Numerical simulation method for weld line development in micro injection molding process

2009 ◽  
Vol 16 (5) ◽  
pp. 774-780 ◽  
Author(s):  
Lei Xie ◽  
Gerhard Ziegmann ◽  
Bing-yan Jiang
Keyword(s):  
Numerical Simulation ◽  
Injection Molding ◽  
Weld Line ◽  
Simulation Method ◽  
Injection Molding Process ◽  
Molding Process ◽  
Micro Injection Molding ◽  
Numerical Simulation Method

scholarly journals Fabrication of Micro-Structured LED Diffusion Plate Using Efficient Micro Injection Molding and Micro-Ground Mold Core

Polymers ◽  
2020 ◽  
Vol 12 (6) ◽  
pp. 1307
Author(s):  
Yanjun Lu ◽  
Wang Luo ◽  
Xiaoyu Wu ◽  
Bin Xu ◽  
Chunjin Wang ◽  
...  
Keyword(s):  
Injection Molding ◽  
Light Emitting Diode ◽  
Low Cost ◽  
Simulation Method ◽  
Groove Depth ◽  
Grinding Wheel ◽  
Injection Molding Process ◽  
Molding Process ◽  
Micro Injection Molding ◽  
Shape Accuracy

In this paper, a new style of micro-structured LED (light-emitting diode) diffusion plate was developed using a highly efficient and precise hybrid processing method combined with micro injection molding and micro-grinding technology to realize mass production and low-cost manufacturing of LED lamps with excellent lighting performance. Firstly, the micro-structured mold core with controllable shape accuracy and surface quality was machined by the precision trued V-tip grinding wheel. Then, the micro-structured LED diffusion plate was rapidly fabricated by the micro injection molding technology. Finally, the influences of micro injection molding process parameters on the illumination of the micro-structured diffusion plate were investigated. The simulated optical results show that the illumination of the micro-structured diffusion plate can achieve a maximum value when the V-groove depth and V-groove angle are designed to be 300 μm and 60°, respectively. The experimental results indicate that the developed micro-structured diffusion plate may improve the illumination by about 40.82% compared with the traditional diffusion plate. The prediction accuracy of the designed light efficiency simulation method was about 90.33%.

scholarly journals Vacuum Venting Enhances the Replication of Nano/Microfeatures in Micro-Injection Molding Process

2016 ◽  
Vol 4 (2) ◽  
Author(s):  
Seong Ying Choi ◽  
Nan Zhang ◽  
J. P. Toner ◽  
G. Dunne ◽  
Michael D. Gilchrist
Keyword(s):  
Injection Molding ◽  
Quantitative Study ◽  
Vacuum Pressure ◽  
Injection Molding Process ◽  
Anodized Aluminum ◽  
Molding Process ◽  
Micro Injection Molding ◽  
Sample Shape ◽  
Final Sample ◽  
Qualitative And Quantitative Study

Vacuum venting is a method proposed to improve feature replication in microparts that are fabricated using micro-injection molding (MIM). A qualitative and quantitative study has been carried out to investigate the effect of vacuum venting on the nano/microfeature replication in MIM. Anodized aluminum oxide (AAO) containing nanofeatures and a bulk metallic glass (BMG) tool mold containing microfeatures were used as mold inserts. The effect of vacuum pressure at constant vacuum time, and of vacuum time at constant vacuum pressure on the replication of these features is investigated. It is found that vacuum venting qualitatively enhances the nanoscale feature definition as well as increases the area of feature replication. In the quantitative study, higher aspect ratio (AR) features can be replicated more effectively using vacuum venting. Increasing both vacuum pressure and vacuum time are found to improve the depth of replication, with the vacuum pressure having more influence. Feature orientation and final sample shape could affect the absolute depth of replication of a particular feature within the sample.

scholarly journals Experimental Validation of Injection Molding Simulations of 3D Microparts and Microstructured Components Using Virtual Design of Experiments and Multi-Scale Modeling

Micromachines ◽  
2020 ◽  
Vol 11 (6) ◽  
pp. 614 ◽  
Author(s):  
Dario Loaldi ◽  
Francesco Regi ◽  
Federico Baruffi ◽  
Matteo Calaon ◽  
Danilo Quagliotti ◽  
...  
Keyword(s):  
Injection Molding ◽  
Process Simulation ◽  
Current Work ◽  
Injection Molding Process ◽  
Process Conditions ◽  
Virtual Design ◽  
Molding Process ◽  
Micro Injection Molding ◽  
Multi Scale ◽  
Filling Time

The increasing demand for micro-injection molding process technology and the corresponding micro-molded products have materialized in the need for models and simulation capabilities for the establishment of a digital twin of the manufacturing process. The opportunities enabled by the correct process simulation include the possibility of forecasting the part quality and finding optimal process conditions for a given product. The present work displays further use of micro-injection molding process simulation for the prediction of feature dimensions and its optimization and microfeature replication behavior due to geometrical boundary effects. The current work focused on the micro-injection molding of three-dimensional microparts and of single components featuring microstructures. First, two virtual a studies were performed to predict the outer diameter of a micro-ring within an accuracy of 10 µm and the flash formation on a micro-component with mass a 0.1 mg. In the second part of the study, the influence of microstructure orientation on the filling time of a microcavity design section was investigated for a component featuring micro grooves with a 15 µm nominal height. Multiscale meshing was employed to model the replication of microfeatures in a range of 17–346 µm in a Fresnel lens product, allowing the prediction of the replication behavior of a microfeature at 91% accuracy. The simulations were performed using 3D modeling and generalized Navier–Stokes equations using a single multi-scale simulation approach. The current work shows the current potential and limitations in the use of micro-injection molding process simulations for the optimization of micro 3D-part and microstructured components.

Numerical simulation of thermoplastic wheat starch injection molding process

1998 ◽  
Vol 38 (12) ◽  
pp. 2029-2038 ◽  
Author(s):  
B. Abbégs ◽  
R. Ayad ◽  
J.-C. Prudhomme ◽  
J.-P. Onteniente
Keyword(s):  
Numerical Simulation ◽  
Injection Molding ◽  
Wheat Starch ◽  
Injection Molding Process ◽  
Molding Process

scholarly journals Numerical Simulation on the Penetration Behavior of the Projectile during the Water Injection Stage of Water-Projectile-Assisted Injection Molding Process

2020 ◽  
Vol 2020 ◽  
pp. 1-15
Author(s):  
Tangqing Kuang ◽  
Qiang Feng ◽  
Tian Liu ◽  
Luohao Zhong ◽  
Yanqing Wang ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Injection Molding ◽  
Water Injection ◽  
Injection Molding Process ◽  
Molding Process ◽  
Pressure Fields ◽  
Hollow Space ◽  
Pressure Water ◽  
Penetration Behavior ◽  
Strain Rate Field

Water-projectile-assisted injection molding (W-PAIM) is a novel molding process for plastic pipes with complicated shape. It utilizes high-pressure water as a power to push a solid projectile to penetrate through the melt to form a hollow space. In order to investigate the penetration behavior of the projectile during the water injection stage of W-PAIM process, numerical simulation of the water injection stage of a W-PAIM pipe with straight and curved segments was carried out. A turbulent flow for the driving water was considered in the motion equation, and the dynamic mesh technology was used to deal with the moving solid projectile. The simulation results, including RWT and the flow fields, were compared with those of water-assisted injection molding (WAIM) pipe with the same outer dimensions. It was found that the residual wall thickness (RWT) of the W-PAIM pipe is much thinner than that of the WAIM pipe. The projectile has a crucial influence on the RWT. The pressure fields of W-PAIM and WAIM are very similar in both straight and curved segments. The velocity field and strain rate field near the penetration front in W-PAIM are quite different from those in WAIM due to the drag flow caused by the projectile penetration.

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