Experimental and Numerical Analysis of Burn Marks and Shrinkage Effect on Injection Molding

2017 ◽  
Author(s):  
Saeed Beheshtian Mesgaran ◽  
Farzad Elhami Nik ◽  
Seyyed Emad Seyyed Mousavi
Keyword(s):  
Injection Molding ◽  
Surface Quality ◽  
Design Procedure ◽  
Injection Molding Process ◽  
Mold Design ◽  
Molding Process ◽  
Trapped Air ◽  
Thin Walls ◽  
New Strategy ◽  
Plastic Parts

Injection Molding is among the most popular processes in plastic parts production. Through this process, burn marks and shrinkage play the most significant role in decreasing surface quality as well as increasing costs, especially when manufacturers use this method in order to produce thin-walled plastic parts. In this paper, a new strategy to remove the defects caused by shrinkage and burn marks has been proposed for the injection molding process of a specific plastic part which is used to keep the doors of an automobiles open during the painting process. Burn marks caused by the trapped air inside thin walls of the part were first simulated in MOLDFLOW 2010 software. Next step is to compare the simulation results to results that are obtained from experimental analysis. Then, Burn marks and shrinkage effects were eliminated by optimization of the process which includes mold design revision by means of SOLIDWORKS software, modification of the simulation in MOLDFLOW and the mold modification in workshop environment by improvising some ejector pins in certain points. Furthermore, shrinkage amount of the part after cooling process was calculated by applying Finite Element Method (FEM) and obtained results were used to optimize the design of the mold. Results demonstrate that mold design optimization would be possible through designing flawless molds that contain certain points for trapped air discharge and calculating shrinkage amount by FEM for optimization of design procedure. Results consequently decrease costs as well as providing surface quality improvement.

Study on Improving the Life of Stereolithography Injection Mold

2012 ◽  
Vol 468-471 ◽  
pp. 1013-1016 ◽  
Author(s):  
Hua Qing Lai
Keyword(s):  
Injection Molding ◽  
Injection Molding Process ◽  
Injection Mold ◽  
Molding Process ◽  
Molded Parts ◽  
Injection Molded ◽  
Plastic Parts ◽  
Assembly Operations ◽  
Conventional Injection Molding ◽  
Shape And Size

Molding is one of the most versatile and important processes for manufacturing complex plastic parts. It is a method of fabricating plastic parts by utilizing a mold or cavity that has a shape and size similar to the part being produced. Molten polymer is injected into the cavity, resulting in the desired part upon solidification. The injection-molded parts typically have excellent dimensional tolerance and require almost no finishing and assembly operations. But new variations and emerging innovations of conventional injection molding have been continuously developed to offer special features and benefits that cannot be accomplished by the conventional injection molding process. This study aims to improving the life of stereolithography injection mold.

Optimization of the Injection Molding Process Parameters Based on Moldflow and Orthogonal Experiment

2013 ◽  
Vol 561 ◽  
pp. 239-243 ◽  
Author(s):  
Yong Nie ◽  
Hui Min Zhang ◽  
Jia Teng Niu
Keyword(s):  
Injection Molding ◽  
Orthogonal Experiment ◽  
Mold Temperature ◽  
Processing Parameters ◽  
Influential Factors ◽  
Injection Molding Process ◽  
Range Analysis ◽  
Molding Process ◽  
Melt Temperature ◽  
Plastic Parts

This article is using Moldflow analysis and orthogonal experimental method during the whole experiment. The injection molding process of motor cover is simulated under various technological conditions.After forming the maximum amount of warpage of plastic parts for evaluation.According to the range analysis of the comprehensive goal, the extent of the overall influence to the processing parameters, such as gate location, melt temperature, mold temperature and holding pressure is clarified.Through analyzing the diagrams of influential factors resulted from the simulation result,the optimized process parameter scheme is obtained and further verified by simulation.

Robust Design in Injection Molding Processing Based on Multi-Objective Ant Colonies Algorithm with Crossover and Variation

2011 ◽  
Vol 88-89 ◽  
pp. 279-284
Author(s):  
Feng Li Huang ◽  
Mei Peng Zhong ◽  
Jin Mei Gu ◽  
G.W. Liu
Keyword(s):  
Standard Deviation ◽  
Injection Molding ◽  
Robust Design ◽  
Injection Molding Process ◽  
Molding Process ◽  
Ant Colonies ◽  
Multi Objective ◽  
Plastic Parts ◽  
Crossover And Mutation ◽  
Plastic Injection

Based on single objective robust design of injection molding process, a bi-objective robust design model based on mean and standard deviation of molding quality and a multi-objective ant colonies algorithm with crossover and mutation based on Pareto optimization are proposed. Aimed at the craft parameters of plastic injection for the top and down shell of remote controller, a model of bi-objective robust design based on mean and standard deviation of warpage quantity is established with an example. And the model is solved by multi-objective ant colonies algorithm of crossover and mutation. The result shows that partial performances of algorithm are superior to that of NSGAII. The actual plastic injection was done by means of the parameters which were gotten by multi-objective robust optimization. The quality of plastic parts was high, and the fluctuation was small.

The Effect of Nano Hydroxyapatite Particles on Morphology and Mechanical Properties of Microcellular Injection Molded Polylactide/Hydroxyapatite Tissue Scaffold

2010 ◽  
Author(s):  
Adam Kramschuster ◽  
Lih-Sheng Turng ◽  
Wan-Ju Li ◽  
Yiyan Peng ◽  
Jun Peng
Keyword(s):  
Mechanical Properties ◽  
Injection Molding ◽  
Low Cost ◽  
Tissue Growth ◽  
Batch Processes ◽  
Injection Molding Process ◽  
High Porosity ◽  
Molding Process ◽  
Tissue Scaffold ◽  
Plastic Parts

The current large demands for transplant organs and tissues has led to extensive research on material synthesis and fabrication methods for biodegradable polymeric scaffolds, which are required to have high porosity, well interconnected pore structure, and good mechanical properties. However, the majority of current scaffold fabrication techniques are either for batch processes or use organic solvents, which can be detrimental to cell survival and tissue growth. The ability to mass produce solvent-free, highly porous, highly interconnected scaffolds with complex geometries is essential to provide off-the-shelf availability [1]. Injection molding has long been used for mass production of complex 3D plastic parts. The low-cost manufacturing, repeatability, and design flexibility inherent in the injection molding process make it an ideal manufacturing process to create 3D scaffolds, as long as high porosity and interconnectivity can be imparted into the finished product.

scholarly journals Estimation of Injection Molding Process for a Thin Fresnel lens By Plastic Flow Simulation

2019 ◽  
Vol 8 (10) ◽  
pp. 3276-3282
Keyword(s):  
Injection Molding ◽  
Plastic Flow ◽  
Flow Analysis ◽  
Flow Simulation ◽  
Fresnel Lens ◽  
Injection Molding Process ◽  
Molding Process ◽  
Manufacturing Defects ◽  
Simulation Results ◽  
Plastic Parts

This paper is based on the plastic flow simulation of a thin Fresnel lens to estimate the injection molding process. Nowadays Fresnel lenses are made of transparent plastics materials instead of silica-based glass to reduce handling and processing cost. For mass manufacturing of plastic parts, the injection molding process is best suited. Thus in this study plastic flow analysis of a thin Fresnel lens is carried for the evaluation of injection molding process. Plastic flow analysis helps in estimating how molten plastic will flow during the process Plastic flow analysis is also very helpful in evaluating the manufacturing defects such as air traps and weld lines without real-time experimentation. The simulation results evaluate the values of the parameters such as fill time, filing pressure, pack pressure, etc. Also, the manufacturing defects observed by the simulation results are reasonable and met the design requirement.

Optimal Design for Injection Molding Process Using Design of Experiments and Finite Element Analysis

2000 ◽  
Author(s):  
K. Park ◽  
J. H. Ahn ◽  
S. R. Choi
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Optimal Design ◽  
Injection Molding ◽  
Design Of Experiments ◽  
Process Parameters ◽  
Injection Molding Process ◽  
Mold Design ◽  
Molding Process ◽  
Element Analysis

Abstract The present work concerns optimal design for the injection molding process of a deflection yoke (coil separator). The optimal design for the injection molding process is developed using design of experiments and finite element analysis. Two design of experiments approaches are applied such as: the design of experiment for mold design and the design of experiments for determination of process parameters. Finite element analyses have been carried out as a design of experiments for mold design: runner system and cooling channel. In order to determine optimal process parameters, experiments have been performed for various process conditions with the design of experiments scheduling.

A Study on Injection Molding Analysis and Structural Analysis with Truck Brake Pedal

2013 ◽  
Vol 535-536 ◽  
pp. 430-433
Author(s):  
Chul Woo Park ◽  
Seong Ho Seo
Keyword(s):  
Injection Molding ◽  
High Efficiency ◽  
Low Cost ◽  
Fem Simulation ◽  
High Strength ◽  
Injection Molding Process ◽  
Brake Pedal ◽  
Molding Process ◽  
Molding Condition ◽  
Plastic Parts

Injection molding process one of the most important methods to produce plastic parts with high efficiency and low cost. Today, Injection molded parts have been increased dramatically the demand for high strength and quality applications. In this study, truck brake pedal is made of Cast iron and plastic materials to replace the frame for the optimization process that minimizes the runner and the gate dimension will determine the size and shape. Runner and gate dimensions of change based on availability of the product. I will discuss the injection molding. This report investigates that the optimum injection molding condition for minimum of runner and gate position. The FEM Simulation CAE tool, MOLDFLOW, is used for the analysis of injection molding process.

Manufacturability Analysis of Multi-Material Objects Molded by Rotary Platen Multi-Shot Molding Process

2003 ◽  
Author(s):  
Xuejun Li ◽  
Satyandra K. Gupta
Keyword(s):  
Injection Molding ◽  
Product Development ◽  
Development Time ◽  
Systematic Approach ◽  
Geometric Algorithms ◽  
Material Objects ◽  
Injection Molding Process ◽  
Mold Design ◽  
Molding Process ◽  
Opening And Closing

This paper describes a systematic approach for manufacturability analysis of multi-material objects molded using rotary platen multi-shot injection molding process. In this paper we first identify potential manufacturability problems that are associated with objects molded by the rotary platen process. Identified problems include infeasibility of molding sequences, unnecessary mold complexity, undesired friction during mold opening and closing, and undesired material flash on finished faces. These problems are unique to multi-material molding and do not occur in traditional injection molding. For each of the above four potential manufacturability problems, this paper also describes geometric algorithms for detecting the potential occurrence of the problem based on the object and mold design, finding its causes, and offering appropriate redesign suggestions. We expect that these algorithms will help in decreasing the product development time and improving the product quality for molded multi-material objects.

scholarly journals Simple equipment for studying the injection molding process

2018 ◽  
Vol 178 ◽  
pp. 02001 ◽  
Author(s):  
Adelina Hriţuc
Keyword(s):  
Injection Molding ◽  
Injection Molding Process ◽  
Molding Process ◽  
Injection Equipment ◽  
Diagram Method ◽  
Constructive Solution ◽  
Injection Process ◽  
Plastic Parts ◽  
Experimental Researches

The injection molding process is largely applied to obtain plastic parts. The problem of finding a simple equipment able to allow the study of the injection process was addressed in the research presented in this paper. Aiming to solve the problem, the main requests valid for the proposed equipment were formulated. Considering some possible versions of the equipment subassemblies, the ideas diagram method and the method of imposed decision were applied to select the most convenient version of the injection equipment. As a result, a constructive solution for a simple injection molding equipment that could be used to develop some experimental researches was identified.

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