Prediction of Wall Thickness Distribution in Simple Thermoforming Moulds (original) (raw)
Related papers
An Experimental Study on Wall Thickness Distribution in Thermoforming
Advances in Science and Technology Research Journal
In this work, Polystyrene (PS) sheets were thermoformed in predetermined conditions. Wall thickness distributions obtained by experimental method in PS thermoformed products. Then the same thickness distributions were predicted by using Geometric Element Analysis (GEA). The thickness results were obtained experimentally, compared to thickness distributions which were predicted by GEA. It has been found that GEA does not precisely reveal thickness distributions.
Application of FDM technology for manufacturing of thermoforming mold
Additive technologies often referred to as 3D printing gain more and more applications that have been the domain of traditional technologies. The present paper deals with Rapid Tooling with FDM technology and its application to thermoforming technology. For the experimental shape of the part a mold was designed and printed from Ultem9085 (PEI), utilizing possibilities offered by FDM technology. For the production of moldings were used PET, PVC and PC foils of thickness 0.25 - 0.75 mm. Produced moldings were evaluated visually and simultaneously wall thickness at selected locations was measured. . The results show the applicability of FDM technology for thermoforming mold production, which offers the designer greater freedom in design compared to conventional technologies.
CAE applications in a thermoforming mould design
IOP Conference Series: Materials Science and Engineering, 2016
Preparation of honeycomb layer is a critical step for successful fabrications of thermoformed based sandwiched structures. This paper deals with an initial investigation on the rapid manufacturing process of corrugated sheet with 120 o dihedral angles. Time history of local displacements and thickness, assuming viscous dominated material model for a 1mm thick thermoformable material, was computed by using ANSYS R Polyflow solver. The quality of formed surfaces was evaluated for selection of mould geometry and assessment of two common variants of thermoforming process. Inadequate mesh refinement of a membrane elements produces satisfactorily detailing and incomplete forming. A perfectly uniform material distribution was predicted using drape forming process. However, the geometrical properties of vacuum formed part are poorly distributed and difficult to control with increasing inflation volumes. Details of the discrepancies and the contributions of the CAE tool to complement traditional trial and error methodology in the process and design development are discussed.
Decreasing of the manufacturing time for a thermoforming mold by applying the DFM principles
MATEC Web of Conferences
In this paper it is analyzed a product machined at the S.C. ULMA PACKAGING S.A. company, which is a "Thermoforming mold" used in order to obtain plastic containers in which the food or non-food product is packed, making part of a thermoforming machine called TFS 200. The aims of this paper are to determine the optimal technological parameters and to study the effects of the DFM principles and the optimal tool path strategy usage on manufacturing time of the "Thermoforming mold". A redesign of the thermoforming mold is presented based on the failed rules and recommendations given by the DFM program and followed by the analysis of the DFM's benefic effect on the manufacturing time.
Journal of KONES, 2018
Remarkable characteristics of high temperature thermoplastic (HTP) matrix used in composite materials reinforced with continuous fibres causes growing application in composite industry. Because of high processing temperature of some semi, crystalline matrix there is limited number of technologies that can be used for part manufacturing. Press forming is an example of technology that allows manufacturing high quality complex parts made of HTP reinforced fibres composite. In order to manufacture part with acceptable quality and mechanical properties, uniform pressure distribution during the process is required. In this article, tooling design process focused on uniform pressure distribution for manufacturing of supporting rib was presented. In order to satisfy this requirement, the rubber stamp was proposed as a tool for manufacturing. Typical press forming process defects were identified and the requirements for rubber stamp were described. It was assumed that the forming process has...
2017
In this study applications and potential uses of 3D printing in the plastic thermoforming industry are studied. Additive manufacturing has revolutionized the modern manufacturing process and engineering design process. Thermoforming is widely used in plastic manufacturing industries to produce a range of polymer products such as products in the packaging industry. Thermoforming moulds are mostly produced using conventional mould building technologies and are made of steel. These mould are robust but only suitable for mass production and take some time to fabricate. 3D printing can find use in thermoforming industry in creating moulds this can produce the moulds quickly, economically as well as prototyping of the packaging material. 3D printing allows ease of production of personalised packaging. With 3D printing the structural design of the package could be customised on request. As more sustainable bioplastic filaments are innovated, the adoption of 3D printing in packaging manufacturing may help save the environment. 3D printing works well with Acrylonitrile Butadiene Styrene (ABS) and polypropylene. This paper looks at the different applications of 3D printing in the plastics thermoforming industry and looks at the viability of the use of this technology as well as the advantages in relation to conventional production technologies.
Numerical Investigation of the Gas Flow Temperature on the Thermoforming and Blow-Molding Processes
Journal of Reinforced Plastics and Composites, 2009
In this article, we consider a finite element approach for analysis of the effect of the air flow temperature on the forming of a thin, isotropic, and incompressible thermoplastic membrane. Also, to take into account the enclosed gas volume, responsible for inflation of the thermoplastic membrane, we considered a thermodynamic approach to express external work in terms of a closed volume. The dynamic pressure load is thus deduced from the van der Waals equation of state. The viscoelastic behavior of the K-BKZ model is considered. Numerical validation is performed by comparing the obtained results with the theoretical results for the HDPE grade. Moreover, the effect of the temperature of the gas on the thickness and stress distribution is presented.
Finite element simulation of thermoforming processes for polymer sheets
Mathematics and Computers in Simulation, 2003
The problem of modelling and the finite element simulation of thermoforming processes for polymeric sheets at various temperatures and for different loading regimes is addressed. In particular, the vacuum forming process for sheets at temperatures of approximately 200 • C and the Niebling process for sheets at temperature of 100 • C with high pressure loading are both described. Discussion is given to the assumptions made concerning the behaviour of the polymers and the physical happenings in the process in order that realistic models of the inflation part of each process may be produced. Stress-strain curves produced from experimental testing of BAYFOL ® at various strain rates and temperatures are presented. A model for the elastic-plastic deformation of BAYFOL ® is described and is used within the finite element framework to simulate the inflation part of the Niebling process. Numerical results for the deformation of sheets into a mould in the Niebling context are presented.
2013
The focus of this study was to determine the influence of molding parameters such as types of mold, sheet and mold temperatures on the wall-thickness distribution of thermoformed parts. The materials used were high impact polystyrene (HIPS) and amorphous polyethylene terephthalate (A-PET). All the thermoformed parts were molded only after the machine had attained a steady state with respect to the preset sheet temperature from 130 to 170 oC and mold temperature of 30, 60, and 80 oC, respectively. Several settings were tried and those leading to an overall satisfactory quality with regard to visual properties were finally chosen. Furthermore, the commercial simulation package (T-SIM) was also extensively verified against experiments performed with simple mold geometry as well as with a more complicated part. Both simulated and measured results suggested that in order to obtain a more uniform wall thickness throughout the entire area of a thermoformed part, it was necessary to use a p...