A numerical approach on achieving uniform thickness distribution in pressure thermoforming

Patil, Jeet; Nandedkar, Vilas M.; Saha, Sandip K.; Mishra, Sushil

doi:10.1016/j.mfglet.2019.07.003

Cited by 7 publications

(4 citation statements)

References 14 publications

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“…In some literature, thermoforming is the matched die-forming process (Ropers, 2017). According to Patil et al (2019a), thermoforming is a technique in which, by imposing sufficient heating and pressure, a thin polymer film is softened and deformed over a mold into the desired shape. Generally, the thermoforming process for suitable mold temperature control involves long cycle times of up to several minutes.…”

Section: Literature Reviewmentioning

confidence: 99%

A Study on the Thermal Distribution of the Thermoforming Process for Polyphenylene Sulfite (Polyphenylene Sulfide) PPS Composites Towards Out of Autoclave Activity

Rashid,

Razali,

Zakaria

et al. 2024

JST

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The thermoforming process is a widely utilized manufacturing technique for shaping thermoplastic materials into various products. Achieving uniform and controlled thermal distribution within the material during thermoforming is crucial to ensure high-quality products and minimize defects. This study investigates and enhances the understanding of thermal distribution in thermoforming processes through simulation analysis before it is done via experiment. This research investigates the thermal distribution in the thermoforming process of Polyphenylene Sulfide composites. The heating element distances were varied during the simulations of the thermoforming process of Polyphenylene Sulfide (PPS) composites, focusing on understanding how different distances affect the material’s deformability, dimensional accuracy, and overall quality. Three heater temperatures with three heater distances are tested. The distance between two heated surfaces is 200, 300 and 500 mm for 320oC, 360oC and 400oC heated surfaces. The desired PPS temperature (320oC) and maximum heater temperature (400oC) are parameters. The test result shows that to achieve 320oC thermoplastic temperature, we can use 385oC IR heater temperature with a heater distance of 200 mm. However, this 200 mm distance might be too close for the operation, and a larger distance might be needed. Using 300 mm or 500 mm can achieve close to 320oC if the heater temperature is set to 400oC. In conclusion, this value is a reference for the distance of the material between the heater during the fabrication process.

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Section: Literature Reviewmentioning

confidence: 99%

A Study on the Thermal Distribution of the Thermoforming Process for Polyphenylene Sulfite (Polyphenylene Sulfide) PPS Composites Towards Out of Autoclave Activity

Rashid,

Razali,

Zakaria

et al. 2024

JST

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“…25 This manifested as a deformation resembling rubber, that is, hyperelastic deformations. Moreover, in the literature, 20,23,[26][27][28][29] it has been determined that the Mooney-Rivlin material model is best suited for simulating the deformation behavior of PMMA at the abovementioned states. Therefore, for the present investigation, the hyperelastic Mooney-Rivlin material model is considered.…”

Section: Numerical Studiesmentioning

confidence: 99%

Effect of hyperelastic pre-stretching on thickness distribution of pressure thermoformed products

Patil

Gaikhe

Vasavada

et al. 2022

Journal of Elastomers & Plastics

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Pressure thermoforming is one of the most used processes, but the thickness gradient in the formed parts limits its application. To control the product thickness distribution, pressure forming is assisted by a punch. However, due to punch contact with the sheet, the process is susceptible to surface defect, which is detrimental to the optical properties of the product. To produce optical parts with zero surface defects and controlled thickness distribution, a novel approach as a means for dimensional control by sheet pre-stretching is proposed and validated numerically. It was found that pre-stretching has a significant effect on the deformation behavior of the product.

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“…As can be seen, the computational results show a good agreement with the experimental measurements, the behavior of both theoretical models being very similar. In fact, regarding the simulation of the thickness distribution in thermoforming, it is possible to find, throughout the literature, several works that use hyperplastic models (e.g., Ghobadnam [30], Bernard et al [31], Oueslati et al [32], Jeet et al [33]) and viscoelastic models (e.g., Cha et al [34], Atami et al [28]). Although researchers are increasingly turning to viscoelastic models for thermoforming applications, according to O'Connor et al [35], there is little agreement on the best model to use for any given polymer material.…”

Section: Multi-objective Evolutionary Algorithmsmentioning

confidence: 99%

Multi-Objective Optimization of Plastics Thermoforming

et al. 2021

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The practical application of a multi-objective optimization strategy based on evolutionary algorithms was proposed to optimize the plastics thermoforming process. For that purpose, in this work, differently from the other works proposed in the literature, the shaping step was considered individually with the aim of optimizing the thickness distribution of the final part originated from sheets characterized by different thickness profiles, such as constant thickness, spline thickness variation in one direction and concentric thickness variation in two directions, while maintaining the temperature constant. As far we know, this is the first work where such a type of approach is proposed. A multi-objective optimization strategy based on Evolutionary Algorithms was applied to the determination of the final part thickness distribution with the aim of demonstrating the validity of the methodology proposed. The results obtained considering three different theoretical initial sheet shapes indicate clearly that the methodology proposed is valid, as it provides solutions with physical meaning and with great potential to be applied in real practice. The different thickness profiles obtained for the optimal Pareto solutions show, in all cases, that that the different profiles along the front are related to the objectives considered. Also, there is a clear improvement in the successive generations of the evolutionary algorithm.

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A numerical approach on achieving uniform thickness distribution in pressure thermoforming

Cited by 7 publications

References 14 publications

A Study on the Thermal Distribution of the Thermoforming Process for Polyphenylene Sulfite (Polyphenylene Sulfide) PPS Composites Towards Out of Autoclave Activity

A Study on the Thermal Distribution of the Thermoforming Process for Polyphenylene Sulfite (Polyphenylene Sulfide) PPS Composites Towards Out of Autoclave Activity

Effect of hyperelastic pre-stretching on thickness distribution of pressure thermoformed products

Multi-Objective Optimization of Plastics Thermoforming

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