ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton © GIT 2011 1 Glass Manufacture ver. 1ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton © GIT 2011 2 Overview • Hand glass manufacture • Sheet glass manufacture • Mechanical sheet glass manufacture • Pilkington float glass process • Bottle manufacture – Codd bottles – Ramune bottlesME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton © GIT 2011 3 Hand Glass ManufactureME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton © GIT 2011 4 Hand Glass ManufactureME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton © GIT 2011 5 French Glass Factory Glass Plate PressME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton © GIT 2011 6 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 7 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 8 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 9 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 10 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 11 Float glass processME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton © GIT 2011 12 Float Glass ProcessME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton © GIT 2011 13 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 14 Constituents of Soda-lime Float Glass Raw Material % Sand 72.6 Soda Ash 13.0 Limestone 8.4 Dolomite 4.0 Alumina 1.0 Others 1.0ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton © GIT 2011 15 Bottles - Blow-Blow ProcessME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton © GIT 2011 16 Ramune BottlesME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton © GIT 2011 17 Codd Bottles Hiram Codd 1838-1877ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton © GIT 2011 18 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 19 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.Coca-Cola Bottle Molds ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton © GIT 2011 20ME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton © GIT 2011 21 Summary • Hand glass manufacture • Sheet glass manufacture • Mechanical sheet glass manufacture • Pilkington float glass process • Bottle manufacture – Codd bottles – Ramune bottlesME 4210: Manufacturing Processes and Engineering - Prof. J.S. Colton © GIT 2011