Ultra-high precision diamond turning of advanced contact lens polymers
- Authors: Liman, Muhammad Mukhtar
- Date: 2020
- Subjects: Contact lenses , Electrostatic lenses Lenses -- Design and construction
- Language: English
- Type: Thesis , Doctoral , PhD
- Identifier: http://hdl.handle.net/10948/46108 , vital:39496
- Description: Contact lens polymer-based materials are extensively used in the optical industry owing to their excellent corrosion resistance, the possibility of mass production and their ability to be processed without external lubrication. Owing to the fast growth in optical industries, contact lens (CL) requires high accuracy and a high surface quality. The demand for high-accuracy and minimal surface roughness drives the development of ultra-high precision machining technology with regard to single point diamond turning (SPDT). Ultra-high precision diamond turning is an advanced manufacturing technique employed in the machining of CLs owing to its capability of producing high optical surfaces with complex shapes and nanometric accuracy. Yet, even with the advances in ultra-high precision machining (UHPM), it is not continuously easy to achieve a highquality surface finish during polymers machining as the adhesion of the tool chip around the tool dictates the presence of electrostatic charges. The electrostatic charges encountered by a cutting tool when turning advanced CLs are important as they reflect the quality and condition of the tool, machine, fixture, and sometimes even the finished surface, which is responsible for tool wear and poor surface quality. This study investigates the role of cutting parameters, namely cutting speed, feed rate and depth of cut on surface roughness (Ra), electrostatic charge (ESC) and material removal rate (MRR), which determines machine economics and the quality of machining contact lens polymers. The experiments were mainly conducted on two different advanced polymeric materials: polymethyl methacrylate (PMMA) and Optimum Extreme (Roflufocon E) CLs. Experimentation was carried out on the Nanoform 250 ultra-grind turning machine with a monocrystalline diamond-cutting tool for machining the PMMA and Roflufocon E CL polymers, covering a wide range of machining parameters. Before conducting the experiments, a design of experiment was conducted according to the response surface methodology (RSM) that is based on the Box-Behnken Design (BBD). In addition, the research study focused on the determination of the optimum cutting conditions leading to minimum Ra and ESC as well as maximum productivity in the SPDT of the PMMA and Roflufocon E CL polymers, using a monocrystalline diamondcutting tool. The optimization was based on RSM together with the desirability function approach. In addition, a mathematical model was developed for Ra, ESC and MRR using a RSM regression analysis for PMMA and Roflufocon E CL polymers by means of Design Expert software. RSM allowed for the optimization of the cutting conditions for minimal Ra and ESC as well as maximal MRR, which provides an effective knowledge base for process parameters to enhance process performance in the SPDT of CL polymers. Furthermore, this study also deals with the development of Ra, ESC and MRR prediction models for the diamond turning of PMMA and Roflufocon E CL polymers, using the fuzzy logic based artificial intelligence (AI) method. The fuzzy logic model has been developed in terms of machining parameters for the prediction of Ra, ESC and MRR. To judge the accuracy and ability of the fuzzy logic model, an average percentage error was used. The comparative evaluation of experiments and the fuzzy logic approach suggested that the obtained average errors of Ra, ESC and MRR using the fuzzy logic system were in agreement with the experimental results. Hence, the developed fuzzy logic rules can be effectively utilized to predict the ESC, Ra and MRR of PMMA and Roflufocon E CL polymers in automated optical manufacturing environments for high accuracy and a reduction of computational cost. Moreover, owing to the brittle nature of optical polymers, the Roflufocon E CL polymer requires ductile-mode machining for improved surface quality. Molecular Dynamics (MD) simulation methods are thus applied to investigate the atomistic reaction at the tool/workpiece surface to clearly study and observe conditions occurring at nanometric scale in polymer machining. This research study is particularly concerned with the comparative analysis of experiments and a MD study of the Roflufocon E optical polymer nano cutting approach to the atomistic visualization of the plastic material flow at the tool/workpiece interface during cutting. The simulated MD acting force, machine stresses, and the temperature at the cutting region were evaluated to access the accuracy of the model. Hence, the nanomachining simulations were found to have a correlation to the experimental machining results.
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- Date Issued: 2020
Electrical-static discharge in single point diamond turning machining of contact lens polymers
- Authors: Kadermani, Mohamed Munir
- Date: 2015
- Subjects: Electric discharges , Electrostatics , Contact lenses , Polymers
- Language: English
- Type: Thesis , Masters , MEngineering (Mechatronics)
- Identifier: http://hdl.handle.net/10948/4055 , vital:20508
- Description: Single Point Diamond Turning (SPDT) is a technology widely applied for the fabrication of contact lenses. One of the limiting factors in polymer machining is wear of the diamond tool due to electrostatic discharge resulting in poor surface quality of the machined products. The research work presented in this dissertation highlights the electrostatic properties of contact lenses during machining operations and the effects these properties have on the surface quality of the work piece materials. Two contact lens samples were experimented on, Definitive 74 (Silicone Hydrogel) and Tyro 97 (Rigid Gas Permeable). The electrostatic surface potentials (ESPs) were measured during turning operations using an electrostatic voltmeter and the surface roughness measurements were taken using a surface profilometer. Response Surface Methodology (RSM) techniques were employed to create predictive models for both surface roughness and ESPs with respect to the cutting speed, feed rate and depth of cut. Predictive surface roughness models were successfully generated for both materials and the cutting speed and feed rate were identified as the parameters with most effect on surface roughness. In addition, an electrostatic model was successfully generated for the Definitive 74 contact lens material which cited the cutting speed and feed rate as the most effective parameters on the material’s electrostatic behaviour. However, no relationship was evident between the machining parameters and electrostatic behaviour of Tyro 97.
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- Date Issued: 2015
Ultra-high precision machining of contact lens polymers
- Authors: Olufayo, Oluwole Ayodeji
- Date: 2015
- Subjects: Contact lenses , Polymers
- Language: English
- Type: Thesis , Doctoral , DPhil
- Identifier: http://hdl.handle.net/10948/3001 , vital:20385
- Description: Contact lens manufacture requires a high level of accuracy and surface integrity in the range of a few nanometres. Amidst numerous optical manufacturing techniques, single-point diamond turning is widely employed in the making of contact lenses due to its capability of producing optical surfaces of complex shapes and nanometric accuracy. For process optimisation, it is ideal to assess the effects of various conditions and also establish their relationships with the surface finish. Presently, there is little information available on the performance of single point diamond turning when machining contact lens polymers. Therefore, the research work undertaken herewith is aimed at testing known facts in contact lens diamond turning and investigating the performance of ultra-high precision manufacturing of contact lens polymers. Experimental tests were conducted on Roflufocon E, which is a commercially available contact lens polymer and on Precitech Nanoform Ultra-grind 250 precision machining. Tests were performed at varying cutting feeds, speed and depth of cut. Initial experimental tests investigated the influence of process factors affecting surface finish in the UHPM of lenses. The acquired data were statistically analysed using Response Surface Method (RSM) to create a model of the process. Subsequently, a model which uses Runge-Kutta’s fourth order non-linear finite series scheme was developed and adapted to deduce the force occurring at the tool tip. These forces were also statistically analysed and modelled to also predict the effects process factors have on cutting force. Further experimental tests were aimed at establishing the presence of the triboelectric wear phenomena occurring during polymer machining and identifying the most influential process factors. Results indicate that feed rate is a significant factor in the generation of high optical surface quality. In addition, the depth of cut was identified as a significant factor in the generation of low surface roughness in lenses. The influence some of these process factors had was notably linked to triboelectric effects. This tribological effect was generated from the continuous rubbing action of magnetised chips on the cutting tool. This further stresses the presence of high static charging during cutting. Moderately humid cutting conditions presented an adequate means for static charge control and displayed improved surface finishes. In all experimental tests, the feed rate was identified as the most significant factor within the range of cutting parameters employed. Hence, the results validated the fact that feed rate had a high influence in polymer machining. The work also established the relationship on how surface roughness of an optical lens responded to monitoring signals and parameters such as force, feed, speed and depth of cut during machining and it generated models for prediction of surface finishes and appropriate selection of parameters. Furthermore, the study provides a molecular simulation analysis for validating observed conditions occurring at the nanometric scale in polymer machining. This is novel in molecular polymer modelling. The outcome of this research has contributed significantly to the body of knowledge and has provided basic information in the area of precision manufacturing of optical components of high surface integrity such as contact lenses. The application of the research findings presented here cuts across various fields such as medicine, semi-conductors, aerospace, defence, telecom, lasers, instrumentation and life sciences.
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- Date Issued: 2015