Effects of Molding Parameters on MIM’s Material Distribution using Numerical Simulation Method

2012 ◽  
Vol 59 (2) ◽  
Author(s):  
Mohd Fazuri Abdullah ◽  
Abu Bakar Sulong ◽  
Norhamidi Muhamad ◽  
Muhamad Afkar Husin
Keyword(s):  
Injection Molding ◽  
Flow Rate ◽  
Computer Aided Design ◽  
Manufacturing Industry ◽  
Injection Pressure ◽  
Global Market ◽  
Element Analysis ◽  
Percentage Difference ◽  
Filling Time ◽  
Injection Temperature

In the competitive world in the global market, manufacturing industry is striving to produce products at high quality, shorter time and low cost. This can be achieved through proper design activities, with assist of finite element analysis (FEA) and computer aided design (CAD). The objective of this project is to study the effect of the molding parameters on the physical characteristics of surgery tool via MIM based on design of experiment (Taguchi method). This numerical results show the behavior of feedstock entering the mould during injection process and the possibility defects that might occur. The quality of the injected product depends on the selection of the feedstock as well as the parameters for injection molding such as injection temperature (A), mold temperature (B), flow rate (C) and injection pressure (D). From the analysis of Taguchi, the optimal levels of process parameters for the shortest filling time is [A3(200ºC), B1(80ºC), C3(20 cm3/s), D3(260 MPa)]. Set of optimal parameters for the smallest shrinkage percentage difference is [A1(180ºC), B3(100ºC), C3(20 cm3/s), D2(255 MPa)]. The most influence injection molding parameters are injection temperature and injection pressure. Follow by the flow rate.

Injection Molding with Natural Rubber

1971 ◽  
Vol 44 (3) ◽  
pp. 620-641 ◽  
Author(s):  
M. A. Wheelans
Keyword(s):  
Injection Molding ◽  
Natural Rubber ◽  
Injection Pressure ◽  
Orifice Diameter ◽  
Thin Sections ◽  
Wide Range ◽  
Filling Time ◽  
Cure Time ◽  
Injection Molded ◽  
Injection Temperature

Abstract Injection moldings with natural rubber compounds having sections varying between 0.16 and 10 cm thick have been prepared. Almost any natural rubber compound can be satisfactorily injection molded. Cure time, and hence cycle time, is highly dependent on injection temperature and the art of injection molding is to inject at the highest possible temperature consistent with freedom from scorch. The injection temperature of natural rubber depends on the injection molding machine variables such as screw speed, screw back pressure and barrel temperature. Injection and mold filling time are dependent on injection pressure and nozzle orifice diameter. Rubber compounding variables influence injection molding behavior. A curing system with a relatively long, safe Mooney scorch time permits a reduction in the cure time of rubber by allowing a high injection temperature. Conventional curing systems are suitable for a wide range of injection moldings but “Efficient Vulcanization ” systems have special advantages in curing thin sections adjacent to thick ones because of their superior reversion resistance. The effects of compound viscosity are described. Extenders are shown to reduce injection temperatures and thus increase cure times. Black and white fillers are examined in their effect on injection temperature, injection time and cure time. Injection molded vulcanizates are similar in mechanical properties and oven aging resistance to vulcanizates prepared by conventional press methods.

Comprehensive Online Control Strategies for Plastic Injection Molding Process

2014 ◽  
Vol 136 (4) ◽  
Author(s):  
Jaho Seo ◽  
Amir Khajepour ◽  
Jan P. Huissoon
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Thermal Control ◽  
Plastic Injection Molding ◽  
Injection Molding Process ◽  
Molding Process ◽  
Element Analysis ◽  
Thermal Dynamics ◽  
Uncertain Dynamics ◽  
Plastic Injection

This study proposes an effective thermal control for plastic injection molding (polymer: Santoprene 8211-45 with density of 790 kg/m3, injection pressure: 1400 psi (9,652,660 Pa)) in a laminated die. For this purpose, a comprehensive control strategy is provided to cover various themes. First, a new method for determining the optimal sensor locations as a prerequisite step for modeling and controller design is introduced. Second, system identification through offline and online training with finite element analysis and neural network techniques are used to develop an accurate model by incorporating uncertain dynamics of the laminated die. Third, an additive feedforward control by adding direct adaptive inverse control to self-adaptive PID is developed for temperature control of cavity wall (cavity size: 52.9 × 32.07 × 16.03 mm). A verification of designed controller's performance demonstrates that the proposed strategy provides accurate online temperature tracking and faster response under thermal dynamics with various cycle-times in the injection mold process.

Optimizing Injection Parameters of Kenaf Filler Polypropylene Composite by Taguchi Method

2017 ◽  
Vol 894 ◽  
pp. 81-84 ◽  
Author(s):  
Mohd Khairul Fadzly Md Radzi ◽  
Norhamidi Muhamad ◽  
Abu Bakar Sulong ◽  
Zakaria Razak
Keyword(s):  
Injection Molding ◽  
Taguchi Method ◽  
Process Condition ◽  
Injection Pressure ◽  
Poor Quality ◽  
Injection Molding Process ◽  
Molding Process ◽  
Injection Parameters ◽  
Pp Composites ◽  
Injection Temperature

Optimization of injection molding parameters provided a solution to achieve strength improvement of kenaf filler polypropylene composites. Since, molded polymers composites possibility being effected by machine parameters and other process condition that may cause poor quality of composites product. Thus in this study, composite of kenal filler reinforced with thermoplastic polypropylene (PP) were prepared using a sigma blade mixer, followed by an injection molding process. To determine the optimal processing of injection parameters, Taguchi method with L27 orthogonal array was used on statistical analysis of tensile properties of kenaf/PP composites. The results obtained the optimum parameters which were injection temperature 190°C, injection pressure 1300 bar, holding pressure 1900 bar and injection rate 20cm3/s. From the analysis of variance (ANOVA), both flow rate and injection temperature give highest contribution factor to the mechanical properties of the kenaf/PP composites.

Numerical and Experimental Study on the Injection Moulding of a Thin-Wall Complex Part

2008 ◽  
Author(s):  
Catalin Fetecau ◽  
Ion Postolache ◽  
Felicia Stan
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Processing Parameters ◽  
Injection Molding Process ◽  
Thin Wall ◽  
Molding Process ◽  
Complex Part ◽  
Filling Time ◽  
Wall Injection

The research presented in this paper involves numerical and experimental efforts to investigate the relative thin-wall injection molding process in order to obtain high dimensional quality complex parts. To better understand the effects of various processing parameters (the filling time, injection pressure, the melting temperature, the mold temperature) on the injection molding of a thin-wall complex part, the molding experiments are regenerated into the computer model using the Moldflow Plastics Insight (MPI) 6.1 software. The computer visualization of the filling phase allows accurate prediction of the location of the flow front, welding lines and air traps. Furthermore, in order to optimize the injection molding process, the effects of the geometry of the runner system on the filling and packing phases are also investigated. It is shown that computational modeling could be used to help the process and mold designer to produce accurate parts.

Characterization of Micro Metal Injection Molding by Using PMMA & PEG

2013 ◽  
Vol 315 ◽  
pp. 992-996
Author(s):  
Mohd Halim Irwan Ibrahim ◽  
Norhamidi Muhamad ◽  
A.B. Sulong
Keyword(s):  
Stainless Steel ◽  
Injection Molding ◽  
Injection Pressure ◽  
Steel Powder ◽  
Mold Temperature ◽  
Point Of View ◽  
Metal Injection Molding ◽  
Volume Percentage ◽  
Shape Retention ◽  
Injection Temperature

Due to its versatility, micro metal injection molding has become an alternative method in powder metallurgy where it can produce small part with a minimal number of waste. The success of micro MIM is greatly influenced by feedstock characteristics. This paper investigated the characterization and optimization which both of them plays an important characteristic in determining the successful of micro MIM. In this paper, stainless steel SS 316L was used with composite binder, which consists of PEG (Polyethelena Glycol), PMMA (Polymethyl Methacrilate) and SA (Stearic Acid). The rheology properties are investigated using Shimadzu Flowtester CFT-500D capillary rheometer. The geometry of water atomised stainless steel powder are irregular shape, therefore it is expected significant changes in the rheological results that can influence the microcomponent, surface quality, shape retention and resolution capabilities. From rheological characteristics, feedstock with 61.5% shows a significant value with several injection parameters were optimized through screening experiment such as injection pressure (A), injection temperature (B), mold temperature (C), injection time (D) and holding time (E). Besides that, interaction effects between injection pressure, injection temperature and mold temperature were also considered to optimize in the Taguchis orthogonal array. Result shows that 61.5%vol contributes a significant stability over a range of temperature and the best powder loading from a critical powder volume percentage (CPVP) and rheological point of view. Furthermore interaction between injection temperature and mold temperature (BxC) give highest significant factor followed by interaction between injection pressure and mold temperature (AxC).

scholarly journals Optimization on the Injection Molding Propypopylene Parameters Using Central Composite Design for Minimizing Defects

2020 ◽  
Vol 55 (2) ◽  
Author(s):  
Moh. Hartono ◽  
Pratikto ◽  
Purnomo B. Santoso ◽  
Sugiono
Keyword(s):  
Injection Molding ◽  
Central Composite Design ◽  
Injection Pressure ◽  
Holding Time ◽  
Clamping Force ◽  
Molding Process ◽  
Injection Speed ◽  
Injection Temperature ◽  
Central Composite ◽  
Plastic Products

This study aims to simultaneously forecast and investigate the optimization process characterization of the design of controlled parameters in the injection process of polypropylene molding including injection pressure combination, clamping force, injection temperature, injection speed, and holding time, and their interaction to produce qualified plastic by minimizing defects. The experimental methods used the central composite design of response surface method with five factors and a variety of levels. This method is more effective because it is an improvement on and a development from previous studies—especially those related to the plastic molding process. Additionally, it can simultaneously predict and optimize the obtaining of the highest quality plastic products as well as minimizing defects. The results are in the form of a combination of control level factors and interactions among the factors that generate the robust output of plastic products with minimum defects. Moreover, the optimum settings of the parameters provides a global solution at an injection temperature of 275°C, injection pressure of 75 bar, injection speed of 98%, clamping force of 88 tons, and a holding time of 8 seconds to generate a response to product probability defects by 0.0062. The benefit is that it can reveal the behavior and characteristics of parameter design and their interactions in the plastic injection molding process to produce qualified plastics and minimize product defects.

Flow of Finite Element Analysis of Metal Powder in Medal Injection Mold Runner

2011 ◽  
Vol 189-193 ◽  
pp. 2255-2258
Author(s):  
Jie Jin ◽  
Xin Bai ◽  
Fang Yin Ning
Keyword(s):  
Injection Molding ◽  
Flow Behavior ◽  
Continuum Theory ◽  
Injection Pressure ◽  
Metal Injection Molding ◽  
Element Analysis ◽  
Circular Section ◽  
Die Filling ◽  
Control Equation ◽  
And Control

Based on the continuum theory, combined with the characteristics of metal injection molding, constructs assumptions and control equation in the die filling process of MIM.With the FLOTRAN hydro-analysis module of ANSYS software, the melt’s velocity ,temperature and pressure fields during injection molding were simulated and compared for different sizes of circular section runners,and discussed the influences between different diameter runners and injection pressure on the flow behavior of melt. The simulation provided theoretical guidance for the design and selection of mold runner in the production.

The Sensitivity Analysis of Wellbore Heat Transfer during the CO2 Injection Process

2014 ◽  
Vol 889-890 ◽  
pp. 1638-1643
Author(s):  
Yi Zhang ◽  
Tong Tong Li ◽  
Yong Chen Song ◽  
Duo Li ◽  
Yang Chun Zhan ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Carbon Dioxide ◽  
Sensitivity Analysis ◽  
Flow Rate ◽  
Injection Pressure ◽  
Simulation Method ◽  
Injection Process ◽  
Injection Flow ◽  
Injection Temperature ◽  
Thomson Coefficient

The sensitivity analysis of wellbore heat transfer during the CO2injection process is of vital importance to Carbon dioxide utilization and sequestration (CCUS). A numerical simulation method is developed to simulate the process of wellbore heat transfer during injecting carbon dioxide by amending the classical heat transfer modelRamey models. It analyses how the selected parameters affect the distribution of the wellbore temperature and pressure, which include CO2injection temperature, pressure and density, the injection flow rate and Joule Thomson coefficient. The results show that, CO2injection temperature has greater impact on the initial level of the temperature distribution; higher injection pressure raises the temperature mainly because of the effect of Joule Thomson coefficient; also, when the injection process lasts a longer time, the distribution is much more stable. When the injection flow rate is higher, the strata temperature has less influence on the flow temperature. The injection pressure and density has very appreciable effect on the pressure distribution. However, the other parameters have less influence on it. The modified simulation method was applied in Jiangsu Caoshe oil field and the simulation results coincided with the measuring data well.

Application of Taguchi Method to Improve Resistance Quality of Graphene/Polypropylene Composites

2019 ◽  
Vol 818 ◽  
pp. 118-122
Author(s):  
Ching Been Yang ◽  
Wei Chang Peng ◽  
Yan Wen Huang ◽  
Hsiu Lu Chiang
Keyword(s):  
Injection Molding ◽  
Taguchi Method ◽  
Optimal Parameter ◽  
Impact Resistance ◽  
Injection Pressure ◽  
High Impact ◽  
Polypropylene Composites ◽  
Injection Temperature ◽  
New Generation

Polypropylene is a widely used thermoplastic with high impact resistance and strong mechanical properties. Graphene has exhibited in a new generation of electronic component materials owing to its high thermal conductivity and low resistivity. In this study, a composite of graphene and polypropylene for injection molding purposes was created. In Taguchi method, an L9 orthogonal array for injection molding experiments was adopted. The process parameters included injection temperature (A), holding time (B), injection pressure (C), and graphene ratio (D). Optimal parameter combinations were determined according to resistivity, and the results were A3B2C1D3: 2956.333 MΩ by original and A1B2C1D3: 2802 MΩ Taguchi analysis, respectively, where the improvement was 5.2%.

Effects of Injection Temperature and Pressure on Green Part Density for Ceramic Injection Molding

2012 ◽  
Vol 622-623 ◽  
pp. 429-432
Author(s):  
Sarizal Md Ani ◽  
Andanastuti Muchtar ◽  
Norhamidi Muhamad ◽  
Jaharah A. Ghani
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
High Density ◽  
Ceramic Injection Molding ◽  
Optimum Parameters ◽  
Green Part ◽  
Injection Temperature ◽  
Temperature And Pressure ◽  
Part Density ◽  
Zirconia Powders

This study investigates the effects of injection temperature and pressure on green part density. The high density of the green parts for the ceramic injection molding (CIM) process improves the material properties of the final product. In this study, the feedstock used was a combination of alumina and zirconia powders with a binder consisting of high density polyethylene, paraffin wax, and stearic acid. Powder loading was fixed at 57% volume. A standard screw-type injection molding machine was used to produce the green parts. The density of the green parts was measured using the Archimedes method. Experimental results show that a 160 °C injection temperature and a 110 MPainjection pressure were the optimum parameters to achieve high density of the green parts. In addition, defect-free green parts were obtained.

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