MFGT 142Polymer Processing Chapter 14 Thermoforming.ppt

MFGT 142Polymer Processing Chapter 14: Thermoforming Thermoforming Process Overview Forming processes straight vacuum, pressure, plug assist reverse draw, free, drape, snap-back, matched die, mechanical Blister pack and skin pack Equipment machine, molds, plant considerations Product considerations materials, shapes, part design Operation and control critical parameters, trouble-shooting maintenance, and safety Thermoforming Advantages Low machine cost Low temperature requirement Low mold cost Low pressure requirement Large parts easily formed Fast mold cycles Disadvantages High cost of raw materials (sheets) High scrap Limited part shapes Only one side of part defined by mold Inherent wall thickness variation Internal stresses common Forming Process Straight Vacuum Forming Figure 13.1 Forming Process Pressure Forming Positive air pressure (14.5 to 300 psi) on top of mold forms the part. Advantages include faster mold cycles, sheet formed with lower temperatures due to higher forming pressure, greater dimensional control and part definition. Figure 13.2 Forming Process Plug-Assist Forming Top side is formed with core form. Vacuum applied to finish forming. Advantages include better wall thickness uniformity especially for cup or box shapes, and reduces stretching or thinning of material during forming. Materials of plug include wood, metal, thermoset polymers. Temperature of plug is a few degrees cooler than plastic to prevent premature cooling. Plug is 10% - 20 % smaller than cavity. Figure 13.3 Forming Process Reverse Draw Forming Used when very deep draws are needed. Material is heated to the sag point and then blown away from the mold which thins the material in the center of the sheet. The size of the bubble is controlled with an electric eye. Plug assist procedures continue to form the part. Advantage is better thickness uniformity. Disadvantage is cycle time. Figure 13.4 Forming Process Free Forming Forming is done without a mold. Part is expande