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

Hytec是加拿大科勒公司的分支机构，生产各种设计和结构的凝胶涂层和丙烯酸浴缸、淋浴器、模块化沐浴系统和淋浴座。在工业领域，热成型是一种众所周知的具有成本效益但复杂的工艺，已被科勒用作制造浴缸和淋浴座的主要方法。然而，偶尔发生的缺陷，如裂纹，带和塑料片撕裂，需要昂贵的维修，有时甚至拒绝零件，这对零件的最终成本产生重大影响。由于缺乏强大的数据收集基础设施来监控过程，以及热成型过程的热学和机械方面的复杂性和不确定性，使得研究过程特征和检测故障来源成为科勒工程师的一项艰巨而具有挑战性的任务。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，从而在实际制造试验之前减轻潜在的缺陷。这样的模型被认为是特别有用的情况下，制造商想要例如生产浴缸零件的新形状。

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.