Finite element analysis of vacuum forming process

Rimowa是高端聚碳酸酯和铝制行李箱制造的领先者。该公司使用一种创新的制造工艺，包括将加热的聚碳酸酯薄板真空成型到金属模具上。每年，Rimowa都会因为真空成型零件的缺陷造成数百万美元的损失，这些零件的角部有褶皱和厚度不均匀。他们无法解决问题，因为这些缺陷的原因尚不清楚。其原因可能是加热后的聚碳酸酯板材拉伸不均匀，以及真空成型后聚碳酸酯板材与金属模具之间的换热。该项目的主要目标是开发真空成形过程的计算模型，并调查制造零件中缺陷的原因。

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.