Selecting process parameter in injection molding via simulation optimization

2011 ◽  
Vol 31 (5) ◽  
Author(s):  
María G. Villarreal-Marroquín ◽  
Rachmat Mulyana ◽  
José M. Castro ◽  
Mauricio Cabrera-Ríos
Keyword(s):  
Injection Molding ◽  
Simulation Optimization ◽  
Mold Temperature ◽  
Optimization Method ◽  
Performance Measure ◽  
Melt Temperature ◽  
Process Variability ◽  
Composite Function ◽  
Automotive Part ◽  
Adaptive Metamodeling

Abstract A simulation optimization method based on design of experiments and adaptive metamodeling techniques is applied in this work to set process parameters in injection molding. The proposed method is used first to select the best processing conditions to injection molding a disposable camera front plate in the presence of either a single performance measure or a composite function of a series of performance measures. Secondly, it is used to select the best injection gate configuration from three different injection scenarios, as well as the values of mold temperature and melt temperature for a real automotive part in order to minimize process variability. The optimization results are discussed in light of the performance of the simulation optimization method.

Injection Molding Process Parameter Optimization for Warpage Minimization Based on Uniform Design of Experiment

2010 ◽  
Vol 37-38 ◽  
pp. 570-575 ◽  
Author(s):  
Bao Shou Sun ◽  
Zhe Chen ◽  
Bo Qin Gu ◽  
Xiao Diao Huang
Keyword(s):  
Injection Molding ◽  
Design Of Experiment ◽  
Simulation Analysis ◽  
Uniform Design ◽  
Mold Temperature ◽  
Optimization Method ◽  
Processing Parameters ◽  
Injection Molding Process ◽  
Molding Process ◽  
Melt Temperature

To optimize injection molding warpage, this paper applies the uniform design of experiment method to search for the optimal injection molding processing parameters. The warpage. simulation analysis is accomplished by emplying Moldflow software. The melt temperature, mold temperature, injection time and packing pressure are regarded as processing parameters, and processing parameters are optimized through establishing a regression equation, and the optimization result and influence factors are analyzed. The results show that uniform design of experiment can reduce number of experiments used effectively and the quality of the product is greatly improved by the optimization method.

scholarly journals A multicriteria simulation optimization method for injection molding

2011 ◽  
Vol 31 (5) ◽  
Author(s):  
María G. Villarreal-Marroquín ◽  
Mauricio Cabrera-Ríos ◽  
José M. Castro
Keyword(s):  
Injection Molding ◽  
Design Of Experiments ◽  
Performance Measures ◽  
Simulation Optimization ◽  
Optimization Method ◽  
Efficient Solutions ◽  
Performance Measure ◽  
Injection Molding Process ◽  
Molding Process ◽  
Plastic Parts

Abstract Injection molding is the most important process for mass-producing plastic products. To help improve and facilitate the molding of plastic parts, advanced computer simulation tools have been developed. While modeling is complicated by itself, the difficulty of optimizing the injection molding process is that the performance measures involving the injection molding process usually show conflicting behaviors. Therefore, the best solution for one performance measure is usually not the best in some other performance measures. This paper introduces a simulation optimization method which considers multiple performance measures and is able to find a set of efficient solutions without having to evaluate a large number of simulations. The main components of the method are metamodeling, design of experiments, and data envelopment analysis. The method is illustrated and detailed here using a simple test example, and it is applied to a real injection molding case. The performance of the method using a different design of experiments is also discussed.

Study on Optical Properties of Microstructure of Lightguiding Plate for Micro Injection Molding and Micro Injection-Compression Molding

2006 ◽  
Vol 505-507 ◽  
pp. 229-234 ◽  
Author(s):  
Yung Kang Shen ◽  
H.J. Chang ◽  
C.T. Lin
Keyword(s):  
Optical Properties ◽  
Injection Molding ◽  
Digital Camera ◽  
Mold Temperature ◽  
Compression Molding ◽  
Micro Injection Molding ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Injection Compression Molding ◽  
Better Than

The purpose of this paper presents the optical properties of microstructure of lightguiding plate for micro injection molding (MIM) and micro injection-compression molding (MICM). The lightguiding plate is applied on LCD of two inch of digital camera. Its radius of microstructure is from 100μm to 300μm by linearity expansion. The material of lightguiding plate uses the PMMA plastic. This paper uses the luminance distribution to make a comparison between MIM and MICM for the optical properties of lightguiding plate. The important parameters of process for optical properties are the mold temperature, melt temperature and packing pressure in micro injection molding. The important parameters of process for optical properties are the compression distance, mold temperature and compression speed in micro injection-compression molding. The process of micro injection-compression molding is better than micro injection molding for optical properties.

scholarly journals Optimization of Process Parameters for Vertical-Faced Polypropylene Bottle Injection Molding

2018 ◽  
Vol 2018 ◽  
pp. 1-9 ◽  
Author(s):  
Youmin Wang ◽  
Zhichao Yan ◽  
Xuejun Shan
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Dwell Time ◽  
Optimization Problem ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Orthogonal Test ◽  
Injection Molding Process ◽  
Injection Time ◽  
Melt Temperature

In order to obtain the optimal combination of process parameters for vertical-faced polypropylene bottle injection molding, with UG, the model of the bottle was drawn, and then, one module and sixteen-cavity injection molding system was established and analyzed using Moldflow. For filling and maintaining pressure during the process of infusion bottle injection molding, the orthogonal test table L25 (56) using CAE was designed for injection molding of the bottle, with six parameters such as melt temperature, mold temperature, injection pressure, injection time, dwell pressure, and dwell time as orthogonal test factors. By finding the best combination of process parameters, the orthogonal experiment was completed, the results were analyzed by range analysis, and the order of influence of each process parameter on each direction of optimization was obtained. The prediction dates of the infusion bottle were gained under various parameters, a comprehensive quality evaluation index of the bottle was formulated, and the multiobjective optimization problem of injection molding process was transformed into a single-objective optimization problem by the integrated weighted score method. The bottle parameters were optimized by analyzing the range date of the weighted scoring method, and the best parameter combination such as melt temperature 200°C, mold temperature 80°C, injection pressure 40 MPa, injection time 2.1 S, dwell pressure 40 MPa, and dwell time 40 S was gained.

Optimization of Injection Molding Process Parameters with Material Properties Based on GA and BP

2013 ◽  
Vol 345 ◽  
pp. 586-590 ◽  
Author(s):  
Xiao Hong Tan ◽  
Lei Gang Wang ◽  
Wen Shen Wang
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Mold Temperature ◽  
Injection Molding Process ◽  
Axial Deformation ◽  
Molding Process ◽  
Melt Temperature ◽  
Bp Network ◽  
Injection Parameters ◽  
Moldflow Simulation

To obtain optimal injection process parameters, GA was used to optimize BP network structure based on Moldflow simulation results. The BP network was set up which considering the relationship between volume shrinkage of plastic parts and injection parameters, such as mold temperature, melt temperature, holding pressure and holding time etc. And the optimal process parameters are obtained, which is agreed with actual results. Using BP network to predict injection parameters impact on parts quality can effectively reduce the difficulty and workload of other modeling methods. This method can be extended to other quality prediction in the process of plastic parts.Keyword: Genetic algorithm (GA);Neural network algorithm (BP);Injection molding process optimization;The axial deformation

The simulation of the warpage rule of the thin-walled part of polypropylene composite based on the coupling effect of mold deformation and injection molding process

2018 ◽  
Vol 25 (3) ◽  
pp. 593-601 ◽  
Author(s):  
Jixiang Zhang ◽  
Xiaoyi Yin ◽  
Fengzhi Liu ◽  
Pan Yang
Keyword(s):  
Injection Molding ◽  
Coupling Effect ◽  
Mold Temperature ◽  
Injection Molding Process ◽  
Plastic Part ◽  
Molding Process ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Thin Walled ◽  
Packing Time

Abstract Aiming at the problem that a thin-walled plastic part easily produces warpage, an orthogonal experimental method was used for multiparameter coupling analysis, with mold structure parameters and injection molding process parameters considered synthetically. The plastic part deformation under different experiment schemes was comparatively studied, and the key factors affecting the plastic part warpage were analyzed. Then the injection molding process was optimized. The results showed that the important order of the influence factors for the plastic part warpage was packing pressure, packing time, cooling plan, mold temperature, and melt temperature. Among them, packing pressure was the most significant factor. The optimal injection molding process schemes reducing the plastic part warpage were melt temperature (260°C), mold temperature (60°C), packing pressure (150 MPa), packing time (2 s), and cooling plan 3. In this situation, the forming plate flatness was better.

Influence of Injection Molding Parameters on Mechanical Properties of Low Density Polyethylene Filled With Multiwalled Carbon Nanotubes

2011 ◽  
Author(s):  
Catalin Fetecau ◽  
Felicia Stan ◽  
Daniel Dobrea ◽  
Dan Catalin Birsan
Keyword(s):  
Mechanical Properties ◽  
Carbon Nanotubes ◽  
Injection Molding ◽  
Young’S Modulus ◽  
Young's Modulus ◽  
Flow Direction ◽  
Mold Temperature ◽  
Low Density Polyethylene ◽  
Low Density ◽  
Melt Temperature

In this paper, we investigated the effect of injection molding parameters such as melt temperature, mold temperature, injection speed and holding pressure on the mechanical properties of low density polyethylene reinforced with 2.5 wt% multi-walled carbon nanotubes. The Taguchi methodology with four factors and two levels was used for the design of the injection molding experiments. The mechanical properties were evaluated by tensile tests in the flow direction at room temperature (23 °C) at crosshead speeds of 1 and 5 mm/min. It was found that the mechanical properties can be modified by manipulating the injection molding parameters. The Young’s modulus of the LDPE-MWNTs composite decreased as the melt temperature increased, while mold temperature, injection molding speed and holding pressure have a moderate influence on the Young’s modulus.

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.

Simulation of Injection Molding of Ultra-Thin Light Guide Plate with Hemispherical Microstructures

2012 ◽  
Vol 503 ◽  
pp. 222-226 ◽  
Author(s):  
Peng Wei Dong ◽  
Zhong Li Zhao ◽  
Da Ming Wu ◽  
Ya Yun Zhang ◽  
Jian Zhuang
Keyword(s):  
Residual Stress ◽  
Injection Molding ◽  
Production Efficiency ◽  
Light Guide ◽  
Low Cost ◽  
Mold Temperature ◽  
Main Element ◽  
Melt Temperature ◽  
Light Guide Plate ◽  
Guide Plate

Micro injection molding is used widely owing to its high accuracy, high production efficiency, low cost and can fabricate products with complex structures. For optical components, the residual stress is a main element for quality. In this research, the light guide plate is used as the study object. The light guide plate was designed by software Pro-E, and was simulated by Moldflow for filling process. Orthogonal method was used in this research. The most important factor that affects residual stress level is mold temperature. The level of the different process parameters on residual stress are mold temperature, packing time, packing pressure and melt temperature.

scholarly journals Optimization and application of temperature field in rapid heat cycling molding

2021 ◽  
pp. 291-291
Author(s):  
Mingliang Hao ◽  
Haimei Li
Keyword(s):  
Injection Molding ◽  
Electric Heating ◽  
Heating System ◽  
Mold Temperature ◽  
Temperature Control System ◽  
Cavity Surface ◽  
Injection Mold ◽  
Molding Process ◽  
Molded Parts ◽  
Automotive Part

The rapid thermal cycle molding (RHCM) belongs to the injection mold temperature control system which is helpful to improve mold ability and enhance part quality. Despite many available literatures, RHCM does not represent a well-developed area of practice. The challenge is the uneven distribution of temperature in the cavity after heating, which mostly leads to defects on the surface of the products. In order to obtain uniform cavity surface temperature distribution of RHCM, the power of heating rods of the electric-heating system in an injection mold was optimized by the response surface method(RSM) in this work. The proposed optimization result was applied to design a complex RHCM injection mold with side core-pulling, holes and different thickness of an automotive part to verify its effectiveness by injection molding. Compared with initial design, the mold temperature uniformity was remarkably improvedby79%. Based on the optimization and injection molding numerical simulation results, the workable molding process to weaken the weld-lines effects on the quality was suggested and the practical injection molded parts were well produced.

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