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Experimental study and numerical analysis of compression molding process for manufacturing precision aspherical glass lenses

Jain, Anurag
http://rave.ohiolink.edu/etdc/view?acc_num=osu1148650470

Abstract Details

2006, Doctor of Philosophy, Ohio State University, Industrial and Systems Engineering.
Compression molding has emerged as a promising technology for manufacturing aspherical glass lenses. In this method a glass gob or blank is pressed in a single operation into the shape of a finished lens. Annealing of the formed lens is then performed to achieve optical quality. The process is net shape, environment friendly and suitable for high volume production but has some inherent limitations which have prevented it from being used for industrial lens production. This dissertation research seeks a fundamental understanding of the molding process by adopting a combined experimental, analytical and numerical Finite Element Method (FEM) approach. Preliminary experiments were performed involving molding of a test aspherical glass lens on a commercial machine to study process capability to manufacture an optic component within the desired specifications. Experiments were also performed to determine the effect of different molding parameters on the final molded lens quality. A compression molding machine was designed and built in the laboratory. High temperature elastic modulus measurements were performed using Brillouin light scattering technique. The measured glass properties were used as input to the numerical simulation of cylinder compression experiments and lens molding. A numerical FEM simulation model of lens molding was developed and predictions were compared with the experiments. A 1D analytical heat transfer model during lens annealing has been presented that takes into account transient heat transfer at the glass-mold boundary. The possibility of implementing molding to make microlens array, freeform lens and diffractive lens has also been demonstrated. Experimental results have showed that molding process is capable of producing precision glass lenses with shape and form accuracy comparable to lenses manufactured using conventional abrasive techniques. Within the range investigated, the experiments did not show a significant influence of the molding parameters on the final lens quality. The predicted lens curve shape results were in good agreement with the experimental measurements. Additionally, numerical simulation was able to predict, residual stress in the glass lens as a function of process parameters which shows that FEM can possibly be used to predict, optimize and improve the performance of a lens molding process.
Allen Yi (Advisor)
201 p.
molding; aspherical lens; glass; viscosity; stress relaxation; structural relaxation; high temperature; numerical simulation; modeling; manufacturing

Recommended Citations

Citations

  • Jain, A. (2006). Experimental study and numerical analysis of compression molding process for manufacturing precision aspherical glass lenses [Doctoral dissertation, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1148650470

    APA Style (7th edition)

  • Jain, Anurag. Experimental study and numerical analysis of compression molding process for manufacturing precision aspherical glass lenses. 2006. Ohio State University, Doctoral dissertation. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1148650470.

    MLA Style (8th edition)

  • Jain, Anurag. "Experimental study and numerical analysis of compression molding process for manufacturing precision aspherical glass lenses." Doctoral dissertation, Ohio State University, 2006. http://rave.ohiolink.edu/etdc/view?acc_num=osu1148650470

    Chicago Manual of Style (17th edition)

osu1148650470
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© 2006, all rights reserved.
This open access ETD is published by The Ohio State University and OhioLINK.