Preform Temperature Research Articles

Handling Analysis of Short Shot Defects From Stretch Blow Molding Machine On 330 Ml Bottle Case Study At PT. XYZ

Stretch blow molding is a manufacturing method used in making hollow plastic products using polymer plastic with rotational symmetry. This method, which has been popular since the 1970s, is usually used to make PET bottle products for soft drinks and mineral water to liquid detergent. In the production process of 330 ml plastic water bottles using a stretch blow machine molding with a pneumatic system, making products usingThis machine has factors that can affect the quality of the bottles produced. Size deviation (even distribution of bottle thickness and bottle slope) not in accordance with specifications resulting in bottles with white shoulders and flanged (shrinkage). The aim of this research is to optimize the settings stretch blow molding machine parameters to produce good quality 330 ml plastic water bottle product. The variables (predictors) chosen are: preblow (bar), preform temperature (ºC), and P1 point (mm).

Research the Dimensional Accuracy of C45 Steel Ring Forgings Produced by Radial Rolling.

The rolling process of rings is a commonly used method for producing annular forgings. There are two primary types of this process: radial-axial rolling and radial rolling. This article presents the research results regarding the latter, in which obtaining a product with the assumed dimensions constitutes a major problem. In industrial practice, the process parameters are based on the experience of technologists and/or by trial and error. This is why the authors considered it justified to undertake the research aimed at determining the influence of the main process parameters, that is, preform temperature and tool speed, on the shape and dimensions of the cross-section, which determine the internal and external diameters of the rolled ring. The research was based on numerical simulations and experimental studies. The results obtained proved that the higher the feed speed of the main roll, the greater the change in the cross-sectional height during rolling, and the smaller the cross-sectional deformation (the so-called fishtail). Nevertheless, a higher preform temperature reduces the final height of the ring and reduces cross-section deformation. On the basis of the obtained test results, guidelines for the process design were postulated, considering the influence of temperature and speed parameters on the final dimensions of the forging and the dimensions of the preform.

Extra-High Pressure in the Core of Silica-Based Optical Fiber Preforms during the Manufacturing Process

The core refractive index n2 of silica-based optical fiber preform heated to 2000 °C was determined experimentally for the first time. The measurements were carried out in the process of preform temperature reduction. It was shown that n2 could increase up to ~1.75 in the visible spectral range at temperatures of ~2000 °C (n2 ≈ 1.46 at room temperature). This fact suggests that pressures close to or exceeding the ultimate strength of silica glass (~20 GPa) occur in the preform core region. The local extra pressure is argued to be a possible cause of the well-known “starburst” phenomenon at the core–cladding interface of preforms with certain core compositions. The observed effect of radial cracks can be interpreted as the result of silica cladding destruction under the action of extra-high pressure in the core.

Determination of The Best Injection Stretch Blow Molding Process Parameters in Polyethylene Terephthalate Bottle Service Performance

Polyethylene terephthalate (PET) bottles which are thermoplastic materials are used very commonly for the storage and transport of carbonated beverages. The most used production method for PET bottles is the Injection Stretch Blow Molding (ISBM) process. There is a variety of parameters affecting the produced PET bottles’ performances. Amongst these parameters, stretch rod movement, blowing pressure and preform surface temperature are the most important ones. Assignation of the optimal design parameters in PET bottles is taken into account. The effects of the parameters such as Preform Temperature (°C), Stretch Rod Position (mm) and Final Pressure (Bar) were analysed with the Taguchi method (TM), Grey relational analysis (GRA) and ECHIP. Body-weight (gr) (R1), Top Load (Pa) (R2), Burst Pressure (Bar) (R3), Stress Crack Resistance (Min.) (R4) and Tg (oC) (R5) were consiedered as performance parameters. The experimental design proposed by Taguchi involves using orthogonal arrays. An L9 orthogonal array was chosen for the procedure. Primarily, the performance parameters were optimized with the ECHIP Design of the Experiment (DOE). Thereafter, all of the factors were optimized together with TM, GRA and ECHIP.

Fabrication and application of co-continuous Al2O3/Al composite by reactive infiltration of molten Al into the preform of SiO2 with cordierite addition

Abstract Interpenetration Al2O3/Al(Si) composites were fabricated by reactive infiltration of molten Al into the preforms with SiO2–4.6 mol.% cordierite at 1150 °C in air. The formation kinetics and microstructures of the composites were investigated. Experimental results show that the addition of cordierite in SiO2 is favorable for wetting of molten Al on the preform, leading to high growth rate of the composite (8.76 mm min –1). The growth rate of the composite was controlled by the infiltration of molten Al into the preform through the open pores and cracks formed during the preform fabrication or through microcracks created during the infiltration process. Since the addition of cordierite in SiO2 can lower the preform sintering temperature, one of its applications is used for ceramic – ceramic or ceramic – metal joints. A strong Al2O3–Al2O3 joint with a shear strength of 109 MPa was fabricated and investigated using the Al2O3/Al(Si) interlayer formed by this method.

Formation of structure and properties of hot-deformed powder steels microalloyed with sodium and calcium during thermal and thermomechanical treatment

One of the main problems limiting further growth in the production of parts by the hot forging of porous performs (HFPP) is that the obtained materials are prone to brittle fracture due to the poor quality of interparticle jointing formed during hot deformation, as well as the presence of impurities in the composition of initial powders. The paper studies the possibility of increasing the mechanical properties and endurance performance of hot-deformed powder steels by doping them with sodium or calcium microadditives and using thermomechanical treatment. Sodium bicarbonate and calcium carbonate were used for microalloying. Carbon was added as pencil graphite powder. The temperature of heating porous preforms before hot forging and the carbon content in steels were varied; the content of microalloying additives was, wt.%: 0.2 for sodium, and 0.3 for calcium. Mechanical properties as well as contact and low-cycle fatigue life were tested on 5 × 10 × 55 mm and 10 × 10 × 55 mm prismatic specimens, as well as ∅ 26 × 6 mm cylindrical specimens. In comparison with carburizing and thermal treatment, thermomechanical treatment improves the impact strength and endurance performance of hot-deformed powder steels with Na or Ca microadditives under the contact and low-cycle fatigue loading, and the hot repressing temperature of porous preforms is reduced without compromising the mechanical properties of powder steels obtained. It may be associated with the formation of a more fine-grained structure and higher microstresses of the crystal lattice. The cooling down of preform surface layers during hot forging process operations creates conditions for ausforming in them.

A new process for minimizing residual silicon and carbon of reaction-bonded silicon carbide via chemical vapor deposition

In order to reduce the amount of excess silicon and carbon, reaction-bonded silicon carbide was fabricated by liquid silicon infiltration using a porous carbon preform prepared by chemical vapor deposition. A carbon preform was fabricated at 1100−1400 ℃ at 6.6 kPa for 1 h using acetylene. The deposited carbon preform has a porous structure with nano-sized carbon particles and uniform pore size distribution. Depending on the deposition temperature of the carbon preform, the porosity, the pore size, and the size of the carbon particles were controlled. As the deposition temperature increased, the porosity and average pore size increased, but the average carbon particle size decreased. The residual silicon of the prepared reaction-bonded silicon carbide was 2.7 % when the porosity of the carbon preform deposited at 1100 °C was 51.1 %. The hardness increased up to 21.7 GPa as the amount of the residual silicon reduced.

Selectively Reinforced Aluminum Metallic Hybrid Composites by Liquid Metal Squeeze Infiltration Process

Present study aims to fabricate selectively reinforced aluminum hybrid composites using varying combinations of porous ceramic preforms containing discontinuous dispersoids of silicon carbide, aluminosilicate fiber, and carbon followed by direct squeeze infiltration processing of molten aluminum into the preforms. Porous preforms are successfully fabricated by the burn out of polyethylene glycol, and aluminum is used as the binder for the sintered body. Selectively reinforced hybrid aluminum composite has been successfully processed using liquid metal squeeze infiltration of porous preforms by controlled process parameters like preform preheating temperature, liquid metal temperature, squeeze pressure, and die temperature.

Modelling and neutron diffraction characterization of the interfacial bonding of spray formed dissimilar steels

The spray forming of thick, dissimilar steel clad tubes with the objective of achieving a high integrity metallurgical bond across the cladding-substrate interface able to withstand residual stresses and subsequent thermo-mechanical processing was investigated by large scale experiments, modelling and extensive microstructural characterization including microscopy, X-ray tomography, neutron scattering and mechanical testing. The simulated residual stress distributions across the cladding-substrate interface, accounting for any as-sprayed porosity and the distribution of martensitic and retained austenite phases, were compared with neutron diffraction measurements and differences used to infer the load transfer behaviour and thus the mechanical integrity of the interface. The mechanical properties of the interfaces were then also measured directly by shear testing. The link between substrate pre-heating, the spray forming temperature, and the resulting preform temperature, porosity, phase fractions, residual stress, strength and integrity of the interface were established and quantified explicitly.

Optimisation of mould surface temperature and bottle residence time in mould for the carbonated soft drink PET containers

Polyethylene terephthalate (PET) bottles, which are usually produced by injection stretch blow moulding (ISBM) are widely used for carbonated soft drinks (CSD) storage and transportation. Stretch rod movement, blow pressure, preform temperature profile, mould surface temperature and material properties are among the most important factors affecting the final product's quality in terms of the thickness distribution, burst pressure and top-load resistance of the bottles. However, the residence time of the blown bottle inside the mould is also an important factor affecting its final properties. Especially in PET bottle production for hot fillings, the residence time is a very important factor because the longer the residence time the better the crystalline structure of the PET. In this production, the lid section is desired to have a fully crystalline form so that it can withstand hot fluids. In this study, the aim was to optimise the mould surface temperature and the blown bottle's residence time inside the mould for 1 L soft drink PET bottle production based on the final properties using the ECHIP 7 design of experiment (DOE) program. The method employed through this program was a quadratic one. Optimum process parameters were determined by the response surface method (RSM) and the process settings ensuring maximum top-load, burst pressure, Tg and degree of crystallinity were regarded to be optimum. It was found that the optimum mould surface temperature and blown bottle residence time inside the mould were 10 °C and 20 s, respectively.

Finite element simulations of stretch-blow moulding with experimental validation over a broad process window

Injection stretch blow moulding is a well-established method of forming thin-walled containers and has been extensively researched for numerous years. This paper is concerned with validating the finite element analysis of the free-stretch-blow process in an effort to progress the development of injection stretch blow moulding of poly(ethylene terephthalate). Extensive data was obtained experimentally over a wide process window accounting for material temperature and air flow rate, while capturing cavity pressure, stretch-rod reaction force and preform surface strain. This data was then used to assess the accuracy of the correlating FE simulation constructed using ABAQUS/Explicit solver and an appropriate viscoelastic material subroutine. Results reveal that the simulation is able to give good quantitative correlation for conditions where the deformation was predominantly equal biaxial whilst qualitative correlation was achievable when the mode of deformation was predominantly sequential biaxial. Overall the simulation was able to pick up the general trends of how the pressure, reaction force, strain rate and strain vary with the variation in preform temperature and air flow rate. The knowledge gained from these analyses provides insight into the mechanisms of bottle formation, subsequently improving the blow moulding simulation and allowing for reduction in future development costs.

A novel methodology to characterize the constitutive behaviour of polyethylene terephthalate for the stretch blow moulding process

The stretch blow moulding (SBM) process is the main method for the mass production of PET containers. And understanding the constitutive behaviour of PET during this process is critical for designing the optimum product and process. However due to its nonlinear viscoelastic behaviour, the behaviour of PET is highly sensitive to its thermomechanical history making the task of modelling its constitutive behaviour complex. This means that the constitutive model will be useful only if it is known to be valid under the actual conditions of interest to the SBM process. The aim of this work was to develop a new material characterization method providing new data for the deformation behaviour of PET relevant to the SBM process. In order to achieve this goal, a reliable and robust characterization method was developed based on an instrumented stretch rod and a digital image correlation system to determine the stress-strain relationship of material in deforming preforms during free stretch-blow tests. The effect of preform temperature and air mass flow rate on the deformation behaviour of PET was also investigated.

Free-stretch-blow investigation of poly(ethylene terephthalate) over a large process window

This paper highlights for the first time a full comprehension of the deformation procedure during the injection stretch blow moulding (ISBM) process of poly(ethylene terephthalate) (PET) containers, namely thin-walled rigid bottles. The processes required to form PET bottles are complicated and extensive; any development in understanding the nature of material deformation can potentially improve the bottle optimisation process. Removing the bottle mould and performing free-stretch-blow (FSB) experiments revealed insight into the bottle forming characteristics at various preform temperatures and blowing rates. Process outputs cavity pressure and stretch-rod force were recorded using at instrumented stretch-rod and preform surface strain mapping was determined using a combination of a unique patterning procedure and high speed stereoscopic digital image correlation. The unprecedented experimental analysis reveals that the deformation behaviour varies considerably with contrasting process input parameters. Investigation into the effect on deformation mode, strain rate and final bottle shape provide a basis for full understanding of the process optimisation and therefore how the process inputs may aid development of the preferred optimised container.

Effect of green preform composition, temperature and duration conditions on microstructure and performance of Al-5Ti-0.2C master alloy

Abstract Al-5Ti-0.2C master alloy was prepared via a simple combustion synthesis approach. By means of different smelting parameters, changes in its microstructure and refining performance were studied. Under short holding conditions (5 – 10 min) increase of Al content in the preform from 10 % to 40 % results in more numerous carbon-rich particles in the master alloy and better refinement performance. Nevertheless, preparation of refiner with satisfactory refining ability requires longer holding conditions (30 min). With prolonged holding time after the combustion, alloys possess similar microstructure and refining efficacy regardless of the chemical composition of the preform. Decrease of smelting temperature from 1 250 °C to 950 °C results in noticeable deterioration of the master alloy refining performance. The reasons, which impede successful utilization of primary benefits provided by combustion reaction, are discussed.

Development of Al 319-Micro Silica Metallic Composite by Squeeze Infiltration Technique

The objective of present investigation is to synthesize porous micro silica based ceramic preform with varying composition of particles using burn out technique and processing of Al-Micro silica metal-ceramic composites by squeeze infiltration method. Direct squeeze infiltration of 319 aluminum alloy on micro silica preform is successfully carried out with the controlled process parameters of initial preform temperature, liquid metal superheat, squeeze pressure and its rate of application, and die temperature. The preform and composites are characterized using optical microscopy, electron microscopy, hardness and compression strength testing. Porous ceramic preform with more than 70% porosity has been fabricated by PEG as pore former. The infiltrated composite have shown uniform and complete infiltration of aluminum alloy in between micro silica particles.

Processing of silica bonded porous SiC preform for metallic composites

Porous SiC ceramics were successfully fabricated by silica bonding of SiC compacts and porogen burnout technique. Silica coating on SiC particle was carried out using TEOS hydrolysis and crystallizes during the sintering process at 1200 °C, which forms a well-developed neck growth between the SiC particles. Different volume fractions of sodium chloride porogen were used to obtain varied porosity content in porous SiC ceramics from 36 to 62.47 % leading to wide-ranging compressive strength from 8.11 to 0.69 MPa. Interconnected bimodal pores were created throughout the sample due to the burnt out of salt and stacking of SiC particles. The pore size distribution of porous SiC measured using mercury intrusion porosimetry shows that average pore size due to the salt particle is around 74–110 µm and stacking of SiC particle result 4–10 µm. Direct squeeze infiltration method is successfully adopted for infiltration of 6061 aluminium molten alloy into SiC preforms with the controlled process parameters of initial preform temperature, liquid metal superheating, squeezed pressure and its rate of application and die temperature. Microstructures have shown complete infiltration of Al alloy into the pores of the SiC preform forming Al composite with good interfacial bonding aided by the presence of MgAl2O4 spinel. The silica coating on SiC surface have a multifunctional role of acting as a binder for the porous preform, enhances the wettability of SiC particle with molten metal during infiltration and prevention of deleterious Al4C3 interfacial reaction product.

High Performance Temperature Detection System for Industrial Automation

Temperature detection technology plays an important role in the industrial automation systems, for example the production of the plastic container in the industrial manufacturing machines. To produce a high quality plastic product, blow molding machines need a high performance and a great precision non-contact temperature detecting system. In this paper, the authors custom design and implement a high performance distributed microcontroller system for non-contact temperature measurement. In practice, this system can detect the temperature of plastic preforms in the heating system of blow molding machines by using infrared temperature sensors and employing the network communication technologies, such as SMBus, UART and RS485 networks. Finally, some experiments are executed to evaluate the performance of the authors' system.

Synthesis of Copper/Silicon-Carbide Composites in a Thermodynamic Disequilibrium

Composites with interpenetrating metal-ceramic microstructures (IPC, interpenetrating composites) can be tailored for specific applications, such as high thermal conductivity combined with low thermal expansion, e.g. for heat sinks. Heat sinks are required in power electronic devices or in future fusion reactor technology where extreme conditions and high cyclic thermo-mechanical loads appear. Due to its rigid ceramic backbone IPCs are expected to reveal high thermal stability. Pure silicon carbide exhibits high thermal conductivity, low coefficient of thermal expansion, high corrosion and wear resistance. But it is also known as a very brittle material when mechanical loads are applied. Thus a composite of silicon carbide with ductile and highly conductive copper seems to be a promising new material for a number of applications.This paper reports the synthesis of Cu-SiC composites using a unique high temperature squeeze casting process (HTSC). Microstructural design of SiC-preforms with open porosity and its synthesis progress is reported. Influence of preform properties, temperature, pressure and atmosphere during HTSC were investigated. A qualitative and quantitative description of the microstructure of the composites and their composition allows the creation of structure-property correlations that take effect retroactively to the casting process.

Optimization design preform billet shape of 7050 aluminum alloy giant plane forgings based on electric field method and MBC toolbox

The preform billet shape of the 7050 aluminum alloy giant plane forgings has been designed using electric field method based on similarity principle. Firstly, the electrostatic field was analysed by using ANSYS software, from which the preform billet shape was obtained based on electrostatic field equipotential lines. The preform shape, press velocity, temperature and friction factor were taken as parameter variables, while the forming load, filling rate and grain size were chosen as optimization goals. The mathematical model was optimized by the use of a Model-Based Calibration (MBC) toolbox for modelling, Three-Dimensional of Design Environment for FORMing (DEFORM-3D) for simulation and CAlibration GEneration (CAGE) toolbox, obtaining the best preform shape and the optimal combination of process parameters (friction factor μ = 0.2, press velocity ν = 9.8 mm/s and billet temperature T = 478 °C) when the equipotential line was ξ = 0.425 V. Finally, comparing with initial preform shape, the results indicate that the optimized preform billet designed by electric field method has an advantage in finish forging, while the forming load of finish forging reduces by about 38 % and the average micrograin size reduces by about 45 %. Therefore, it provides an effective method for designing preform billet shape of complex forgings.

Temperature controlling process to eliminate metallurgical defects in spray forming with twin scanning atomiser

Relations among pouring temperature, billet temperature distribution and deposit distance in spray forming procedures were analysed in this paper. Research results indicated that the top surface temperature of preforms would rise steadily even when the pouring temperature was kept steady. To illustrate this phenomenon by experiment, commercial software was used to simulate the temperature gradient in preforms during and after deposition. A hot spot was found forming in a superalloy billet that would shrink into hot cracking during the cooling process that usually forms at two-thirds of the billet’s total height. A novel process, called ‘thermal controlling’, was designed based on this finding to reduce metallurgical defects in large billets, including superalloys and high speed steel. The principle is that the top surface temperature of the preforms should be sustained in order to maintain an optimised ratio of liquid to solid. Several billets were produced at the Beijing Institute of Aeronautical Materials with this method, and no hot cracking was found. During the experiment on spray forming, the ratio of liquid to solid metal increases more than expected, which leads to a high risk of hot cracking. The hot spot is the main reason for the formation of metallurgical defects. The temperature controlling method is an effective way to reduce or eliminate defects in superalloy preforms. The thermal controlling method can reduce the microporosity that contributes to yielding high density materials.