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com
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Available
ScienceDirect
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online atonline
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Procedia CIRP 00 (2019) 000–000
ScienceDirect
Procedia CIRP 00 (2019) 000–000
ScienceDirect www.elsevier.com/locate/procedia
www.elsevier.com/locate/procedia

ProcediaProcedia
CIRP 00CIRP
(2017)
81000–000
(2019) 1307–1312
www.elsevier.com/locate/procedia

52nd
52nd CIRP
CIRP Conference
Conference on
on Manufacturing
Manufacturing Systems
Systems

The
The effect
effect of
of the
28thdeformation
the deformation rate
rate on the
on May
CIRP Design Conference, wall
the 2018, thickness
wallNantes, France of
thickness of 1.5LT
1.5LT PET
PET
bottle
bottle during
during ISBM
ISBM (Injection
(Injection Stretch
Stretch Blow
Blow Molding)
Molding) process
process
A new methodology to analyze thea functional band physical architecture of
A.Lontos
A.Lontosa,,oriented
A.
A. Gregorioub*
existing products for an assembly product
Gregoriou * family identification
a,bFrederick
University Cyprus, 7, Y. Frederickou Str.
a,b
Frederick University Cyprus, 7, Y. Frederickou Str.
Pallouriotisa, Nicosia 1036
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
Pallouriotisa, Nicosia 1036
Cyprus
Cyprus
* Corresponding author. Tel.: +00357 22394394; fax: +00357 22438234. E-mail address: andreasgregoriou2586@gmail.com
* Corresponding
Écoleauthor. Tel.:Supérieure
Nationale +00357 22394394;
d’Arts et fax: +00357
Métiers, Arts22438234.
et MétiersE-mail address:
ParisTech, LCFC andreasgregoriou2586@gmail.com
EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France

* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu

Abstract
Abstract
The biaxial orientation of deformation during the ISBM process forms the final desired volume of the plastic container. The ISBM process
The biaxial orientation of deformation during the ISBM process forms the final desired volume of the plastic container. The ISBM process
Abstract
comprises stretching and blowing of a preheated preform inside a mold for the formation of a beverage container. The current study deals with
comprises stretching and blowing of a preheated preform inside a mold for the formation of a beverage container. The current study deals with
the numerical investigation of the effect of deformation rate on the final bottle thickness wall distribution. It was considered that the stretching
the numerical investigation of the effect of deformation rate on the final bottle thickness wall distribution. It was considered that the stretching
Inrod
today’s
velocitybusiness
varies environment,
from 0.6-0.8m/s the and
trendthetowards more pressure
preblowing product variety and customization
from 0.4-1.6MPa. is unbroken.
Additionally, Due to of
the advantage thisstretching
development,
versusthefree
need of
blow
rod velocity varies from 0.6-0.8m/s and the preblowing pressure from 0.4-1.6MPa. Additionally, the advantage of stretching versus free blow
agile and reconfigurable
conditions production
is being discussed. It wassystems
found that emerged
highesttoiscope with various
the stretching products
velocity, and product
the higher families. material
is the resulting To design and optimize
concentration at production
the base of
conditions is being discussed. It was found that highest is the stretching velocity, the higher is the resulting material concentration at the base of
systems as Additionally,
the bottle. well as to choose
it wasthe optimal
found that product
the highermatches,
preblowingproduct analysis
pressure methods thick
accumulates are needed.
materialIndeed, most ofregion
at the central the known
of themethods aimthe
bottle while to
the bottle. Additionally, it was found that the higher preblowing pressure accumulates thick material at the central region of the bottle while the
analyze
upper anda product
bottomorregions
one product
of the family on the
bottle get physical level. Different product families, however, may differ largely in terms of the number and
thinner.
upper and bottom regions of the bottle get thinner.
nature
© 2019 ofThe
components. This fact by
Authors. Published impedes
ElsevieranLtd.
efficient
This iscomparison and article
an open access choice under
of appropriate product family
the CC BY-NC-ND combinations for the production
license
©
© 2019
2019AThe
The Authors. Published
Authors. Published by by Elsevier
Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
Ltd.
system. new methodology is proposed to analyze
(http://creativecommons.org/licenses/by-nc-nd/3.0/) existing products in view of their functional and physical architecture. The aim is to cluster
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
This products
is an open
these
Peer-review inaccess
new
under article under
assembly
responsibility the scientific
oriented
of the CC BY-NC-ND
product families license
committeefor the (http://creativecommons.org/licenses/by-nc-nd/3.0/)
optimization
of the 52nd CIRPofConference
existing assembly lines and the
on Manufacturing creation of future reconfigurable
Systems.
Peer-review
Peer-review under responsibility
underBased
responsibility of the
the scientific
of Flowscientific committee of
committee of the
the 52nd
52nd CIRP
CIRP Conference
Conference on on Manufacturing
Manufacturing Systems.
Systems.
assembly systems. on Datum Chain, the physical structure of the products is analyzed. Functional subassemblies are identified, and
a Keywords:
functionalISBM;
analysis
PET;isStretching
performed. Moreover,
velocity; a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the
Preblowing
Keywords: ISBM; PET; Stretching velocity; Preblowing
similarity between product families by providing design support to both, production system planners and product designers. An illustrative
example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
©1. Introduction
1.2017 The Authors. Published by Elsevier B.V.
Introduction mechanical
mechanical and and barrier
barrier properties
properties [2-9].
[2-9]. In
In injection
injection stretch
stretch
Peer-review under responsibility of the scientific committee of the 28th CIRP blow molding
Design process,
Conference 2018. the parison (or preform) is injection
blow molding process, the parison (or preform) is injection
The international plastic bottling and beverage container molded
The
Keywords:
international
Assembly; Design
plastic
method;
bottling
Family of
and beverage
identification
container molded on on to to aa steel
steel rod.
rod. ThenThen the the molded
molded preform
preform is is
market is expected to reach the value USD 192048 billion up transferred
market is expected to reach the value of USD 192048 billion up transferred to the next station where the application of
to the next station where the application of
to
to 2023
2023 from from USD USD 140107 140107 in in 2017.
2017. The The benefits
benefits of stretching
of stretching via via aa stretch
stretch rodrod and
and thethe application
application of of an
an internal
internal
implementing plastic containers instead of other materials for pressure
implementing plastic containers instead of other materials for pressure causes the preform to expand within the mold.
causes the preform to expand within the mold. TheThe
beverage storage
storage areare the
the lightweight
lightweight packaging
packaging and and the
the superior heated blown
1.beverage
Introduction superior of heated blown preform
the product preform
range and
takes
takes the
the volume
volume of
characteristics of the
the mold
mold and
manufactured and with
with
and/or
barrier
barrier properties
properties of of plastics
plastics inin moisture
moisture and and generally
generally against rapid
rapid cooling
against assembled cooling in this
solidifies
solidifies forming the
system. forming the desired
In this context, desired
the main
bottle/beverage
bottle/beverage
challenge in
the environmental
theDueenvironmental conditions [1]. Additionally, plastic container shape [4], [6].
to the fastconditions development [1]. in Additionally,
the domain plastic
of container shape
modelling [4], [6].is now not only to cope with single
and analysis
containers
containers can can take almost every desired
desiredofvolume even
even with The
communication take
and almost
an ongoingevery trend volume
digitization with
and The advantages
products, advantages of
of biaxial
a limited product biaxial orientation
orientation
range
of
of stresses
or existing stresses generated
productgenerated
families,
complex wall textures due to the physics of the raw material during the ISBM process are the high transparency of
complex wall manufacturing
digitalization, textures due toenterprises
the physicsare of facing
the raw material but
important during
also the
to beISBMable toprocess
analyzeare and the high transparency
to compare of the
products to define the
during the fabrication
during the fabrication process. Hence that, the implementation container and improved mechanical properties (rigidity and
challenges in today’sprocess. market Hence that, the implementation
environments: a continuing container
new product and improved
families. It can mechanical
be observed properties (rigidity
that classical and
existing
of
of hollow plastics fabrication
fabricationoftechniques requires
requires more research impact resistance) [11]. ISBM
hollowtowards
tendency plastics reduction techniques
product development more research
times and impact families
product resistance) are [11].
regroupedISBMin is is classified
classified
function
in
in to
of clients
categories.
to or
categories.
features.
through
through the the years.
years. Plastic
Plastic In beverage
beverage containers are mainly Single stage and Two stage ISBM. In Single stage, preform
shortened product lifecycles. addition,containers
there is anare mainly However,
increasing Single stage and Two
assembly stageproduct
oriented ISBM.families
In Singlearestage,
hardlypreform
to find.
formed by Injection Stretch Blow Molding process (ISBM). injection, and stretching and blowing take place in
formed of
demand by customization,
Injection Stretch Blow
being Molding
at the same timeprocess
in a(ISBM).
global injection, and stretching
On the product and blowing
family level, productstake place
differ in a insingle
mainly
a single
two
ISBM
ISBM is the common
common choice of plastic containers equipment while
competition is with
the competitors choice
all over of the plastic
world. This containers
trend, equipment
main while in
characteristics: in Two
Two stage ISBM
(i) thestage
numberISBM preform
preform injection
of components injection takes
and (ii)takes
the
manufacturers for
for the fabrication of of beverage packages. The place
manufacturers
which is inducing the
the fabrication
development beverage
from macro packages.
to microThe type placeofin aa different
incomponents equipments.
different (e.g.
equipments.
mechanical,
The molded
molded preform
Theelectrical, preform can
can be
electronical). be
most
most widely accepted material for the
the fabrication of
of hollow stored and
markets, widely
resultsaccepted material lot
in diminished for sizes fabrication
due to augmenting hollow stored and then
Classical then reheated
reheated prior
methodologies prior to
to the
the stretching
considering stretching and
and blowing.
mainly single blowing.
products
plastics is
is the
plasticsvarietiesthe PET
PET (PolyEthylene
(PolyEthylene Terephthalate)
Terephthalate) due
due to its
to[1].
its or solitary, already existing product families analyze the
product (high-volume to low-volume production)
To cope with this augmenting variety as well as to be able to product structure on a physical level (components level) which
2212-8271 © 2019 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
identify
2212-8271 possible
© 2019 The optimization
Authors. Publishedpotentials in
by Elsevier Ltd.
(http://creativecommons.org/licenses/by-nc-nd/3.0/) the
This is existing
an open access causes difficulties
article under the CC BY-NC-ND regarding
license an efficient definition and
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
production system, it is important to have a precise knowledge comparison of different product families. Addressing this
Peer-review under responsibility of the scientific committee of the 52nd CIRP Conference on Manufacturing Systems.
Peer-review under responsibility of the scientific committee of the 52nd CIRP Conference on Manufacturing Systems.
2212-8271 © 2019 The Authors. Published by Elsevier Ltd.
This is an©open
2212-8271 2017access article Published
The Authors. under theby CC BY-NC-ND
Elsevier B.V. license (http://creativecommons.org/licenses/by-nc-nd/3.0/)
Peer-review
Peer-review under
under responsibility
responsibility of scientific
of the the scientific committee
committee of the of theCIRP
28th 52ndDesign
CIRPConference
Conference2018.
on Manufacturing Systems.
10.1016/j.procir.2019.04.018
1308 A. Lontos et al. / Procedia CIRP 81 (2019) 1307–1312
2 A. Lontos et al. / Procedia CIRP 00 (2019) 000–000

The key for optimization of stretch blow molding process is

the deeper understanding of material deformation under the
various strain conditions that take place during the ISBM
process. Our previous study was concentrated on the effect of
preform length on the final wall thickness distribution. It was
found that as longer is the preform, much better is the material
uniformity along the axial distance of the bottle. Thus, it can be
concluded that the minimum distance that the material is forced
to travel along the axial direction of the mold, the less are the
thick spots that are formed in the preform, resulting in a bottle
with very small deviations on the material distribution [2].
An earlier study employed by Daver and Demirel is
concentrated on the deformation behavior of PET bottles during
the ISBM process for the formation of 350ml juice bottle. They
exhibited their study by taking into consideration four
different model cases. In model 1 the stretching is applied at the
same time with pre-blow pressure, in model 2 the stretch moves
Fig. 1. a) 3D shell domain with initial and boundary conditions, b)
the half distance along the vertical length of the mold, in model
discretized shell domain with 271016 elements.
3, the stretch rod does not move at all. In fourth case the
preblow initiates shortly after the stretch rod touches the bottom
3.5seconds. Figure 2 shows the preform temperature profile.
of the preform. They have found that model the second and
The molds temperature remained constant
fourth case exhibit the highest burst and top load strength. They
also refer that in case 1 and 3 the results are very closed.
at 343K or 70°C in an effort to maintain the preform slightly
The current study carries the numerical effort for the
above glass-rubber transition region ( ̴ 80°C).
investigation of the effect of stretch rod velocity and preblow
The equation of conduction heat flux density which governs the
pressure magnitude on the final product wall thickness
heat transfer between mold walls and preform is shown below.
distribution. Both conditions are significant deformation
parameters that influence the material transportation from one
𝑞𝑞 = 𝑘𝑘∇𝑇𝑇 (1)
section of the preform to another. It is worth noting that very
few research studies in literature discuss the effect of stretching
Where,
and blowing in material deformation. k is the thermal conductivity of mold material (for aluminum
k = 205 𝑊𝑊�𝑚𝑚𝑚𝑚) and T is the temperature difference between
the preform and the mold walls. The gain of the mold
Nomenclature temperature selection in the actual stretch blow molding
process is the generation of strain-induced crystals during
k Thermal conductivity [𝑊𝑊 ⁄𝑊𝑊𝑊𝑊 ]]
stretching and blowing [10]. Higher percentage of crystals
q Conduction heat flux density [𝑊𝑊 ⁄𝑊𝑊� ]
within the material implies in better mechanical properties of
∇𝑇𝑇 Local temperature gradient [𝐾𝐾]
the polymer [11].
Tin Initial temperature of preform
To investigate the effect of deformation rate on the wall
V Stretch rod velocity[𝑚𝑚⁄𝑚𝑚 ]
thickness distribution of the final product, seven cases were
taken into consideration.
2. Numerical problem  Case 1: Free blow conditions, Preblowing pressure
0.4MPa, Final blowing 2.25MPa.
2.1. Solution domain  Case 2: Vs=0.6m/s, Preblowing pressure 0.4MPa,
Final blowing 2.25MPa
Figure 1a) illustrates the cross-section of the shell solution  Case 3: Vs=0.7m/s, Preblowing pressure 0.4MPa,
domain with initial and boundary conditions while the Final blowing 2.25MPa
discretized domain with 271076 elements that has been  Case 4: Vs=0.8m/s, Preblowing pressure 0.4MPa,
imported for the simulation is presented in figure 1b). The Final blowing 2.25MPa
numerical problem takes into consideration two half molds that  Case 5: Vs=0.8m/s, Preblowing pressure 1MPa, Final
are moving towards the preform and clamp it. blowing 2.25MPa
The stretch rod is presented by a small red nose shown in  Case 6: Vs=0.8m/s, Preblowing pressure 1.6MPa,
figure 1a). Tin is the initial preform temperature obtained by Final blowing 2.25MPa
allowing the three preforms to quench within the mold from In Case 1 there is not application of stretching. In Cases 2-4 the
378K or 105°C for 3.5 seconds. During the real SBM process, stretching rod velocity varies from 0.6-0.8m/s respectively.
there is a short time delay before stretching and blowing. This The purpose of cases 5 and 6 is to investigate the effect of
time delay is often called ‘preform cooling’ time [4]. In this preblowing. Case 4 seems to gain the most desired thickness
study, it was assumed that the preform cooling time is distribution characteristics along the walls of the bottle. Thus,
the stretch rod velocity in Cases 5 and 6 was set equal to that
 A. Lontos et al. / Procedia CIRP 81 (2019) 1307–1312 1309
A. Lontos et al. / Procedia CIRP 00 (2019) 000–000 3

of Case 4. The duration of each process parameter in each case 3. Simulation results
study is shown in table 1. In all cases the preform weighs
58.3gr. All cases were modeled in ANSYS Polyflow software 3.1. Effect of stretching velocity
with the Eulerian numerical scheme. The material data for the
preform were taken from another study[12]. Figure 3 and 4 show the simulated final product with
thickness contours and thickness plot respectively. Case 1
results in a product with very poor thickness uniformity along
the entire length of final product. The greater amount of raw
material is accumulated on the upper side of the bottle which is
expected to lead in poor mechanical properties. The first
conclusion is that the absence of stretching leads in very poor
material concentration at the base of the bottle. The existence
of stretching in Cases 2-4 leads in a similar trend of material
accumulation along the axial distance of the bottle. Although
the material thickness uniformity gets more intense in Cases 3-
4 with Case 4 to gain a slightly more desired results than those
obtained in Case 3. This can be clearer observed in Figure 4. In
both Figures 3-4, it can be concluded that amounts of material
are transferred from the upper side to the bottom in Cases 2-4.
As it can be seen in Figure 4, in Cases 2-4 the material
Fig. 2. Initial temperature profile of the preform. concentration along the central axial distance of the bottle is
similar. Despite this phenomenon, the fact that constitutes the
Table 1. Activation time and duration of process parameters.
Activation time
stretching velocity in Case 4 ideal, is the transfer of the excess
Preform
Molds Coolling Stretching Preblowing Final blowing
Case
Motion [s] within [s] [s] [s]
mold [s]

1 0-0.01 0.01-3.51 - 3.51-3.551 3.551-3.851

2 0-0.01 0.01-3.51 3.51-3.7258 3.7258-3.7668 3.7668-4.0668

3 0-0.01 0.01-3.51 3.51-3.6949 3.6949-3.7359 3.7359-3.7769

4 0-0.01 0.01-3.51 3.51-3.6718 3.6718-3.7128 3.7128-3.6718

5 0-0.01 0.01-3.51 3.51-3.6718 3.6718-3.7128 3.7128-3.6718

6 0-0.01 0.01-3.51 3.51-3.6718 3.6718-3.7128 3.7128-3.6718

Fig. 4. Axial thickness distribution plot for Cases 1-4.

Fig. 3. Simulated final product with thickness contours for Cases 1-4.
raw material from the upper region towards the bottom region
of the bottle resulting in a product with satisfying thickness
distribution. The spikes that are appeared on the results in
Figure 4 are believed to be caused due to the non-slip boundary
condition on the mold walls.
The increase in stretching velocity is associated with increase
in thicker spots at the very bottom side of the bottle. Slightly
thicker spots at the very bottom region are expected to increase
the steadiness of the bottle during packaging. It is worth noting
that the increase in stretch rod velocity is associated as well
with small decrease of excess material concentration at the
center of the very bottom side. The excess concentration of raw
material at that region is believed that is being reduced with the
combination of high axial and radial deformation rate. Figure 5
shows the cross section of the numerical problem with
thickness contours. The results were taken just after
1310 A. Lontos et al. / Procedia CIRP 81 (2019) 1307–1312
4 A. Lontos et al. / Procedia CIRP 00 (2019) 000–000

preblowing. As the stretch rod velocity increases the material mold walls and the preform material ceases to move. The
is more readily deformed in radial direction as well. stresses contours are represented by blue colour which
This phenomenon can be explained by the fact that the material therefore corresponds to trivial amounts of stresses.
at the upper side gets thinner with the increase of stretch rod
velocity generating a direction component that accumulates
material slightly above the very bottom side of the bottle.

Fig. 7. Cross section of the numerical problem with stresses contours for
Cases 2-4.
Fig. 5. Cross section of the numerical problem with thickness contours.
3.2. Effect of preblowing pressure

Figure 8 indicates the thickness contours for the effect of

preblowing pressure on the final wall thickness distribution.
Case 4 has been compared with 10 and 16 bar of preblowing
pressures. It is clear that that as the preblowing pressure
increases the concentration of material along the central axial
region of the bottle increases while it decreases on the upper
and lower most regions. The most optimum preblowing case is
the case with 0.4MPa preblowing pressure (Case 4). Figure 9

Fig. 6. Cross section of the numerical problem with strain rate contours for
Cases 2-4.

Figure 6 shows the cross section of the numerical problem with

strain rate contours after stretching. The more readily deformed
material after stretching shown in Figure 5 can be clearer
understood by Figure 6. Since the increase of stretching rod
velocity constitutes the material gets thinner and thinner,
allowing higher deformation rates at the main region of the
bottle. The upper most side of the preform ceases firsts to move
after the contact with the mold walls. In Figure 5 and 6, it can
be observed that the preform subjected to higher stretching
velocity touches first the mold walls. The initiation of contact
increases the strain rate as well but the latter decreases while
Fig. 8. Simulated final product with thickness contours for Cases 4-6.
the material ceases to move. Figure 7 shows the stresses
contours which follow the same similar trend as the strain rate
contours. The uppermost region of the bottle touches first the
 A. Lontos et al. / Procedia CIRP 81 (2019) 1307–1312
A. Lontos et al. / Procedia CIRP 00 (2019) 000–000
shows the plot of thickness distribution along the axial
direction of the bottle.
Fig. 9. Axial thickness distribution plot for Cases 4-6.
Figure 10 and 11 show cross section of the numerical problem
with strain and stresses contours respectively. As it is observed
both preblowing cases with 10 and 16 bar are capable to form
final product before the effect of the final blowing pressure.
The conclusion that can be extracted is that 10 bar pressure can
form a 1.5Lt PET bottle in a very short time.
Taking into consideration the target of material uniformity,
the most optimum case for the fabrication of 1.5Lt PET bottle
is Case 4, since it provides the highest possible material
uniformity along the entire axial direction of the bottle and
enhances the thickness at bottom most region. The latter affects
the rigidity and therefore the steadiness of the bottle.
Fig. 10. Cross section of the numerical problem with strain rate contours for
Cases 4-6.
1311
5
Fig. 11. Cross section of the numerical problem with stresses contours for
Cases 4-6.
4. Conclusions
Seven numerical cases were taken into consideration for the
examination which fulfills the requirements of the highest
possible uniformity. In all cases the preforms weights 58.3gr.
It was found that as higher is the stretching velocity more
material is transferred towards the bottom region of the mold
leading to a more uniform final product. In such cases the
preform gets thinner at its upper region and therefore allows
higher deformation rates in radial direction. It is believed that
the combination of the axial and radial deformation capability
obtained in Case 4 exhibited the appropriate material motion
characteristics in order to obtain a satisfied uniformity. Thus,
the key in good uniformity along the entire length of a bottle is
the combination of high axial and radial strain rates, similar to
those obtained in Case 4. The effect of preblowing pressures
was taken into consideration as well. It was found that the
higher is the preblowing pressure, the highest is the
accumulation of material along the central distance of the bottle
while leading to a final product with much thinner upper and
bottom regions. It is worth noting that Case 4 provides thicker
bottom regions which enhances the steadiness of the bottle. The
comparison between numerical results and experimental is
going to be held in the future. Additionally, the results obtained
in this effort are going to be used for the development of a
mathematical model that predicts the quality of the final
bottle/beverage container. The output of the mathematical
model is going to be a number of scale that evaluates the whole
ISBM process.
1312 A. Lontos et al. / Procedia CIRP 81 (2019) 1307–1312
6 A. Lontos et al. / Procedia CIRP 00 (2019) 000–000

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