International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 04 | Apr 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1238 Simulation Of Blow Molding Of Polyethylene Bottle Using Ansys Polyflow Amit V. Kadam 1 , Shital Patel 2 , Ashish Vajir 3 1 Student, Department of Mechanical Engineering, Bharati Vidyapeeth College of Engineering, Navi Mumbai, India. 2 Guide, Department of Mechanical Engineering, Bharati Vidyapeeth College of Engineering, Navi Mumbai, India. 3 Chief Technical Officer, M/S Shirsh Technosolutions Pvt. Ltd., Mumbai, India ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - Blow Molding is one of the most versatile and economical process available for molding hollow materials. One of the most important key components during the production of these methods is appropriate selection of technological parameters of processing, as well as initial geometrical features of preform (thickness distribution), to provide positive functional characteristics of final products. ANSYS Polyflow software is used extensively to design and optimize processes such as extrusion, thermoforming, blow molding, glass forming, fiber drawing and concrete shaping. ANSYS Polyflow software shall be used to predict the blow molding behavior on the effect 34 mm diameter parison the final wall thickness distribution and stress contour occurred. Polyethylene (PE) ASTM D4101 shall be used as the parison materials and aluminum as mould material. PE has excellent moisture resistance, low density, good fatigue resistance, high flexural strength and good impact strength. This project consists of the blow molded part of 100ml medicine bottle. The objective is to optimize a blow molding process such as to achieve the required thicknesses with material economy. The problem deals with the cavity filling stage of the molding process that encompasses bending and its effect with change in wall thickness and designs; and studying the hoop stiffness of different bottle designs were the secondary focus here. Key Words: blow molding; ANSYS Polyflow software; parison; bottle designs; Polypropylene; hoop stiffness; hollow materials; preform. 1. INTRODUCTION In today's competitive foundry industry, manufacturers are aiming for reliable products with characteristics such as light weight, high-quality parts, defect-free output and minimal lead time, all at the lower level of investment. One of the obstacles of its emergence as a major product on the market is the added cost of fabrication and a large uniform thickness distribution. Blow molding technologies will be used in these studies for the improving the quality of plastic products for the replacement of conventional blow molding techniques. Blow techniques have many advantages over that conventional blow molding such as higher part quality in more uniform wall thickness distribution, maintained the mechanical properties, lower regrind content and lower flash weight. The temperature control, blow pressure, time control, thermal properties and die design is a important variable that need to be consider in production to has a better final products . Packaging is an important step of the production process that involves delivery of the final product to end users. In particular, materials used in beverage packaging that deals with carbonated and non- carbonated drinks has shifted from glass and Aluminum to high performance polymers such as polyethylene (PE) owing to their superior mechanical properties, ease of manufacturing and low cost. For example, one can readily see the melt temperature is suggestive of the lower cost in manufacturing since glass has the highest of the three and polymers the lowest. Even with the lower cost to process PE, the industry has evolved to further expand the gap. One of the greatest pushes in this area is called “light weighting,” where unnecessary material is designed out of the package, saving weight. Light weighting not only reduces the material usage but also minimizes impact on the environment; this has been a driving force behind substantial research in this area. For design optimization, it is critical to evaluate the structural performance of bottles under different loading conditions. Injection stretch blow molding is a manufacturing process of PE that yields non- uniform thickness and material properties along the length of the bottle. Understanding the behaviour of PE, observing the changes in non-uniform thickness and material distribution are also key factors in assessing the design and structural performance. 1.1 PROBLEM DEFINITION ANSYS Polyflow software shall be used to predict the blow molding behaviour on the effect 34 mm dia parisonon the final wall thickness distribution and stress contour occurred. Polypropylene (PE) ASTM D4101 shall be used as the parison materials and aluminium as mould material. PE has excellent moisture resistance, low density, good fatigue resistance, high flexural strength and good impact strength [1, 2]. The PE property is shown in Table 1. The graphical sketch of bottle is referred the design according by M/S Shirsh Technosolutions Pvt. Ltd. .The design cavity should meet the equation 1 and 2 requirements. Blow ratio equation for one cavity mould halves (M, 2009) Cavity–Cavity Blow Ratio = W>D (1) Blow ratio equation for 2 cavity mould halves Cavity – Core Blow Ratio = W>2D (2) w=diameter and a depth, d=radius (2:1)