Identification of a thermo-elasto-viscoplastic behavior law for the simulation of thermoforming of high impact polystyrene

Thermoforming of high impact polystyrene sheets (HIPS) requires technical knowledge on material behavior, mold type, mold material, and process variables. Accurate thermoforming simulations are needed in the optimization process. Determining the behavior of the material under thermoforming conditions is one of the key parameters for an accurate simulation. The aim of this work is to identify the thermomechanical behavior of HIPS in the thermoforming conditions. HIPS behavior is highly dependent on temperature and strain rate. In order to reproduce the behavior of such material, a thermo-elasto-viscoplastic constitutive law was implement in the finite element code ABAQUS. The proposed model parameters are considered as thermo-dependent. The strain-dependence effect is introduced using Prony series. Tensile tests were carried out at different temperatures and strain rates. The material parameters were then identified using a NSGA-II algorithm. To validate the rheological model, experimental blowing tests were carried out on a thermoforming pilot machine. To compare the numerical results with the experimental ones the thickness distribution and the bubble shape were investigated.