Simulation of Shrinkage and Warpage of Rotationally Moulded Polymer Parts

Jitendra Seregar; Mark McCourt; Mark Kearns; Peter Martin; Gary Menary

doi:10.1016/j.promfg.2020.04.303

Simulation of Shrinkage and Warpage of Rotationally Moulded Polymer Parts

Jitendra Seregar^*, Mark McCourt, Mark Kearns, Peter Martin, Gary Menary

^*Corresponding author for this work

Research output: Contribution to journal › Article › peer-review

3 Citations (Scopus)

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Abstract

The rotomoulding industry is impeded by long manufacturing cycle times, due to insufficient time required for the materials to achieve a stable state on cooling. Thermal residual stresses are induced in rotomoulded parts due to uncontrolled heat transfer, producing shrinkage and warpage in parts. There is little information about quantifying shrinkage and warpage due to a lack of available experimental data. The main aim of this work is to develop simulation model for shrinkage and warpage occurrence in rotomoulded polymer parts. In this work, the Abaqus FE modelling tool is used for obtaining the thermal coefficients data required in shrinkage model. The simulation results obtained by cooling of the molten polymer fuel tank part has provided information about heat transfer coefficient data. It is expected that once model is developed taking into account the effect of crystallization in polymers on shrinkage, it will be used to simulate shrinkage and warpage in actual rotomoulded parts. However, in this work only preliminary results are discussed. This simulation work provides a scientific understanding needed to achieve desired optimum mould surface temperature for improved cycle time, whilst minimizing shrinkage and warpage occurrence.

Original language	English
Pages (from-to)	987-990
Number of pages	4
Journal	Procedia Manufacturing
Volume	47
DOIs	https://doi.org/10.1016/j.promfg.2020.04.303
Publication status	Published - 26 Apr 2020
Event	23rd International Conference on Material Forming, ESAFORM 2020 - Cottbus, Germany Duration: 04 May 2020 → …

Bibliographical note

Funding Information:
The authors acknowledge and thankful to Special EU Programmes Body (SEUPB) for the financial support provided under EU INTERREG VA programme. Special thanks are also due to Dr Ed Wright of RotoSim ltd. for valuable discussions and suggestions.

Publisher Copyright:
© 2020 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) Peer-review under responsibility of the scientific committee of the 23rd International Conference on Material Forming.

Copyright:
Copyright 2020 Elsevier B.V., All rights reserved.

Keywords

Rotational Moulding
Rotomoulding Simulation
Shrinkage and Warpage
Simulation

ASJC Scopus subject areas

Industrial and Manufacturing Engineering
Artificial Intelligence

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10.1016/j.promfg.2020.04.303Licence: CC BY-NC-ND

Simulation of Shrinkage and Warpage of Rotationally Moulded Polymer Parts
© 2020 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND licence: https://creativecommons.org/licenses/by-nc-nd/4.0/
Final published version, 848 KBLicence: CC BY-NC-ND

Advanced simulation of the rotational moulding process
Seregar, J. (Author), Martin, P. (Supervisor) & Menary, G. (Supervisor), Jul 2023
Student thesis: Doctoral Thesis › Doctor of Philosophy

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Cite this

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title = "Simulation of Shrinkage and Warpage of Rotationally Moulded Polymer Parts",

abstract = "The rotomoulding industry is impeded by long manufacturing cycle times, due to insufficient time required for the materials to achieve a stable state on cooling. Thermal residual stresses are induced in rotomoulded parts due to uncontrolled heat transfer, producing shrinkage and warpage in parts. There is little information about quantifying shrinkage and warpage due to a lack of available experimental data. The main aim of this work is to develop simulation model for shrinkage and warpage occurrence in rotomoulded polymer parts. In this work, the Abaqus FE modelling tool is used for obtaining the thermal coefficients data required in shrinkage model. The simulation results obtained by cooling of the molten polymer fuel tank part has provided information about heat transfer coefficient data. It is expected that once model is developed taking into account the effect of crystallization in polymers on shrinkage, it will be used to simulate shrinkage and warpage in actual rotomoulded parts. However, in this work only preliminary results are discussed. This simulation work provides a scientific understanding needed to achieve desired optimum mould surface temperature for improved cycle time, whilst minimizing shrinkage and warpage occurrence.",

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author = "Jitendra Seregar and Mark McCourt and Mark Kearns and Peter Martin and Gary Menary",

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AU - Kearns, Mark

AU - Martin, Peter

AU - Menary, Gary

N1 - Funding Information: The authors acknowledge and thankful to Special EU Programmes Body (SEUPB) for the financial support provided under EU INTERREG VA programme. Special thanks are also due to Dr Ed Wright of RotoSim ltd. for valuable discussions and suggestions. Publisher Copyright: © 2020 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) Peer-review under responsibility of the scientific committee of the 23rd International Conference on Material Forming. Copyright: Copyright 2020 Elsevier B.V., All rights reserved.

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Y1 - 2020/4/26

N2 - The rotomoulding industry is impeded by long manufacturing cycle times, due to insufficient time required for the materials to achieve a stable state on cooling. Thermal residual stresses are induced in rotomoulded parts due to uncontrolled heat transfer, producing shrinkage and warpage in parts. There is little information about quantifying shrinkage and warpage due to a lack of available experimental data. The main aim of this work is to develop simulation model for shrinkage and warpage occurrence in rotomoulded polymer parts. In this work, the Abaqus FE modelling tool is used for obtaining the thermal coefficients data required in shrinkage model. The simulation results obtained by cooling of the molten polymer fuel tank part has provided information about heat transfer coefficient data. It is expected that once model is developed taking into account the effect of crystallization in polymers on shrinkage, it will be used to simulate shrinkage and warpage in actual rotomoulded parts. However, in this work only preliminary results are discussed. This simulation work provides a scientific understanding needed to achieve desired optimum mould surface temperature for improved cycle time, whilst minimizing shrinkage and warpage occurrence.

AB - The rotomoulding industry is impeded by long manufacturing cycle times, due to insufficient time required for the materials to achieve a stable state on cooling. Thermal residual stresses are induced in rotomoulded parts due to uncontrolled heat transfer, producing shrinkage and warpage in parts. There is little information about quantifying shrinkage and warpage due to a lack of available experimental data. The main aim of this work is to develop simulation model for shrinkage and warpage occurrence in rotomoulded polymer parts. In this work, the Abaqus FE modelling tool is used for obtaining the thermal coefficients data required in shrinkage model. The simulation results obtained by cooling of the molten polymer fuel tank part has provided information about heat transfer coefficient data. It is expected that once model is developed taking into account the effect of crystallization in polymers on shrinkage, it will be used to simulate shrinkage and warpage in actual rotomoulded parts. However, in this work only preliminary results are discussed. This simulation work provides a scientific understanding needed to achieve desired optimum mould surface temperature for improved cycle time, whilst minimizing shrinkage and warpage occurrence.

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Simulation of Shrinkage and Warpage of Rotationally Moulded Polymer Parts

Abstract

Bibliographical note

Keywords

ASJC Scopus subject areas

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Student theses

Advanced simulation of the rotational moulding process

Cite this