Treffer: FE-Analysis of Stretch-Blow Moulded Bottles Using an Integrative Process Simulation.

The two-stage stretch-blow moulding process has been established for the large scale production of high quality PET containers with excellent mechanical and optical properties. The total production costs of a bottle are significantly caused by the material costs. Due to this dominant share of the bottle material, the PET industry is interested in reducing the total production costs by an optimised material efficiency. However, a reduced material inventory means decreasing wall thicknesses and therewith a reduction of the bottle properties (e.g. mechanical properties, barrier properties). Therefore, there is often a trade-off between a minimal bottle weight and adequate properties of the bottle. In order to achieve the objectives Computer Aided Engineering (CAE) techniques can assist the designer of new stretch-blow moulded containers. Hence, tools such as the process simulation and the structural analysis have become important in the blow moulding sector. The Institute of Plastics Processing (IKV) at RWTH Aachen University, Germany, has developed an integrative three-dimensional process simulation which models the complete path of a preform through a stretch-blow moulding machine. At first, the reheating of the preform is calculated by a thermal simulation. Afterwards, the inflation of the preform to a bottle is calculated by finite element analysis (FEA). The results of this step are e.g. the local wall thickness distribution and the local biaxial stretch ratios. Not only the material distribution but also the material properties that result from the deformation history of the polymer have significant influence on the bottle properties. Therefore, a correlation between the material properties and stretch ratios is considered in an integrative simulation approach developed at IKV. The results of the process simulation (wall thickness, stretch ratios) are transferred to a further simulation program and mapped on the bottles FE mesh. This approach allows a local determination of the material properties and thus a more accurate prediction of the bottle properties. The approach was applied both for a mechanical structural analysis and for a barrier analysis. First results point out that the approach can improve the FE analysis and might be a helpful tool for designing new stretch-blow moulded bottles. [ABSTRACT FROM AUTHOR]