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Abstract
The tremendous development in digital technology in the last few decades has increased the demand for ultra-precision optical components with enhanced optical performance, such as aspherical or freeform lenses. Typically, lenses made of polymers have been widely used in the industry. But due to the superior optical properties of glass, there is a steady increase in demand for glass-based optical components. However, conventional manufacturing processes become time-consuming and expensive when used for manufacturing aspherical glass components. Precision glass molding (PGM) technology offers an alternate method of production for aspherical glass lenses and irregular optical products. Compared to the conventional manufacturing process, it has the advantages of high forming accuracy, short manufacturing cycles, low cost, and high-volume production. However, the process has a few drawbacks, such as lens profile deviations, stress birefringence. These drawbacks must be addressed before the glass molding process can be a viable option for mass-producing optical components.As such, in this dissertation, a coupled thermo-mechanical finite element model is established to simulate the precision glass molding process on two different glass types, D-ZK3 (CDGM) and P-SK57 (Schott). The glass is modeled as a thermo-viscoelastic material by defining the stress and structural relaxation parameters. A new testing technique based on the cylinder compression test is developed in this study to extract the viscoelastic parameters at different temperatures. The obtained material parameters, when used in the numerical simulations, showed a good agreement with the experimental data throughout the testing temperature range. Further, the viscosity of the glass (a highly sought-after property of glass in precision molding) is obtained as a by-product of the proposed material calibration test. Finally, the structural relaxation parameters are obtained from the impulse excitation test based on ASTM standard E1876. All the experiments required for fully calibrating the viscoelastic response of the glass are performed on a precision glass molding machine, Moore Nanotech GPM170 machine. The obtained material parameters are used in the finite element model to predict the lens deviations and the stresses in the molded lens. A mold compensation technique is used to correct the mold profiles for any deviations. The lens molded using the corrected molds is shown to fall within the designer's specifications. However, it was observed that the process parameters used during the molding process have an influence on the deviations and the stresses in the molded lens. Therefore, it is essential to optimize the molding process prior to implementing mold compensation techniques. The developed numerical model is used to analyze the impact of various process stages and parameters on the optical quality of molded lenses. Based on the observations, a modified molding process was developed, which is shown to minimize the influence of the molding parameters on the deviations and the residual stress. In addition, it was demonstrated that the modified manufacturing process reduces the total cycle time for producing a glass lens of comparable optical quality by more than 50\%, reducing the manufacturing cost of a molded glass lens.