Vacuum forming of thermoplastic foam

Simulation-Based Approach for Probing Rheology-Processing-Structure Relationships in Foam Blow Molding

The broad objective of this work was to demonstrate a modelling and simulation framework for foam blow molding using commercially available simulation software. The simulation framework would have to account for the initial morphology of the foam, the relationship between the morphology and the rheological and deformation characteristics of the foam at high temperatures and high strains that are typically encountered during blow molding, and correlate the strains developed during blow molding to the morphological aspects in the resulting blow molded part. These aspects are addressed in this paper using simulations of uniaxial tensile deformation of a virtual representative volume element of a foam microstructure (rendered in DIGIMAT-FE) to derive the nonlinear tensile response of the foam at high temperatures (using ABAQUS). The resulting simulated stress-strain curve is employed to parameterize a nonlinear rheological constitutive equation. These parameters are then employed for the homogenized representation of the foam in the blow molding simulation carried out in B-SIM, a commercially available simulation software for blow molding. The regions where the simulated parison has undergone primarily uniaxial elongation are then mapped back to the expected local foam morphology using the transfer functions derived from the RVE simulations. These steps result in a preliminary and simple demonstration of the simulation framework, and offer a template that can be detailed further with experimental rheological information on actual foamed parisons, and more detailed post-processing algorithms to correlate multiaxial elongations with microstructure.