Effects of ultrasonic injection molding conditions on the plate processing characteristics of PMMA

2018 ◽  
Vol 38 (9) ◽  
pp. 905-914
Author(s):  
Yi-Jen Yang ◽  
Chung-Ching Huang
Keyword(s):  
Injection Molding ◽  
Manufacturing Industry ◽  
Flow Behavior ◽  
Pressure Sensors ◽  
Flow Characteristics ◽  
Local Heat ◽  
Skin Layer ◽  
Polymer Processing ◽  
Melt Flow ◽  
Diverse Field

AbstractPolymer processing is a crucial and diverse field in the manufacturing industry. We investigated the process characteristics and effects of injection molding using ultrasonic vibration. An ultrasonic device was installed in an injection mold; polymer was directly vibrated during injection. An ultrasonic oscillation device 45 mm in diameter was placed in the cavity and used to vibrate a poly(methyl methacrylate) melt at 19 kHz. The amplitude of the acoustic unit was set at 15 μm for the measurements. Moreover, cavity pressure sensors were positioned at the front and rear sides of the vibration region to determine the melt flow behavior under ultrasonic-assisted injection molding conditions. Because of the absorption of ultrasonic energy, local heat was generated inside the resin, thus improving the flow characteristics of the melt. Moreover, the melt flow behavior around the skin layer was changed; the molecular orientation and high shear effect were reduced. Furthermore, the freezing rate of the melt was reduced; thus, the amount of melt pressure lost through the cavity was decreased and the residual stress inside the injection-molded component generated during the photoelastic stress analysis was lower.

Application of ultrasonic-assisted injection molding for improving melt flowing and floating fibers

2016 ◽  
Vol 36 (2) ◽  
pp. 119-128 ◽  
Author(s):  
Yi-Jen Yang ◽  
Chung-Ching Huang ◽  
Jie Tao
Keyword(s):  
Injection Molding ◽  
Glass Fiber ◽  
Flow Behavior ◽  
Line Strength ◽  
Pressure Sensors ◽  
Weld Line ◽  
Flow Characteristics ◽  
Local Heat ◽  
Melt Flow ◽  
Ultrasonic Assisted

Abstract In this study, we investigated the use of ultrasonic technology in assisted injection molding and mold designs. We used an ultrasonic device installed in a mold to vibrate a melt directly, thereby converting kinetic energy into thermal energy. In addition, we developed three flat specimens of different thicknesses (3, 1, and 3-1-3 mm) produced by ultrasonic-assisted injection molds. An ultrasonic oscillation device 45 mm in diameter was placed in the cavity and used to vibrate a polycarbonate or a polycarbonate with 30% glass fiber melt at a frequency of 20 kHz. Furthermore, cavity pressure sensors were positioned at the front and rear of the vibration region for analyzing the melt flow behavior under ultrasonic-assisted injection molding conditions. Because of the absorption of ultrasonic energy, local heat was generated inside the resin, thus forming an oscillatory flow during the packing and holding stages, improving the flow characteristics of the melt, and changing the melt flow behavior around the skin layer to reduce the molecular orientation and high shear effect. The freezing rate of the melt was also reduced to eliminate the glass fiber streaks, floating fibers, and fiber orientation, particularly for thinner parts; the hesitation phenomena were then improved to increase the weld line strength.

Pressure Effects on Rheological Behavior of Melt Polymers – A Discussion in Relation to Polymer Processing

1986 ◽  
Vol 7 (1) ◽  
pp. 47-76 ◽  
Author(s):  
Yasushi Oyanagi ◽  
Kazuhisa Kubota
Keyword(s):  
Shear Stress ◽  
Injection Molding ◽  
Rheological Properties ◽  
Flow Behavior ◽  
Experimental Studies ◽  
Polymer Processing ◽  
Pressure Effects ◽  
Deformation Pattern ◽  
Melt Flow ◽  
Bulk Compressibility

Abstract Polymers have large bulk compressibility in the molten state /1/ and their rheological properties are largely affected by pressure applied in polymer processing. The volumetric strain induced by pressure consists of instantaneous and retarded elastic strains, both of which are proportional to pressure, and recover reversibly when pressure is removed. In many crystalline polymers, as observed by B. Maxwell for polyethylene, retarded elastic strain is large, and due mostly to pressure crystallization. This paper describes results of experimental studies relating pressure effects on rheological properties of melt polymers with polymer processing and bulk properties of products. The following items are discussed: pressure induced shear stress, analysis of local deformation pattern, critical shear stress for melt flow fracture, relationship between power law index and bulk compressibility, effects of hydrostatic pressure on melt flow behavior, pressure efficiency of injection molding, jetting phenomena, shrinkage in injection moldings, residual strain, and super-high-pressure injection molding process.

Numerical study of polymer melt flow in a three-dimensional sudden expansion: viscous dissipation effects

2014 ◽  
Vol 34 (8) ◽  
pp. 755-764
Author(s):  
Mustafa Tutar ◽  
Ali Karakus
Keyword(s):  
Viscous Dissipation ◽  
Stokes Equations ◽  
Numerical Study ◽  
Flow Behavior ◽  
Flow Analysis ◽  
Three Dimensional ◽  
Flow Characteristics ◽  
Polymer Melt ◽  
Sudden Expansion ◽  
Melt Flow

Abstract This numerical paper presents the effects of viscous dissipation on both hydrodynamic flow behavior and thermal flow characteristics of fluid included in rheological polymer flow analysis. The shear rate dependence of the viscosity is modeled using a modified form of the Cross constitutive equation, while the density changes are modeled using the modified Tait state of equation. The Navier-Stokes equations are solved in a sequential, decoupled manner with energy conservation equations using a finite volume method based fluid flow solver. Hydrodynamic and thermal boundary layer developments in an asymmetric sudden expansion for different velocity and melt flow injection temperature boundary and geometry conditions are determined under the influence of viscous dissipation effects and the results are compared with each other to measure the relative effects of viscous dissipation on the interactions of these layers for a commercial polymer melt flow, namely polypropylene (PP). The numerical results demonstrate that proposed mathematical and numerical formulations for viscosity and density variations including viscous heating terms lead to more accurate representation of the polymer melt flow and heat transfer phenomena in plane channels or mold cavity associated with a sudden expansion.

The Flow Behavior of Core Material and Breakthrough Phenomenon in Sandwich Injection Molding

2003 ◽  
Vol 18 (4) ◽  
pp. 405-411 ◽  
Author(s):  
D. Watanabe ◽  
U. S. Ishiaku ◽  
T. Nagaoka ◽  
K. Tomari ◽  
H. Hamada
Keyword(s):  
Injection Molding ◽  
Flow Behavior ◽  
Core Material

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.

scholarly journals Study on External Gas-Assisted Mold Temperature Control with the Assistance of a Flow Focusing Device in the Injection Molding Process

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 965 ◽  
Author(s):  
Nguyen Truong Giang ◽  
Pham Son Minh ◽  
Tran Anh Son ◽  
Tran Minh The Uyen ◽  
Thanh-Hai Nguyen ◽  
...  
Keyword(s):  
Injection Molding ◽  
Temperature Control ◽  
Mold Temperature ◽  
Injection Molding Process ◽  
Melt Flow ◽  
Flow Focusing ◽  
Molding Process ◽  
Heating Efficiency ◽  
Flow Length ◽  
Insert Plate

In the injection molding field, the flow of plastic material is one of the most important issues, especially regarding the ability of melted plastic to fill the thin walls of products. To improve the melt flow length, a high mold temperature was applied with pre-heating of the cavity surface. In this paper, we present our research on the injection molding process with pre-heating by external gas-assisted mold temperature control. After this, we observed an improvement in the melt flow length into thin-walled products due to the high mold temperature during the filling step. In addition, to develop the heating efficiency, a flow focusing device (FFD) was applied and verified. The simulations and experiments were carried out within an air temperature of 400 °C and heating time of 20 s to investigate a flow focusing device to assist with external gas-assisted mold temperature control (Ex-GMTC), with the application of various FFD types for the temperature distribution of the insert plate. The heating process was applied for a simple insert model with dimensions of 50 mm × 50 mm × 2 mm, in order to verify the influence of the FFD geometry on the heating result. After that, Ex-GMTC with the assistance of FFD was carried out for a mold-reading process, and the FFD influence was estimated by the mold heating result and the improvement of the melt flow length using acrylonitrile butadiene styrene (ABS). The results show that the air sprue gap (h) significantly affects the temperature of the insert and an air sprue gap of 3 mm gives the best heating rate, with the highest temperature being 321.2 °C. Likewise, the actual results show that the height of the flow focusing device (V) also influences the temperature of the insert plate and that a 5 mm high FFD gives the best results with a maximum temperature of 332.3 °C. Moreover, the heating efficiency when using FFD is always higher than without FFD. After examining the effect of FFD, its application was considered, in order to improve the melt flow length in injection molding, which increased from 38.6 to 170 mm, while the balance of the melt filling was also clearly improved.

scholarly journals Dynamic flight load measurements with MEMS pressure sensors

2021 ◽  
Author(s):  
Christian Raab ◽  
Kai Rohde-Brandenburger
Keyword(s):  
Pressure Distribution ◽  
Pressure Sensors ◽  
Flow Characteristics ◽  
Flight Test ◽  
Measurement Technology ◽  
Test Program ◽  
Aerodynamic Pressure ◽  
Pressure Distributions ◽  
Time Histories ◽  
Mems Pressure Sensors

AbstractThe determination of structural loads plays an important role in the certification process of new aircraft. Strain gauges are usually used to measure and monitor the structural loads encountered during the flight test program. However, a time-consuming wiring and calibration process is required to determine the forces and moments from the measured strains. Sensors based on MEMS provide an alternative way to determine loads from the measured aerodynamic pressure distribution around the structural component. Flight tests were performed with a research glider aircraft to investigate the flight loads determined with the strain based and the pressure based measurement technology. A wing glove equipped with 64 MEMS pressure sensors was developed for measuring the pressure distribution around a selected wing section. The wing shear force determined with both load determination methods were compared to each other. Several flight maneuvers with varying loads were performed during the flight test program. This paper concentrates on the evaluation of dynamic flight maneuvers including Stalls and Pull-Up Push-Over maneuvers. The effects of changes in the aerodynamic flow characteristics during the maneuver could be detected directly with the pressure sensors based on MEMS. Time histories of the measured pressure distributions and the wing shear forces are presented and discussed.

Effects of Embedded Vortices on Film-Cooled Turbulent Boundary Layers

1989 ◽  
Vol 111 (1) ◽  
pp. 71-77 ◽  
Author(s):  
P. M. Ligrani ◽  
A. Ortiz ◽  
S. L. Joseph ◽  
D. L. Evans
Keyword(s):  
Heat Transfer ◽  
Boundary Layers ◽  
Film Cooling ◽  
Free Stream ◽  
Flow Behavior ◽  
Local Heat Transfer ◽  
Local Heat ◽  
Turbulent Boundary Layers ◽  
Stream Velocity ◽  
Longitudinal Vortices

Heat transfer effects of longitudinal vortices embedded within film-cooled turbulent boundary layers on a flat plate were examined for free-stream velocities of 10 m/s and 15 m/s. A single row of film-cooling holes was employed with blowing ratios ranging from 0.47 to 0.98. Moderate-strength vortices were used with circulating-to-free stream velocity ratios of −0.95 to −1.10 cm. Spatially resolved heat transfer measurements from a constant heat flux surface show that film coolant is greatly disturbed and that local Stanton numbers are altered significantly by embedded longitudinal vortices. Near the downwash side of the vortex, heat transfer is augmented, vortex effects dominate flow behavior, and the protection from film cooling is minimized. Near the upwash side of the vortex, coolant is pushed to the side of the vortex, locally increasing the protection provided by film cooling. In addition, local heat transfer distributions change significantly as the spanwise location of the vortex is changed relative to film-cooling hole locations.

Sign in / Sign up

Export Citation Format

Share Document