MOULDABILITY OF WOOD FILLER REINFORCED POLYPROPYLENE COMPOSITE FOR INJECTION MOULDED ENGINE COVER USING MOULD FILING SIMULATION

2016 ◽  
Vol 78 (6-9) ◽  
Author(s):  
Mohd Khairul Fadzly Md Radzi ◽  
Abu Bakar Sulong ◽  
Baharuddin Mohd Zanggi ◽  
Norhamidi Muhammad
Keyword(s):  
Numerical Simulation ◽  
Shear Stress ◽  
Flow Rate ◽  
Injection Moulding ◽  
Average Velocity ◽  
Moulding Process ◽  
Filling Stage ◽  
Injection Moulding Process ◽  
Filling Time ◽  
Sink Marks

Feasibility studies about processing lignocellulosic reinforced polymer composites by injection moulding have been receiving widespread attention nowadays. The aim of this research was to identify the optimal selection of parameters, significant parameters, and effects of the injection-moulding parameters during the post filling-stage. In this simulation study, the modelling of an automotive component, namely the Proton Waja CAMPRO car engine cover, required a 3-D model and mesh generation to obtain the mouldability of its composite material using the injection moulding process. Autodesk Moldflow Insight® was used to simulate and analyse the injection-moulding process. Therefore, 60 wt% of wood filler reinforced polypropylene was evaluated under optimised injection parameters (injection temperature, mould temperature, injection pressure and flow rate) during the post-filling stage simulation (filling time, average velocity, volumetric shrinkage, sink marks, and shear stress). In addition, numerical simulation by the Taguchi method consisting of S/N ratio and ANOVA were used in this research to determine which significant factors would affect all responses. Based on the numerical simulation results, the flow rate shows the most significant parameter for the reduction of filling time, volumetric shrinkage, sink marks, and shear stress while also enhancing the average velocity on the car engine cover. 

scholarly journals Numerical Simulation on Moulded Thin-Walled Parts via Injection Moulding Process

2014 ◽  
Vol 575 ◽  
pp. 73-77
Author(s):  
M.D. Azaman ◽  
S.M. Sapuan ◽  
Shamsuddin Sulaiman ◽  
E.S. Zainudin ◽  
Abdan Khalina
Keyword(s):  
Numerical Simulation ◽  
Shear Stress ◽  
Residual Stresses ◽  
Current Trend ◽  
Light Weight ◽  
Moulding Process ◽  
Injection Moulding Process ◽  
Low Shear Stress ◽  
Thin Walled ◽  
Low Shear

The current trend in the industry is to produce thin, light weight, and environmental products. In this project, flat or shallow thin-walled parts were designed and moulded lignocellulosic polymer composites (PP + 50 wt% wood) to visualize the processability via moulding simulation. This studied focused on the filling, shear stress at wall, and in-cavity residual stresses behaviors. The shallow thin-walled part is preferable in moulding PP + 50 wt% wood due to economically in processing, low shear stress distribution and low residual stresses than the flat thin-walled part.

scholarly journals Numerical Simulation of the Multi-Component Injection Moulding Process

1997 ◽  
Vol 12 (3) ◽  
pp. 216-227 ◽  
Author(s):  
W. F. Zoetelief ◽  
G. W. M. Peters ◽  
H. E. H. Meijer
Keyword(s):  
Numerical Simulation ◽  
Injection Moulding ◽  
Moulding Process ◽  
Injection Moulding Process

Optimization of Injection Moulding Process from the View of Cavity Filling Time and Product Cooling Time

2014 ◽  
Vol 621 ◽  
pp. 208-213
Author(s):  
Katarina Monkova ◽  
Slavomir Hric
Keyword(s):  
Injection Moulding ◽  
3D Model ◽  
Cooling System ◽  
Moulding Process ◽  
Mould Filling ◽  
Injection Moulding Process ◽  
Filling Time ◽  
Moulding Machine ◽  
Mould Cavity ◽  
Cavity Filling

The article deals with the mould cooling system design. The goal of design presented in the article was to propose the mould form so to be achieved the shortest time for both mould filling and product cooling. Studied product is intended to serve as a stopper in the automotive spotlight. After filling of mould cavity, the melt has to cool at 100 ° C, only then it is possible to accede to the next phase, which is final pressure. So the cooling and filling time is directly proportional to the reduction of production cost. 3D model of the mould was created in Autodesk Inventor Proffesional software and then solidification of material was simulated in Autodesk Moldflow Insight software. There were considered four types of cooling system in the article and the best one from the view of time was manufactured and placed into the injection moulding machine Arburg Allrounder 320 C.

Bio Inspired Algorithms for Injection Moulding Optimization

2013 ◽  
Vol 683 ◽  
pp. 771-774 ◽  
Author(s):  
Pedro Carreira ◽  
Nuno Alves ◽  
Carina Ramos ◽  
Paulo J. Bártolo
Keyword(s):  
Cycle Time ◽  
Injection Moulding ◽  
Optimization Strategy ◽  
Moulding Process ◽  
Injection Moulding Process ◽  
Filling Time ◽  
Living Organisms ◽  
Nature Inspired Algorithms ◽  
Optimum Solution ◽  
The Cost

Social behaviors of living organisms found in nature, like food searching, environment fitness and survival are inspiration for meta-heuristic mathematical models. Replicating these natural organism behaviors, several optimization algorithms have been developed and applied to technological processes. In this work, some nature inspired algorithms are applied to the injection problem in order to optimize the injection runners’ geometry, so that the overall cycle time is minimized. A key issue is the injection moulding process, as it strongly determines the cost per part. A global optimization strategy was implemented for the injection moulding cycle time, covering the main steps of process, filling time, cooling time, packing time and opening time. To achieve the optimum solution for each design variable and obtain the best time solution overall, it will enable to evaluate optimality, robustness, convergence, and variables dispersion for each used algorithm.

Optimum Injection Moulding Processing Condition to Reduce Shrinkage and Warpage for Polypropylene-Nanoclay-Bamboo Fibre with Compatibilizer

2017 ◽  
Vol 889 ◽  
pp. 51-55 ◽  
Author(s):  
M.H. Othman ◽  
Sulaiman Hasan ◽  
Mohd Halim Irwan Ibrahim ◽  
Siti Zubaidah Khamis
Keyword(s):  
Injection Moulding ◽  
Processing Condition ◽  
Screw Speed ◽  
Melt Temperature ◽  
Moulding Process ◽  
Bamboo Fibre ◽  
Packing Pressure ◽  
Injection Moulding Process ◽  
Filling Time

The purpose of this research is to optimise the processing condition of injection moulding towards samples made from polypropylene-nanoclay-bamboo fibre with compatibilizer. The defects that have been controlled upon the optimisation were shrinkage and warpage. The selection of injection moulding processing condition was packing pressure, melt temperature, screw speed and filling time. The research started by drying the bamboo fibres at 120°C. Then, the 1 wt. % fibres were mixed with 79 wt. % of polypropylene, 15 wt. % of compatibilizer and 5 wt. % of nanoclay. The mixing process was performed by using Brabender Plastograph machine. After that, pallets were produced by using Plastic Granulator machine for injection moulding process. The optimisation process was accomplished by adopting the Taguchi method. According to the results, the value of warpage defect between compounding for 1 wt. % fibre and without fibre content was not significant. However the optimum setting of 170°C melt temperature, 35% packing pressure, 30% screw speed and 2 seconds filling time can significantly reduce shrinkage. In conclusion, the optimum processing condition of polypropylene-nanoclay, fibre bamboo had been achieved, and the existence of fibre obviously giving a promising manufacturing opportunity to improve the quality of the injected moulding products.

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