Design and numerical modeling of the thermoforming process of a WPC based formwork structure

Abstract In this study, we have explored the numerical modelling of the thermoforming of high-density polyethylene wood particle composites (WPC) into a formwork intended for construction applications. By using the parameters identified from oscillatory shear test, the Lodge model is used to describe the viscoelastic behavior of the WPC sheet. The forming stage of the WPC sheet is performed under the action of gas flow governed by the van der Waals equation of state. The thermoformability is firstly determined by simulating a free blowing of HDPE and highly charged WPC. Then, the numerical simulation of the formwork thermoforming is carried out on four types of WPC. The results have shown that the structure is subjected to increasing stress as the wood particle content increases, which consequently increases the risk of failure. Nevertheless, thermoforming is possible for WPC sheets with less than 40% wood content. Simulations of the formwork under loadings have also shown good mechanical resistance at low thicknesses.