| Abstract | BlowView is a 2.5D finite element based simulation software, developed at NRC and dedicated to simulate conventional extrusion blow molding, twin-sheet extrusion blow molding, suction blow molding, stretch blow molding and thermoforming processes. This versatile engineering simulation software is highly automated, flexible and user-friendly, yet allows users in-depth analysis capabilities for a wide range of materials, and includes warpage, optimization and permeability applications. Conventional and twin-sheet extrusion blow molding processes are extensively used in manufacturing automotive parts. These processes consist of three main phases: parison/sheet formation, inflation and part cooling and solidification. The parison/sheet formation is the most critical stage, as the final dimensions and mechanical performance of the part are directly related to the initial extrudate shape, which often requires the use of advanced die shaping technologies such as: VWDS, PWDS, SFDR, DSM, and/or a combination of all four. These complex extrusion technologies are all accessible in the BlowView software, and can be simultaneously synchronized and optimized with the machine programming points. An illustration of the optimization methodology, and the gain in terms of part weight reduction, will be presented for an industrial case study. For stretch blow molding & thermoforming applications, the heating stage is of primary importance. The software’s capability to simulate the complex heating stages for thin gauge roll-fed plastic sheets and plastic preforms, including radiation and preferential heating, as well as the inflation/vacuum stages will be highlighted and discussed. A robust and reliable contact algorithm has been implemented in order to manage the sheet/plug, preform/rod and part/mold contact. Finally, the latest advances in 3D forming will be presented on various blow molded parts to predict the induced welding deformation in the pinch zones, which are subjected to high strain ratios. |
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