Three-dimensional simulations of non-isothermal flow for gas penetration in complex cavity during gas assisted injection moulding process

2017 ◽  
Vol 96 (4) ◽  
pp. 978-988 ◽  
Author(s):  
Qiang Li ◽  
Haifeng Niu
Keyword(s):  
Injection Moulding ◽  
Three Dimensional ◽  
Isothermal Flow ◽  
Moulding Process ◽  
Injection Moulding Process ◽  
Complex Cavity ◽  
Gas Penetration ◽  
Three Dimensional Simulations

The effect of pressure and temperature on microthermoforming thermoplastic films integrated in the injection moulding process

2016 ◽  
Vol 36 (6) ◽  
pp. 597-605 ◽  
Author(s):  
Ariane Jungmeier
Keyword(s):  
Injection Moulding ◽  
Large Scale ◽  
Three Dimensional ◽  
Scale Production ◽  
Moulding Process ◽  
Cycle Times ◽  
Large Scale Production ◽  
Flow Length ◽  
Injection Moulding Process ◽  
Fitting In

Abstract Injection moulding is a widespread large-scale production technology for the manufacturing of thermoplastic parts, with small wall thicknesses limiting the feasible flow length. Introducing microthermoforming into the injection moulding process with dynamic mould temperature control enables the production of film-based, plane microstructured parts with further three-dimensional functional structures (e.g. for handling or for fitting in devices/assembly groups). Investigations show that considerable forming is possible with pressures up to 140 bar and forming temperatures far below the glass transition temperature of 50-μm-thick polycarbonate films in cycle times of <3 min. Generally speaking, the novel technology is expected to allow for multifunctional, thin-walled microstructured parts at large scales with short cycle times.

Non-isothermal Modelling and Optimisation Methodology of the Injection Moulding of Rubber Products

2017 ◽  
Vol 25 (2) ◽  
pp. 153-160
Author(s):  
A.V. Baranov
Keyword(s):  
Mathematical Model ◽  
Heat Conduction ◽  
Process Parameters ◽  
Injection Moulding ◽  
Heat Evolution ◽  
Isothermal Flow ◽  
Main Process ◽  
Moulding Process ◽  
Injection Moulding Process ◽  
Stationary Heat Conduction

The process of injection moulding is regarded as a combination of separate operations linked by certain process parameters. The first part of this study presents a mathematical model of the non-isothermal flow of rubber mixes along mould sprue channels, taking into account all the main features of the injection moulding process. On the basis of this model, an attempt is made to develop a methodology for optimising the injection stage. Diagrams linking the main process parameters are plotted. The second part of the study is devoted to the final stage of this cycle – the vulcanisation stage. The presented mathematical model of non-stationary heat conduction takes into account the heat evolution from the chemical reaction of vulcanisation and the temperature dependence of all thermophysical properties. On this basis, an attempt to develop optimisation methodology for this stage is presented. Diagrams are plotted that link the main process parameters of the vulcanisation stage with the previous stages of plasticisation and injection.

Evaluation of Cadmould Software to Simulate the Filling Phase of a Natural Rubber Compound in Injection Moulding Process

2013 ◽  
Vol 747 ◽  
pp. 571-574 ◽  
Author(s):  
Zulkifli Mohamad Ariff ◽  
T.H. Khang
Keyword(s):  
Natural Rubber ◽  
Injection Moulding ◽  
Input Data ◽  
Cure Kinetics ◽  
Rubber Compound ◽  
Moulding Process ◽  
Related Data ◽  
Mould Filling ◽  
Injection Moulding Process ◽  
Material Input

The possibility of using Cadmould software to simulate the filling behaviour of a natural rubber compound during an injection moulding process was investigated. For the simulation process, the determination of required material input data involving the rheological and cure kinetics data of the designed rubber compound were conducted. It was discovered that the acquired data were able to function as reliable material input data as they were comparable with related data available in the Cadmould software materials database. Verification of the simulated filling profiles by experimental short shots specimens showed that the Cadmould Rubber Package was able to predict the realistic filling behaviour of the formulated natural rubber compound inside the mould cavity when the measured material data were utilized. Whereas, the usage of available material database from the software failed to model the mould filling progression of the intended natural rubber compound.

Multi-Response Parameters Optimisation for Energy-Efficient Injection Moulding Process via Dynamic Shainin DOE Method

2013 ◽  
Vol 554-557 ◽  
pp. 1669-1682 ◽  
Author(s):  
Kam Hoe Yin ◽  
Hui Leng Choo ◽  
Dunant Halim ◽  
Chris Rudd
Keyword(s):  
Energy Consumption ◽  
Process Parameters ◽  
Injection Moulding ◽  
Shop Floor ◽  
Operational Experience ◽  
Moulding Process ◽  
Part Quality ◽  
Control Factors ◽  
Injection Moulding Process ◽  
Signal Response

Process parameters optimisation has been identified as a potential approach to realise a greener injection moulding process. However, reduction in the process energy consumption does not necessarily imply a good part quality. An effective multi-response optimisation process can be demanding and often relies on extensive operational experience from human operators. Therefore, this research focuses on an attempt to develop a more user-friendly approach which could simultaneously deal with the requirements of energy efficiency and part quality. This research proposes a novel approach using a dynamic Shainin Design of Experiment (DOE) methodology to determine an optimal combination of process parameters used in the injection moulding process. The Shainin DOE method is adopted to pinpoint the most important factors on energy consumption and the targeted part quality whereas the ‘dynamic’ term refers to the signal-response system. The effectiveness of the proposed approach was illustrated by investigating the influence of various dominant parameters on the specific energy consumption (SEC) and the Charpy impact strength (CIS) of polypropylene (PP) material after being injection-moulded into impact test specimens. From the experimental results, barrel temperature was identified as the signal factor while mould temperature and cooling time were used as control factors in the full factorial experiments. Then, response function modelling (RFM) was built to characterise the signal-response relationship as a function of the control factors. Finally, RFM led to a trade-off solution where reducing part-to-part variation for CIS resulted in an increase of SEC. Therefore, the research outcomes have demonstrated that the proposed methodology can be practically applied at the factory shop floor to achieve different performance output targets specified by the customer or the manufacturer’s intent.

Modelling for Injection Moulding Process Based on Principal Component Regression Method

2011 ◽  
Author(s):  
Nong Gu. ◽  
Dougas Creighton ◽  
Saeid Nahavandi ◽  
Francisco Chinesta ◽  
Yvan Chastel ◽  
...  
Keyword(s):  
Injection Moulding ◽  
Principal Component Regression ◽  
Principal Component ◽  
Regression Method ◽  
Moulding Process ◽  
Injection Moulding Process

Monitoring of Polymer Plastication in the Injection Moulding Process

2013 ◽  
Author(s):  
Thuy Linh Pham ◽  
Jean Balcaen ◽  
Sambor Chhay ◽  
Yves Bereaux ◽  
Jean-Yves Charmeau
Keyword(s):  
Injection Moulding ◽  
Optical Glass ◽  
Experimental Studies ◽  
Fibre Length ◽  
Rotation Frequency ◽  
Direct Function ◽  
Moulding Process ◽  
Melt Pool ◽  
Injection Moulding Process ◽  
Mechanical Dissipation

In injection moulding or in extrusion, plastication is the step during which polymer pellets are melted by the means of mechanical dissipation provided by a rotating screw and by thermal conduction coming from a heated metallic barrel. This step is crucial for melt thermal homogeneity, charge dispersion and fibre length preservation. Although there have been a large number of theoretical and experimental studies of plastication during the past decades, mostly on extrusion and mostly using the screw extraction technique, extremely few of them have dealt with trying to visualise plastication, let alone measuring the plastication profile in real-time. As a matter of fact, designing such an equipment is an arduous task. We designed an industry-sized metallic barrel, featuring 3 optical glass windows; each window possessing 3 plane faces itself to allow for visualisation and record by synchronised cameras and lightening by lasers. The images recorded can be further analysed by digital image processing. Preliminary results confirm the plastication theory and show a compacted solid bed and a melt pool side by side. The total plastication length is a direct function of screw rotation frequency as it is obvious from results on the melt pool width, which increases when the screw rotation frequency decreases. However, some evidence of solid bed breakage has been recorded, whereby the solid bed does not diminish continuously along the screw but is fractured in the compression zone.

scholarly journals A model of the injection moulding process

1995 ◽  
Vol 37 (1) ◽  
pp. 1-15 ◽  
Author(s):  
J. Whale ◽  
N. Fowkes ◽  
G. Hocking ◽  
D. Hill
Keyword(s):  
High Pressure ◽  
Steady State ◽  
Injection Moulding ◽  
Temperature Profiles ◽  
Average Pressure ◽  
Moulding Process ◽  
Injection Moulding Process ◽  
Steady State Model ◽  
The Relationship ◽  
Average Pressure Gradient

AbstractThis paper is concerned with the injection moulding process, in which hot molten plastic is injected under high pressure into a thin cold mould. Assuming that the velocity and temperature profiles across the mould maintain their shape, a simple steady state model to describe the behaviour of a Newtonian fluid during the filling stage is developed. Various phenomena of the process are examined, including the formation of a layer of solid plastic along the walls of the mould, and the relationship between the flux of liquid plastic through the mould and the average pressure gradient along the mould. In any given situation, it is shown that there is a range of pressures and injection temperatures which will give satisfactory results.

Sign in / Sign up

Export Citation Format

Share Document