scholarly journals Modeling the Blow-Blow Forming Process in Glass Container Manufacturing: A Comparison Between Computations and Experiments

2011 ◽  
Vol 133 (2) ◽  
Author(s):  
C. G. Giannopapa ◽  
J. A. W. M. Groot
Keyword(s):  
Computer Simulation ◽  
Temperature Distribution ◽  
Simulation Model ◽  
Glass Container ◽  
Glass Temperature ◽  
Computer Simulation Model ◽  
Forming Process ◽  
Glass Thickness ◽  
Glass Containers ◽  
Container Manufacturing

The blow-blow forming process is a widely used technique in glass container manufacturing (e.g., production of glass bottles and jars). This process typically takes few seconds and is characterized by large deformations and temperature gradients. In the work of Giannopapa (2008, “Development of a Computer Simulation Model for Blowing Glass Containers,” ASME J. Manuf. Sci. Eng., 130, p. 041003), the development of a computer simulation model for glass blowing was presented and demonstrated on dummy problems with an initially uniform glass temperature. The objective of this paper is to extend and further develop the simulation model to be used for industrial purposes. To achieve this, both steps of the blow-blow forming process of glass containers are simulated and tested against real industrial problems. In this paper, a nonuniform temperature distribution is considered for the blowing of the preform, which is reconstructed from temperature data provided by the industry. The model is validated by means of several examples regarding conservation properties, behavior of the flow, and comparison of the glass thickness with experimental measurements. Furthermore, by means of these examples, the sensitivity of the glass thickness to inaccuracies in the measurement and reconstruction of the initial temperature distribution is verified.

Numerical Shape Optimization in Industrial Glass Blowing

2014 ◽  
Vol 136 (6) ◽  
Author(s):  
J. A. W. M. Groot ◽  
C. G. Giannopapa ◽  
R. M. M. Mattheij
Keyword(s):  
Computer Simulation ◽  
Simulation Model ◽  
Optimization Method ◽  
Computer Simulation Model ◽  
Control Points ◽  
Industrial Glass ◽  
Forming Process ◽  
Glass Containers ◽  
Marquardt Algorithm ◽  
Container Manufacturing

Industrial glass blowing is an essential stage of manufacturing hollow glass containers, e.g., bottles, jars. A glass preform is brought into a mold and inflated with compressed air until it reaches the mold shape. A simulation model for blowing glass containers based on finite element methods, which adopts a level set method to track the glass–air interfaces, has previously been developed [Giannopapa and Groot, 2007, “A Computer Simulation Model for the Blow–Blow Forming Process of Glass Containers,” Paper No. PVP2007-26408, pp. 79–86; Giannopapa, C. G., 2008, “Development of a Computer Simulation Model for Blowing Glass Containers,” ASME J. Manuf. Sci. Eng., 130(4), p. 041003; Giannopapa and Groot, 2011, “Modeling the Blow–Blow Forming Process in Glass Container Manufacturing: A Comparison Between Computations and Experiments,” ASME J. Fluids Eng., 133(2), p. 021103]. A considerable challenge in glass blowing is the inverse problem: to determine an optimal preform from the desired container shape. In previous work of the authors [Groot et al., 2009, “Numerical Optimisation of Blowing Glass Parison Shapes,” ASME Paper No. PVP2009-77946; Groot et al., 2011, “Development of a Numerical Optimization Method for Blowing Glass Parison Shapes,” ASME J. Manuf. Sci. Eng., 133(1), p. 011010] a numerical method was introduced for optimizing the shape of the preform. The optimization method described the shape of the preform by parametric curves, e.g., Bezier-curves or splines, and employed a modified Levenberg–Marquardt algorithm to find the optimal positions of the control points of the curves. A combined finite difference and Broyden method was used to compute the Jacobian of the residual with respect to changes in the positions of the control points. The objective of this paper is to perform an error analysis of the optimization method previously introduced and to improve its accuracy and performance. The improved optimization method is applied to modeled containers of industrial relevance, which shows its usefulness for practical applications.

scholarly journals A Computer Simulation Model for the Blow-Blow Forming Process of Glass Containers

2007 ◽  
Author(s):  
C. G. Giannopapa ◽  
J. A. W. M. Groot
Keyword(s):  
Level Sets ◽  
Energy Exchange ◽  
Computer Simulation Model ◽  
Forming Process ◽  
Fast Marching ◽  
Time Step ◽  
Final Thickness ◽  
Process Step ◽  
Glass Containers ◽  
Container Manufacturing

In glass container manufacturing (e.g. production of glass bottles and jars) an important process step is the blowing of the final product. This process is fast and is characterized by large deformations and the interaction of a hot glass fluid that gets into contact with a colder metal, the mould. The objective of this paper is to extend and further develop our finite element model [1] to be used for industrial purposes. To achieve this both steps of the forming of glass containers, namely blow-blow needs to be simulated and tested against real industrial problems. The model should be able to correctly represent the flow of glass, the energy exchange during the process and provide the final thickness of the final product. For tracking the geometry of the deforming inner and outer interface of glass, the level set technique is applied on a fixed mesh. At each time step the coupled problem of flow and energy exchange is solved by the model. Here the flow problem is only solved for the domain enclosed by the mould, whereas in the energy calculations, the mould domain is also taken into account. A non uniform temperature distribution is considered for the blowing of the preform. For all the calculations the material parameters (like viscosity) are based on the glass position, i.e. the position of the level sets. The velocity distribution, as found from this solution procedure, is then used to update the two level sets by means of solving a convection equation. A fast marching re-initialization algorithm is applied after each time step in order to let the level sets re-attain the property of being a signed distance function. The model is validated by several examples focusing on both the overall behavior (such as conservation of mass and energy) and the local behavior of the flow (such as glass-mould contact) and temperature distributions.

Development of a Numerical Optimization Method for Blowing Glass Parison Shapes

2011 ◽  
Vol 133 (1) ◽  
Author(s):  
J. A. W. M. Groot ◽  
C. G. Giannopapa ◽  
R. M. M. Mattheij
Keyword(s):  
Computer Simulation ◽  
Simulation Model ◽  
Level Set ◽  
Optimization Method ◽  
Pressure Vessels ◽  
Computer Simulation Model ◽  
Level Set Function ◽  
Glass Containers ◽  
Wide Range ◽  
Air Interfaces

Industrial glass blowing is an essential stage of manufacturing glass containers, i.e., bottles or jars. An initial glass preform is brought into a mold and subsequently blown into the mold shape. Over the past few decades, a wide range of numerical models for forward glass blow process simulation has been developed. A considerable challenge is the inverse problem: to determine an optimal preform from the desired container shape. A simulation model for blowing glass containers based on finite element methods has previously been developed (Giannopapa, 2008, “Development of a Computer Simulation Model for Blowing Glass Containers,” ASME J. Manuf. Sci. Eng., 130, p. 041003; Giannopapa and Groot, 2007, “A Computer Simulation Model for the Blow-Blow Forming Process of Glass Containers,” 2007 ASME Pressure Vessels and Piping Conference and 8th International Conference on CREEP and Fatigue at Elevated Temperature). This model uses level set methods to track the glass-air interfaces. The model described in a previous paper of the authors showed how to perform the forward computation of a final bottle from the given initial preform without using optimization. This paper introduces a method to optimize the shape of the preform combined with the existing simulation model. In particular, the new optimization method presented aims at minimizing the error in the level set representing the glass-air interfaces of the desired container. The number of parameters used for the optimization is restricted to a number of control points for describing the interfaces of the preform by parametric curves, from which the preform level set function can be reconstructed. Numerical applications used for the preform optimization method presented are the blowing of an axisymmetrical ellipsoidal container and an axisymmetrical jar.

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