Design Sensitivity Analysis Applied to Injection Molding Process: Injection Pressure and Multi-Gate Location Optimization

2000 ◽  
Author(s):  
Kalonji K. Kabanemi ◽  
Jean-François Hétu ◽  
Abdessalem Derdouri
Keyword(s):  
Sensitivity Analysis ◽  
Injection Molding ◽  
Injection Pressure ◽  
Pressure Profile ◽  
Design Sensitivity ◽  
Design Sensitivity Analysis ◽  
Injection Molding Process ◽  
Molding Process ◽  
Filling Fraction ◽  
Design Variables

Abstract In this work, we develop a numerical simulation method to optimize the injection molding process using the design sensitivity analysis (DSA). The optimization concerns the filling stage and focuses on the number and location of gates in a mold cavity as well as the injection pressure, considered as one of the key processing parameters, in order to minimize the fill time. Since the problem to be solved involves transient flow with free surfaces, the direct differentiation method is used to evaluate the sensitivities of the Hele-Shaw, filling fraction and the energy equations with respect to the design variables used in the analysis. The mesh domain parameterization is coped with using B-spline functions. Sensitivity equations are solved by means of finite element method. The proposed numerical approach is combined with the sequential linear and quadratic programming method of the DOT optimization tools to find the new design variables at each iteration. Starting with any initial gate locations and injection pressure profile, the method enables us to find the optimal gate locations together with the optimal injection pressure profile. Finally, numerical results involving complex mold geometries are presented and discussed to assess the validity and robustness of the proposed method.

Design Sensitivity Analysis of Nonlinear Multidisciplinary Multibody Systems in the MIXEDMODELS Platform

2007 ◽  
Author(s):  
Shilpa A. Vaze ◽  
Prakash Krishnaswami ◽  
James DeVault
Keyword(s):  
Sensitivity Analysis ◽  
Multibody Systems ◽  
Design Sensitivity ◽  
Differential Algebraic Equations ◽  
The State ◽  
Design Sensitivity Analysis ◽  
Design Parameters ◽  
State Variables ◽  
Sensitivity Coefficients ◽  
Design Variables

Most state-of-the-art multibody systems are multidisciplinary and encompass a wide range of components from various domains such as electrical, mechanical, hydraulic, pneumatic, etc. The design considerations and design parameters of the system can come from any of these domains or from a combination of these domains. In order to perform analytical design sensitivity analysis on a multidisciplinary system (MDS), we first need a uniform modeling approach for this class of systems to obtain a unified mathematical model of the system. Based on this model, we can derive a unified formulation for design sensitivity analysis. In this paper, we present a modeling and design sensitivity formulation for MDS that has been successfully implemented in the MIXEDMODELS (Multidisciplinary Integrated eXtensible Engine for Driving Metamodeling, Optimization and DEsign of Large-scale Systems) platform. MIXEDMODELS is a unified analysis and design tool for MDS that is based on a procedural, symbolic-numeric architecture. This architecture allows any engineer to add components in his/her domain of expertise to the platform in a modular fashion. The symbolic engine in the MIXEDMODELS platform synthesizes the system governing equations as a unified set of non-linear differential-algebraic equations (DAE’s). These equations can then be differentiated with respect to design to obtain an additional set of DAE’s in the sensitivity coefficients of the system state variables with respect to the system’s design variables. This combined set of DAE’s can be solved numerically to obtain the solution for the state variables and state sensitivity coefficients of the system. Finally, knowing the system performance functions, we can calculate the design sensitivity coefficients of these performance functions by using the values of the state variables and state sensitivity coefficients obtained from the DAE’s. In this work we use the direct differentiation approach for sensitivity analysis, as opposed to the adjoint variable approach, for ease in error control and software implementation. The capabilities and performance of the proposed design sensitivity analysis formulation are demonstrated through a numerical example consisting of an AC rectified DC power supply driving a slider crank mechanism. In this case, the performance functions and design variables come from both electrical and mechanical domains. The results obtained were verified by perturbation analysis, and the method was shown to be very accurate and computationally viable.

scholarly journals Study on Stability of a Novel Binder System Based on Palm Stearin in Metal Injection Moulding Application

2007 ◽  
Vol 4 (2) ◽  
pp. 1
Author(s):  
Muhammad Hussain Ismail ◽  
Norhamidi Muhamad ◽  
Aidah Jumahat ◽  
Istikamah Subuki ◽  
Mohd Afian Omar
Keyword(s):  
Injection Molding ◽  
Flow Characteristics ◽  
Injection Pressure ◽  
Palm Stearin ◽  
Steel Powder ◽  
Metal Injection Molding ◽  
Injection Molding Process ◽  
Binder System ◽  
Molding Process ◽  
Flow Activation Energy

Metal Injection Molding (MIM) is a wellestablished technology for manufacturing a variety of complex and small precision parts. In this paper, fundamental rheological characteristics of MIM feedstock using palm stearin are theoretically analyzed and presented. The feedstock consisted of gas atomized 316L stainless steel powder at three different particle size distributions and the binder system of palm stearin (PS) and polyethylene (PE). The powder loading used was 60vol % for all samples (monosize 16 µm, monosize 45 µm, and bimodal 16 µm + 45 µm) and the binder system of 40vol %(PS/PE = 40/60). The viscosity of MIM feedstock at different temperatures and shear rates was measured and evaluated. Results showed that, the feedstock containing palm stearin exhibited suitable rheological properties by increasing the fluidity of feedstock in MIM process. The rheological results also showed a pseudoplastic flow characteristics, which poses higher value of shear sensitivity (n) and lower value of flow activation energy (E), that are both favourable for injection molding process. The green parts were successfully injected and exhibited adequate strength for handling by optimizing the injection pressure and temperature.

scholarly journals LCI Databases Sensitivity Analysis of the Environmental Impact of the Injection Molding Process

2015 ◽  
Vol 7 (4) ◽  
pp. 3792-3800 ◽  
Author(s):  
Ana Elduque ◽  
Carlos Javierre ◽  
Daniel Elduque ◽  
Ángel Fernández
Keyword(s):  
Sensitivity Analysis ◽  
Environmental Impact ◽  
Injection Molding ◽  
Injection Molding Process ◽  
Molding Process

Design Sensitivity Analysis for the Meshfree Shell Structure

2001 ◽  
Author(s):  
Kyung K. Choi ◽  
Nam H. Kim ◽  
Mark E. Botkin
Keyword(s):  
Sensitivity Analysis ◽  
Shell Structure ◽  
Design Sensitivity ◽  
Design Sensitivity Analysis ◽  
Analysis Method ◽  
Sensitivity Equation ◽  
Material Derivative ◽  
Design Variables ◽  
Sensitivity Analysis Method ◽  
Shell Formulation

Abstract A unified design sensitivity analysis method for a meshfree shell structure with respect to sizing, shape, and configuration design variables is presented in this paper. A shear deformable shell formulation is characterized by a CAD connection, thickness degeneration, meshfree discretization, and nodal integration. The design variable is selected from the CAD parameters, and a consistent design velocity field is then computed by perturbing the surface geometric matrix. The material derivative concept is used to obtain a design sensitivity equation in the parametric domain. Numerical examples show the accuracy and efficiency of the proposed design sensitivity analysis method compared to the analytical solution and the finite difference solution.

Design Sensitivity Analysis and Optimization of Nonlinear Anisotropic Structures

2004 ◽  
Vol 261-263 ◽  
pp. 809-814
Author(s):  
Tae Hee Lee ◽  
J.J. Jung
Keyword(s):  
Sensitivity Analysis ◽  
Nonlinear Analysis ◽  
Yield Criterion ◽  
Design Sensitivity ◽  
Euler Method ◽  
Design Sensitivity Analysis ◽  
Design Variables ◽  
Nonlinear Constitutive Equation ◽  
Anisotropic Structures ◽  
Hill's Yield Criterion

Nonlinear analysis of anisotropic structures is described by using Hill's yield criterion that anisotropic yield contour is assumed to be retained its shape during the hardening process. Nonlinear constitutive equation of anisotropic material is derived using plastic potential concept. Linear strain hardening model is utilized and forward Euler method is employed as a stress integration method. Newton-Raphson method is implemented for numerical nonlinear analysis. Direct differentiation method differentiating directly the equilibrium equation with respect to design variables is applied to design sensitivity analysis of nonlinear anisotropic plate. The results of design sensitivity analysis are compared with those of finite difference method to verify the accuracy. Optimization is accomplished for a rectangular plate using evaluated sensitivity coefficients.

Three-dimensional optimum design of the cooling lines of injection moulds based on boundary element design sensitivity analysis

2002 ◽  
Vol 216 (7) ◽  
pp. 1067-1071 ◽  
Author(s):  
H Zhou ◽  
D Li ◽  
S Cui
Keyword(s):  
Sensitivity Analysis ◽  
Objective Function ◽  
Boundary Element ◽  
Optimum Design ◽  
Three Dimensional ◽  
Design Sensitivity ◽  
Boundary Integral ◽  
Optimization Techniques ◽  
Design Sensitivity Analysis ◽  
Design Variables

A three-dimensional numerical simulation using the boundary element method is proposed, which can predict the cavity temperature distributions in the cooling stage of injection moulding. Then, choosing the radii and positions of cooling lines as design variables, the boundary integral sensitivity formulations are deduced. For the optimum design of cooling lines, the squared difference between the objective temperature and the temperature of the cavity is taken as the objective function. Based on the optimization techniques with design sensitivity analysis, an iterative algorithm to reach the minimum value of the objective function is introduced, which leads to the optimum design of cooling lines at the same time.

Comprehensive Online Control Strategies for Plastic Injection Molding Process

2014 ◽  
Vol 136 (4) ◽  
Author(s):  
Jaho Seo ◽  
Amir Khajepour ◽  
Jan P. Huissoon
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Thermal Control ◽  
Plastic Injection Molding ◽  
Injection Molding Process ◽  
Molding Process ◽  
Element Analysis ◽  
Thermal Dynamics ◽  
Uncertain Dynamics ◽  
Plastic Injection

This study proposes an effective thermal control for plastic injection molding (polymer: Santoprene 8211-45 with density of 790 kg/m3, injection pressure: 1400 psi (9,652,660 Pa)) in a laminated die. For this purpose, a comprehensive control strategy is provided to cover various themes. First, a new method for determining the optimal sensor locations as a prerequisite step for modeling and controller design is introduced. Second, system identification through offline and online training with finite element analysis and neural network techniques are used to develop an accurate model by incorporating uncertain dynamics of the laminated die. Third, an additive feedforward control by adding direct adaptive inverse control to self-adaptive PID is developed for temperature control of cavity wall (cavity size: 52.9 × 32.07 × 16.03 mm). A verification of designed controller's performance demonstrates that the proposed strategy provides accurate online temperature tracking and faster response under thermal dynamics with various cycle-times in the injection mold process.

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