Search Results (13)

Stretch blow molding (SBM) is widely utilized in industrial applications, yet the deformation characteristics of materials during this process are intricate and challenging to precisely articulate. To accurately forecast the stress–strain response of polyethylene terephthalate (PET) in SBM, a hybrid Artificial Neural Network (ANN)-based constitutive model has been developed. The model has been created by combining a physical-based function for capturing the small-strain behavior in parallel with an ANN-based model for capturing the temperature-dependent large-strain nonlinear viscoelastic behavior. The architecture of the ANN has been designed to ensure stability in a load-controlled scenario, thus making it suitable for use in FEA simulations of stretch blow molding. Data for training the model have been generated by a new semi-automatic experimental rig which is able to produce 850 stress–strain curves over a wide range of process conditions (temperature range 95–115 °C and strain rates ranging from 1/s to 100/s) directly from blowing preforms using a combination of high-speed video, digital image correlation and sensors for pressure and force. The model has already been implemented in the commercial FEA package Abaqus via a VUMAT subroutine, with its performance validated by comparing the prediction of the evolution of preform shape during blowing vs. high-speed images. In conclusion, the developed hybrid ANN model, when integrated into Abaqus, offers a more accurate simulation of SBM processes, contributing to improved design efficiency and product quality. Full article

Polyethylene terephthalate (PET) is widely used in the food and beverage packaging sector due to its chemical and mechanical properties. Although PET is a fossil-based polymer, its recyclability significantly contributes to reducing the environmental impacts caused by excessive plastic consumption. However, the growing demand for post-consumer recycled PET (PET-PCR) food packaging has raised concerns about the efficiency of decontamination processes involved in recycling this material. This review initially addresses PET synthesis processes, highlighting injection stretch blow molding as the predominant technique for packaging production. It then discusses reverse logistics as a strategy to promote sustainability through the recovery of post-consumer packaging, such as plastic bottles. This review examines mechanical and chemical recycling methods used in PET-PCR production, food safety requirements including positive lists of permitted substances, contaminant migration limits, non-intentionally added substances (NIASs), and updated criteria for the National Health Surveillance Agency (ANVISA) of food-grade PET-PCR resins. Finally, the review explores future prospects for using PET-PCR in the food and beverage packaging sector, assessing its environmental impacts and potential technological advancements to enhance its sustainability and safety. Full article

This research explores how varying proportions of virgin polyethylene terephthalate (vPET) and recycled polyethylene terephthalate (rPET) in vPET-rPET blends, combined with preform thermal conditions during the stretch blow molding (SBM) process, influence PET bottles’ microscopic characteristics. Key metrics such as viscosity, density, crystallinity, amorphous phase relaxation, and microcavitation were assessed using response surface methodology (RSM). Statistical analysis, including Analysis of variance (ANOVA) and its power, supported the interpretation of results. The first part of the work details the experimental design and statistical methods. Positron annihilation lifetime spectroscopy (PALS) and amorphous phase density analysis revealed reduced free volume size, a substantial increase in free volume quantity, and a transformation toward ellipsoidal geometries, highlighting significant structural changes in the material. At the same time, the intrinsic viscosity (IV) and PALS studies indicate that the solid-state post-condensation effect (SSPC) is linked with microcavitation through post-condensation product diffusion. The conclusions, which resulted from the microstructure analysis, affected the material’s mechanical strength and were validated by pressure resistance tests of the bottles. Full article

Polyethylene terephthalate (PET) is widely used in bottle production by stretch blow molding processes (SBM processes) due to its cost-effectiveness and low environmental impact. The presented literature review focuses on microcavitation and solid-state post-condensation effects that occur during the deformation of PET in the SBM process. The literature review describes cavitation and microcavitation effects in PET material and solid-state post-condensation of PET on the basis of a three-phase model of the PET microstructure. A three-phase model of PET microstructure (representing the amorphous phase in two ways, depending on the ratio of the trans-to-gauche conformation of the PET macromolecule and the amount of free volume) with a nucleation process, a crystallization process, and the use of positron annihilation lifetime spectroscopy (PALS) to analyze PET microstructure are discussed in detail. The conceptual model developed based on the literature combines solid-state post-condensation with microcavitation via the diffusion of the post-condensation product. This review identifies the shortcomings of the developed conceptual model and presents them with five hypotheses, which will be the basis for further research. Full article

Polyethylene terephthalate (PET) is widely used in bottle production due to its cost-effectiveness and low environmental impact. The first part of this article describes the research and statistical analysis methodology of the influence of the virgin PET (vPET) and recycled PET (rPET) content in the vPET-rPET blend, as well as the preform heating/cooling conditions in the stretch blow molding (SBM) process on the microscopic bottle properties. Microscopic properties such as crystallinity, density, viscosity, relaxation degree of the amorphous phase, and microcavitation in PET were examined. This study reveals that microcavity and solid-state post-condensation effects occur during PET deformation in the SBM process. The increase in free volume, indicating microcavitation, was confirmed by measuring positron annihilation lifetime spectroscopy (PALS). PALS and density of the amorphous phase studies prove a reduction in the dimensions of the free volumes, with a simultaneous significant increase in their number and ellipsoidization. It can be associated with crystallite rotation in a temperature-dependent non-crystalline matrix. The occurrence of solid-state post-condensation effects was confirmed by measuring the intrinsic viscosity. The conclusions resulting from the analysis of the microstructure affecting the mechanical strength of the material were validated by pressure resistance tests of the bottles. Full article

Stretch blow molding serves as the primary technique employed in the production of polyethylene terephthalate (PET) bottles. Typically, a stretch blow molding machine consists of various components, including a preform infeed system, transfer system, heating system, molding system, bottle discharge system, etc. Of particular significance is the temperature control within the heating system, which significantly influences the quality of PET bottles, especially when confronted with environmental temperature changes between morning and evening during certain seasons. The on-site operators of the stretch blow molding machine often need to adjust the infrared heating lamps in the heating system several times. The adjustment process heavily relies on the personnel’s experience, causing a production challenge for bottle manufacturers. Therefore, this paper takes the heating system of the stretch blow molding machine as the object and uses the deep reinforcement learning method to develop an intelligent approach for adjusting temperature control parameters. The proposed approach aims to address issues such as the interference of environmental temperature changes and the aging variation of infrared heating lamps. Experimental results demonstrate that the proposed approach achieves automatic adjustment of temperature control parameters during the heating process, effectively mitigating the influence of environmental temperature changes and ensuring stable control of preform surface temperature within ±2 $℃$ of the target temperature. Full article

With the spread of the Industry 4.0 concept, implementing Artificial Intelligence approaches on the shop floor that allow companies to increase their competitiveness in the market is starting to be prioritized. Due to the complexity of the processes used in the industry, the inclusion of a real-time Quality Prediction methodology avoids a considerable number of costs to companies. This paper exposes the whole process of introducing Artificial Intelligence in plastic injection molding processes in a company in Portugal. All the implementations and methodologies used are presented, from data collection to real-time classification, such as Data Augmentation and Human-in-the-Loop labeling, among others. This approach also allows predicting and alerting with regard to process quality loss. This leads to a reduction in the production of non-compliant parts, which increases productivity and reduces costs and environmental footprint. In order to understand the applicability of this system, it was tested in different injection molding processes (traditional and stretch and blow) and with different materials and products. The results of this document show that, with the approach developed and presented, it was possible to achieve an increase in Overall Equipment Effectiveness (OEE) of up to 12%, a reduction in the process downtime of up to 9% and a significant reduction in the number of non-conforming parts produced. This improvement in key performance indicators proves the potential of this solution. Full article

This study investigates the initial stage of the thermo-mechanical crystallization behavior for uni- and biaxially stretched polyethylene. The models are based on a mesoscale molecular dynamics approach. We take constraints that occur in real-life polymer processing into account, especially with respect to the blowing stage of the extrusion blow-molding process. For this purpose, we deform our systems using a wide range of stretching levels before they are quenched. We discuss the effects of the stretching procedures on the micro-mechanical state of the systems, characterized by entanglement behavior and nematic ordering of chain segments. For the cooling stage, we use two different approaches which allow for free or hindered shrinkage, respectively. During cooling, crystallization kinetics are monitored: We precisely evaluate how the interplay of chain length, temperature, local entanglements and orientation of chain segments influence crystallization behavior. Our models reveal that the main stretching direction dominates microscopic states of the different systems. We are able to show that crystallization mainly depends on the (dis-)entanglement behavior. Nematic ordering plays a secondary role. Full article

Finite-element (FE) simulations that go beyond the linear elastic limit of materials can aid the development of polymeric products such as stretch blow molded angioplasty balloons. The FE model requires the input of an appropriate elastoplastic material model. Up to the onset of necking, the identification of the hardening curve is well established. Subsequently, additional information such as the cross-section and the triaxial stress state inside the specimen is required. The present study aims to inversely identify the post-necking hardening behavior of the semi-crystalline polymer polyamide 12 (PA12) at different temperatures. Our approach uses structural FE simulations of a dog-bone tensile specimen in LS-DYNA with mesh sizes of 1 mm and 2 mm, respectively. The FE simulations are coupled with an optimization routine defined in LS-OPT to identify material properties matching the experimental behavior. A Von Mises yield criterion coupled with a user-defined hardening curve (HC) were considered. Up to the beginning of necking, the Hockett–Sherby hardening law achieved the best fit to the experimental HC. To fit the entire HC until fracture, an extension of the Hockett–Sherby law with power-law functions achieved an excellent fit. Comparing the simulation and the experiment, the following coefficient of determination $R^2$ could be achieved: Group I: $R^2$ > 0.9743; Group II: $R^2$ > 0.9653; Group III: $R^2$ > 0.9927. Using an inverse approach, we were able to determine the deformation behavior of PA12 under uniaxial tension for different temperatures and mathematically describe the HC. Full article

In situ synchrotron X-ray scattering was used to reveal the transient microstructure of poly(L-lactide) (PLLA)/tungsten disulfide inorganic nanotubes (WS₂NTs) nanocomposites. This microstructure is formed during the blow molding process (“tube expansion”) of an extruded polymer tube, an important step in the manufacturing of PLLA-based bioresorbable vascular scaffolds (BVS). A fundamental understanding of how such a microstructure develops during processing is relevant to two unmet needs in PLLA-based BVS: increasing strength to enable thinner devices and improving radiopacity to enable imaging during implantation. Here, we focus on how the flow generated during tube expansion affects the orientation of the WS₂NTs and the formation of polymer crystals by comparing neat PLLA and nanocomposite tubes under different expansion conditions. Surprisingly, the WS₂NTs remain oriented along the extrusion direction despite significant strain in the transverse direction while the PLLA crystals (c-axis) form along the circumferential direction of the tube. Although WS₂NTs promote the nucleation of PLLA crystals in nanocomposite tubes, crystallization proceeds with largely the same orientation as in neat PLLA tubes. We suggest that the reason for the unusual independence of the orientations of the nanotubes and polymer crystals stems from the favorable interaction between PLLA and WS₂NTs. This favorable interaction leads WS₂NTs to disperse well in PLLA and strongly orient along the axis of the PLLA tube during extrusion. As a consequence, the nanotubes are aligned orthogonally to the circumferential stretching direction, which appears to decouple the orientations of PLLA crystals and WS₂NTs. Full article

The technology of filling drinks without preservatives (such as fresh juices, iced tea drinks, and vitaminized drinks) is carried out using hot filling. Mainly due to the production costs and lower carbon footprint, polyethylene terephthalate (PET) bottles are increasingly used in this technology. In this paper, the main aim is to describe and interpret the results of statistical analysis of the influence of the temperature of the blow mold in the SBM (stretch blow molding) process and the method of hot filling on the macroscopic and microscopic bottle properties. The macroscopic bottle properties were defined by the thickness profile, pressure resistance, thermal stability, and the coefficients of blowing kinetics. In addition, the influence of the SBM process on the microscopic PET material properties (in the bottle) relative to the microscopic preform properties was analyzed. The microscopic properties were defined by the degree of crystallite, density, and relaxation of the amorphous phase of the PET material. For this purpose, response surface experiments were performed for the two analyzed factors, i.e., the temperature of the blow mold and the method of hot filling. The sample size was investigated to determine the minimum number of repetitions (number of bottles in the measurement series) required to achieve acceptable measurement uncertainty. The research conducted shows that, despite fulfilling the postulate of acceptable measurement uncertainty, in terms of the power of ANOVA (analysis of variance) in DOE (design of experiment), the accepted number of bottles in the measurement series is too small. The tests of the bottle material density, material crystallite, and relaxation of amorphous phase relative to the preform material density, material crystallite, and relaxation of amorphous phase show that microcavity effects occur during the deformation of the PET material, and that these are associated with the orientation of the microstructure. The blow kinetics study shows that there is a gradient of flow of the bottle material over the thickness of the bottle wall during blowing, and it has been deduced that the air temperature between the blow mold and the wall of the blown bottle has an impact on the kinetics of blowing the bottle. Full article

The technology of filling drinks without preservatives (such as fresh juices, iced tea drinks, vitaminized drinks) is carried out using hot filling. Mainly due to the production costs and lower carbon footprint, polyethylene terephthalate bottles, commonly called PET, are increasingly used in this technology. In this paper, the main aim is to describe the statistical analysis methodology of the influence of the temperature of the blow mold in the SBM process and the method of hot filling on the macroscopic and microscopic bottle properties. The macroscopic bottle properties were defined by the thickness profile, pressure resistance, thermal stability, and the coefficients of blowing kinetics. Moreover, the influence of the SBM (stretch blow moulding) process on the microscopic PET material properties (in the bottle) relative to the microscopic preform properties was analyzed. The microscopic properties were defined by the degree of crystallite, density, and relaxation of the amorphous phase of the PET material. For this purpose, response surface experiments were performed for the two analyzed factors (independent variables), i.e., the temperature of the blow mold and the method of hot filling. The sample size was investigated to determine the minimum number of repetitions (number of bottles in the measurement series) required to achieve acceptable measurement uncertainty. The research conducted shows that despite fulfilling the postulate of acceptable measurement uncertainty, in terms of the power of ANOVA (analysis of variance) in DOE (design of experiment) the accepted number of bottles in the measurement series is too small. The tests of the bottle material density, material crystallite, and relaxation of amorphous phase relative to the preform material density, material crystallite, and relaxation of amorphous phase show that the microcavity effects occur during the deformation of the PET material, and that these are associated with the orientation of the microstructure. The blow kinetics study shows that there is a gradient of flow of the bottle material over the thickness of the bottle wall during blowing, and it has been deduced that the air temperature between the blow mold and the wall of the blown bottle has an impact on the kinetics of blowing the bottle. Full article

Coronary Heart Disease (CHD) is one of the leading causes of death worldwide, claiming over seven million lives each year. Permanent metal stents, the current standard of care for CHD, inhibit arterial vasomotion and induce serious complications such as late stent thrombosis. Bioresorbable vascular scaffolds (BVSs) made from poly l-lactide (PLLA) overcome these complications by supporting the occluded artery for 3–6 months and then being completely resorbed in 2–3 years, leaving behind a healthy artery. The BVS that recently received clinical approval is, however, relatively thick (~150 µm, approximately twice as thick as metal stents ~80 µm). Thinner scaffolds would facilitate implantation and enable treatment of smaller arteries. The key to a thinner scaffold is careful control of the PLLA microstructure during processing to confer greater strength in a thinner profile. However, the rapid time scales of processing (~1 s) defy prediction due to a lack of structural information. Here, we present a custom-designed instrument that connects the strain-field imposed on PLLA during processing to in situ development of microstructure observed using synchrotron X-ray scattering. The connection between deformation, structure and strength enables processing–structure–property relationships to guide the design of thinner yet stronger BVSs. Full article