Bubble morphological evolution and surface defect formation mechanism in the microcellular foam injection molding process

RSC Advances ◽  
2015 ◽  
Vol 5 (86) ◽  
pp. 70032-70050 ◽  
Author(s):  
Lei Zhang ◽  
Guoqun Zhao ◽  
Guiwei Dong ◽  
Shuai Li ◽  
Guilong Wang
Keyword(s):  
Injection Molding ◽  
Surface Defect ◽  
Defect Formation ◽  
Morphological Evolution ◽  
Injection Molding Process ◽  
Multiphase Model ◽  
Microcellular Foam ◽  
Molding Process ◽  
Foam Injection Molding ◽  
Surface Collapse

A multiphase model was established to simulate the bubble morphological evolution in MFIM, and a new phenomenon of surface collapse and pits with the gradient depth was discovered.

scholarly journals About the numerous cost and processing advantages of the microcellular foam injection molding process for thermoplastics materials in the automobile industry

2015 ◽  
Vol 9 (2) ◽  
pp. 6-14
Author(s):  
Alexandru Oprea-Kiss ◽  
Imre Kiss
Keyword(s):  
Injection Molding ◽  
Automobile Industry ◽  
Dimensional Stability ◽  
Injection Molding Process ◽  
Microcellular Foam ◽  
Molding Process ◽  
Microcellular Injection Molding ◽  
And Performance ◽  
Plastic Parts ◽  
Foam Injection Molding

Today one of the goals of the automobile industry is to reduce weight. And physical foaming has already demonstrated its potential in this sector, improving the value and performance of applications under the bonnet: engine and gearbox cases, inlet air filters, cockpits, radiator baffles and so on. Around the world, the microcellular injection molding (MuCell) is used in thousands of applications in the automotive, packaging, technical molding, office machinery and electric and electronic component industries. The research opportunities purpose is to obtain even lighter pieces, with greater dimensional stability and with an excellent surface finish, in other words, perfect plastic parts. More component functionality with reduced weight, and cost control at the same time: MuCell is a process to physically foam thermoplastics, which combines technical and economic objectives. Besides weight reduction, it also provides improved dimensional stability of the moulded parts.

scholarly journals Shrinkage and Warpage Minimization of Glass-Fiber-Reinforced Polyamide 6 Parts by Microcellular Foam Injection Molding

Polymers ◽  
2020 ◽  
Vol 12 (4) ◽  
pp. 889 ◽  
Author(s):  
Youngjae Ryu ◽  
Joo Seong Sohn ◽  
Chang-Seok Yun ◽  
Sung Woon Cha
Keyword(s):  
Injection Molding ◽  
Polyamide 6 ◽  
Injection Molding Process ◽  
Microcellular Foam ◽  
Molding Process ◽  
Glass Fiber Reinforced ◽  
Molded Parts ◽  
Injection Molded ◽  
Process Factors ◽  
Foam Injection Molding

Shrinkage and warpage of injection-molded parts can be minimized by applying microcellular foaming technology to the injection molding process. However, unlike the conventional injection molding process, the optimal conditions of the microcellular foam injection molding process are elusive because of core differences such as gas injection. Therefore, this study aims to derive process conditions to minimize the shrinkage and warpage of microcellular foam injection-molded parts made of glass fiber reinforced polyamide 6 (PA6/GF). Process factors and levels were first determined, with experiments planned accordingly. We simulated designed experiments using injection molding analysis software, and the results were analyzed using the Taguchi method, analysis of variance (ANOVA), and response surface methodology (RSM), with the ANOVA analysis being ultimately demonstrating the influence of the factors. We derived and verified the optimal combination of process factors and levels for minimizing both shrinkage and warpage using the Taguchi method and RSM. In addition, the mechanical properties and cell morphology of PA6/GF, which change with microcellular foam injection molding, were confirmed.

Microcellular Foam Injection Molding of Thermoplastics Using Green Physical Blowing Agent

2016 ◽  
Vol 875 ◽  
pp. 77-111
Author(s):  
S.J.A. Rizvi
Keyword(s):  
Injection Molding ◽  
Membrane Separation ◽  
Batch Process ◽  
Injection Molding Process ◽  
Microcellular Foam ◽  
Molding Process ◽  
Blowing Agents ◽  
Carbon Dioxide Gas ◽  
Microcellular Injection Molding ◽  
Foam Injection Molding

The microcellular injection molding technology, commercially offered by Trexel Inc. and other manufacturers, is primarily a close cell foaming technique. This process is capable of offering light weight non-porous thermoplastics moldings. The foaming of thermoplastics with open cellular morphology has got various high end applications among others like tissue engineering and membrane separation. Some of the researchers were successful in synthesis of open cellular thermoplastics at laboratory scale via solid state batch process. The growing demand for microporous thermoplastics, especially the biodegradable plastics (e.g. Polylactic acid), motivated the researchers develop a specialized microcellular injection molding process for processing of open cell thermoplastics using physical blowing agents such as supercritical nitrogen or carbon dioxide gas. A brief of theoretical and conceptual treatment of microcellular injection molding is presented.

Process comparison on the microstructure and mechanical properties of fiber-reinforced polyphenylene sulfide using MuCell technology

2018 ◽  
Vol 37 (15) ◽  
pp. 1020-1034 ◽  
Author(s):  
Christoph Lohr ◽  
Björn Beck ◽  
Frank Henning ◽  
Kay André Weidenmann ◽  
Peter Elsner
Keyword(s):  
Mechanical Properties ◽  
High Pressure ◽  
Injection Molding ◽  
Fiber Orientation ◽  
Polyphenylene Sulfide ◽  
Injection Molding Process ◽  
Fiber Reinforced ◽  
Molding Process ◽  
Glass Fiber Reinforced ◽  
Foam Injection Molding

The MuCell process is a special injection molding process which utilizes supercritical gas (nitrogen) to create integral foam sandwiches. The advantages are lower weight, higher specific properties and shorter cycle times. In this study, a series of glass fiber-reinforced polyphenylene sulfide foam blanks are manufactured using the MuCell injection molding process. The different variations of the process (low-pressure also known as structural foam injection molding) and high-pressure foam injection molding (also known as “core back expansion,” “breathing mold,” “precision opening,” decompression molding) are used. The sandwich structure and mechanical properties (tensile strength, bending strength, and impact behavior) of the microcellular and glass fiber-reinforced polyphenylene sulfide foams are systematically investigated and compared to compact material. The results showed that the injection parameters (injection speed, foaming mechanism) played an important role in the relative density of microcellular polyphenylene sulfide foams and the mechanical properties. It could be shown that the specific tensile strength decreased while increasing the degree of foaming which can be explained by the increased number of cells and the resulting cell size. This leads to stress peaks which lower the mechanical properties. The Charpy impact strength shows a significant dependence on the fiber orientation. The specific bending modulus of the high-pressure foaming process, however, surpasses the values of the other two processes showing the potential of this manufacturing variation especially with regard to bending loads. Furthermore, a high dependence of the mechanical properties on the fiber orientation of the tested specimens can be found.

Optimization Design for Automotive Interior Trimmings Based on Moldflow

2012 ◽  
Vol 522 ◽  
pp. 515-519
Author(s):  
Zheng Ying Lin ◽  
Wan Li Hou
Keyword(s):  
Injection Molding ◽  
Optimization Design ◽  
Mode Locking ◽  
Injection Molding Process ◽  
Microcellular Foam ◽  
Molding Process ◽  
Technical Parameters ◽  
Simulation And Optimization ◽  
Numerical Value Simulation ◽  
Automotive Interior

Took the auxiliary fascia console lid of automotive interior trimmings for example, the preliminary plastic was designed by Pro/Engineer, then the Moldflow analysis on the plastic was performed. Those irrational factors of both injection technical parameters and structure of the plastic, which would occur in the injection molding process, were modified after analyzing simulation results. The rational plastic was obtained by repeating simulation and optimization, which indicated that the simulation-based optimization could improve the plastic quality and efficiency of injection molding. Meanwhile, the comparisons of mode locking force and molding time between microcellular foam and non-foam injection molding were also carried out, which showed the significance of numerical value simulation in injection molding processes.

Estimation of the foaming temperature of mold-opening foam injection molding process

2016 ◽  
Vol 52 (6) ◽  
pp. 619-641 ◽  
Author(s):  
Raymond KM Chu ◽  
Lun Howe Mark ◽  
Davoud Jahani ◽  
Chul B Park
Keyword(s):  
Injection Molding ◽  
Injection Molding Process ◽  
Molding Process ◽  
Foam Injection Molding ◽  
Foaming Temperature

Filling Behavior of Polymer Material into Sub-^|^mu;m Structure in Injection Molding Process

2013 ◽  
Vol 133 (4) ◽  
pp. 105-111
Author(s):  
Chisato Yoshimura ◽  
Hiroyuki Hosokawa ◽  
Koji Shimojima ◽  
Fumihiro Itoigawa
Keyword(s):  
Injection Molding ◽  
Polymer Material ◽  
Injection Molding Process ◽  
Molding Process
Sign in / Sign up

Export Citation Format

Share Document