Abstract. Glass blowing to create bottles with specific thickness distribution profiles requires several experimental iterations. Such iterations are expensive and increase the time to market. The use of simulation pretends to decrease the amount of prototypes by doing virtual validation of glass blowing molds. To feed simulations with realistic physical values, a gob drop test has been designed. This test provides valuable experience on the use of the software and validates heat transfer, viscosity and other physical parameters. Gob drop test was chosen for the possibility to record the test with infrared thermal cameras. Gob obtained similar shapes when dropped on a cast iron plate for both central and side sections with longer cooling of about 25ºC. Such technique allowed the user to gain experience on the use of software and obtain valuable physical parameters for future glass blowing optimization.
Glass forming to produce perfume bottles with specific thickness distribution profiles is based on trial and error and requires several tests in production line. These tests are expensive and time‐consuming, which increases time to market. The use of a numerical model aims to reduce the number of prototypes by performing virtual tests of the mold equipment and the process conditions. This article presents results of numerical simulations of the blow and blow forming process to predict glass thickness distribution. Correlation of the simulation results of the glass temperature with experimental infrared measurements on the glass skin and experimental validation of glass forming simulations and influence of the blank mold cavity in the thickness distributions of perfume bottles are provided. Finally validation of the results of axisymmetrical and three‐dimensional models for axisymmetric bottles defining a useful technique to use the right blank mold for desired thickness distribution while reducing the trial and error testing.
Blow and blow forming process for glass bottle is already validated for 2D axisymmetrical bottles. Current research evaluates the capabilities of the 3D simulations with more complex geometries. This article presents the results of a numerical and experimental study of a non-axisymmetrical glass bottle. In this study, a perfume bottle with a square-based prism geometry and a new set of industrial process conditions have been evaluated. To validate the numerical results, the predicted temperatures in the glass domain have been correlated with experimental infrared measurements of the glass at various stages of the forming process. A comparison of the predicted glass thickness distributions with the section profiles obtained from the manufactured glass bottles is also provided. Finally, transition from the 2 Da to 3D model resulted in new difficulties and capabilities that are also discussed. This study validates simulations with experimental results to help in the design process of molds to avoid undesired thickness distributions and even fracture of glass containers for low thickness 3D corners.
After the successful validation of the axisymmetric and three-dimensional models to simulate the blow and blow forming process using two axisymmetrical bottles, the capabilities of the 3D model have been evaluated by performing simulations with more complex geometries. This article presents the results of a numerical and experimental study of a non-axisymmetrical glass bottle. In this study, a perfume bottle with a square-based prism geometry and a new set of industrial process conditions have been evaluated. To validate the numerical results, the predicted temperatures in the glass domain have been correlated with experimental infrared measurements of the glass at various stages of the forming process. A comparison of the predicted glass thickness distributions with the section profiles obtained from the manufactured glass bottles is also provided. Finally, transition from the 2Da to 3D model resulted in new difficulties and capabilities that are also discussed.
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