Cooling Process Window Development for Injection Molding

1995 ◽  
Vol 10 (4) ◽  
pp. 351-358
Author(s):  
B. Xie ◽  
D. Bigio
Keyword(s):  
Injection Molding ◽  
Process Window ◽  
Cooling Process

Injection Molding Process Windows Considering Two Conflicting Criteria: Simulation Results

2012 ◽  
Author(s):  
Alicia B. Rodríguez ◽  
Esmeralda Niño ◽  
Jose M. Castro ◽  
Marcelo Suarez ◽  
Mauricio Cabrera
Keyword(s):  
Injection Molding ◽  
Multiple Criteria ◽  
Process Window ◽  
Injection Molding Process ◽  
Processing Conditions ◽  
Molding Process ◽  
Multiple Criteria Optimization ◽  
Simulation Results ◽  
Main Ideas

In this work, two criteria in conflict are considered simultaneously to determine a process window for injection molding. The best compromises between the two criteria are identified through the application of multiple criteria optimization concepts. The aim with this work is to provide a formal and realistic strategy to set processing conditions in injection molding operations. In order to keep the main ideas manageable, the development of the strategy is constrained to two controllable variables in computer simulated parts.

MPI-Based Injection Molding Process Optimization Analysis of the Control Plastic Cover

2011 ◽  
Vol 271-273 ◽  
pp. 1224-1227
Author(s):  
Fang Qi Cheng
Keyword(s):  
Injection Molding ◽  
Process Simulation ◽  
Filling Pressure ◽  
Injection Molding Process ◽  
Cooling Process ◽  
Forming Process ◽  
Molding Process ◽  
Optimization Analysis ◽  
Mould Design ◽  
Plastic Products

To avoid the defects of plastic products and improve product quality have been an important problem for mold designers. In this paper, Autodesk Moldflow software are applied to a plastic control cover injection molding process simulation and find out the actual molding process and true conditions of the dynamic filling, pressure and cooling process in the process of forming. The forming process of parameters such as pressure, temperature and speed are given in order to improve the accuracy of the mould design and product precision.

scholarly journals Gate Design in Injection Molding of Microfluidic Components Using Process Simulations

2016 ◽  
Vol 4 (2) ◽  
Author(s):  
David Maximilian Marhöfer ◽  
Guido Tosello ◽  
Aminul Islam ◽  
Hans Nørgaard Hansen
Keyword(s):  
Injection Molding ◽  
Simulation Software ◽  
Process Window ◽  
Actual Process ◽  
Flow Front ◽  
Steel Mold ◽  
Polymer Flow ◽  
Process Simulations ◽  
Simulation Results ◽  
Gate Design

Just as in conventional injection molding of plastics, process simulations are an effective and interesting tool in the area of micro-injection molding. They can be applied in order to optimize and assist the design of the microplastic part, the mold, and the actual process. Available simulation software is however actually made for macroscopic injection molding. By means of the correct implementation and careful modeling strategy though, it can also be applied to microplastic parts, as it is shown in the present work. Process simulations were applied to two microfluidic devices (a microfluidic distributor and a mixer). The paper describes how the two devices were meshed in the simulations software to obtain a proper simulation model and where the challenges arose. One of the main goals of the simulations was the investigation of the filling of the parts. Great emphasis was also on the optimization of selected gate designs for both plastic parts. Subsequently, the simulation results were used to answer the question which gate design was the most appropriate with regard to the process window, polymer flow, and part quality. This finally led to an optimization of the design and the realization of this design in practice as actual steel mold. Additionally, the simulation results were critically discussed and possible improvements and limitations of the gained results and the deployed software were described. Ultimately, the simulation results were validated by cross-checking the flow front behavior of the polymer flow predicted by the simulation with the actual flow front at different time steps. These were realized by molding short shots with the realized molds and were compared to the simulations at the global, i.e., part level and at the local, i.e. feature level.

A Knowledge-Based Tuning Method for Injection Molding Machines

2000 ◽  
Author(s):  
Dongzhe Yang ◽  
Kourosh Danai ◽  
David Kazmer
Keyword(s):  
Injection Molding ◽  
A Priori ◽  
Statistical Design ◽  
Process Window ◽  
Feasible Region ◽  
Statistical Design Of Experiments ◽  
Tuning Method ◽  
Part Quality ◽  
Knowledge Based ◽  
Experienced Operator

Abstract Complexity of manufacturing processes has hindered methodical specification of machine setpoints for improving productivity. Traditionally in injection molding, the machine setpoints are assigned either by trial and error, based on heuristic knowledge of an experienced operator, or according to an empirical model between the inputs and part quality attributes obtained from statistical design of experiments (DOE). In this paper, a Knowledge-Based Tuning (KBT) Method is presented which takes advantage of the a priori knowledge of the process, in the form of a qualitative model, to reduce the demand for experimentation. The KBT Method is designed to provide an estimate of the process feasible region (process window) as the basis of finding the optimal setpoints, and to update its knowledge-base according to new input-output data that becomes available during tuning. The KBT Method’s utility is demonstrated in production of digital video disks (DVDs).

CAE-Based Injection Molding Analysis of Mobile Phone Battery Cover

2012 ◽  
Vol 538-541 ◽  
pp. 1130-1133
Author(s):  
Jun Kai Yang ◽  
Yun Jie Xu
Keyword(s):  
Injection Molding ◽  
Mobile Phone ◽  
Product Quality ◽  
Product Design ◽  
Cell Phone ◽  
Production Costs ◽  
Improve Quality ◽  
Cooling Process ◽  
Cover Design ◽  
Plastic Parts

In this thesis, CAE software is used to carry out the injection molding analysis of mobile phone battery cover and simulate the filling and cooling process so as to determine the formability of plastic parts and product quality. In the process of product design, it can also predict possible defects so as to optimize mold structure, save production costs, and improve quality and efficiency of cell phone battery cover design.

Micro Powder Injection Molding (µPIM): Review

2011 ◽  
Vol 52-54 ◽  
pp. 91-96 ◽  
Author(s):  
Heng Shye Yunn ◽  
Norhamidi Muhamad ◽  
Abu Bakar Sulong
Keyword(s):  
Injection Molding ◽  
Large Volume ◽  
Powder Injection Molding ◽  
Process Parameter ◽  
Process Window ◽  
Powder Injection ◽  
Wide Range ◽  
Volume Production ◽  
Low Costs

Micro powder injection molding (µPIM) is the combination of micro injection molding and powder injection molding (PIM) technology. The increasing demands on market of microparts further intensify the development of this technology. µPIM process enables the use of a wide range of materials and broadens the applications of micro components. This process is well suitable for large volume production of micro-components at low costs. Requirement of powder and binder is more stringent since product fabricate in micron scale, therefore criterion of the powder and binder has been reviewed in this paper. In addition, the process parameter and development in the computer aid plays an important due to the narrow process window requires even tighter as the quality of the micro-component is sensitive to the parameter. This paper outlines recent development in µPIM. Challenges and further explore for µPIM is concluded in the last part of this paper.

Influence of Packing Phase Parameters in the Optimization of Mechanical, Weight Reduction and Dimensional Properties of Microcellular Foaming Injection Molding of Polypropilene

2012 ◽  
Vol 445 ◽  
pp. 319-324 ◽  
Author(s):  
Angel Fernandez ◽  
Manuel Muniesa
Keyword(s):  
Mechanical Properties ◽  
Injection Molding ◽  
Weight Reduction ◽  
Mechanical Performance ◽  
Process Window ◽  
Foam Density ◽  
Microcellular Foam ◽  
Molded Part ◽  
Microcellular Foaming ◽  
Conventional Injection Molding

Microcellular foaming of injected plastics offers the possibility to manufacture parts with reductions in costs and weight if compared with conventional injection molding. For this reason there is an increasing interest in challenging applications such as HEV (hybrid and electrical vehicles) and lightweight material applications in general. Complexity of microcellular injection molding is very high because the final properties of the material obtained depend largely on the processing conditions and these in turn unalterable factors such as mold design and manufacturing. The shrinkage of the molded part must be applied as an oversize of the mold cavity in the design phase. Shrinkage of a microcellular foam depends on the reduction of foam density. Moreover, the piece is designed to get a mechanical performance and meet the dimensional tolerances. Knowing that the reduction of foam density implies a reduction of the mechanical properties and influences the final piece dimensions the conclusion is that the microcellular injection process has a very small process window to fit all these factors. This research focuses on two objectives. First is the variation of post-molding shrinkage in terms of reduction of weight to determine the process window. Second is the determination of mechanical properties which do not show a proportional reduction but exponentially with weight reduction components. The results obtained with a 750 Tons. injection moulding machine equipped with a MuCell plastication unit and a large spiral mold have shown small variations in the dimensions for a predetermined process window and smaller reduction of mechanical properties with weight reductions for 20% talc filled polypropylene. The goal of this applied research is that all experiments have been developed with scaled-industry tools (large injection molding machine, Mucell unit and mold and test parts) comparing with conventional injection molding.

The Cooling Time of Gas Assisted Injection Molding

2011 ◽  
Vol 221 ◽  
pp. 422-428
Author(s):  
Qiu Xiang Bu ◽  
Xiao Zhang ◽  
Hai Ying Chen ◽  
Qing Zhen Yin
Keyword(s):  
Mathematical Model ◽  
Injection Molding ◽  
Wall Thickness ◽  
Cooling Time ◽  
Cooling Process ◽  
Liquid Phases ◽  
Solid Liquid Interface ◽  
Solid Liquid ◽  
The Mathematical Model ◽  
Plastic Products

The mathematical model of solid-liquid interface is obtained by making an idealized hypothesis for parameters of the cooling process in gas-assisted injection molding, and simplifying the mathematical model. And then the cooling time of plastic products in the process is obtained by using two ways of solving the solid and liquid phases. And verified by example the conclusions that some plastic products of gas-assisted injection molding, when the materials and workmanship conditions are constant, cooling time of the airway is proportional to the square of the wall thickness is obtained.

A Knowledge-Based Tuning Method for Injection Molding Machines

2000 ◽  
Vol 123 (4) ◽  
pp. 682-691 ◽  
Author(s):  
Dongzhe Yang ◽  
Kourosh Danai ◽  
David Kazmer
Keyword(s):  
Injection Molding ◽  
Empirical Model ◽  
A Priori ◽  
Process Window ◽  
Feasible Region ◽  
A Priori Knowledge ◽  
Qualitative Model ◽  
Trial And Error ◽  
Knowledge Based ◽  
Priori Knowledge

Complexity of manufacturing processes has hindered methodical specification of machine setpoints for improving productivity. Traditionally in injection molding, the machine setpoints are assigned either by trial and error, based on heuristic knowledge of an experienced operator, or according to an empirical model between the inputs and part quality attributes, which is obtained from statistical design of experiments (DOE). In this paper, a Knowledge-Based Tuning (KBT) Method is presented which takes advantage of the a priori knowledge of the process, in the form of a qualitative model, to reduce the demand for experimentation. The KBT Method provides an estimate of the process feasible region (process window) as the basis of finding the suitable setpoints, and updates its knowledge-base using the data that become available during tuning. As such, the KBT Method has several advantages over conventional tuning methods: (1) the qualitative model provides a generic form of representation for linear and nonlinear processes alike, therefore, there is no need for selecting the form of the empirical model through trial and error, (2) the use of a priori knowledge eliminates the need for initial trials to construct an empirical model, so an initial feasible region can be identified as the basis of search for the suitable setpoints, and (3) the search within the feasible region leads to a higher fidelity model of this region when the input/output data from consecutive process iterations are used for learning. The KBT Method’s utility is demonstrated in production of digital video disks (DVDs).

Influence Factors of Efficient Injection Molding of Plastic Precise Gear by Simulation of CAE Software and Visualization Experiment

2006 ◽  
Vol 11-12 ◽  
pp. 721-724
Author(s):  
Peng Cheng Xie ◽  
Wei Min Yang ◽  
Yu Mei Ding ◽  
Gao Pin Yang ◽  
Jing Zhang
Keyword(s):  
Injection Molding ◽  
Cross Section ◽  
Influence Factors ◽  
Injection Molding Process ◽  
Visualization Technique ◽  
Cooling Process ◽  
Molding Process ◽  
Visualization Experiment ◽  
Visualization Technology ◽  
Single Cavity

The filling process of plastic precise gear is simulated by CAE software and the factors that influence injection molding accuracy in single cavity mold are discussed in this paper. With the assistant of visualization technology, the mechanism of filling unbalance which influences efficient injection molding was especially studied. The model of filling unbalance was supposed that was verified experimentally by visualization technique. It is clarified that the mechanism of filling unbalance results from dissymmetrical temperature distribution on the cross-section of runner, which is strongly influenced by the shear heat and the cooling process in the runner. At the same time, a new method was proposed for improving the filling imbalance by applying appropriate injection molding process without any changes in runner shape of multi-cavity mold.

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