A study of the bulge-forming of polycarbonate (PC) sheet

Based on experimental data concerning the tensile mechanical properties of polycarbonate at high temperature [Prog. Chem. Ind. 21 (6) (2002) 395], 1 and 4 mm thick hemispherical parts and basin-shaped parts of PC have been manufactured by bulge-forming and the effects of the processing parameters have been deduced. Numerical simulation for PC bulge-forming has been performed with the software DYNAFORM and a material model for PC has been established. The experimental data agree well with that of numerical simulation. An analysis of the manufacturing procedure and the changing wall thickness has shown that the thinnest part the hemisphere is at the bottom, the side walls gradually thickening to a flat curve. The thinnest region of the basin-shaped part is the point linking the bottom and the side walls. Consequently, the thickness at the bottom is uniform while the thickness of side wall changes.