Fluid–structure‐interaction simulations of forming‐air impact thermoforming

Wagner, Simon; Sheikhi, Rasoul; Kayatz, Fabian; Münsch, Manuel; Hauptmann, Marek; Delgado, Antonio

doi:10.1002/pen.25926

Cited by 4 publications

(3 citation statements)

References 46 publications

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“…Thus, it would be possible to direct more force vectors towards the sidewalls of materials to enable better forming. The performance of such a configuration has already been tested in laboratory studies on plastic thermoforming, as shown in Figure 11 35,36 . The studies described used directional pressure for optimising the thickness distribution of plastic samples.…”

Section: Resultsmentioning

confidence: 99%

“…The performance of such a configuration has already been tested in laboratory studies on plastic thermoforming, as shown in Figure 11. 35,36 The studies described used directional pressure for optimising the thickness distribution of plastic samples. Nevertheless, fibre-based materials can also benefit from further research on such systems.…”

Section: Effect Of Forming Operation and Tooling On Shape Accuracymentioning

confidence: 99%

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Effects of thermoforming operation and tooling on the thermoformability of plastic‐coated fibre‐based materials

et al. 2023

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Advances in the three‐dimensional (3D) forming of fibre‐based materials require the formulation of more formable materials and the development of process lines, machinery, and tools. Using a thermoforming process to convert fibre‐based materials into 3D forms is an emerging area of research which requires further investigation into the practicality of the process line and tooling in forming such materials. Accordingly, this study evaluated the impact of the thermoforming process operation and tooling on the thermoformability of plastic‐coated paperboards. The main objective was to provide design recommendations for the future development of thermoforming lines, followed by guidelines for tooling design to improve the performance of materials utilising the currently available machinery. This study examined the thermoforming behaviour of two different plastic‐coated paperboards in vacuum and pressure thermoforming by investigating their maximum acquired depth, shape accuracy, and damage mechanisms. The research findings, based on the depth and linear elongation achieved, indicate that the inferior performance of plastic‐coated paperboards in thermoforming cannot be wholly attributed to restrictions in the three‐dimensional formability of materials; the inability of the current process lines to utilise the maximum potential of materials can also lead to their inferior performance. Notably, the method of pressure supply and cooling of materials requires adjustment of these materials. From a tooling perspective, owing to the spring‐back effects, the enlargement of the mould dimensions should be considered during the design stage. Additionally, based on potential opportunities with the current unmodified machinery and materials, products in the size of standard food trays have a higher likelihood of being optimised with tooling design than smaller sized shapes, which still require additional developments in materials. Moreover, designing moulds without draft angles can reduce the risk of rupture owing to the prevention of localised stress formation in materials.

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Section: Resultsmentioning

confidence: 99%

Section: Effect Of Forming Operation and Tooling On Shape Accuracymentioning

confidence: 99%

Effects of thermoforming operation and tooling on the thermoformability of plastic‐coated fibre‐based materials

et al. 2023

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“…Both induce more favorable thickness gradients (Ayadi et al 2020;Duarte and Covas 2008;Martin and Duncan 2007;Marathe et al 2016;McCool and Martin 2010;Sasimowski 2017). Recently, Wagner et al (2022), applied controlled pressure forming to improve the thickness distribution of a cup using a female mold.…”

Section: Introductionmentioning

confidence: 99%

Improving the thickness distribution of parts with hybrid thermoforming

Duarte

Ribeiro

Ferreira

et al. 2022

International Polymer Processing

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With the aim of improving the thickness gradient of thermoformed parts, and thus increase their performance and/or reduce their weight, the concept of hybrid thermoforming is introduced, whereby local thickness differences in extruded sheets are created prior to thermoforming. Material is removed by CO2 ablation or 3D printing of an over-thickness at specific locations of sheets previously extruded. The feasibility and potential usefulness of the approach is explored experimentally for the production of a truncated conical cup, since this is a well-characterized application. The conventional thickness distributions obtained by conventional vacuum forming are significantly changed with the new strategy and can be tuned by adequately selecting the locations and amount of material do be removed and/or added.

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Experimental and numerical investigation of the effects of sheet material, plug-assist tool material, and process conditions on the mechanical pre-stretching stage of plug-assist thermoforming

Atmani

Abbès

et al. 2022

Int J Adv Manuf Technol

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Fluid–structure‐interaction simulations of forming‐air impact thermoforming

Cited by 4 publications

References 46 publications

Effects of thermoforming operation and tooling on the thermoformability of plastic‐coated fibre‐based materials

Effects of thermoforming operation and tooling on the thermoformability of plastic‐coated fibre‐based materials

Improving the thickness distribution of parts with hybrid thermoforming

Experimental and numerical investigation of the effects of sheet material, plug-assist tool material, and process conditions on the mechanical pre-stretching stage of plug-assist thermoforming

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