Experimental study and finite element analysis of the injection blow molding process

A finite element numerical analysis of preform inflation associated with the injection blow molding process has been developed using a neo-Hookean constitutive model. The analysis is capable of predicting final wall thickness distributions for axisymmetric mold geometries. Experimental studies were conducted on a Uniloy injection blow molding machine (Model 189-3 and Model 122). A twelve ounce (355 mL) cylindrical bottle mold was instrumented with contact sensors, thermocouples, and pressure transducers. Visualization studies of the inflation process were performed using specialized tooling and high-speed video cameras. The experimental studies provide justification for analyzing the deformation by means of a static elastic approach. The predicted wall thickness distribution is in reasonable agreement with the experimental data. Nonuniformities in the temperature distribution in the preform were found to have the most significant impact on the inflation behavior and the resulting wall thickness.     

Measurement and calculation of parison dimensions and bottle thickness distribution during blow molding

Experimental data are reported regarding the dynamics of the blow molding process, including parison formation, growth, and inflation. These data have been obtained with the aid of high speed cinematography and pinch mold experiments, in conjunction with two commercial blow molding polyethylene resins. It is shown that pinch mold experiments alone do not yield accurate data regarding thickness and diameter swell. Furthermore, the inflation process involves decreasing rates of inflation with time, as a result of the rise in viscosity due to the cooling of the parison during inflation. Mathematical procedures are proposed for a first-order estimation of parison length and swell as a function of time and the inflation behavior after clamping. In the absence of more dependable basic procedures, the proposed treatment is employed to estimate the effective transient swell functions for the parison using experimental data obtained under the specified conditions. The mathematical treatment is extended to determine the thickness distribution of the bottle. Good agreement is obtained between experimental and calculated results.     

Experimental and theoretical investigation of the inflation of variable thickness parisons

In today's blow molding of complex parts, an optimal resin distribution is critical to a successful operation. These goals are mostly attained through a technique known as parison programming. The process involves varying the die gap during extrusion and therefore results in a parison having a variable thickness along its length. The subsequent inflation of a variable thickness parison is a complex phenomenon involving the interaction of many process variables. The final thickness distribution and inflation patterns were obtained for various programmed parisons. Constant, one step, two step, and sinusoidal thickness parisons were studied. The inflation patterns were monitored by employing a transparent mold in conjunction with a video camera. The experimental data indicated the presence of an oscillatory inflation pattern for some of the variable thickness parisons. The experimental final part thickness distribution for these cases was highly nonlinear. Theoretical predictions of the final thickness distribution were also obtained for some of the cases. The simulation is based on the inflation of a Mooney-Rivlin hyperelastic material. A wide range of deformation is accounted for by introducing an evolutionary Mooney constant, dependent on the level of deformation.     

An inverse estimation of initial temperature profile in a polymer process

Since one of the most important parameter in polymer processing such as injection stretch blow molding is temperature distribution in the thickness direction, an inverse method has been applied to estimate this profile. This process comprises of four steps. In the first step the preform is injection molded, and in the second and third step it is stretched by a rod to its final length and then inflated and in the last step it is discharged from the mold. In such kind of polymer flows viscous dissipation plays a remarkable role in the evolution of temperature profile. Some theoretical temperature profile has been applied to confirm the validation of the inverse algorithm. Different solution techniques are applied in this article to the inverse problem under consideration, namely: the conjugate gradient and Levenberg–Marquardt method. After the preform is injection molded, which is the first step, it is removed from the mold, which corresponds to time t = 0. At this moment an infrared camera is used to record the surface temperature of the preform with a certain time step. With regard to variation of thermal properties with temperature, the inverse problem becomes nonlinear. These experimental data provided by the infrared camera are then used to estimate the temperature profile at the end of injection process before stretching and inflation took place. POLYM. ENG. SCI., 48:133–140, 2008. © 2007 Society of Plastics Engineers     

Numerical simulation of thickness variation effect on resin transfer molding process

In this work, a computer model has been developed to investigate the effect of reinforcement thickness variation and edge effect on infiltration and mold filling in resin transfer molding (RTM) process. The developed code is able to predict the flow front location of the resin, the pressure, and the temperature distribution at each time step in a mold with complex geometries. It can also optimize the positioning of injection ports and vents. The filling stage is simulated in a full two‐dimensional space by using control volume/finite element method CV/FEM and based upon an appropriate filling algorithm. Results show that the injection time as well as flow front progression depends on the edge effect, the variation of reinforcement thickness, and the position of injection ports; this highlights that the inclusion of these effects in RTM simulation is of definite need for the better prediction and optimization of the process parameters. The validity of our developed model is evaluated in comparison with analytical solutions for simple geometries, and excellent agreements are observed. POLYM. COMPOS., 2012. © 2011 Society of Plastics Engineers     

Analytical solutions for fiber orientation in 2-D flows of dilute suspensions

Analytical solutions for fiber orientation in dilute solutions are presented for both 2-D planar and axisymmetric flow. The viscosity is assumed to be independent of position along the flow direction, but varies through the thickness of the mold cavity. For the particular case of a laminate of two fluids, an analytical solution is derived. Based upon the assumption that the fluid adjacent to the mold wall exhibits reduced viscosity due to non-isothermal considerations, the fluid kinematics simplify, and an analytical solution to Jeffery's orientation equation is derived. Since the fiber orientation analysis is based on Jeffery's equation, it is valid only for dilute suspensions, i.e. for fiber volume fraction < 1/(fiber aspect ratio)². Qualitatively, the analytical results obtained provide superior correlation with experimental results, indicating that non-isothermal fluid flow may play an important role in the development of the fiber orientation distribution in the molded component.     

Overall numerical simulation of extrusion blow molding process

This paper focuses on the overall numerical simulation of the parison formation and inflation process of extrusion blow molding. The competing effects due to swell and drawdown in the parison formation process were analyzed by a Lagrangian Eulerian (LE) finite element method (FEM) using an automatic remeshing technique. The parison extruded through an annular die was modeled as an axisymmetric unsteady nonisothermal flow with free surfaces and its viscoelastic properties were described by a K‐BKZ integral constitutive equation. An unsteady die‐swell simulation was performed to predict the time course of the extrudate parison shape under the influence of gravity and the parison controller. In addition, an unsteady large deformation analysis of the parison inflation process was also carried out using a three‐dimensional membrane FEM for viscoelastic material. The inflation sequence for the parison molded into a complex‐shaped mold cavity was analyzed. The numerical results were verified using experimental data from each of the sub‐processes. The greatest advantage of the overall simulation is that the variation in the parison dimension caused by the swell and drawdown effect can be incorporated into the inflation analysis, and consequently, the accuracy of the numerical prediction can be enhanced. The overall simulation technique provides a rational means to assist the mold design and the determination of the optimal process conditions.     

Analysis of the vacuum infusion molding process

The vacuum infusion molding process is becoming increasingly popular for the production of large composite parts. A comprehensive model of the process has not been proposed yet, making its optimization difficult. The flexible nature of the vacuum bag coupled to the varying pressure inside the mold cavity results in a variation of the cavity thickness during the impregnation. A complete simulation model must incorporate this phenomenon. In this paper, a complete analysis of the vacuum infusion molding process is presented. The analysis is not restricted to the theoretical aspects but also reviews the effect of the main processing parameters. The parameters investigated in this paper are thought to be those of most interest for the process, i.e. the compaction of the reinforcement, the permeability, the infusion strategy and the presence of flow enhancement layers. Following the characterization experiments, a 1‐D model for the vacuum infusion molding process is presented. This model is derived assuming that an elastic equlibrium holds in the mold cavity during mold filling. Even though good agreement was found between simulation results and experiments, it is concluded that additional work is needed on the numerical model to integrate interesting findings from the experimental part.     

Electrochemical micromachining of nitinol by confined-etchant-layer technique

The confined etchant layer technique has been applied to fabricate complex three-dimensional microstructures on nitinol for the first time. HF and HNO₃ were locally and simultaneously electrogenerated at the mold surface to etch a nitinol workpiece. NaOH was used as an efficient scavenger to confine the etchant close to the mold. Cyclic voltammetry was employed to study the electrochemical behavior of a Pt electrode in the etching solution in order to choose an appropriate potential for etchant generation on the mold. The thickness of the confined etchant layer was estimated to be several micrometers by inspecting the deviation of the sizes of the etched spots from the sizes of those on the microelectrode. Thus, the composition of the electrolyte could be optimized for better etching precision. By optimizing the composition of the electrolyte, complex microstructures on a Pt-Ir mold bearing the logo “XMU” of Xiamen University were successfully fabricated on nitinol. The etched patterns were approximately negative copies of the mold, and the precision of duplication could easily reach the micrometer scale.     

Integrated numerical modeling of the blow molding process

The numerical modeling of the extrusion blow molding of a fuel tank is considered in this work. The integrated process phases are consecutively simulated, namely, parison formation, clamping, and inflation, as well as part solidification, part deformation (warpage), and the buildup of residual stresses. The parison formation is modeled with an integral type viscoelastic constitutive equation for the sag behavior and a semi-empirical equation for the swell behavior. A nonisothermal viscoelastic formulation is employed for the clamping and inflation simulation, since parison cooling during extrusion strongly affects the inflation behavior. Once the parison is inflated, it solidifies while in the mold and after part ejection. Warpage and residual stress development of the part are modeled with a linear viscoelastic solid model. Numerical predictions are compared with experimental results obtained on an industrial scale blow molding machine. Good agreement is observed. A process optimization based on a desired objective function, such as uniform part thickness distribution and/or minimal part weight, is performed. The integrated clamping, inflation, and cooling stages of the process are considered. The optimization is done by the systematic manipulation of the parison thickness distribution. Iterations are performed employing a gradient based updating scheme for the parison thickness programming, until the desired objective of uniform part thickness is obtained.     

Statistical analysis of product variability associated with continuous and cut sheet thermoforming operations

Extensive published data exist with regard to the variation of part weight and dimensions for products manufactured by injection molding and blow molding. Relatively little information is available with regard to thermoformed parts. Such data are of considerable practical and theoretical value in establishing realistic processing targets in commercial processing operations. Experimental data have been systematically collected over an extended time from three continuous roll-fed thermoforming processes, as well as a cut sheet forming process. Two of the continuous processes studied were high-volume production lines. One of the operations produced 16-ounce drinking cups from a blend of a styrene-butadiene block copolymer with polystyrene. The other commercial continuous process manufactured tubs from high-density polyethylene. The third process studied involved a pilot plant test former used to produce 10-ounce drinking cups from the styrenebutadiene/polystyrene blend material. All three continuous processes employ plug assist in conjunction with a multi-cavity mold. The measured parameters included the weight of individual parts, and the wall thickness measured at several different locations. The cut sheet forming process employed a plug assist with a single-cavity mold for the production of a scanner cover. The polymer used consisted of a blend of an acrylic and a poly(vinyl chloride) resin. The deformation and wall thickness of the scanner cover were measured at several different locations.     

Amplification effect of platelet type nanoparticles on the orientation behavior of injection molded nylon 6 composites

The effect of platelet type nanoparticles and processing conditions; mold temperature and injection speed, on the development of local microstructure in injection molded nylon 6 parts was investigated. The molded parts exhibit two crystal forms (α and γ) of nylon 6 in varying proportions from skin to core. The γ crystals preferentially grow near the surface regions and α crystal fraction increases with distance from the surface in all molded parts. However, the spatial variation of crystal phases across the thickness in nanocomposites differs from that of unfilled nylon 6. Nanoplatelets induce high levels of orientation of the polymer matrix throughout the thickness of the molded part even at high mold temperatures where nonisothermal effects are highly suppressed and confined to very close proximity of surfaces. These high chain orientation levels observed in nanoparticle filled systems is a result of the shear amplification effect that occurs in small spaces between adjacent nanoparticles of differing velocity. The local preferential crystalline orientation of nylon 6 resin and nanoparticles across the thickness of the molded parts are investigated using a series of structure characterization techniques including microbeam wide angle X-ray, SAXS and TEM.     

Stretch and inflation of hyperelastic membranes as applied to blow moldiing

The free and confined inflation of isotropic homogeneour membranes of general shape are considered. The material is assumed to obey the Mooney-Rivin constitutive model, and the resulting partial differential equations, governing the deformation field, are solved using a Galerkin based finite-element procedure. The method is illustrated through examples of both free and conflined inflation, as well as simulationeus stretch and inflation. Measurements were carried out on the final thickness distributionof containers blow-molded inour laboratory. These containers typically cover a wide range of geometry adn size, including bottles with handles. Comparison between theory and experiment leads generally to good agreement, despite the limitation of the membrane hypothesis.     

Bending strength of composite laminates with an elliptical hole

Great efforts have been made in analyzing the strength of notched laminates under in-plane loadings. However, no work has been reported on notched laminates under bending, because of the complexity of theoretical stress analysis. In this study, a simplified approach has been used to analyze the notched strength of laminated composites with an elliptical hole under bending. This approach combines notched sample experiments and finite element results. Based upon the consideration that not only the stress distribution at one ply, but also the stress variation across the laminate thickness, should be taken into account, two failure models are presented: a modified point stress model and a modified average stress model. Two characteristic parameters are presented to evaluate the notched strength of the laminated plates.     

Rotated, circular arc models of stress in silos applied to core-flow and vertical rat-holes

Rotated, circular arc geometry models have been developed to describe core-flow and vertical rat-holes in cylindrical hoppers and silos.The conceptual problem of the variation of incremental element thickness has been overcome, resulting in models of greater theoretical rigour.Models have been developed in an average stress and point stress form. Analysis shows that stresses vary with vessel radius through an arc angle parameter, ε, as well as with bed depth.The models indicate that conditions at a rat-hole annulus wall are quite different from the mean stress or wall stress and this has implications for stability and flow.A modified failure criterion, based upon azimuthal stress has been used to assess the stability of deep rat-holes, and a range of rat-hole stability determined, which is dependent upon material properties and vessel diameter.Predicted stress distributions are functions of assumed internal stress distribution relationships. More physical data are required in this area to enable reliable modelling.     

Dynamic modeling of blown‐film extrusion

Past dynamic studies of blown‐film extrusion have been confined to the stability analysis of the linearized equations. The full set of nonlinear equations comprises a system of partial differential and algebraic equations with boundary conditions that vary from author to author. In this paper, the Numerical‐Method‐of‐Lines, which combines finite‐difference methods with ordinary differential/algebraic equation integrators, is used to solve the full system. Appropriate boundary conditions are selected to give physical results that compare well with experiment. An important boundary condition is the “minimum order reduction” condition on the gradient of the bubble‐tube radius with respect to distance above the extrusion die (the axial position). Transient startups and operational disturbances are examined. Calculations show the influence of oscillations in operating conditions such as heat transfer or inflation pressure on the bubble‐tube radius and film thickness. Steady‐state results obtained by integrating the transient equations for a sufficiently long time are qualitatively in agreement with experiment, in contrast to past simulations of these equations.     

Nonisothermal method for calculating the mold equipment of an apparatus for compacting the hot products of self-propagating high-temperature synthesis

The existing methods for calculating molding equipment are discussed. Their common disadvantage lies in the fact that they do not reflect the unsteady-state state and the gradient nature of heat exchange during self-propagating high-temperature synthesis (SHS) inside a mold. The results of the application of mathematical modeling in the study of the temperature fields that appear in mold equipment during SHS compaction are described. It is recommended that the thermal method be used for calculating the mold equipment, and a theoretical rationale is given to justify the application of this method. The paper cites examples of calculating the wall thickness of the mold by the standard and proposed methods. It is shown that a nonisothermal calculation allows for a significant decrease in the wall thickness and, accordingly, the mass of the mold.     

Hierarchical structure gradients developed in injection-molded PVDF and PVDF–PMMA blends. I. Optical and thermal analysis

The structural gradients developed along and across the flow direction of injection-molded PVDF and PVDF/PMMA parts were investigated by optical microscopy and thermal analysis techniques. The spatial variation of crystallinity across the thickness direction was found to be insensitive to the process variables: injection speed and mold temperature. This relatively flat crystallinity profile across the thickness of the parts was found to decrease with the increase of PMMA concentration. The blends become noncrystallizable beyond about 40–45% PMMA concentration. The influence of flow history on the structural evolution across the thickness was observed in the peak position of the cold crystallization region. This peak temperature showed a minimum at depths where shear effects are at their maximum. This was attributed to the increased levels of chain orientation frozen in the amorphous portions of these regions which crystallize at lower temperatures upon heating. © 1998 John Wiley & Sons, Inc. J Appl Polym Sci 68: 909–926, 1998     

Injection molding shrinkage of PP: Experimental progress

Injection molding shrinkage deals with dimensional differences between a molded part and the cavity. By adding an array of orthogonal marks into a mold, local shrinkage values may be obtained by comparing dimensions of this array with dimensions of the array replicated on the surface of the parts. A profilograph is employed to obtain dimensional measurements, in the parallel to flow direction and in the cross flow direction. A sensitivity analysis is conducted to determine aspects of shrinkage evaluation causing uncertainty on the results. Prominent sources of uncertainty found are mark straightness defect and part warpage. Uncertainty on shrinkage is evaluated to 0.00025 mm/mm for a distance between the marks of 6.350 mm. Shrinkages have been evaluated locally for molded plates. Different distribution forms were observed for parallel to flow and cross flow shrinkage. Important anisotropy is also observed. The effects of holding pressure and injection velocity on shrinkages have been evaluated using a 2³ factorial design of experiment for three locations on the plates. Finally, shrinkages for three mold geometries have been compared: constant thickness plate, variable in thickness symmetrical plate, and variable in thickness asymmetrical plate. Variable in thickness plates showed the importance of solidification dynamics on final shrinkages. POLYM. ENG. SCI., 46:1275–1283, 2006. © 2006 Society of Plastics Engineers     

An investigation of the kinematics of stretch blow molding poly(ethylene terephthalate) bottles

An experimental study of the kinematics of inflation of poly(ethylene terephthalate) (PET) parisons in a Corpoplast stretch blow molding process is reported. LVDT displacement transducers have been placed at various positions along the length and at the top of a specially designed and built mold. A six-channel LVDT demodular circuit was built and attached to a minicomputer. Studies were conducted at 90 and 100°C at various pressures. Kinematic models were developed for the parison inflation, and stress fields along the deforming surface of the parison were computed using membrane theory.