Three‐dimensional simulation of thermoforming process and its comparison with experiments

Three‐dimensional solid element analysis and the membrane approximated analysis employing the hyperelastic material model have been developed for the simulation of the thermoforming process. For the free inflation test of a rectangular sheet, these two analyses showed the same behavior when the sheet thickness was thin, and they deviated more and more as the sheet thickness increased. In this research, we made a guideline for the accuracy range of sheet thickness for the membrane analysis to be applied. The simulations were performed for both vacuum forming and the plug‐assisted forming process. To compare the simulation results with experiments, laboratory scale thermoforming experiments were performed with acrylonitrile‐butadiene‐styrene (ABS). The material parameters of the hyperelastic model were obtained by uni‐directional hot tensile tests, and the thickness distributions obtained from experiments corresponded well with the numerical results. Non‐isothermal analysis that took into account the sheet, temperature distribution measured directly from the experiments was also performed. It was found that the non‐isothermal analysis greatly improved the predictability of the numerical simulation, and it is important to take into account the sheet temperature distribution for a more reliable simulation of the thermoforming process.     

Investigation into thermoformability of hot compacted polypropylene sheet

Abstract

This paper describes an investigation into the thermoformability of a new class of oriented polymeric material recently developed, namely hot compacted polypropylene sheet. Exploitation of any new material requires an intimate understanding of a whole range of factors, amongst which thermoformability is pre-eminent. This is particularly true for oriented polymeric materials, for while the preferred molecular alignment gives enhanced properties such as stiffness, strength, and resistance to impact, the downside is that the stretched molecular chains tend to limit further flow under stress, making thermoforming difficult. The aim of the present study was to establish the critical parameters for successful thermoforming of hot compacted polypropylene sheet.

Elevated temperature tensile tests were used to investigate the stress–strain behaviour of the compacted materials. The crucial parameters were found to be the post-yield modulus, which gives a measure of the resistance of the material to large scale deformation, and the strain to failure, which gives the upper limit on deformation. The post-yield modulus was found to be significantly affected by the test temperature and the high strain hardening behaviour of the material confirmed that significant force is required to thermoform the compacted polypropylene sheets. A hemispherical mould, with built-in gripping plate, was used to carry out a study of the thermoforming behaviour of the compacted sheets, and the results were found broadly to confirm the conclusions of the tensile tests. A linear relationship was found between the tensile force and the postforming force, reinforcing the synergy between the two tests. In addition the forming tests showed that the best temperatures to use were either side of the melting point of the melted and recrystallised phase, depending on the amount of postforming deformation required. Different gripping arrangements were investigated both in which the sheet was fully gripped and in which the sheet was allowed to flow into the mould during forming. The different schemes were found to control whether a successful component could be produced under different conditions and at different ultimate strains. Finally, the tests with the hemispherical mould showed that thermoforming this shape requires significant interlaminar shear deformation, and above 15% strain this resulted in destruction of the interlayer bond. For strains greater than this, successful thermoforming could only be achieved by allowing the material to flow into the mould.     

Influence of initial sheet temperature on ABS thermoforming

Understanding the effects of material and processing parameters on the thermoforming process is critical to the optimization of processing conditions and the development of better materials for high quality products. In this study we investigated the influence of initial temperature distribution over the sheet on the part thickness distribution of a vacuum snap‐back forming process. The linear viscoelastic properties along with the Wagner two parameter nonlinear viscoelastic constitutive model were utilized for numerical simulation of the thermoforming operation. Simulations of pre‐stretched vacuum thermoforming with a relatively complex mold for a commercial refrigerator liner were conducted. THe effects of temperature distribution over the sheet on the part thickness distribution were determined to examine process sensitivity and optimization. Effects of the temperature distribution on the material rheology and polymer/mold friction coefficient are primarily responsible for the changes in the thickness distribution. We found that even small temperature differences over the sheet greatly influenced bubble shape and pole position during the bubble growth stage and played a critical role in determining the part thickness distribution. These results are discussed in terms of rheological properties of polymers such as elongational viscosity and strain hardening.     

Thermoforming triangular troughs

This analysis for thermoforming triangular troughs focuses on the manufacturing process speed and follows the method of Kershner and Giacomin for thermoforming cones. We distinguish between what happens before and after (free versus constrained forming) the melt touches the prismatic mold. Neither free nor constrained forming yields analytical solutions for the required forming time. Our analysis is restricted to the fabrication of triangular troughs from nearly Newtonian melts, the second simplest relevant problem in commercial thermoforming. The simplest relevant problem, thermoforming cones, yielded analytical solutions for the forming time. Whenever we thermoform straight edges into rigid packaging, the problem of a melt stretching into a triangular trough arises. POLYM. ENG. SCI., 2009. © 2008 Society of Plastics Engineers     

Sensitivity of operating conditions and material properties for thermoforming process

Abstract

The thermoforming process involves three stages: sheet reheat; forming; and solidification. A polymeric sheet is heated in an oven to the desired forming temperature distribution. The sheet is then deformed to take the shape of the mould cavity and subsequently solidified. The deformation of the sheet is assisted by the application of a pressure differential and/or the use of a moving plug.     

Thermoforming shrinkage prediction

Most thermoforming product development processes rely on costly and time‐consuming forming trials to determine the adequacy of the mold and process. In this paper, an analytical method is developed for shrinkage predictions on the basis of a visco‐elastic constitutive material model with initial conditions from a commercial thermoforming simulation. The theoretical analysis has been developed to accommodate different sets of materials, process conditions, and mold geometry. The shrinkage model consists of a transient thermal analysis for temperature solution; a stretching phase analysis for Inflation‐induced stress estimation; a post‐contact analysis for thermal stress and relaxation; and a post‐molding strain analysis based on stress solution. The shrinkage prediction analysis has been developed and validated with a complex geometry thermoforming application. The results indicate that the shrinkage estimates provided by the analysis were within the objective tolerances of 0.1%, as measured in terms of absolute prediction error of part dimensions.     

Infrared sheet heating in roll fed thermoforming: Part 2 - Factors influencing inverse heating solution

Abstract

Two methodologies for solving the inverse heating problem in thermoforming, i.e. setting the temperature of the heaters that provide a prescribed temperature of the sheet to be formed against the mould, are compared in terms of temperature gradients across the thickness and sensitivity to the most important process parameters. The influences of sheet thickness, sheet emissivity, room temperature, and distance between the heater bank and the forming station on the thermal homogeneity of the sheet are also discussed.     

Advance on processing of compostable and thermally stable biodegradable polyester blends

Flexible and semiflexible packagings can be manufactured by cast extrusion of plastic sheet and thermoforming of containers. Thermal stability is often required as packaging items after being thermoformed can come in contact with hot food/beverage, especially during hot filling operations. In this framework, the present study deals with the design and manufacturing by thermoforming of plastic containers that are, at the same time, compostable and suitable for high-temperature applications (~100 °C). First, extrusion compounding of Poly(l -lactic acid) (PLLA)-based biodegradable polyester blends was performed. In particular, the effect on the material properties of different types of nucleating agents was investigated. Combinations of micro-lamellar talc, poly(d -lactic acid) (PDLA), ethylene bisstearamide (EBS), and titanium dioxide (TiO₂) were studied. The formulations involving EBS boast the highest crystallinity and the fastest onset of the crystalline phase on sheets produced by cast extrusion. Conversely, the formulations involving TiO₂ feature the lowest degree of crystallinity and the slowest onset of the crystalline phase. Combinations of talc and PDLA exhibit an intermediate behavior. Second, thermoforming of the plastic foils was performed. A very different trend of the crystallization after thermoforming is shown. Indeed, crystallinity is the highest for the formulations involving talc and PDLA, the lowest for the ones containing EBS. In conclusion, the biodegradable polyester blends are found to be suitable for the manufacturing of compostable and thermostable packaging items by cast extrusion and thermoforming. Final crystallization of the material and the resulting thermal stability can be fine-tuned by modulating type and amount of nucleating agents. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2020 , 137, 48722.     

Instrumented thermoforming of advanced thermoplastic composites. III: Relative performance of various prepregs in forming double curvature parts

Thermoforming of a double curvature hemispherical cap-shaped part from different continuous carbon fiber-reinforced thermoplastic composite prepregs has been investigated. A novel three-piece matched die mold was used for shaping the prepregs directly from 16-ply unconsolidated lay-ups. For poly(ether ether ketone) (PEEK)-based prepregs, PEEK/graphite fiber unidirectional tapes and commingled knitted three-dimensional fabric yielded parts that possessed good shape conformity and were free of any major delamination. Encouraging results were also obtained for modified polysulfone (PXM-8505) based unidirectional fabric as well as PEEK/graphite knitted bidirectional fabrics. Several other prepregs performed rather poorly in forming acceptable quality parts. Fiber alignment was found to be better for fabric prepregs than unidirectional tapes. Both stretching and “draw in” of the material occur during deformation, even though the relative contribution depends strongly on the prepreg form. Our thermoforming studies suggest a cycle time of 10 min or less to form good quality parts, which is an attractive feature, considering that cycle times are typically several hours for conventional thermosetting resins.     

Blotching in roll coating

After thermoforming, plastic parts are stacked for shipping, and these parts tend to stick together. Called nesting, sheet stock is often first coated with a silicone compound before thermoforming to prevent this. The coating usually consists of a small amount of lubricant dispersed in a majority of carrier fluid, and this fluid must then dry before reaching the sheet winder or else the coating blotches. This coupling of coating and drying to determine when to expect blotching is examined. Roll coating involves a dimensionless group called the elasticity number that governs the thickness of the coating to be dried. The drying section involves the evaporation of the coating carrier fluid, and then diffusion into the dry surrounding atmosphere. When analyzing the drying, a new dimensionless group that governs blotching is discovered, called blotchability. The result of this analysis allows practitioners to determine which operating conditions cause blotching, and how to eliminate it. Roll coating uses a deflecting rubber roll to apply vanishingly thin coatings (≤1 μm), an interesting elastohydrodynamic problem.     

Thickness variation in the thermoforming of poly(methyl methacrylate) and high-impact polystyrene sheets

The influence of material flow properties on the variation of wall thickness in a thermoformed part was investigated by measuring the thickness reduction at the pole of free-formed axisymmetric domes of poly(methyl methacrylate) and high-impact polystyrene. It was found that at a given pole height, the thickness reduction in poly(methyl methacrylate) was less than in high-impact polystyrene, i.e., the wall thickness in a part formed from poly(methyl methacrylate) will be more uniform than in a part formed from high-impact polystyrene by the same technique. This difference in formability was ascribed to a difference in the dependence of the flow stress σ at the thermoforming temperatures on time. The flow stress of both materials was given by σ = Kt^m′?ⁿ, but whereas n was approximately 1 for both materials, m′ was ?0.052 and ?0.33 for poly(methyl methacrylate) and high-impact polystyrene, respectively. A physical argument and simple analysis led to the conclusion that a large (negative) value of the “stress relaxation index” in a material reduces the degree of uniformity of sheet thickness in a formed part.     

Thermoforming of liquid crystalline polymer sheets

Liquid crystalline polymer (LCP) extruded sheets were further processed by the conventional thermoforming method. The available processing temperature range was defined through the structural, thermal, and elevated temperature mechanical characterization of the extruded sheet. This temperature range was found for LCP to be quite narrow, in the proximity of the crystal-mesophase transition. The structural changes imposed on the LCP sheet during forming and its thermal stability were investigated using wide angle X-ray diffraction, mainly for the determination of the chain orientation distribution, DSC, and dynamic mechanical analysis. Thermoforming onto a symmetrical male mold was found to enhance the orientation in the extrusion machine direction and even change the preferred orientation in the extrusion transverse direction to orientation along the thermoforming direction. Annealing at the thermoforming temperature range results in a more ordered and thermally stable structure accompanied by just a slight orientation loss.     

Improved mathematical modeling for the sheet reheat phase during thermoforming

In any thermoforming process, plastic sheet heating is the most important phase as it is responsible for final part quality as well as overall process efficiency and productivity. The goal of the study reported here was to improve existing mathematical models to accurately predict the temperature profile inside a heated sheet, where the model could be used to better control the overall thermoforming process. A mathematical model with temperature dependent, variable sheet material properties including density, thermal diffusivity, specific heat, and thermal conductivity was developed and validated against experimental data. Models with constant and variable plastic sheet properties were created, simulated, and compared in Matlab. The models were validated by experiments which obtained temperature profiles at different depths within a plastic sheet by inserting thermocouples and recording temperatures. Further, the effect of sheet color on heating was investigated by considering two extreme cases: white (transparent) and black (opaque) colored sheets, and the effect of oven air temperature and velocity on sheet heating was also investigated. Results indicated that a variable properties model was needed to control sheet reheating especially with narrow forming windows, and that the heating profiles required for colored and noncolored sheets were very different. POLYM. ENG. SCI., 2012. © 2011 Society of Plastics Engineers     

Carrier films behavior during thermoforming process studied using dynamic mechanical thermal analysis (DMTA)

Dynamic mechanical thermal analysis was used to investigate the thermal transitions and modulus/temperature behavior of thermoformable carrier films, and to relate the information obtained to carrier film behavior during the thermoforming process. In this study the glass transition temperatures (T _g) and the temperatures at which crystallization occurred during heating (T _c) of four thermoformable carrier films were measured by using a dynamic mechanical thermal analyzer (DMTA). These films are good candidates for the automotive process, which uses painted carrier films as moldable automotive coatings (MAC). The modulus/temperature behavior of the films was also observed over a wide temperature range, which included thermoforming temperatures. Although films of PETG and PCTG 5445, co-polyesters based on poly(1,4-cyclohexylene dimethylene terephthalate), are thermoformable, their T _g values, 92 and 99 °C, respectively, are not high enough to allow current paint systems (with bake temperature of 100–110 °C) to cure on the films without causing severe film deformation.     

Dynamic characteristics of plug‐assist thermoforming process

Plug‐assist thermoforming is a well‐known technique in polymer processing because of its interesting features. The dynamic value of driving‐force for the stretching process is determined based on equilibrium equation. This amount of force is required for applying to a plug to stretch a sheet. It is used for calculation of the required theoretical work and power of a plug‐assist thermoforming process. By using a nonlinear viscoelastic rheological model in the proposed mathematical model, its validity was examined by performing experimental tests on ABS sheets. POLYM. ENG. SCI., 2009. © 2008 Society of Plastics Engineers     

Wall thickness distribution in thermoformed food containers produced by a Benco aseptic packaging machine

Effects of process parameters such as forming temperature, forming air pressure and heating time on wall thickness distribution in plug‐assist thermoformed food containers using multilayered material were investigated. Multilayered rollstockbase material formed into containers by thermoforming process using a Benco aseptic packaging machine. Forming temperatures in the range of 131–170°C, airforming pressures of 2, 3, 3. 5 and 4 bars, and heating times of 66, 74, 84, 97 and 114 seconds were used in the thermoforming process. Analysis of wall thickness data obtained for the thermoforming parameters used in this study showed that wall thickness was significantly affected by forming temperature, pressure and heating time at 0.05 significance level. Besides the processing parameters, wall location, container side, and their interactions significantly affected wall thickness. Forming temperature was found to be the principle parameter influencing wall thickness distribution in a plug‐assist thermoforming operation. The optimum operating conditions of the packaging machine for the thermoforming process are: 146–156°C for forming temperature, 2–4 bars for air‐forming pressure and 74–97 seconds for heating time.     

Wrinkling in polymer film‐polymer substrate systems and a technique to minimize these surface distortions

Thermally induced wrinkling during thermoforming of a commercial multi‐layered polymer film/substrate laminate has been reported. The differential thermal expansion of component layers coupled with phase transition of the substrate with increasing temperature, determined the critical conditions for wrinkling with a specific wavelength and amplitude. An effective technique to minimize wrinkling by biaxially stretching the samples at high temperature before the forming operation, has been proposed. The samples were biaxially stretched by inflating the samples using a specially designed blowing unit retrofitted to a conventional vacuum thermoformer. This method involved heating, inflation and forming, together to provide stretch‐assisted thermoforming. During biaxial stretching the stored compressive stresses in a wrinkled sample were relieved before the forming step, producing a decorative part without losses in surface appearance. POLYM. ENG. SCI., 57:31–43, 2017. © 2016 Society of Plastics Engineers     

Interlayer adhesion of coextruded films: Effect of biaxial stretching

In order to understand the effect of thermoforming on the interlayer adhesion of coextruded films, a peel test was performed for coextruded films after being stretched. To simulate the non‐uniaxial stretching nature of actual thermoforming processes, planar stretching and biaxial stretching were applied to the coextruded films prior to the peel test. Both the planar stretching and biaxial stretching were performed at an optimum thermoforming temperature under well‐controlled stretch rates to a predetermined stretch ratio. It was found that there was a significant amount of reduction of interlayer adhesion due to stretching. Furthermore, the loss of interlayer adhesion at the optimum thermoforming temperature was linearly related to thickness drawdown as a result of stretching regardless of stretching modes. Therefore, it is suggested that the effect of thermoforming on interlayer adhesion of coextruded films can be easily estimated from the thickness distribution of thermoformed parts. Polym. Eng. Sci. 44:948–954, 2004. © 2004 Society of Plastics Engineers.     

Vacuum forming of thermoplastic foam

The process of thermoforming of foam sheet is analyzed using both finite element modeling and experiments. A simple constitutive model for finite tensile deformations of closed cellular material around its glass transition temperature is proposed, starting from well-known results from Gibson and Ashby (1988). The model is implemented in a finite element code and applied in isothermal vacuum forming simulations. The distributions of thickness and in plane strains are in adequate accordance to the experimental results.     

Effects of ABS rubber particles on rheology,melt failure,and thermoforming

The rubber particles included in rubber modified polymeric materials such as acrylonitrile‐butadiene‐styrene (ABS) polymer and impact modified polymers play an important role in determining their rheological properties, processing behavior, and mechanical properties. In this study both small strain oscillatory shear viscosity in the frequency range from 10^?2 to 10² s^?1 and uniaxial elongational viscosity behavior at two elongation rates ( = 0.1 and 1.0 s^?1) over the range of temperatures from 140°C to 200°C were measured for commercial ABS polymers with different contents and deformability of rubber particles. The influences of rubber content and deformability on rheological properties such as melt elasticity, elongational viscosity, strain hardening and/or softening, the onset of nonuniform deformation, and thermoforming performance were investigated. The Wagner two‐parameter nonlinear viscoelastic constitutive model was used to describe strain hardening behavior, while the Considère criterion was used to determine the onset point of nonuniform deformation. The part thickness distribution obtained through use of a vacuum snap‐back forming process was simulated to investigate the effects of rheological changes associated with different rubber particles on the thermoforming performance. It was found that ABS polymers with larger contents of hard rubber particles exhibited more melt elasticity, stronger strain hardening, a maximum of biaxial elongational viscosity, onset of nonuniform deformation at later time, and better thermoforming performance. Strain hardening and the Considère criterion provide simple, reliable indicators of the thermoforming performance of ABS polymers.