Optimum configuration of fin trees in cooling channels of injection moulding process

Warpage deflection is one of the common pitfalls in plastic injection moulding which is always affected the quality and accuracy of the plastic products. It occurs due to the influences of mould temperature during injection moulding process and it is related to the number of cooling system existed in the mould. Therefore, this paper studies the effect of cooling channels on warpage of dumbbell plastic part having different number of cooling channel using Moldflow software. Warpage analysis was run using four and eight cooling channels. Parameters involved in this study are injection time, packing time, melt temperature and mould temperature. The result of warpage from simulation analysis was projected on the graphic having different colour which is presented the actual value of warpage. It is found from warpage simulation result that the maximum warpage for four cooling channels is 1.283mm and the maximum warpage for eight cooling channels is 1.280mm. It shows that the increasing of the number of cooling channel from four to eight channels in the injection mould reduces the warpage deflection about 0.2%. Thus, the result shows that the number of cooling system in the mould plays an important role on the quality of plastic part during injection moulding process.

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Improving Warpage with Milled Groove Square Shape Conformal Cooling Channels

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.700.31 ◽

2016 ◽

Vol 700 ◽

pp. 31-41

Author(s):

Z. Shayfull ◽

S. Sharif ◽

Azlan Mohd Zain ◽

S.M. Nasir ◽

R. Mohd Saad

Keyword(s):

Injection Moulding ◽

Injection Molding Process ◽

Molding Process ◽

Cross Sectional ◽

Conformal Cooling ◽

Moulding Process ◽

Cooling Channels ◽

Thermal Distribution ◽

Conformal Cooling Channels ◽

Injection Moulding Process

Warpage is a common issue in an injection moulding process due to non-uniform temperature variation causing differential shrinkage on the moulded parts. In designing moulds for injection molding process, it is very difficult to achieve efficient cooling with uniform thermal distribution. Most of researchers focus on an optimisation of processing parameters to improve the warpage. However, the conformal cooling channels have advantages with the uniform distance between center of cooling channels and mould surfaces in order to get a better thermal distribution thus reducing the warpage. This paper presents the Milled Grooved Square Shape (MGSS) conformal cooling channels which provide more uniform in cooling and have a bigger effective cooling surface area cross sectional area and comparing to circular and others type of cooling channels with similar cross section. A case study on front panel housing is investigated and the possibility of fabrication the conformal cooling channels on hard tooling for injection moulding process which is easier to design, fabricate and assemble compared to other method are presented. The performance designs of straight drilled are compared to the two types of MGSS conformal cooling channels by using Autodesk Moldflow Insight (AMI) 2012. The analyses show that the both types of MGSS conformal cooling channel suggested can provide a more uniform thermal distribution and able to reduce the warpage on the molded part compared to the straight drilled cooling channels.

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Milled Groove Square Shape Conformal Cooling Channels in Injection Moulding Process

Materials and Manufacturing Processes ◽

10.1080/10426914.2013.763968 ◽

2013 ◽

pp. 130122112458009 ◽

Cited By ~ 4

Author(s):

Z. Shayfull ◽

S. Sharif ◽

Azlan MohdZain ◽

R. MohdSaad ◽

M. A. Fairuz

Keyword(s):

Injection Moulding ◽

Conformal Cooling ◽

Moulding Process ◽

Cooling Channels ◽

Conformal Cooling Channels ◽

Injection Moulding Process

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Use of a Holistic Design and Manufacturing Approach to Implement Optimized Additively Manufactured Mould Inserts for the Production of Injection-Moulded Thermoplastics

Journal of Manufacturing and Materials Processing ◽

10.3390/jmmp4040100 ◽

2020 ◽

Vol 4 (4) ◽

pp. 100

Author(s):

Loucas Papadakis ◽

Stelios Avraam ◽

Demetris Photiou ◽

Simona Masurtschak ◽

Juan Carlos Pereira Falcón

Keyword(s):

Cycle Time ◽

Injection Moulding ◽

Mould Insert ◽

Conformal Cooling ◽

Moulding Process ◽

Cooling Channels ◽

Injection Process ◽

Conformal Cooling Channels ◽

Injection Moulding Process ◽

Design And Manufacture

Injection moulding is one the most familiar processes for manufacturing of plastic parts by injecting molten thermoplastic polymers into a metallic mould. The cycle time of this process consists of the phases of injection, packing, cooling, and ejection of the final product. Shortening of cycle time is a key consideration to increase productivity. Therefore, in this manuscript the adoption of additively manufactured mould inserts with conformal cooling channels by means of selective laser melting (SLM) with the aim to reduce process cycles is presented. The design and manufacture of a mould insert with conformal cooling channels for producing pressure fitting thermoplastic parts is described. Numerical analysis of the injection process and simulation of shape distortions after SLM were conducted providing useful results for the design and manufacture of the mould insert. The results of the numerical analyses are compared with experimental 3D geometrical data of the additively manufactured mould insert. Temperature measurements during the real injection moulding process demonstrating promising findings. The adoption of the introduced method for the series production of injection moulded thermoplastics proves a shortening of cycle times of up to 32% and a final product shape quality improvement of up to 77% when using mould inserts with conformal cooling channels over the conventional mould inserts.

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Application of Whale Optimisation Algorithm in Injection Moulding Process

International Journal of Advanced Trends in Computer Science and Engineering ◽

10.30534/ijatcse/2019/2081.62019 ◽

2019 ◽

Vol 8 (1.6) ◽

pp. 130-134

Author(s):

NurAini Zakaria

Keyword(s):

Injection Moulding ◽

Moulding Process ◽

Optimisation Algorithm ◽

Injection Moulding Process

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Production of Superhydrophobic Surfaces Using a One-Step Variothermal Injection Moulding Process

Micro and Nanosystems ◽

10.2174/1876402911103030222 ◽

2011 ◽

Vol 3 (3) ◽

pp. 222-225 ◽

Cited By ~ 4

Author(s):

W. Michaeli ◽

M. Schongart ◽

F. Klaiber ◽

S. Beckemper

Keyword(s):

Injection Moulding ◽

Superhydrophobic Surfaces ◽

Moulding Process ◽

Injection Moulding Process ◽

One Step

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Evaluation of Cadmould Software to Simulate the Filling Phase of a Natural Rubber Compound in Injection Moulding Process

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.747.571 ◽

2013 ◽

Vol 747 ◽

pp. 571-574 ◽

Cited By ~ 1

Author(s):

Zulkifli Mohamad Ariff ◽

T.H. Khang

Keyword(s):

Natural Rubber ◽

Injection Moulding ◽

Input Data ◽

Cure Kinetics ◽

Rubber Compound ◽

Moulding Process ◽

Related Data ◽

Mould Filling ◽

Injection Moulding Process ◽

Material Input

The possibility of using Cadmould software to simulate the filling behaviour of a natural rubber compound during an injection moulding process was investigated. For the simulation process, the determination of required material input data involving the rheological and cure kinetics data of the designed rubber compound were conducted. It was discovered that the acquired data were able to function as reliable material input data as they were comparable with related data available in the Cadmould software materials database. Verification of the simulated filling profiles by experimental short shots specimens showed that the Cadmould Rubber Package was able to predict the realistic filling behaviour of the formulated natural rubber compound inside the mould cavity when the measured material data were utilized. Whereas, the usage of available material database from the software failed to model the mould filling progression of the intended natural rubber compound.

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Rule-based explanations based on ensemble machine learning for detecting sink mark defects in the injection moulding process

Journal of Manufacturing Systems ◽

10.1016/j.jmsy.2021.07.001 ◽

2021 ◽

Vol 60 ◽

pp. 392-405

Author(s):

Josue Obregon ◽

Jihoon Hong ◽

Jae-Yoon Jung

Keyword(s):

Machine Learning ◽

Injection Moulding ◽

Rule Based ◽

Moulding Process ◽

Ensemble Machine Learning ◽

Injection Moulding Process ◽

Sink Mark

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Multi-Response Parameters Optimisation for Energy-Efficient Injection Moulding Process via Dynamic Shainin DOE Method

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.554-557.1669 ◽

2013 ◽

Vol 554-557 ◽

pp. 1669-1682 ◽

Cited By ~ 1

Author(s):

Kam Hoe Yin ◽

Hui Leng Choo ◽

Dunant Halim ◽

Chris Rudd

Keyword(s):

Energy Consumption ◽

Process Parameters ◽

Injection Moulding ◽

Shop Floor ◽

Operational Experience ◽

Moulding Process ◽

Part Quality ◽

Control Factors ◽

Injection Moulding Process ◽

Signal Response

Process parameters optimisation has been identified as a potential approach to realise a greener injection moulding process. However, reduction in the process energy consumption does not necessarily imply a good part quality. An effective multi-response optimisation process can be demanding and often relies on extensive operational experience from human operators. Therefore, this research focuses on an attempt to develop a more user-friendly approach which could simultaneously deal with the requirements of energy efficiency and part quality. This research proposes a novel approach using a dynamic Shainin Design of Experiment (DOE) methodology to determine an optimal combination of process parameters used in the injection moulding process. The Shainin DOE method is adopted to pinpoint the most important factors on energy consumption and the targeted part quality whereas the ‘dynamic’ term refers to the signal-response system. The effectiveness of the proposed approach was illustrated by investigating the influence of various dominant parameters on the specific energy consumption (SEC) and the Charpy impact strength (CIS) of polypropylene (PP) material after being injection-moulded into impact test specimens. From the experimental results, barrel temperature was identified as the signal factor while mould temperature and cooling time were used as control factors in the full factorial experiments. Then, response function modelling (RFM) was built to characterise the signal-response relationship as a function of the control factors. Finally, RFM led to a trade-off solution where reducing part-to-part variation for CIS resulted in an increase of SEC. Therefore, the research outcomes have demonstrated that the proposed methodology can be practically applied at the factory shop floor to achieve different performance output targets specified by the customer or the manufacturer’s intent.

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