness and Flexibility
Polycarbonate is extremely hard, brittle and not flexible.	ABS is hard and flexible due to rubbery part.
Processability
Polycarbonates require high temperatures to process, so their processability is low.	ABS has good processability.

MANUFACTURING MACHING FOR LENS LIGHT

INJECTION MOLDING MACHINE

TOOLING AXIS

• The direction in which the mold or core and cavity opens is the tooling axis.

CLASS A SURFACE

• Class-A (or 'Strak') is a term used in specifically in automotive design.
• It describes the final production surface data for the aesthetic parts of the car.
• The term 'Class A' is often misunderstood, but it's generally seen as the 'Holy Grail' of surface modeling.
• Class A surface is used to show to the customer visulization,and it is a aesthetic surface.

CLASS B SURFACE

• The Class B finish is a quality finish with only minimal imperfections.
• A Class B finish is the most common finish for exterior surfaces.
• It is normally specified on surfaces such as external covers, panels, and parts that are fairly prominent.
• It is a offset surface of A,Which the surface were can not able to see Over the customer.

CLASS C SURFACE

• The Class C finish allows more imperfections than Class A or B.
• Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled, or surfaces which the Customer feels do not need to meet a high cosmetic finish.

DRAFT ANALYSIS

• The draft analysis technique is used to analyze whether our part model created in CAD is manufacturable based on the draft condition applied.
• Here the part should get easily removed from the panel dies .

DRAFT ANALYSIS OF CLASS A LENS

DRAFT ANALYSIS OF FINAL COMPONENT OF LENS