Thermal and Structural Analysis of the Blow Moulded Air Duct

Abstract

In this study, one of the plastic automotive parts, Air Duct, manufactured through blow moulding process is reviewed and investigated with a practical process point of view using structural mechanics approach. First, current blow moulding process was examined to find governing factors of the process which can be improved or adjusted for better quality control of finished product. Secondly, numerical analysis was conducted on the post-mould process in order to predict the deformation in the final products with properly assumed initial and boundary conditions. The simulation results showed that the degree of warpage under current blow moulding process could be predicted at a reasonable accuracy. It was also discovered that the distortions of the holes are strongly dependent on it location and surrounding, and the current cooling method should be improved to improve the quality. Based on the simulation results and literature survey, a better post-mould cooling method was suggested. In addition, the problem in cooling system was identified, and redesigning scheme was recommended.