Improving the predictions of injection molding simulation software

2011 ◽  
Vol 51 (12) ◽  
pp. 2542-2551 ◽  
Author(s):  
U. Vietri ◽  
A. Sorrentino ◽  
V. Speranza ◽  
R. Pantani
Keyword(s):  
Injection Molding ◽  
Simulation Software ◽  
Injection Molding Simulation

The Use of Advanced Aluminum Alloys for Enhanced Productivity in Plastic Injection Molding

2000 ◽  
Author(s):  
Jim Nerone ◽  
Karthik Ramani
Keyword(s):  
Aluminum Alloys ◽  
Injection Molding ◽  
Wall Thickness ◽  
Simulation Software ◽  
Cooling Time ◽  
Coolant Temperature ◽  
Steel Mold ◽  
Cooling Channels ◽  
Injection Molding Simulation ◽  
Increased Strength

Abstract New aluminum alloys, QC-7® and QE-7®, have thermal conductivities four times greater than traditional tool steels, and have significantly increased strength and hardness compared to traditional aluminum materials. Molds were constructed of P-20 tool steel and QE-7® aluminum and were used to provide experimental data regarding thermal mold characteristic and confirm injection molding simulation predictions using C-Mold®. The relationships between cooling time reduction (using aluminum alloys) and polymer type, cooling channel depth, part wall thickness, and coolant temperature were explored both experimentally and using simulation software. It was shown that the potential reduction in cooling time varied from 5% to 25%. The most significant percentage improvements were observed in parts with part wall thickness of 0.05″ to 0.10″ and in molds with cooling channels at a depth ratio (D/d) of 2.0. The thermal pulses in the steel mold 0.10″ from the surface were approximately 63% larger than in aluminum mold.

Gate Location Optimization in Injection Molding Processing

2000 ◽  
Author(s):  
Baojiu Lin ◽  
Won Gil Ryim
Keyword(s):  
Injection Molding ◽  
Simulation Software ◽  
Innovative Technology ◽  
Software Module ◽  
Location Optimization ◽  
Gate Location ◽  
Part Quality ◽  
Design Cycle ◽  
Injection Molding Simulation ◽  
Complex Models

Abstract Improvements in part quality and cost reduction are the primary objectives of CAE use in the injection molding industry. Engineers use advanced injection molding simulation software to analyze and verify their part designs. Traditionally, engineers have had to rerun simulations to verify the effects of changes in gate locations. For complex models, simulations are very time consuming. To reduce the design cycle time, a Design Optimization Module is developed by C-MOLD. One of the functions of this new software module is to automatically select optimal gate locations. This innovative technology is the result of close R&D collaboration between C-MOLD and LG-PRC in Korea. An overview of gate location optimization technology is presented in this paper, and several examples are also presented as illustration.

Verification CAE System for Plastic Injection

2016 ◽  
Vol 834 ◽  
pp. 79-83 ◽  
Author(s):  
Lukáš Satin ◽  
Jozef Bílik
Keyword(s):  
Injection Molding ◽  
Simulation Software ◽  
3D Scanner ◽  
Injection Process ◽  
Major Subject ◽  
Technology Process ◽  
Injection Molding Simulation ◽  
Plastic Parts ◽  
Cae System ◽  
Plastic Injection

This article is focused on the field of computer simulation and it is subsequent verification in practice. The work highlights the injection process, the simulation software that is specialized in injection molding and the technology process of injection itself. The major subject of the thesis is the use of the computer aided injection molding technology by using the CAE systems. The experimental part of the thesis deals with the production of the 3D model specific plastic parts in two modifications, injection molding simulation in the system Moldex3D and digitization of moldings on the optical 3D scanner. In the thesis we also provide measuring realization on digitized models and comparison of the parts size with the computer model. In conclusion we summarize the results achieved from the comparison. The thesis is carried out in cooperation with the Simulpast s.r.o.

A novel method for predicting degrees of crystallinity in injection molding during packing stage

2017 ◽  
Vol 233 (1) ◽  
pp. 204-214 ◽  
Author(s):  
Peng Zhao ◽  
Weimin Yang ◽  
Xiaoman Wang ◽  
Jiangang Li ◽  
Bo Yan ◽  
...  
Keyword(s):  
Injection Molding ◽  
Prediction Method ◽  
Mold Temperature ◽  
Simulation Software ◽  
Complex Flow ◽  
Packing Pressure ◽  
Injection Molding Simulation ◽  
Novel Method ◽  
High Cooling Rates ◽  
Density Results

Being able to predict products’ degrees of crystallinity and thereby optimize their crystallization processes is of great significance for producing high-quality polymeric products in injection molding. However, it is rather difficult to theoretically establish the relationship between the crystallization results and processing conditions (high cooling rates and pressures, strong and complex flow fields). Injection molding simulation software can simulate polymers’ density results during packing stage, and these predicted density results can be used to calculate polymers’ crystallinity results. Based on this idea, a novel method was proposed to predict the degrees of crystallinity for polymers during packing stage. In this method, pressure and temperature results are first simulated by an injection molding simulation software, and then the density results are calculated based on a pressure–volume–temperature model. Next, the crystallinity results are solved according to the densities of the fully crystalline part and the purely amorphous part. Finally, two case studies are conducted to verify the proposed crystallinity prediction method. Moreover, the effects of packing parameters (mold temperature, packing pressure, and packing time) on polymers’ crystallization behaviors are investigated. The experimental results show that the proposed method is correct and effective.

Comparison of injection molding processability of polylactic acid and high density polyethylene via computational approach

2013 ◽  
Vol 33 (2) ◽  
pp. 121-132 ◽  
Author(s):  
Lee Tin Sin ◽  
Yi-Ru Ng ◽  
Soo-Tueen Bee ◽  
Tiam-Ting Tee ◽  
A. R. Rahmat ◽  
...  
Keyword(s):  
Injection Molding ◽  
Polylactic Acid ◽  
High Density Polyethylene ◽  
Simulation Software ◽  
High Density ◽  
Computational Method ◽  
Clamp Force ◽  
Injection Molding Simulation ◽  
Velocity Pressure ◽  
Mean Time

Abstract The purpose of this paper is to compare the injection molding processability of polylactic acid (PLA) and high density polyethylene (HDPE) via a computational method. This study was conducted using injection molding simulation software Moldflow® using an iPhone 4 case (I4C) to evaluate the filling and packing stages of PLA and HDPE. The fill time, velocity/pressure switch over (VPSO), frozen layer fraction, time to freeze, volumetric shrinkages and clamp force were analyzed. The results showed that PLA requires a slightly longer time to fill the cavity compared to HDPE. At the mean time, the VPSO of PLA was larger than HDPE, as a result of the higher viscosity characteristic of PLA. From the packing analysis, it was found that the extent of shrinkage for PLA and HDPE was 4.11% and 4.78%, respectively. This result shows that an I4C produced by either PLA or HDPE have very close dimensions. In other words, the redesign of mold to fulfill the different shrinkage extent for PLA and HDPE is unnecessary, which indicates a cost of production saving. Finally, the manufacturing of PLA required a higher tonnage injection molding machine compared to HDPE where the clamp tonnage of PLA is 2.5 times higher than HDPE.

Development of a Novel Pvt Measuring Technique

2012 ◽  
Vol 729 ◽  
pp. 126-131 ◽  
Author(s):  
Ferenc Szabó ◽  
József Gábor Kovács
Keyword(s):  
Injection Molding ◽  
Input Data ◽  
Measuring Method ◽  
Mold Temperature ◽  
Simulation Software ◽  
Processing Conditions ◽  
Pvt Data ◽  
Injection Molding Simulation ◽  
Volume Relation

The pressure-temperature-specific volume relation of polymers is important not only for physical chemistry, but they are very significant input data for injection molding simulation software. Todays methods for measuring pvT data are slow, measurements can take days to be carried out, and in many cases the accuracy of the measurement is unsatisfactory. In our work, a new measuring method has been developed which makes the determination of the pvT relation faster compared to conventional processes within injection molding processing conditions. For the measurements a special injection mould was developed, in which the pvT relation of the material can be determined from the shrinkage in the mold. The data measured by the new method using polypropylene at a mold temperature of 23°C were compared to the data given in the database of the simulation software.

Design for Injection Molding: Using Process Simulation to Assess Tolerance Feasibility

1994 ◽  
Author(s):  
David R. Busick ◽  
Kurt A. Beiter ◽  
Kos Ishii
Keyword(s):  
Injection Molding ◽  
Process Simulation ◽  
Process Variations ◽  
Simulation Software ◽  
Injection Molding Process ◽  
Molding Process ◽  
Injection Molding Simulation ◽  
Injection Molded ◽  
Effective Use ◽  
Dimensional Errors

Abstract This paper proposes an effective use of process simulation in the dimensional tolerancing of injection molded thermoplastic components. The complexities of the injection molding process make it difficult for designers to assign dimensional tolerances. No standard method exists for predicting the feasibility of a design tolerance. Advances in injection molding simulation software offer information that could aid in tolerancing. However, engineers have not effectively used these programs for tolerancing. This paper proposes a methodology for using process simulation in evaluating the feasibility of a tolerance scheme. The methodology entails using simulation to quantify the dimensional errors due to process variations and estimate sensitivities. Comparison of simulation results with tolerances specified by designers helps them evaluate whether the desired tolerances are feasible. The paper describes the steps required for estimating the dimensional errors and defines criticality as a measure of tolerance feasibility. A plastic housing for an electrical switch serves as an illustrative example.

scholarly journals Temperature Profile in Rubber Injection Molding: Application of a Recently Developed Testing Method to Improve the Process Simulation and Calculation of Curing Kinetics

Polymers ◽  
2021 ◽  
Vol 13 (3) ◽  
pp. 380
Author(s):  
Martin Traintinger ◽  
Roman Christopher Kerschbaumer ◽  
Bernhard Lechner ◽  
Walter Friesenbichler ◽  
Thomas Lucyshyn
Keyword(s):  
Injection Molding ◽  
Temperature Profile ◽  
Pressure Sensors ◽  
Simulation Software ◽  
Relative Degree ◽  
Actual State ◽  
Process Conditions ◽  
Inlet Temperature ◽  
Degree Of Cure ◽  
Mass Temperature

Injection molding of rubber compounds is an easily conducted yet sophisticated method for rubber processing. Simulation software is used to examine the optimal process conditions, identify failure scenarios, and save resources. Due to the complexity of the entire process, various aspects have to be considered in the numerical approach. This contribution focused on a comparison of process simulations with various definitions of the material’s inlet temperature, ranging from a stepwise increase, but constant temperature, to an exact axial mass temperature profile prior to injection. The latter was obtained with a specially designed, unique test stand consisting of a plasticizing cylinder equipped with pressure sensors, a throttle valve for pressure adjustments, and a measurement bar with thermocouples for the determination of the actual state of the mass temperature. For the verification of the theoretical calculations, practical experiments were conducted on a rubber injection molding machine equipped with the mold used in the simulation. The moldings, obtained at different vulcanization time, were characterized mechanically and the results were normalized to a relative degree of cure in order to enable comparison of the real process and the simulation. Considering the actual state of the mass temperature, the simulation showed an excellent correlation of the measured and calculated mass temperatures in the cold runner. Additionally, the relative degree of cure was closer to reality when the mass temperature profile after dosing was applied in the simulation.

Key Technologies Research on Color Contour Map of 3D Injection Molding Simulation Results

2012 ◽  
Vol 217-219 ◽  
pp. 1998-2001
Author(s):  
Tie Geng ◽  
Qing Hai Ren ◽  
Wei Qing Tu ◽  
Dan Dan Liu
Keyword(s):  
Injection Molding ◽  
Color Image ◽  
Three Dimensional ◽  
Physical Field ◽  
Contour Map ◽  
Image Rendering ◽  
Color Range ◽  
Key Technologies ◽  
Injection Molding Simulation ◽  
Simulation Results

According to the color contour map of the 3D injection molding simulation results, the commonly used color contour map drawing algorithm was researched, and a three-dimensional color image rendering algorithm which based on the "physical field values and color range mapping" was given too. And the key technologies of the algorithm which was used to draw 3D color contour map were introduced in detail. In the end, an example was given.

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