Identification of Controlling Parameters on Thermal Deformation of Mobile Device by Injection Molding Process

2013 ◽  
Vol 135 (1) ◽  
Author(s):  
Eunyoung Chang ◽  
Seungwon Shin ◽  
Haseung Chung
Keyword(s):  
Injection Molding ◽  
Mobile Device ◽  
Thermal Deformation ◽  
Processing Parameters ◽  
Final Part ◽  
Injection Molding Process ◽  
Original Design ◽  
Molding Process ◽  
Part Quality ◽  
Complicated Geometries

Injection molding process is a widely used manufacturing technique to massively produce the components of mobile device with various sizes and complicated geometries. However, the final part quality, especially dimension or geometry, referring to the original design specifications is not often acceptable due to various reasons. This study aims at developing the numerical model to predict the final part quality and subsequently identifying the critical reasons for existing problems. moldflow and abaqus software have been simultaneously used to simulate the injection molding process and thermal deformation arising after ejection step from the mold. In order to validate the model, the deformation predicted by the developed model was compared with experimental results, and both results showed good agreement. We also carried out design of experiment (DOE) to investigate the effect of various processing parameters that affect the final deformation of injection molded product. The developed model and information derived from DOE are expected to provide useful resources to the initial stage of mobile device design.

Effect of Micro-Injection Molding Process Parameters for Warpage in Micro Plate Devices

2014 ◽  
Vol 898 ◽  
pp. 265-268
Author(s):  
Duo Yang
Keyword(s):  
Injection Molding ◽  
Processing Parameters ◽  
Injection Molding Process ◽  
Processing Parameter ◽  
Range Analysis ◽  
Molding Process ◽  
Factors Affecting ◽  
Plastic Materials ◽  
Best Parameter ◽  
Packing Time

The injection molding process of micro plate devices requires several concerns in order to produce a quality output. In part of determining the best parameter settings, among other considerations that need to be taken are the types of plastic materials selected and the mold design. Molding parameters such as packing time, cooling temperature, molding and melting temperatures, packing and injection pressures are the most important factors affecting warpage of the micro plate part. These factors and their interactions were investigated in this research. The effects of processing parameter on the warpage of flat micro devices were analyzed according to the Taguchi method. In this paper, based on the range analysis, the parameter effective sequence was got, as well as the best processing parameters. The molding packing time has the strongest effects on the warpage, and the molding temperature is the secondary parameter. The cooling time has the lowest effects.

Optimization of the Injection Molding Process Parameters Based on Moldflow and Orthogonal Experiment

2013 ◽  
Vol 561 ◽  
pp. 239-243 ◽  
Author(s):  
Yong Nie ◽  
Hui Min Zhang ◽  
Jia Teng Niu
Keyword(s):  
Injection Molding ◽  
Orthogonal Experiment ◽  
Mold Temperature ◽  
Processing Parameters ◽  
Influential Factors ◽  
Injection Molding Process ◽  
Range Analysis ◽  
Molding Process ◽  
Melt Temperature ◽  
Plastic Parts

This article is using Moldflow analysis and orthogonal experimental method during the whole experiment. The injection molding process of motor cover is simulated under various technological conditions.After forming the maximum amount of warpage of plastic parts for evaluation.According to the range analysis of the comprehensive goal, the extent of the overall influence to the processing parameters, such as gate location, melt temperature, mold temperature and holding pressure is clarified.Through analyzing the diagrams of influential factors resulted from the simulation result,the optimized process parameter scheme is obtained and further verified by simulation.

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.

Dynamic Response Optimization for Cemented Carbide Injection Molding

2014 ◽  
Vol 68 (4) ◽  
Author(s):  
Sri Yulis M. Amin ◽  
Norhamidi Muhamad ◽  
Khairur Rijal Jamaludin
Keyword(s):  
Injection Molding ◽  
Palm Stearin ◽  
Processing Parameters ◽  
Cemented Carbide ◽  
Metal Injection Molding ◽  
Injection Molding Process ◽  
Molding Process ◽  
Response Optimization ◽  
Injection Molded ◽  
Injection Temperature

The need to optimize the injection molding parameters for producing cemented carbide parts via Metal Injection Molding process is crucial to ensure the system’s robustness towards manufacturer and customer’s satisfactions. Defect free product with best density can be produced while reducing time and cost in manufacturing. In this work, the feedstock consisting of WC-Co powders, mixed with palm stearin and polyethylene binder system was injection molded to produce green parts. Several processing variables, namely powder loading, injection temperature, holding pressure and flowrate, were optimized towards the density of the green body, as the response factor. By considering humidity level at morning and evening conditions as the noise factor, the results show the optimum combination of injection molding parameters that produces best green density. The green part exhibited best density by following this optimum processing parameters, A2B3C1D1, that are flowrate at 20 ccm/s, powder loading at 63% vol., injection temperature at 140°C, and holding pressure at 1700 bar.

Influence of Injection Molding Process Parameters on Sink Marks of Injection Parts Based on Moldflow

2013 ◽  
Vol 347-350 ◽  
pp. 1163-1167
Author(s):  
Ling Bai ◽  
Hai Ying Zhang ◽  
Wen Liu
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Mold Temperature ◽  
Processing Parameters ◽  
Injection Molding Process ◽  
Molding Process ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Sink Marks ◽  
Research Show

Moldflow software was used to obtain the best gate location and count. Influence of injection molding processing parameters on sink marks of injection-piece was studied based on orthogonal test. The effects of different process parameters were analyzed and better process parameters were obtained. Results of research show that decreasing melt temperature, mold temperature, the increasing injection time and packing pressure can effectively reduce the sink marks index.

Injection Molding Process Parameter Optimization for Warpage Minimization Based on Uniform Design of Experiment

2010 ◽  
Vol 37-38 ◽  
pp. 570-575 ◽  
Author(s):  
Bao Shou Sun ◽  
Zhe Chen ◽  
Bo Qin Gu ◽  
Xiao Diao Huang
Keyword(s):  
Injection Molding ◽  
Design Of Experiment ◽  
Simulation Analysis ◽  
Uniform Design ◽  
Mold Temperature ◽  
Optimization Method ◽  
Processing Parameters ◽  
Injection Molding Process ◽  
Molding Process ◽  
Melt Temperature

To optimize injection molding warpage, this paper applies the uniform design of experiment method to search for the optimal injection molding processing parameters. The warpage. simulation analysis is accomplished by emplying Moldflow software. The melt temperature, mold temperature, injection time and packing pressure are regarded as processing parameters, and processing parameters are optimized through establishing a regression equation, and the optimization result and influence factors are analyzed. The results show that uniform design of experiment can reduce number of experiments used effectively and the quality of the product is greatly improved by the optimization method.

Effects of surface microstructure and molding parameters on injection bonding strength of polyphenylenesulphide-aluminum alloy

2020 ◽  
Vol 10 (5) ◽  
pp. 640-647
Author(s):  
Zhenyu Xu ◽  
Ning Li
Keyword(s):  
Aluminum Alloy ◽  
Injection Molding ◽  
Bonding Strength ◽  
Direct Injection ◽  
Processing Parameters ◽  
Surface Microstructure ◽  
Injection Molding Process ◽  
Molding Process ◽  
Orthogonal Test Design ◽  
Highly Correlated

The direct injection molding process of PPS-aluminum alloy composite parts under vacuum condition was conducted and the processing parameters were optimized through the numerical simulation and orthogonal test design. The effect of surface microstructure of the aluminum alloy splines and injection molding processing parameters on the bonding strength of the composite parts were discussed. The results show that the bonding strength of the composite parts increases with not only the increase in the diameter and quantity of the microscopic pores and also the surface roughness of the aluminum alloy splines. The bonding strength can also been improved under a higher vacuum. The bonding strength is highly correlated to the micromechanical interlocking structure formed by the PPS embedding into the rough surface of the aluminum alloy splines.

scholarly journals Surface Homogeneity of Injection Molded Parts

2018 ◽  
Vol 62 (4) ◽  
pp. 284-291 ◽  
Author(s):  
László Zsíros ◽  
József Gábor Kovács
Keyword(s):  
Injection Molding ◽  
Evaluation Method ◽  
Solid Phase ◽  
Color Space ◽  
Processing Parameters ◽  
Injection Molding Process ◽  
Mold Surface ◽  
Molding Process ◽  
Molded Parts ◽  
Injection Molded

In this paper we are presenting a novel method for color inhomogeneity evaluation. We proved that this method has a higher than 95 % linear correlation coefficient if results are correlated with human visual evaluations.We applied this evaluation method to analyze the homogenization in the injection molding process, therefore we measured the homogenization properties of various solid phase masterbatches on injection molded parts. We tested the effects of the processing parameters of injection molding and analyzed various dynamic and static mixers as well. We have also measured the influence of the mold surface texture on the sensation of inhomogeneities on the part surface.We have carried out our tests on an injection grade ABS material using various masterbatches. The method was based on the digitization of the molded flat specimens. The images of these specimens were evaluated with an own developed formula using the CIELAB color space resulting high correlation with human visual inspections.

scholarly journals Novel Analysis Methodology of Cavity Pressure Profiles in Injection-Molding Processes Using Interpretation of Machine Learning Model

Polymers ◽  
2021 ◽  
Vol 13 (19) ◽  
pp. 3297
Author(s):  
Jinsu Gim ◽  
Byungohk Rhee
Keyword(s):  
Injection Molding ◽  
Pressure Profile ◽  
Polymer Materials ◽  
Quality Analysis ◽  
Injection Molding Process ◽  
Cavity Pressure ◽  
Molding Process ◽  
Part Quality ◽  
Analysis Methodology ◽  
Molding Condition

The cavity pressure profile representing the effective molding condition in a cavity is closely related to part quality. Analysis of the effect of the cavity pressure profile on quality requires prior knowledge and understanding of the injection-molding process and polymer materials. In this work, an analysis methodology to examine the effect of the cavity pressure profile on part quality is proposed. The methodology uses the interpretation of a neural network as a metamodel representing the relationship between the cavity pressure profile and the part weight as a quality index. The process state points (PSPs) extracted from the cavity pressure profile were used as the input features of the model. The overall impact of the features on the part weight and the contribution of them on a specific sample clarify the influence of the cavity pressure profile on the part weight. The effect of the process parameters on the part weight and the PSPs supported the validity of the methodology. The influential features and impacts analyzed using this methodology can be employed to set the target points and bounds of the monitoring window, and the contribution of each feature can be used to optimize the injection-molding process.

Numerical Simulation of Co-Injection Molding

2000 ◽  
Author(s):  
James T. Wang
Keyword(s):  
Injection Molding ◽  
Process Design ◽  
Core Layer ◽  
Skin Layer ◽  
Injection Molding Process ◽  
Molding Process ◽  
Part Quality ◽  
Polymer Properties ◽  
Polymer Distribution ◽  
The Cost

Abstract In the co-injection molding process, two (or more) different polymers are injected into the cavity simultaneously or sequentially. Different properties of these two polymers and their distribution in the cavity greatly affect the applications of this molding process. The skin layer can use special polymers to provide good appearance and texture, strength, chemical resistance, EMI shielding and other functions. The core layer can use recycled or inexpensive materials. Together these can improve part quality and lower the cost. However, due to the dynamic interaction of two polymers in the manufacturing process and their difference in properties, process control becomes more complicated and process design becomes a challenge. The rules used for the traditional injection molding process design may not always be useful for co-injection molding any more. An integrated CAE software has been developed to simulate the co-injection molding process. In this study, the capability and usefulness of the CAE tool will be shown. The control of polymer distribution will be discussed. The effects of polymer properties and their distribution on part quality will also be studied.

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