Finite element analysis of vacuum forming process

Rimowa是高端聚碳酸酯和铝制行李箱制造业的领导者。该公司采用了一种创新的制造工艺，包括将加热的聚碳酸酯片材真空成型到金属模具上。每年，Rimowa都会因为有缺陷的真空成型部件而损失数百万美元，这些部件在角落处有皱纹和厚度不均匀。他们无法解决这个问题，因为这些缺陷的原因是未知的。其原因可能包括加热的聚碳酸酯片材的不均匀拉伸以及真空成型后聚碳酸酯片材与金属模具之间的热传递。本计画的主要目的是建立真空成型制程的计算模型，并探讨制造零件产生缺陷的原因。

Rimowa is a leader in manufacturing of high-end polycarbonate and aluminum suitcases. The company uses an innovative manufacturing process that involves vacuum forming of heated polycarbonate sheet on to metallic moulds. Every year, Rimowa loses millions of dollars because of defective vacuum molded parts that have wrinkles and non-uniform thickness at the corners. They are unable to fix the problem because the reasons for these defects are unknown. The reasons could range from non-uniform stretching of the heated polycarbonate sheet to heat transfer between polycarbonate sheet and metallic mould after vacuum forming. The primary objective of this project is to develop a computational model of the vacuum forming process and investigate the reasons for defects in the fabricated parts.