Visualization analysis of flow front behavior during filling process of injection mold cavity by two-axis tracking system

The gating system of an injection mold for car bumper was studied. A design optimization scheme is proposed to optimize both the number and locations of the gates by analyzing the filling process, in order to reduce the part war page and weld line, numerical simulation of injection mold filling process is combined with the design optimization method to find the optimum number of gates and their locations to achieve balanced f low and less weld lines while satisfying the limit of injection pressure. Moldflow software was applied to make analysis and comparison of various gating system in terms of their filling time, injection pressure and clamp force, weld line and distribution of air traps, and an optimized gating system was obtained. The result shows that this method can effectively reduce costs, shorten development cycle and improve the efficiency of molding design.

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Coated Composite Crosstie Mold Structure Design Used for Experiment with Inventor, Moldflow and Ansys

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.561.196 ◽

2013 ◽

Vol 561 ◽

pp. 196-200

Author(s):

Yu Guang Gong ◽

Zhi Wen Zong ◽

Ying Yu ◽

Bai Yuan Lv

Keyword(s):

Simulation Analysis ◽

Displacement Vector ◽

Processing Parameters ◽

Structure Design ◽

Mold Cavity ◽

Von Mises Stress ◽

Process Conditions ◽

Injection Mold ◽

Injection Process ◽

Von Mises

Coated crosstie products and counter mold components are created in 3-D model using Inventor software, preparing for CAE analysis. By using Moldflow software , to determine products gate location, filling, packing, cooling, push-out processing, as well as the injection process conditions optimization of simulation analysis to find possible defects, modify and optimize the design, determine the best processing parameters and conditions. Binding using Ansys11.0 software to analyze rail sleeper mold cavity deformation, structure stress, get distribution of property of von Mises stress and displacement vector sum, in the mold cavity on the contact surface. By changing the cavity wall thickness, and other factors to improve the force which it is subjected, providing references to structure optimization of injection mold design. It has been proven that in collaborative application of these three softwares, the design of the injection mold is a very efficient and easy.

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Simulations of cyclic transient mold cavity surface temperatures in injection mold-cooling process

International Communications in Heat and Mass Transfer ◽

10.1016/0735-1933(92)90011-6 ◽

1992 ◽

Vol 19 (4) ◽

pp. 559-568 ◽

Cited By ~ 22

Author(s):

Shia-Chung Chen ◽

Yung-Chien Chung

Keyword(s):

Mold Cavity ◽

Cavity Surface ◽

Injection Mold ◽

Cooling Process ◽

Surface Temperatures

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Development of production technology of rolling stock cast parts

E3S Web of Conferences ◽

10.1051/e3sconf/202126405013 ◽

2021 ◽

Vol 264 ◽

pp. 05013

Author(s):

Otabek Toirov ◽

Nodirjon Tursunov

Keyword(s):

Middle Part ◽

Mold Cavity ◽

Rolling Stock ◽

Head Part ◽

Gating System ◽

Filling Process ◽

Current Production ◽

Computer Simulation Program ◽

Cast Parts ◽

Railway Rolling Stock

Using the computer simulation program ProCAST, the analysis of the processability of the gating system used in the current production of the SK “Foundry-Mechanical Factory” in the manufacture of large cast parts of railway rolling stock was performed. Based on computer modeling, a new design of a gating system with a dispersed metal motive with different sizes of feeder sections was developed, providing simultaneous parallel filling of all parts of the mold cavity. The feature of the proposed design of the gating system is the presence of an extended horizontal collector and the supply of metal to the end parts of the casting. With this design, two counter-flows are formed in the mold cavity, their fusion occurs in the middle part of the casting in a cooled and highly polluted state, since during the filling process, the head part of the flow collects sand inclusions along the way, is oxidized and saturated with hydrogen. These factors are a prerequisite for the formation of various defects in castings.

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Structural Optimization of a Dual-Sensing Module for Temperature and Pressure Measurement in Injection Mold Cavity

Volume 9: Mechanical Systems and Control, Parts A, B, and C ◽

10.1115/imece2007-42250 ◽

2007 ◽

Author(s):

Zhaoyan Fan ◽

M. Haris Hamid ◽

Robert X. Gao ◽

Stephen Johnston ◽

David Kazmer

Keyword(s):

Interaction Analysis ◽

Polymer Melt ◽

Mold Cavity ◽

Injection Molding Process ◽

Optimized Design ◽

Injection Mold ◽

Molding Process ◽

Optimal Dimension ◽

Fea Model ◽

Sensor Module

This paper presents the design and optimization of a temperature-pressure sensing module that is structurally integrated into an injection mold. The sensor extracts energy from the polymer melt pressure differential during the injection molding process and uses ultrasonic pulses as the wireless information transmission carrier. The dimension of the piezo ceramic rings that scavenge energy from the mold pressure change is optimized to minimize the volume of the sensor while maintaining the minimum Signal-to-Noise Ratio (SNR) required for reliable signal reception. An analytical expression of the optimal dimension is presented. Based on the optimized design, the sensor module package, together with the injection mold steel and the polymer melt that flows over the sensor into the mold cavity, was modeled using the finite element method. To quantify the behavior of polymer melt and its effect on sensors output, a coupled fluid-structure interaction analysis was performed to examine the mold-melt interface, by using the solution-looping and mesh-morphing techniques. A case study of the sensor design for a 40 mm thick injection mold was investigated by using the presented optimization method and FEA model. Results show that the volume of the piezo stack can be reduced to 0.7 cm3 while meeting the minimum SNR requirement. The minimum insulator thickness of 1 mm is presented by the FEA model to maintain the thermal induced error below 0.5%.

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Application of UV-LIGA technology to machining micro-injection mold cavity of cell culture device

Optics and Precision Engineering ◽

10.3788/ope.20132105.1228 ◽

2013 ◽

Vol 21 (5) ◽

pp. 1228-1233 ◽

Cited By ~ 2

Author(s):

马雅丽 MA Ya-li ◽

刘文开 LIU Wen-kai ◽

刘冲 LIU Chong ◽

杜立群 DU Li-qun

Keyword(s):

Cell Culture ◽

Mold Cavity ◽

Injection Mold ◽

Liga Technology

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The Optimization of Vacuum Casting Filling Velocity Based on Numerical Simulation

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.522.221 ◽

2012 ◽

Vol 522 ◽

pp. 221-226

Author(s):

Nan Nan Xu ◽

Zhuang Ya Zhang ◽

Hai Guang Zhang ◽

Tian Lv ◽

Yuan Yuan Liu ◽

...

Keyword(s):

Numerical Simulation ◽

Casting Process ◽

Optimization Method ◽

Uniform Flow ◽

Front Velocity ◽

Flow Front ◽

Filling Process ◽

Vacuum Casting ◽

Simulation And Optimization ◽

The Given

In the process of vacuum casting, non-uniform flow front velocity about pouring material will lead to casting non-uniform shrinkage and warping deformation. Ideal filling pattern should make pouring material fill into the mold cavity with uniform flow front velocity. Give an optimization method of vacuum casting process, optimize the filling velocity in the filling process by combining numerical simulation and optimization method, and make the flow front velocity of pouring material uniform in the filling process, further reduce the warping deformation of casting. The example shows that the optimal model and the given solution algorithm is feasible.

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