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A numerical simulation model for predicting the fuel hydrocarbon permeation as well as the barrier layer thickness optimization for multilayer plastic fuel tanks is presented. The diffusion model is based on Fick's laws of diffusion for a steady/unsteady state permeation regime through a multilayer polymeric wall under isothermal condition. A continuum approach based on an homogenization technique is used to model solvent diffusion through an n layer film. The hydrocarbon flux determination through the multilayer film is solved using homogenization techniques that ensure continuity of partial pressure at the polymer-polymer inter-diffusion interface. Since the pinch-off zone is known to be the major source of emission per unit area, a method has been developed to automatically detect it at the end of the extrusion blow molding process and the diffusion model is adapted to adequately evaluate the hydrocarbon permeation through this specific area.

Blow moulding is one of the most important polymer processing methods for producing complex thermoplastic automotive parts. Contrary to injection molding, little attention has focused on process control and simulation of blow molding processes. Yet, there are still several problems that affect the overall success of forming these parts. Among them are thermally induced stresses, relevant shrinkage and part warpage deformations caused by inappropriate mold design and/or processing conditions. Tolerance issues are critical in automotive applications and therefore part deformation due to solidification needs to be controlled and optimized accordingly. The accurate prediction tool of part deformation due to solidification, under different cooling conditions in automotive formed parts, is important and highly suited for part designers to help achieve an efficient production.

The heating stage is of primary importance in stretch blow molding and thermoforming processes. Computational methods using the finite element technique for modeling the radiation heating stage of thick gauge plastic preforms and thin gauge, roll-fed plastic sheets are presented and discussed. The theoretical approach as well as the experimental validation are also presented. For stretch blow molding, the energy absorbed by the preform is adjusted by accounting for the selective heating process. An oriented preform is heated from two sides on a mandrel with a pre-defined pattern. This results in a controlled, optimized and uniform material distribution on the bottle which is essential to meet the growing needs of the packaging industry. For this purpose, preferential heating combined with the use of universal preforms produces a range of standard bottles having excellent aesthetic features without sacrificing the physical properties.

Controlling the forming of large thermoplastic parts from a simulation requires very precise predictions of the pressure and volume profile evolution. Present pressure profile based simulations adequately predict the thickness distribution of a part, but the forming pressure and volume profile development lack the precision required for process control. However new simulations based on the amount of power required to form the material can accurately predict these pressure and volume profiles. In addition online monitoring of the forming power on existing machines can be easily implemented by installing a flow rate and pressure meter at the gas entrance, and if necessary, exits of the part. An important additional benefit is that a machine thus equipped can function as an online rheometer that can characterize the viscosity of the material at the operating point by tuning the simulation to the online measurements.