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.
- Full Text:
- Date Issued: 2015
- 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.
- Full Text:
- 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.
- Full Text:
- Date Issued: 2015
- 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.
- Full Text:
- Date Issued: 2015
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