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Numerical study of stretch-blow molding of PET bottles

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Proceedings of the World Congress on Engineering 2010 Vol II
WCE 2010, June 30 - July 2, 2010, London, U.K.

Numerical Study of Stretch-blow Molding of

PET Bottles
S. Bagherzadeh, F. R. Biglari, K. Nikbin, M. Mirsaeidi

 model for used PET in stretch blow molding process. This

Abstract— In this research work, numerical modeling of the
stretch-blow molding (SBM) of polyethylene terephthalate (PET)
bottles is studied by finite element method (FEM). In this paper,
due to symmetry of part geometry, the bottle is considered as
axisymmetric model. A hyperelastic constitutive material model
was used in variant high temperatures and strain rates. Instead of
blowing process, hydrostatic pressure with convention heat
transfer has been used. Comparisons of experimental
observations with numerical results can predict an overall trend
of thickness distribution. In contrast, some differences can be seen
in some regions. These results were used for an overall prediction
of bottle properties such as final bottle thickness and a defect free
production. Moreover, the parametric studies are conducted on
the effect of friction condition, heat transfer coefficient and initial
pre-blowing air entrance time delay on bottle thickness. It was
concluded that the proposed model is applicable for simulating
the stretch blow molding process of PET bottles. This model is
capable to offer a helpful knowledge in design of optimum
preform and production of bottles.
model showed reasonable material movement and deformation
process but no accurate thickness prediction. Ogden’s model of
elasticity is widely used in thermoforming to give relatively
accurate thickness predictions. However, it neglects the rate
effect of deformation [4]. Recently some experimental work
was reported on the orientation and crystallization of PET films
subjected to uniaxial or biaxial drawing under industrial
processing conditions [5]. Pham et al. [6] have conducted the
simulation of SBM process using BlowSIM software which has
some shortcomings in the definition of true material behavior.
This study presents a fully coupled temperature-displacement
FEM of SBM of PET bottles using ABAQUS. In this model,
the constitutive behavior of PET is modeled in form of
hyperelastic materials. Hydrostatic pressure and convection
heat transfer has been used for air flow modeling. Particular
attention is paid to thermal and contact modeling, material
model, and selection of proper element types.

Keywords — Finite element analysis, stretch-blow molding, PET

bottles, parameter study

INTRODUCTION

I njection stretch-blow molding (ISBM) is one of major

methods in blow-molding processes for making hollow
polyethylene terephthalate (PET) bottles. In this process, the
PET resin is first injected into an axisymmetric U shaped mold
to make structurally amorphous preforms. Then, the preforms
are heated in an infrared oven higher than the glass transition
temperature. Next, it is stretched simultaneously with a stretch
rod and blown up with high-pressure air inside, to create bottles
with desired outer shapes. At last, the bottles are cooled and
ejected from the mold (Figure1). The Finite-Element-Analysis Fig. 1 stretch-blow molding process
(FEA) can be used to simulate blowing process for
optimization purposes.
The prediction of deformation process of polymers has been CONSTITUTIVE BEHAVIOR OF PET
the subject of widespread research over the past three decades. According to Figure 1, in the stretch-blow molding process,
A lot of research efforts based on experimental techniques to the bottle wall experiences a biaxial tension in two directions of
realize accurate deformation mechanics of polymers [1,2]. In axial and hoop. The material behavior under biaxial
next years other investigations tended to simulate or predict the deformation can be measured using the Membrane-Inflation
mechanical behavior of the polymer under different loading Rheometer that has been developed at IKV by Haberstroh and
conditions. Schmidt et al. [3] have presented a viscoelastic Detrois [5]. The results of these measurements are stress/strain
curves as shown in Figure 2 for PET at very high strain rates
Submitted March 9 by F. R. Biglari who is associate professor in mechanical (10 /s), as they happen during the SBM process.
engineering at Amirkabir University of Technology, Hafez Avenue, Tehran,
Iran. (corresponding author’s phone: 00982166405844; e-mail: biglari@
aut.ac.ir).

ISBN: 978-988-18210-7-2 WCE 2010

ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)
Proceedings of the World Congress on Engineering 2010 Vol II
WCE 2010, June 30 - July 2, 2010, London, U.K.

400
strains in hyperelastic materials. Several different strain energy
potentials are available [9]. In this paper, the material
350
PET 90 oC
y = Ax3 +Bx2 + Cx + D
parameters have been obtained from experimental results of
True Stress (MPa)

300 PET 100 oC biaxial tension of PET under high strain rate at different
PET110 oC
250 Poly. (PET 90 oC)
temperatures. Different test data curve fit was evaluated using
Poly. (PET 100 oC) embedded hyperelasticity models in ABAQUS. Comparison of
200
Poly. (PET110 oC) imported test data showed a close agreement with the third
150 order reduced polynominal model.
100

50
FINITE ELEMENT SIMULATION
0 Figure (3-a) shows the FE model used in this study. Because
0 1 2 3 4 5 6 of model symmetry only half of the geometry is model that is
Elongation (%) called axisymmetric model. Numerical simulations have been
Fig. 2 Stress/Strain curve for PET at 10 s-1 strain rate [5]. performed using FE code ABAQUS 6.7 as a fully coupled
temperature-displacement with ABAQUS/Standard solver.

The stress-strain plot at elevated temperatures shows a

significant increase after a certain stretch ratio. The stress
rise starts at elongation of 2% due to high amount of straining
induced by crystallization. This is normally called strain
hardening effect. A hyperelastic strain energy function of third
order was used as constitutive model for the deformation
material behavior (Yeoh, 1996). The material is considered to
be incompressible. The specific strain energy W is expressed as
a function of the first invariant I1 of the strain tensor:
W = C10 ( I 1 - 3 ) + C20 ( I 1 - 3 )2 + C30 ( I 1 - 3 )3 (1)
Where W is the strain energy potential, I1 is first invariant that
measures the distortion in the material and Cij is material
parameters, which may be a function of temperature. Also can
be written:
I 1  12  22  32 (2) (b) (a)
Fig. 3 FE Model (a) perform mesh (b) Initial perform temperature
Where λ are the principle stretches, For equibiaxial distribution
deformation λ1 = λ2 = λ and assume that material is
incompressible therefore the first invariant can be achieved as: In this model preform and stretch rod are assumed as
1 2  3  1 deformable parts and mold is considered as a rigid part. Some
(3)
of the geometrical data for modeled preform and mold has been
1 listed in Table I.
3  (4)
2
With substitution of eq. (3), (4) into eq. (2): TABLE I
Preform and mold geometries
I1  22  4 (5) component Length Middle radius Inner radius
(mm) (mm) (mm)
Applying the theory of virtual work yields for the stress:
Preform 77 23 10
1 W I 1 1
  (C10  2C 20 (22   4  3) 
2 I 1  2 (6) Mold 151 60 25
3C 30 (22  4  3) 2 )(4  45 )

Now according to experimental works upon biaxial testing of

PET at literature and using the least-squares method,
coefficients Ci0 have been determined. In the next step, the
achieved coefficients have been entered into ABAQUS
material properties as the three order strain energy model.
ABAQUS uses a strain energy potential (W), rather than a
Young's modulus and Poisson's ratio, to relate stresses to
Both the stretch rod and mold are aluminum and assumed to
behave in a linear elastic state. The properties of the used
aluminum and PET at environmental temperature are showed
in Table II.

ISBN: 978-988-18210-7-2 WCE 2010

ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)
Proceedings of the World Congress on Engineering 2010 Vol II
WCE 2010, June 30 - July 2, 2010, London, U.K.

TABLE II agreement in trend can be seen along most part of the bottle.
Material properties The difference between these results has several reasons such
E C α ρ K as viscous behavior of PET or error at wall thickness during the
Mat. υ measurement.
(GPa) (j/kg◦C) (1/ºC) (kg/m3) (w/mºC)
1
0.9 Present (FEM)
Al 70 963 1.2E-5 2740 159 0.3
Experimental measurment[7]
0.8

Thickness (mm)
PET - 1200 7E-5 1050 0.24 - 0.7
(Note: E: elastic modulus, C: specific heat, α: Coefficient of 0.6
Expansion, ρ: density, K: Conductivity, υ: Poisson ratio) 0.5
0.4
0.3
Heat transfer between the high-pressure air and the preform
0.2
inner surface that does not contact the stretch rod is modeled by
0.1
surface convection. Whereas the heat transfers between the
0
mold and the preform outer surface is modeled by Gap 0 25 50 75 100 125 150 175
Conductance in ABAQUS. The initial temperature distribution Distance from bottle bottom (mm)
in the preform was obtained from the literature [7] shown in
Fig. 5 predicted bottle thickness distribution
Figure (3-b).
Figure 6 shows the material movement at three defined
positions in the preform. The solid lines represent the FE model
RESULTS AND DISCUSSIONS
movement and the dashed lines represent the measured points
From simulation results, eight segments of the modeled that are conducted in the literature [7]. It can be seen that the
deformation process are shown in Figure 4. As they show, the simulation models deformation of underneath bottle area with
deformation process consists of three steps generally. First, the lower accuracy. There are two possible causes for this
preform is expanded by the stretch rod (full stretching step). difference. First, the infrared camera did not measure
After pass a specific time, low air pressure is applied to avoid accurately enough the initial preform temperature distribution,
the preform from necking in and touching the stretch rod. After which has great effects on the process. Secondly, the material
the stretch rod reaches final position, the full blow pressure is properties in the hyperelastic model used in this study are not
applied and the bottle is formed in radial direction (high obtained from the material used to product the bottle.
pressure step). Width (mm)
0 10 20 30 40 50
0

-10 Present FEM(Y=19mm)

-20 Present FEM(Y=38m)

-30 Presen FEM(Y=57mm)

-40 Experimental(Y=19mm) [7]

-50 Experimental(Y=38mm)[7]
Length (mm)

-60 Experimental(Y=67mm)[7]

t = 0.18 s t = 0.15 s t = 0.1 s t=0s -70

-80

-90

-100

-110

-120

-130

-140

t = 1.8 s t = 0.6 s t = 0.35 s
Fig. 4 Bottle formation process
Figure 5 compares the predicted bottle wall thickness
distribution obtained from numerical modeling with the
experimental measurements by Yang et al. [7]. A good
-150
t = 0.2 s
-160
Fig. 6 Material movement at three specific points
The modeled temperature distribution has been presented in
the bottle bottom and neck region at the end of the process

ISBN: 978-988-18210-7-2 WCE 2010

ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)
Proceedings of the World Congress on Engineering 2010 Vol II
WCE 2010, June 30 - July 2, 2010, London, U.K.

(Figure 7a-b). It can be observed that the two ends remain
warm with great temperature differences between the inner and
outer surfaces while at this time the other part of the bottle is
cold comparatively.
process. It can be lead to different heat transfer condition in
inner and outer surfaces preform and various strain magnitude
through thickness. Also, it can be a reason for the more tearing
tendency in this region in the bottle production.
3.5

I nne r surfa ce
3

Equivalent Strain (PEEQ)

O uter surface
2.5

1.5
Tearing tendency region
1

0.5
(a) Bottle neck region
0
0 25 50 75 100 125 150 175
Distance from bottle bottom (mm)

Fig. 9 Final equivalent plastic strain distribution in outer/inner

surfaces

(b) Bottle bottom region
Fig. 7 Temperature distribution contour for neck and bottom regions
For studying on the cooling rate of different location of
bottle, two points of inner/outer elements on the neck and
bottom are supposed. Figure 8 presents the temperature record
of four nodes that are located at inner/outer surfaces of two
locations. It can be notice that the temperature drop rate varies
significantly from one location to another. The cooling rates on
the outer surface are generally much higher than the inner
points at the pre-blowing stage because of the low thermal
conductivity of PET material. These differences can be having
important effects on various parameters such as the
crystallization and mechanical strength of the final bottles.
120
110 Inner surface-Neck
Inner surface-bottom
100
Outer surface-Neck
90
Temperature(◦C)
PARAMETER STUDY
According to experimental observations in the production set
of PET bottle can say that usual problems stretch blow molding
(SBM) process of this bottles such as bottle bottom thickening,
tearing nearby stretch rod head, non-uniform wall thickness
distribution and so on. Therefore, in this process optimal
preform design and effective process parameters aided
optimization approaches are desirable to attain uniform final
bottle with expected properties. The more investigations of
SBM process such as optimum preform design are future aims
this paper. Therefore three important parameters friction
coefficient, convection heat transfer coefficient and air blowing
entrance time are studied.
Figure 10 shows a parameter study on the effect of sticking
friction coefficient on the bottle bottom thickness. The
increasing of friction between rod and inner bottle surface
could result in an increase of bottom thickness and mechanical
strength in this region due to more contact cooling with rod
surface but it can be caused material waste.

Outer surface-bottom 0.315

80
70 0.31
Bottle bottom thickness(mm)

m=1.0
60 0.305 m=0.5
50
0.3 m=0.25
40
30 0.295
20 0.29
10 0.285
0 0.28
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
0.275
Time (mm)
0.27
Fig. 8 Temperature history during process for neck and bottom
locations (cooling history) 0.265
0 2 4 6 8 10 12 14 16
Lateral distance from centerline(mm)
Figure 9 present equivalent plastic strain distribution on
Fig.10 Effect of friction coefficient on bottle bottom thickness
bottle inner and outer surfaces. As can be observed, the strain
distribution is same except bottom bottle region. it is because Also, Figure 11 presents effects of heat transfer coefficient
stretch rod contact with preform for long time during the (h1) as convection type between the stretch rod and the bottle

ISBN: 978-988-18210-7-2 WCE 2010

ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)
Proceedings of the World Congress on Engineering 2010 Vol II
WCE 2010, June 30 - July 2, 2010, London, U.K.

preform on the bottle bottom thickness. Similar to the friction situation has the more uniform thickness and the further tearing
coefficient investigation, heat transfer coefficient affects only tendency.
the bottom region, which is in contact with the stretch rod
initially. A lower h1 leads to have a thinner bottle bottom. This
is since a low heat transfer coefficient decreases the
temperature of the bottom region less than a high one so that the
bottom remains softer to stretch relatively.
0.315
0.31
h1=2000
0.305
0.3 h1=1000
Thicknesss(mm)

0.295
0.29
0.285
0.28
0.275
0.27
0.265
0.26
0 2 4 6 8 10 12 14 16
Lateral distance from centerline(mm)
Fig. 11 Bottle bottom thickness distribution for various heat transfer
coefficients

For investigation of air entrance time effect, FE simulation

with three different air pressure delay time is performed. These Td = 0.2 s Td= 0.18 s Td =0.15 s
times delay (Td) were 0.15, 0.18, 0.2 sec. The deformation Fig. 12 Von-mises stress distribution for three different delay times of
steps observation showed that at Td=0.15 sec preform are air blowing on stretched preform
separate from stretching rod after air entrance. This Figure 13 show total bottle wall thickness at three different
phenomenon can be result in wall thickening and bottle bottom air pressure entrance times (different stretching time). As can
thinning finally (Figure 11). be expected, the sooner air entrance cause to wall thickening
and bottom thinning and the more material waste rather than
other conditions. Also, the more stretching result in the more
uniform thickness and bottle fracture probability.
1
0.9
0.8 Td=0.15sec

0.7 Td=0.18sec
Tickness(mm)

0.6 Td=0.2sec

0.5
0.4
0.3
0.2
0.1
t = 0.2 sec t= 0.18 sec t =0.15sec
0
Fig. 11 Three deformation steps of SBM process with Td=0.15 sec
0 25 50 75 100 125 150 175
In the next two situation (Td= 0.18, 0.2 sec) this event don’t Distance from bottom bottle(mm)
happen. The difference between these models is in fact in the Fig. 13 Final bottle wall thickness comparison at three various air
initial preform stretching time. This model with the more air pressure entrance times
pressure delay time (Td) experiences the further stretching by
rod and it will has the more uniform final wall thickness CONCLUSION
certainly. Then the longer stretching time can result in
increasing of tensile stress in the stretched preform and An investigation of a fully coupled temperature–
occasion tearing defect. Figure 12 show equivalent stress displacement of SBM of PET bottles has been presented using
distribution on stretched preform. It is clear that the last ABAQUS. Extensive finite element analyses have been carried
out to predict the deformation, the distribution of strain,
temperature and thickness. Comparisons of numerical results

ISBN: 978-988-18210-7-2 WCE 2010

ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)
Proceedings of the World Congress on Engineering 2010 Vol II
WCE 2010, June 30 - July 2, 2010, London, U.K.

with the literature demonstrate that the model can satisfactorily

predict bottle thickness and material distributions. The
difference in material movement deformation can be owing to
viscous behavior of PET. The result of Strain and stress
distributions showed that the most critical area is area nearby
bottle bottom.
Parameter study on effective parameters of process showed
that heat transfer coefficient, friction condition and time delay
of air blowing step effect on final bottle thickness and other
properties. The more stretching of preform result in the more
uniform thickness and but bottle fracture probability so it need
to optimum adjustment.

REFERENCES
[1] J. Garbarski, “The application of an exponential-type function for the
modeling of viscoelasticity of solid polymers”, Journal of Polymer
Engineering and Science 32, 1992, pp. 107-114.
[2] P. Krishnaswamy, M. E. Tuttle, A. F. Emery, Journal of Polymer
Engineering Science Vol.32 no 16, 1992, pp. 1086-1096.
[3] F. M. Schmidt, J. F. Agassant, M. Bellet, L. Desoutter, “Viscoelastic
simulation of PET stretch/blow molding process“, Non-Newtonian Fluid
Mechanic, 1996.
[4] K. Kouba, O. Baetos, L. Valchopoulos, ”Computer simulation of
thermoforming in complex shapes”, polymer Engineering and science,
vol. 32, 2004, pp. 699-704.
[5] E. Haberstroh, C. Detrois, “Capabilities and Limitations of Injection Blow
Moulding Simulation”, Institut für Kunststoff verarbeitung (IKV), RWTH
Aachen, 1999.
[6] X.T. Pham, F. Thibault, L.T. Lim, ”Modeling and simulation of stretch
blow molding of polyethylene terphthalate”, Polymer Engineering and
Science, 2004, pp. 275-285.
[7] Z.J. Yang, E. Harkin-Jones, G. H. Menary, C. G. Armstrong, ”Coupled
temperature–displacement modeling of injection stretch-blow moulding
of PET bottles using Buckley model”, J of Mat. Proc. Tech. 153, 2004,
pp. 20–27.
[8] ABAQUS/CAE, Analysis User’s Manual, Version 6.7.
[9] E. G. Denardin, H. Tokumoto, D. Samios, “Stress-Strain behavior of
Poly(ethylene Terphthalate) (PET)during large plastic deformation“,
Springer-Verlag , July 2005.

ISBN: 978-988-18210-7-2 WCE 2010

ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)
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