A laser dragging process to ablate a groove pattern and more
sophisticated 3D features on a polycarbonate (PC) sheet through a
shape of mask opening is analyzed. To predict the machined profile
during the dragging process, a mathematical model describing the
relationship between laser machining parameters and the produced
profile is developed. The proposed model is verified
experimentally. This study depicts the results of the experiment
and numerical simulation in both single and cross dragging using
elliptic, triangular and rectangular masks. The operating
parameters include the dragging velocity, pulse repetition rate,
pulse number, fluence and the opening dimension of the mask
pattern. A good agreement between the experiment and simulation
with deviation less than 14% is demonstrated. Based on the proposed
model, miniature lamp lens can be manufactured by varying laser
operating parameters, mask shape and dimensions. Further, the
advantage of the micro-size lamp lens on light efficiency is
explored. The results illustrate the optical systems with the
micro-feature lamp lens can offer better optical performance than
those with macro-feature lamp lens.
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