TY - JOUR
T1 - CAE applications in a thermoforming mould design
AU - Marjuki, A. R.
AU - Mohd Ghazali, F. A.
AU - Ismail, N. M.
AU - Sulaiman, S.
AU - Mohd Khairuddin, I.
AU - Majeed, Anwar P.P.A.
AU - Jaafar, A. A.
AU - Mustapha, F.
AU - Basri, S.
N1 - Publisher Copyright:
© Published under licence by IOP Publishing Ltd.
PY - 2016/3/3
Y1 - 2016/3/3
N2 - Preparation of honeycomb layer is a critical step for successful fabrications of thermoformed based sandwiched structures. This paper deals with an initial investigation on the rapid manufacturing process of corrugated sheet with 120° dihedral angles. Time history of local displacements and thickness, assuming viscous dominated material model for a 1mm thick thermoformable material, was computed by using ANSYS® Polyflow solver. The quality of formed surfaces was evaluated for selection of mould geometry and assessment of two common variants of thermoforming process. Inadequate mesh refinement of a membrane elements produces satisfactorily detailing and incomplete forming. A perfectly uniform material distribution was predicted using drape forming process. However, the geometrical properties of vacuum formed part are poorly distributed and difficult to control with increasing inflation volumes. Details of the discrepancies and the contributions of the CAE tool to complement traditional trial and error methodology in the process and design development are discussed.
AB - Preparation of honeycomb layer is a critical step for successful fabrications of thermoformed based sandwiched structures. This paper deals with an initial investigation on the rapid manufacturing process of corrugated sheet with 120° dihedral angles. Time history of local displacements and thickness, assuming viscous dominated material model for a 1mm thick thermoformable material, was computed by using ANSYS® Polyflow solver. The quality of formed surfaces was evaluated for selection of mould geometry and assessment of two common variants of thermoforming process. Inadequate mesh refinement of a membrane elements produces satisfactorily detailing and incomplete forming. A perfectly uniform material distribution was predicted using drape forming process. However, the geometrical properties of vacuum formed part are poorly distributed and difficult to control with increasing inflation volumes. Details of the discrepancies and the contributions of the CAE tool to complement traditional trial and error methodology in the process and design development are discussed.
UR - http://www.scopus.com/inward/record.url?scp=84973146835&partnerID=8YFLogxK
U2 - 10.1088/1757-899X/114/1/012012
DO - 10.1088/1757-899X/114/1/012012
M3 - Conference article
AN - SCOPUS:84973146835
SN - 1757-8981
VL - 114
JO - IOP Conference Series: Materials Science and Engineering
JF - IOP Conference Series: Materials Science and Engineering
IS - 1
M1 - 012012
T2 - Joint Conference of 2nd International Manufacturing Engineering Conference, iMEC 2015 and 3rd Asia-Pacific Conference on Manufacturing Systems, APCOMS 2015
Y2 - 12 November 2015 through 14 November 2015
ER -