Thermoforming of polymers into intricate geometries entails deliberate control over material deformation to ensure the quality of the final product. Whereas current industrial practices primarily rely on trial and error approaches to identify the proper manufacturing parameters, simulation can expedite the process by offering insight into the interplay of different governing factors. In this paper, we develop a coupled thermal-mechanical finite element model to simulate vacuum thermoforming of a polycarbonate sheet into a finished product. We strive for a fundamental understanding of the interaction between polymer deformation and heat transfer processes that influence the thickness distribution in the final geometry. We employ a nonlinear thermo-visco-hyperelastic model for temperature- and rate-dependent behavior of polycarbonate along with a thermal contact conductivity at the interface of the mold and polymer. Thickness distribution of the simulated part matches well with the measured results of the manufactured part. Through simulation, we further explore certain strategies to redistribute the material in the final product. Our model, which accounts for essential mechanical and thermal aspects of thermoforming processes, provides a means to predict the quality of thermoformed parts in both design and manufacturing phases.

将聚合物热成型为复杂的几何形状需要对材料变形进行有控制的控制，以确保最终产品的质量。当前的工业实践主要依靠试验和错误方法来确定适当的制造参数，而仿真可以通过洞察不同控制因素之间的相互作用来加快过程。在本文中，我们开发了一个热-机械耦合有限元模型，以模拟将聚碳酸酯片材真空热成型为最终产品的过程。我们努力从根本上理解影响最终几何形状厚度分布的聚合物变形和传热过程之间的相互作用。我们采用非线性热-粘-超弹性模型来处理聚碳酸酯的温度和速率相关行为，以及在模具和聚合物界面处的热接触传导率。模拟零件的厚度分布与制造零件的测量结果非常匹配。通过模拟，我们进一步探索了某些策略来重新分配最终产品中的材料。我们的模型考虑了热成型过程的基本机械和热方面，提供了一种在设计和制造阶段预测热成型零件质量的方法。我们将进一步探索某些策略来重新分配最终产品中的材料。我们的模型考虑了热成型过程的基本机械和热方面，提供了一种在设计和制造阶段预测热成型零件质量的方法。我们将进一步探索某些策略来重新分配最终产品中的材料。我们的模型考虑了热成型过程的基本机械和热方面，提供了一种在设计和制造阶段预测热成型零件质量的方法。