scholarly journals Study on the Mechanism of Interfacial Friction Heating in Polymer Ultrasonic Plasticization Injection Molding Process

Polymers ◽  
2019 ◽  
Vol 11 (9) ◽  
pp. 1407 ◽  
Author(s):  
Tao Peng ◽  
Bingyan Jiang ◽  
Yang Zou
Keyword(s):  
Injection Molding ◽  
Heating Temperature ◽  
Fem Simulation ◽  
Polymeric Materials ◽  
Interfacial Friction ◽  
Heating Process ◽  
Injection Molding Process ◽  
Ultrasonic Frequency ◽  
Friction Heating ◽  
Micro Parts

Ultrasonic Plasticization Injection Molding (UPIM) is an effective way to manufacture polymeric micro parts and has great potential for energy saving with processing polymeric materials of a small amount. To better control the UPIM process and improve the quality of micro parts, it is necessary to study the heat generation mechanism. In this paper, the interfacial friction heating process of UPIM was studied by finite element (FEM) simulation and experiment, and the temperature change in the friction interface was estimated. Then, the effects of different process parameters such as ultrasonic frequency and ultrasonic amplitude on the friction heating process were analyzed. The results showed that the rising trend of friction heating temperature was transient (finished within 1 s), and the change trend of FEM simulation was consistent with experimental results. Adjusting ultrasonic frequency and amplitude has a significant influence on the friction heating process. Increasing the ultrasonic frequency and amplitude can improve the efficiency of friction heating.

Tribology study of hydroxyapatite (HAp) scaffold blended single based binder via rheology and mechanical properties

2017 ◽  
Vol 69 (3) ◽  
pp. 414-419
Author(s):  
Mimi Azlina Abu Bakar ◽  
Siti Norazlini Abd Aziz ◽  
Muhammad Hussain Ismail
Keyword(s):  
Mechanical Properties ◽  
Injection Molding ◽  
Palm Stearin ◽  
Polymeric Materials ◽  
High Energy ◽  
Single Step ◽  
Injection Molding Process ◽  
Plastic Behavior ◽  
Molding Process ◽  
Content Type

Purpose This paper aims to investigate the vital characteristic of an innovative ceramic injection molding (CIM) process for orthopedic application with controlled porosity and improved tribological and mechanical properties which were affected by complex tribological interactions, whether lubricated like hip implants and other artificial prostheses. The main objective is to maximize the usage of palm stearin as a single based binder as the function of flow properties during injection molding process. Design/methodology/approach The binder used in this present study consists of 100 per cent palm stearin manufactured by Kempas Oil Sdn Bhd and supplied by Vistec Technology Sdn Bhd. The feedstock was prepared by using a Z-blade mixer (Thermo Haake Rheomix OS) and Brabender mixer model R2400. The feedstock prepared was injection molded using a manually operated vertical benchtop machine with an average pressure of about 5-7 bars. The firing step included the temporary holds at intermediate temperatures to burn out organic binders. At this stage, the green molded specimen was de-bound using a single-step wick-debinding method. Findings The maximum content of ceramic material is applied to investigate the efficiencies of net formulation that can be achieved by ceramic materials. The longer the viscosity will change with shear rate, the higher the value of n obtained instead. From the slope of the curves obtained in Figure 3, the value of n for the feedstock was determined to be less than 1, which indicates a pseudoplastic behavior and suitability for the molding process. Moreover, high shear sensitivity is important in producing complex and intrinsic specimens which are leading products in the CIM industry. Originality/value The feedstock containing HAp powder and palm stearin binder was successfully prepared at very low temperature of 70°C, which promoting a required pseudo-plastic behavior during rheological test. The single binder palm stearin should be optimized in other research works carried out, as palm stearin is most preferred compared to other polymeric materials that provided high energy consumption when subjected to the sintering process. Besides the binder is widely available in Malaysia, low cost and harmless effect during debinding process.

scholarly journals The Feasibility of an Internal Gas-Assisted Heating Method for Improving the Melt Filling Ability of Polyamide 6 Thermoplastic Composites in a Thin Wall Injection Molding Process

Polymers ◽  
2021 ◽  
Vol 13 (7) ◽  
pp. 1004 ◽  
Author(s):  
Thanh Trung Do ◽  
Tran Minh The Uyen ◽  
Pham Son Minh
Keyword(s):  
Injection Molding ◽  
Heating Rate ◽  
Temperature Control ◽  
Cavity Surface ◽  
Heating Process ◽  
Injection Molding Process ◽  
Thin Wall ◽  
Molding Process ◽  
Filling Ability ◽  
Wall Injection

In thin wall injection molding, the filling of plastic material into the cavity will be restricted by the frozen layer due to the quick cooling of the hot melt when it contacts with the lower temperature surface of the cavity. This problem is heightened in composite material, which has a higher viscosity than pure plastic. In this paper, to reduce the frozen layer as well as improve the filling ability of polyamide 6 reinforced with 30 wt.% glass fiber (PA6/GF30%) in the thin wall injection molding process, a preheating step with the internal gas heating method was applied to heat the cavity surface to a high temperature, and then, the filling step was commenced. In this study, the filling ability of PA6/GF30% was studied with a melt flow thickness varying from 0.1 to 0.5 mm. To improve the filling ability, the mold temperature control technique was applied. In this study, an internal gas-assisted mold temperature control (In-GMTC) using different levels of mold insert thickness and gas temperatures to achieve rapid mold surface temperature control was established. The heating process was observed using an infrared camera and estimated by the temperature distribution and the heating rate. Then, the In-GMTC was employed to produce a thin product by an injection molding process with the In-GMTC system. The simulation results show that with agas temperature of 300 °C, the cavity surface could be heated under a heating rate that varied from 23.5 to 24.5 °C/s in the first 2 s. Then, the heating rate decreased. After the heating process was completed, the cavity temperature was varied from 83.8 to about 164.5 °C. In-GMTC was also used for the injection molding process with a part thickness that varied from 0.1 to 0.5 mm. The results show that with In-GMTC, the filling ability of composite material clearly increased from 2.8 to 18.6 mm with a flow thickness of 0.1 mm.

Study on the solidification kinetics of high-density polyethylene during thin-walled injection molding process

2012 ◽  
Vol 32 (6-7) ◽  
pp. 355-363 ◽  
Author(s):  
Shuang-quan Deng ◽  
Bin Yang ◽  
Ji-bin Miao ◽  
Ru Xia ◽  
Jia-sheng Qian ◽  
...  
Keyword(s):  
Injection Molding ◽  
High Density Polyethylene ◽  
Polymeric Materials ◽  
High Density ◽  
Injection Molding Process ◽  
Structure Property ◽  
X Ray Diffraction ◽  
Molding Process ◽  
Solidification Kinetics ◽  
Thin Walled

Abstract In this work, the effect of the initial and secondary temperature differences on the solidification behaviors of high-density polyethylene (HDPE) during the thin-walled injection molding (TWIM) was intensively investigated. Simulated temperature profiles using the enthalpy transformation methodology were compared with an in situ temperature measurement, and reasonable agreement was achieved between calculations and measurements. Two-dimensional wide-angle X-ray diffraction characterization shows that the formation of oriented crystal structures was considerably affected by the thermal gradient within the injection-molded article. The present study can be practically significant to the optimization of the cooling parameters during the TWIM of crystalline polymers as well as to the further study on the relationship among “processing-structure-property” of polymeric materials.

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.

Estimate the Melt Flow Length with Internal Induction Heating for the Injection Molding Process

2020 ◽  
Vol 863 ◽  
pp. 97-102
Author(s):  
Huynh Duc Thuan ◽  
Tran Anh Son ◽  
Pham Son Minh
Keyword(s):  
Temperature Distribution ◽  
Injection Molding ◽  
Heating Rate ◽  
Induction Heating ◽  
Heating System ◽  
Mold Temperature ◽  
Heating Process ◽  
Injection Molding Process ◽  
Molding Process ◽  
Internal Induction

In this paper, an induction heating system was applied to the heating stage in the injection molding process. Through simulation and experiment, the heating process was estimated by the temperature distribution and the heating rate. In the simulation, the mold temperature was increased from 30°C to 180°C in 9 s. Therefore, the heating rate was higher than 16°C/s, which represents a positive result in the field of mold heating. Additionally, the temperature distribution revealed that the higher temperature is concentrated on the gate area, while the outside of the mold cavity is at a lower temperature. The same parameters were applied to both the experiment and the simulation, and the results were in good agreement.

Obtaining of Biopolymer from Onion Used as a Binder in Powder Injection Molding Process

2018 ◽  
Vol 27 ◽  
pp. 50-55
Author(s):  
Mihaela Gabriela Dumitru ◽  
Cristina Teișanu ◽  
Oana Gîngu
Keyword(s):  
Injection Molding ◽  
Polymeric Materials ◽  
Powder Injection Molding ◽  
Powder Injection ◽  
Injection Molding Process ◽  
Natural Polymers ◽  
Molding Process ◽  
Natural Sources ◽  
Onion Bulbs

The very important strategy in parts processing by powder injection molding (PIM) technology is the use of organic polymeric materials made from raw and auxiliary materials and from renewable natural sources. Using natural polymers to obtain binders for PIM use is of particular interest. The inulin extraction from the onion bulbs has a major alternative in this area.

scholarly journals Improving the Melt Flow Length of Acrylonitrile Butadiene Styrene in Thin-Wall Injection Molding by External Induction Heating with the Assistance of a Rotation Device

Polymers ◽  
2021 ◽  
Vol 13 (14) ◽  
pp. 2288
Author(s):  
Pham Son Minh ◽  
Minh-Tai Le
Keyword(s):  
Injection Molding ◽  
Induction Heating ◽  
Cycle Time ◽  
Heating Surface ◽  
Heating Process ◽  
Injection Molding Process ◽  
Thin Wall ◽  
Melt Flow ◽  
Molding Process ◽  
Flow Length

In injection molding, the temperature control of the dynamic mold is an excellent method for improving the melt flow length, especially of thin-wall products. In this study, the heating efficiency of a novel heating strategy based on induction heating was estimated. With the use of this heating strategy, a molding cycle time similar to the traditional injection molding process could be maintained. In addition, this strategy makes it easier to carry out the heating step due to the separation of the heating position and the mold structure as well as allowing the ease of magnetic control. The results show that, with an initial mold temperature of 30 °C and a gap (G) between the heating surface and the inductor coil of 5 mm, the magnetic heating process can heat the plate to 290 °C within 5 s. However, with a gap of 15 mm, it took up to 8 s to reach 270 °C. According to the measurement results, when the mold heating time during the molding process increased from 0 to 5 s, the flow length increased significantly from 71.5 to 168.1 mm, and the filling percentage of the thin-wall product also increased from 10.2% to 100%. In general, the application of external induction heating (Ex-IH) during the molding cycle resulted in improved melt flow length with minimal increase in the total cycle time, which remained similar to that of the traditional case.

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