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Glass Manufacture

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ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011

Overview
Hand glass manufacture Sheet glass manufacture Mechanical sheet glass manufacture Pilkington float glass process Bottle manufacture
Codd bottles Ramune bottles
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Hand Glass Manufacture

ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011

Hand Glass Manufacture

ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011

French Glass Factory

Glass Plate Press


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Rolled glass
Single roll
Molten glass is poured onto a metal table and a single metal roll is used to flatten it into a sheet.

Double roll
Molten glass is passed between a pair of rotating metal rolls to form the sheet.

ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011

Cylinder Drawn Glass


The first mechanical method of drawing glass, 40 ft high cylinders of glass were drawn vertically from a circular tank. The glass was annealed and then cut into 7 10 ft cylinders, which were then cut lengthways, reheated and flattened. This process was used in the UK up to the end of the 1920's.
ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011 7

Flat Drawn Glass


Molten glass is pulled vertically through a slit in a large one-piece refractory block that is floating on the glass surface. The annealing lehr is mounted vertically over the draw chamber. The glass was drawn until it cooled sufficiently to allow it to be cut. The Belgians invented the original process but it did not reach the UK until 1919.
ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011 8

Flat Drawn Glass


Drawn glass is generally more pristine than rolled glass because its surface has remained untouched during forming.

ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011

Single and twin ground polished plate.


Glass is cast and then ground and polished on a conveyor belt, to a fine quality without distortion.

ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011

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Float glass process

ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011

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Float Glass Process

ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011

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Sir Alastair Pilkington


In 1952, Alastair Pilkington conceived the idea of forming a ribbon of glass by floating the melted raw materials at high temperature over a bath of molten tin. It took seven years and more than 7 million (80 million in today's money) to develop the process. Pilkington set out to replace the twin grinding and polishing process for making plate glass. The float glass process superseded not only that process, but also the sheet glass process for making ordinary windows. It was to become the universal process for the manufacture of high quality flat glass.
ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011 13

Constituents of Soda-lime Float Glass


Raw Material Sand Soda Ash Limestone % 72.6 13.0 8.4

Dolomite Alumina
Others

4.0 1.0
1.0
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ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011

Bottles - Blow-Blow Process

ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011

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Ramune Bottles

ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011

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Codd Bottles

Hiram Codd 1838-1877

ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011

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Codd Bottles
In 1870, Hiram Codd designed and patented a system for keeping fizzy drinks in bottles with a glass marble stopper. When the bottle is filled, pressure in the bottle keeps the marble against a rubber washer at the top making a seal. To open the bottle, the marble is pressed down into the neck chamber. Tried changing marble shape to oval to dissuade children from breaking the bottles to get the marbles.

ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011

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Ramune Bottle
In its early days, Ramune was sold in a bottle with a cork cap wound tight with wire to keep the cork from popping out. In 1888, when Codd's patent rights expired, Tamakichi Tokunaga, of Osaka, began developing a Ramune bottle using a marble cap throughout Japan. As to how the first soda arrived in Japan is another question. Some think that it was Admiral Perry in 1853 while others believe it was on a British merchant ship in 1860. Whichever way I'm glad it is still around to enjoy.
ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011 19

Coca-Cola Bottle Molds

ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011

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Summary
Hand glass manufacture Sheet glass manufacture Mechanical sheet glass manufacture Pilkington float glass process Bottle manufacture
Codd bottles Ramune bottles
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ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton GIT 2011

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