Glass Design and Modelling


3D glass forming

& stress analysis

for round & non-round containers

  

 

 

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ELFEN Glass Design 3D (gd3D) is a suite of numerical modelling programs which are designed to provide glassmakers with decision support system tools to aid in the design, production and quality control of glass containers. The programs combine the latest numerical technology and years of glassmaking measurements and experience to provide practical, representative simulation tools that glassmakers can use and benefit from.

ELFEN gd3D may be used to simulate the forming process of round glass containers on an IS machine from gob load through parison forming, invert and final blow to mould open.

 

In addition the software can assess the integrity of the formed containers subject to head loads, internal pressure and impact loads. ELFEN gd3D has its origins in joint research with IPGR*.

The joint research programme was a blend of numerical modelling developments, experimental measurements and considerable trialling by the partners.

    *Note: IPGR – International Partners in Glass Research

Benefits of the software

Key Features

  • Simulation of forming processes: blow blow (BB), press and blow (PB) and narrow neck press and blow (NNPB).
  • Stress analysis of containers for head loads, internal pressure and impact loads.
  • Failure prediction based on comparing predicted stress results against specified failure stress levels.
  • Graphical user interface has pre and post processors with data input using glass industry terminology.
  • Interfaces to CAD packages for transfer of tooling geometry.
  • Results of forming analyses can be transferred directly to the stress analysis modules.
Container Set-up for Pendulum Test

Container Set-up for Pendulum Test

Maximum Tensile Stress Levels for an Impact Analysis

Maximum Tensile Stress Levels for an Impact Analysis

Assessment of the Predicted Results with Failure Stress Limits

Assessment of the Predicted Results with Failure Stress Limits

3D Container Geometry for Design Analysis

3D Container Geometry for Design Analysis

Parison Plot and Tracking Points

Parison Plot and Tracking Points

Prediction of Wall Thickness Distribution

Prediction of Wall Thickness Distribution

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Forming

The ELFEN gd3D Forming module has been designed to allow the professional engineer/designer in the glass container manufacturing industry to improve quality and efficiency. The software can be used to:

  • Predict the glass thickness distribution in the final product under a variety of conditions
  • Perform “virtual prototyping” of new containers,
  • Perform lightweighting trials,
  • Assess the effects of changing parison, plug and plunger shape,
  • Investigate the influence of process conditions and glass composition upon final container shape,
  • Assess the effects of mould cooling on the forming process.

The software is used to simulate the forming of round containers using BB, PB or NNPB technology. The processes are modelled from the delivery of the gob to the blank mould through parison formation, invert, run down and final blow.

The numerical models incorporate state of the art technology to correctly represent the physics of the glass behaviour and the process conditions so that the simulations can capture the response of the forming process to:

  • Glass composition
  • Process timings
  • Gob temperature
  • Mould and air temperature
  • Viscosity and shear thinning effects

The ELFEN gd3D Forming module is an easy to use integrated package aimed at those working in the glass industry. The data required for each analysis is input via a customised graphical user interface, using terms that the glass industry understand and data which is readily available to the glassmaker.


Integrity

The ELFEN gd3D Integrity module is designed to help glass containers manufacturers and associated companies predict how containers will withstand head and pressure loads. 

Stress distributions may be predicted on both the inner and outer surfaces, for any round or non-round containers.

Implementation of the package within a company's design and production procedures will enable the users to:-

  • Assess the initial design of container profiles based upon design wall thicknesses.
  • Monitor the stress resistance of manufactured containers from measured wall thicknesses or thicknesses predicted by ELFEN gd3D Forming module.
  • Dynamic loads available are designed to simulate real situations such as collision line impacts, pendulum tests and drop impacts.

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Software Modules

ELFEN gd3D Forming

ELFEN gd3D Forming has been designed to simulate the forming process of glass containers from gob delivery through parison formation, invert and final blow until mould open. The types of forming process modelled include BB, PB and NNPB.

ELFEN gd3D Integrity (Static)

This module analyses the integrity of containers subjected to head loads and internal pressure loads. Assessment of a container’s integrity can be made by comparing the predicted results against experimentally determined failure stress curves.

ELFEN gd3D Integrity (Dynamic)

ELFEN gd3D Integrity (Dynamic) analyses the integrity of containers subjected to impact loads, such as filling line collisions.