summerschool2011 - plastic shaping part ii
TRANSCRIPT
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CCCLEMCLEM
VACUUM FORMINGVACUUM FORMINGVACUUM FORMING VACUUM FORMING
dHr. Verheust V.
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
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Overview• Vacuum forming ?
• Commonly used techniques
• Design: opportunities restrictions
• Finishing g
• Projectsj
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Vacuum forming ?Thermoplastic, semimanufactured product in plate form p
3-D product
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Vacuum forming - process
3 stages in the process
Heating up Forming Cooling
(plate thickness sort of material)(plate thickness, sort of material)(form place dependent)
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Forming
Heated plateMould
Clamp systemp y
Temp. control channels
Vacuum channel
channels
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Forming machines 2 basic concepts 2 basic concepts
• Single-station (discontinuous)
• Multi-station(quasi-continuous)(q )
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Forming machines
Single-station Multi-station (carrousel)
3 different treatment stations(loading/unloading, heating, forming)
1 treatment station
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(loading/unloading, heating, forming)
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Commonly used techniques • Positive forming
– Usual positive forming – Forming using pre-blowing – Forming a vacuum
• Negative forming – Usual negative forming – Forming with stamp – Forming using pre-blowing, stamp and vacuum
Hi h f i (HPF)• High pressure forming (HPF)• Twin sheet forming g
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Usual positive forming
Heating
Elastic
iForming
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Usual positive forming
V i bl ll hi k improvement via• Variable wall thickness improvement viapre-blowing or
vacuum• Inside – correct dimensions
vacuum
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Application
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Positive forming + pre-blowing
• Better division of wall thickness via pre-blowing
1. Pre-blowing
2. Vacuum
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Positive forming + pre-blowing
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Applications
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Application
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Positive forming + vacuum
• Better division of wall thickness via vacuum
Vacuum
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Application
Lighting hood (base: 500 x 350)
(h i ht 600)(height: 600)
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Negative forming
Variable wall thickness
Vacuum
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Negative forming
Improvement via• Variable wall thickness Improvement via stamp
• Outside – correct dimensions
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Application
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Negative with stamp • Better division of wall thickness via stamp
1. Stamp1. Stamp stretching
2 V2. Vacuum
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Applications
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Negative forming with pre-Negative forming with preblowing, stamp and vacuum
• Better division of wall thickness Better division of wall thickness
1. Pre-blowing
2 St2. Stamp stretching
3. Vacuum
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Applications
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High pressure forming (HPF)
At atmosphere High pressure
A t l ?Acute angles? •Almost always negative
•Acute angles no problem
•Adding texture to the surface is possible
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Negative HPF
• Variable wall thickness • Adding texture to the surface is possible
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Negative HPF with stamp
• Better division of wall thickness via stamp• Adding texture to the surface is possible
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Twin sheet forming
• 2 sheets are heated up simultaneously + formed + welded
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Design:Design:opportunities restrictionsopportunities restrictions
• Variable wall thickness
Positive Negative
• 1 side with correct dimensions as a result of contact with mould
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Design:Design:opportunities restrictions
• Ideal angle
opportunities restrictions g
135 °, ideal 90°, good 60°, to be avoided
to be avoided better best
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Design:Design:opportunities restrictions
• Conics
opportunities restrictions
A id d t th h th ibl• Avoid undercuts, though they are possible
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Design:Design:opportunities restrictions
• Depth of draw
opportunities restrictions p
Stamp necessary ?necessary ?
S d d• Secondary draw Strong thinning of wall thickness
Stamp from above i h ll d
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with controlled temperature
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Design:Design:opportunities restrictions
• Draw ratio
opportunities restrictions
initial thickness average final thickness
Draw ratio = sum of all surfaces initial surface
=
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FinishingFrom plate to final product
Vacuum forming with automatic loader
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automatic loader
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FinishingFrom plate to final product
5-axis milling 3D measurement bench
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bench
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Projects
• Realised projects in very diverse domains – Medical sector
Automotive sector / transport– Automotive sector / transport– Industry– Design & display– Art – ...
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Projects
• Medical sector
Part of radiology device Communication aid
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Projects
• Automotive sector / transport
Bodywork Roof part
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Projects
• Industry
Housing of a loom Internal door
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Projects
• Design & display
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Projects
• Art
Pieces of scenery
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