Towards simulation-based optimization of the thermoforming process of lightweight acrylic bathtubs

基于模拟的轻质亚克力浴缸热成型工艺优化

• 批准号: 543548-2019
• 负责人: Seethaler, Rudolf
• 金额: $ 1.82万
• 依托单位: University of British Columbia
• 依托单位国家: 加拿大
• 项目类别: Engage Grants Program
• 财政年份: 2019
• 资助国家: 加拿大
• 起止时间: 2019-01-01 至 2020-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=681246
• 关键词: Towards; simulation; based; optimization; thermoforming

Hytec, a division of Kohler Canada, produces gelcoat and acrylic baths, showers, modular bathing systems and shower bases with diverse designs and structures . Thermoforming, a well-known cost-effective yet complex process in the industry sector, has been used at Kohler as the primary approach to manufacturing bathtubs and shower bases. However, the occasional occurrence of defects, such as cracks, webbings, and plastic sheet tearing, requires costly repairs or sometimes even reject parts that significantly impact the final cost of parts.The absence of robust data collection infrastructure for monitoring the process, as well as the complexity and uncertainty in the thermal and mechanical aspects of the thermoforming process turns investigating the process characteristics and detecting the sources of the failures into a laborious and challenging task for Kohler's engineers.The goal of the proposed ENGAGE project is to help Hytec to start developing advanced numerical models that can predict the quality of thermoforming parts, and hence to mitigate potential defects ahead of actual manufacturing trials. Such models are deemed particularly useful for cases where the manufacturer would like to e.g. produce bathtub parts with new shapes.

Hytec是加拿大科勒的一个部门，生产具有不同设计和结构的胶衣和丙烯酸浴缸、淋浴器、模块化洗浴系统和淋浴器底座。 热成型是工业领域一种众所周知的成本效益高但复杂的工艺，科勒将其作为制造浴缸和淋浴底座的主要方法。然而，偶尔出现的缺陷，如裂纹、腹板和塑料板撕裂，需要昂贵的维修，有时甚至需要拒收零件，这会显著影响零件的最终成本。缺乏强大的数据收集基础设施来监控过程，以及热成型工艺的热和机械方面的复杂性和不确定性，转而研究工艺特性并检测对于科勒的工程师来说，这是一项艰巨而富有挑战性的任务。拟议的ENGAGE项目的目标是帮助Hytec开始开发先进的数值模型，可以预测热成型零件的质量，从而在实际生产试验之前减少潜在的缺陷。这种模型被认为对于制造商想要例如生产具有新形状的浴缸部件的情况特别有用。