A thermoformed part has a total surface area of 1000 cm2 and a required thickness of 1mm. It is formed from a blank sheet with a total usable surface area of 500 cm2 (not counting the part of the sheet used for clamping) and a thickness of 2 mm. When forming the part, the walls often tear. Indicate what might be the problem
What will be an ideal response?
The area ratio of 1:2 indicates that the thickness will be reduced from 2 mm to 1 mm in the final part, assuming that the wall thicknesses are uniform. Uniform wall thicknesses are not likely with thermoforming and so some portions of the walls will be much thinner than the required 1 mm and will be likely to rupture when drawn.
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