Glass bottle forming process modeled in...
Transcript of Glass bottle forming process modeled in...
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Glass bottle forming process
modeled in STAR-CCM+
Presented by:
Ferrari Simone
Structural and Fluid Dynamic Simulation Department
R&D Bottero Group
Star Global Conference 2014 Vienna, 17–19 March 2014
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Agenda
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Cuneo – (Headquarter)
Trana
Vicenza
Treviso
Pesaro
Italy
France
St. Jeannet
Germany
Grevenbroich
Donauwörth
United Kingdom
Rochdale
Company profile
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Shanghai
Foshan
Bengbu
China
USA
Kernesville
Brasile
Diadema
Company profile
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Business and products
Flat Glass Hollow Glass
Bottero business and products
Special trailers
COMETTO industries
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Focus on Hollow Glass Division
Hollow Glass
Offers a complete range for glass forming from fore-hearths to lehr
Glass Conditioning
Gob Forming
Container Forming
Ware Handling
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Container Forming
Glass Conditioning
Gob Forming
Focus on Hollow Glass Division
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Press & Blow process
The gob is guided into a blank mold 1
A plunger rises from the neck side and
presses the gob forming the “Parison” 2
The mold opens and the partially formed
container is released and inverted through
180 degrees
3
The container is transferred to the blow
mold 4
Air is injected to blow the container into
shape 5
Finished container 6
Container Forming Cycle
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Bottero E-MOC
Blank and Mold Mechanism
Innovation in glass
industry
Top mounted
Parallel Molds motion
Retrofittable
IS mold compatible
360° Axial and Radial Cooling
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Glass Viscosity vs. T
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Glass Bottle Forming
IR Thermo-Measurement
Forming steps
Simulation Steps
Step 1
Blank Side
Parison Forming
Step 2
Invert Mechanism
Reheating
Step 3
Blow Side
Stretching
Step 4
Blow Side
Bottle Forming
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Step 1) Blank Side – Parison Forming
Conjugate Heat Transfer
Simulation:
• Input: T Glass Gob
• Conduction and Radiation
• Physical Material
Properties
• Unsteady: Time =
Machine Timing
Equipment Thermal Images Volume Temperature Distribution
Steady State Simulation
Plunger
Neck-Ring
Blank
Mold
Parison
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Step 1) Blank Side – Parison Forming
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Step 2) Invert Mechanism – Reheating
Conjugate Heat Transfer
Simulation:
• T Glass from Step 1
• Air Convection: T Air
• Conduction and Radiation
• Unsteady: Time = Machine
Timing
From Blank Side... ... to Blow Side
Rotation 180°
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Step 2) Invert Mechanism – Reheating
Rotation 180°
Hard Parison
Soft Parison
Ready to stretch… Parison surface Temperature
From Blank Side... ... to Blow Side
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Step 3) Blow Side – Stretching
VOF Simulation 3D
• 2 Phases: Glass and Air
• Conduction and Air Convection
• Gravity
• Unsteady: Time = Machine
Timing
Input:
3D Temperature Distribution from the
Reheating Step
Input:
Viscosity (T)
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Step 3) Blow Side – Stretching
Physical Interpretation
Gravity, Conduction, Temperature, Viscosity…
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Step 3) Blow Side – Stretching
Stretching extremely depends on:
• Parison Design
• Process Variables (e.g. Molten Glass T, Molds Contact time)
Higher Molten Glass T Simulation 5°C higher T
000 000 000
000 0
00
000
0
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Step 4) Blow Side – Bottle Forming
VOF Simulation
• Blow Pressure
• Vacuum Pressure
• Unsteady: Time =
Machine Timing
Vacuum
Holes
Blow Head
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Step 4) Blow Side – Bottle Forming
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Final Bottle Results
Thickness Profile
• Compromise between structural properties and bottle weight
• Stretching is the Key-Step
Simulation Measure
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• Simulation is based on physical parameters in both thermal and dynamic properties
Conclusions
• The VOF model handles glass viscosity from liquid (100 P) to solid (109 P) with high time-steps
• The simulation variables are the machine settings (e.g. cycle timing, molten glass T)
• Application cases:
- Parison Design to reduce the trials on molds and on machines
- Effects of non-idealities on process variables
Next goal is the optimization of the entire forming process to reach faster production and lighter bottles
CONCLUSIONS