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Study of the Glass Press Molding Process Study of the glass press molding process Diplomová práce Studijní program: N2301 – Mechanical Engineering Studijní obor: 2302T010 – Machines and Equipment Design Autor práce: Selma Kunosic Vedoucí práce: doc. Ing. Tomáš Vít, Ph.D. Liberec 2016 Study of the glass press molding process Diploma thesis Study programme: N2301 – Mechanical Engineering Study branch: 2302T010 – Machines and Equipment Design Author: Selma Kunosic Supervisor: doc. Ing. Tomáš Vít, Ph.D. Liberec 2016 TABLE OF CONTENTS 1. Introduction ..................................................................................................................................... 8 1.1. Glass versus plastics as lens materials .................................................................................... 9 1.2. Advantages and benefits ......................................................................................................... 9 2. Research objectives ....................................................................................................................... 11 3. Literature overview ....................................................................................................................... 12 4. About the process ......................................................................................................................... 14 4.1. Heating cycle ......................................................................................................................... 15 4.2. Soaking cycle ......................................................................................................................... 15 4.3. Pressing cycle......................................................................................................................... 15 4.4. Gradual cooling cycle............................................................................................................. 16 4.5. Rapid cooling cycle ................................................................................................................ 16 5. Fundamental of glass rheology ..................................................................................................... 17 5.1. Glass terminology .................................................................................................................. 17 5.2. Glass transition temperature and its significance ................................................................. 17 5.3. Viscoelasticity ........................................................................................................................ 19 5.4. Stress relaxation and creep ................................................................................................... 21 5.5. Structural relaxation .............................................................................................................. 23 5.6. Linearity and thermorheological simplicity ........................................................................... 26 6. Lens molding experiments ............................................................................................................ 28 6.1. Material of glass .................................................................................................................... 29 6.2. Molds and ring ....................................................................................................................... 31 6.3. Inserts .................................................................................................................................... 32 6.4. Experiment ............................................................................................................................ 33 6.5. Light white interferometry .................................................................................................... 36 7. Numerical simulation .................................................................................................................... 39 7.1. Inputs ..................................................................................................................................... 40 7.1.1. Materials ........................................................................................................................ 40 7.1.2. Boundary conditions...................................................................................................... 42 7.2. Cycles in simulation ............................................................................................................... 45 7.3. Results ................................................................................................................................... 47 7.4. Numerical simulation of molding of aspheric lens ................................................................ 50 7.4.1. Aspheric geometry ........................................................................................................ 50 7.4.2. Materials ........................................................................................................................ 51 7.4.3. Results ........................................................................................................................... 53 8. Conclusion and future work .......................................................................................................... 55 9. Literature ....................................................................................................................................... 56 1 LIST OF FIGURES Figure 4.1 Placing of raw glass gob/ blank material on the lower mold, (b) Heating of the glass and mold assembly to the molding temperature, (c) Pressing (molding) of the glass material between the mold halves and (d) Forced cooling of the lens and mold assembly to near room temperature and lens release ............................................................................................................................................ 14 Figure 5.1 Glass transition region .......................................................................................................... 18 Figure 5.2 Spring and dashpot ............................................................................................................... 19 Figure 5.3 Standard Maxwell linear model for viscoelasticity .............................................................. 20 Figure 5.4 Generalized Maxwell model for viscoelasticity .................................................................... 21 Figure 5.5 Stress relaxation vs. time...................................................................................................... 22 Figure 5.6 Creep vs. time ....................................................................................................................... 22 Figure 5.7 Phenomenon of structural relaxation a) Viscoelastic material subjected to a step change in temperature b) Corresponding response of a property like volume for e.g. with time when subjected to a step change in temperature ........................................................................................................... 24 Figure 5.8 Volume vs. temperature behavior for a viscoelastic material like glass .............................. 25 Figure 5.9 Thermo-rheological simple behavior ................................................................................... 26 Figure 6.1 Nanotech 140GPM ............................................................................................................... 28 Figure 6.2 Geometry of parts used in press molding ............................................................................ 29 Figure 6.3 Ring, guide and insert ........................................................................................................... 33 Figure 6.4 Molding setup ....................................................................................................................... 34 Figure 6.5 Process sheet showing the variation of mold temperature, position and molding force as a function of time during the experiment................................................................................................ 34 Figure 6.6 Different cycles in glass molding process ............................................................................. 35 Figure 6.7 Shape of the CuZnPb insert (coated with Al2O3) before molding......................................... 37 Figure 6.8 Shape of the CuZnPb insert (coated with Al2O3) after molding........................................... 37 Figure 6.9 Shape of the NiP coated stainless steel insert before molding ............................................ 37 Figure 6.10 Shape of the NiP coated stainless steel insert after molding ............................................. 38 Figure 6.11 Shape of the glass (CuZnPb side) after molding ................................................................. 38 Figure 6.12 Shape of the glass (NiP side) after molding ........................................................................ 38 Figure 7.1 Geometry of glass and molds modeled in MSC Marc .......................................................... 40 Figure 7.2 a) Fixed displacement in x-direction applied on lower mold b) Change in position applied on upper mold ....................................................................................................................................... 43 2 Figure 7.3 Boundary conditions applied on the geometry in the simulation a) Position of upper
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