Design for Injection Molding: Using Process Simulation to Assess Tolerance Feasibility

1994 ◽  
Author(s):  
David R. Busick ◽  
Kurt A. Beiter ◽  
Kos Ishii
Keyword(s):  
Injection Molding ◽  
Process Simulation ◽  
Process Variations ◽  
Simulation Software ◽  
Injection Molding Process ◽  
Molding Process ◽  
Injection Molding Simulation ◽  
Injection Molded ◽  
Effective Use ◽  
Dimensional Errors

Abstract This paper proposes an effective use of process simulation in the dimensional tolerancing of injection molded thermoplastic components. The complexities of the injection molding process make it difficult for designers to assign dimensional tolerances. No standard method exists for predicting the feasibility of a design tolerance. Advances in injection molding simulation software offer information that could aid in tolerancing. However, engineers have not effectively used these programs for tolerancing. This paper proposes a methodology for using process simulation in evaluating the feasibility of a tolerance scheme. The methodology entails using simulation to quantify the dimensional errors due to process variations and estimate sensitivities. Comparison of simulation results with tolerances specified by designers helps them evaluate whether the desired tolerances are feasible. The paper describes the steps required for estimating the dimensional errors and defines criticality as a measure of tolerance feasibility. A plastic housing for an electrical switch serves as an illustrative example.

Interfacial Characteristics of Insert-Injection Molding by Using Acoustic Emission

2017 ◽  
Vol 728 ◽  
pp. 258-263
Author(s):  
Badin Pinpathomrat ◽  
Suchalinee Mathurosemontri ◽  
Supaphorn Thumsorn ◽  
Hiroyuki Hamada
Keyword(s):  
Acoustic Emission ◽  
Injection Molding ◽  
Adhesive Strength ◽  
Fracture Behavior ◽  
Acoustic Emissions ◽  
Injection Molding Process ◽  
Test Machine ◽  
Molding Process ◽  
Bonding Area ◽  
Injection Molded

Aim of this study focused on insert injection molding process, which is molded the melted polymer around an inserted part placed in the molded cavity of injection molding process. The interfacial adhesive strength between the inserted and an injected polymer parts were investigated by Intron universal test machine in order to investigate the effect of material in inserted and injected part. During tensile testing the acoustic emissions (AE) measurement was applied to evaluate the fracture behavior of insert injection molding. It was found that interfacial adhesive strength of insert injection molded of all specimens increased according with increasing the bonding area of adhesive interface. The fracture mode of the insert injection molded specimens was depended on the length of bonding area of the inserted part. The fracture of mode of the insert-injection molded specimens was confirmed by acoustic emission.

scholarly journals Experimental Validation of Injection Molding Simulations of 3D Microparts and Microstructured Components Using Virtual Design of Experiments and Multi-Scale Modeling

Micromachines ◽  
2020 ◽  
Vol 11 (6) ◽  
pp. 614 ◽  
Author(s):  
Dario Loaldi ◽  
Francesco Regi ◽  
Federico Baruffi ◽  
Matteo Calaon ◽  
Danilo Quagliotti ◽  
...  
Keyword(s):  
Injection Molding ◽  
Process Simulation ◽  
Current Work ◽  
Injection Molding Process ◽  
Process Conditions ◽  
Virtual Design ◽  
Molding Process ◽  
Micro Injection Molding ◽  
Multi Scale ◽  
Filling Time

The increasing demand for micro-injection molding process technology and the corresponding micro-molded products have materialized in the need for models and simulation capabilities for the establishment of a digital twin of the manufacturing process. The opportunities enabled by the correct process simulation include the possibility of forecasting the part quality and finding optimal process conditions for a given product. The present work displays further use of micro-injection molding process simulation for the prediction of feature dimensions and its optimization and microfeature replication behavior due to geometrical boundary effects. The current work focused on the micro-injection molding of three-dimensional microparts and of single components featuring microstructures. First, two virtual a studies were performed to predict the outer diameter of a micro-ring within an accuracy of 10 µm and the flash formation on a micro-component with mass a 0.1 mg. In the second part of the study, the influence of microstructure orientation on the filling time of a microcavity design section was investigated for a component featuring micro grooves with a 15 µm nominal height. Multiscale meshing was employed to model the replication of microfeatures in a range of 17–346 µm in a Fresnel lens product, allowing the prediction of the replication behavior of a microfeature at 91% accuracy. The simulations were performed using 3D modeling and generalized Navier–Stokes equations using a single multi-scale simulation approach. The current work shows the current potential and limitations in the use of micro-injection molding process simulations for the optimization of micro 3D-part and microstructured components.

MPI-Based Injection Molding Process Optimization Analysis of the Control Plastic Cover

2011 ◽  
Vol 271-273 ◽  
pp. 1224-1227
Author(s):  
Fang Qi Cheng
Keyword(s):  
Injection Molding ◽  
Process Simulation ◽  
Filling Pressure ◽  
Injection Molding Process ◽  
Cooling Process ◽  
Forming Process ◽  
Molding Process ◽  
Optimization Analysis ◽  
Mould Design ◽  
Plastic Products

To avoid the defects of plastic products and improve product quality have been an important problem for mold designers. In this paper, Autodesk Moldflow software are applied to a plastic control cover injection molding process simulation and find out the actual molding process and true conditions of the dynamic filling, pressure and cooling process in the process of forming. The forming process of parameters such as pressure, temperature and speed are given in order to improve the accuracy of the mould design and product precision.

Study on Improving the Life of Stereolithography Injection Mold

2012 ◽  
Vol 468-471 ◽  
pp. 1013-1016 ◽  
Author(s):  
Hua Qing Lai
Keyword(s):  
Injection Molding ◽  
Injection Molding Process ◽  
Injection Mold ◽  
Molding Process ◽  
Molded Parts ◽  
Injection Molded ◽  
Plastic Parts ◽  
Assembly Operations ◽  
Conventional Injection Molding ◽  
Shape And Size

Molding is one of the most versatile and important processes for manufacturing complex plastic parts. It is a method of fabricating plastic parts by utilizing a mold or cavity that has a shape and size similar to the part being produced. Molten polymer is injected into the cavity, resulting in the desired part upon solidification. The injection-molded parts typically have excellent dimensional tolerance and require almost no finishing and assembly operations. But new variations and emerging innovations of conventional injection molding have been continuously developed to offer special features and benefits that cannot be accomplished by the conventional injection molding process. This study aims to improving the life of stereolithography injection mold.

scholarly journals Application of Moldflow Simulation in Injection Molding of Plastic Tank

2017 ◽  
Vol 9 (1) ◽  
pp. 79-88
Author(s):  
Piotr Tutak
Keyword(s):  
Injection Molding ◽  
Simulation Software ◽  
Injection Molding Process ◽  
Development Cost ◽  
Molding Process ◽  
Improve Product ◽  
Air Cooler ◽  
Moldflow Simulation

Abstract This article presents an application of moldflow simulation to optimize the injection molding process of charge air cooler plastic tank. The work shows the advantages of this kind of simulation software and information that it can provide. It also explains how big role today play simulation softwares and how they can improve product and reduce development cost.

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.

Application of a multilayer injection molding process for thick-walled optical components

2016 ◽  
Vol 36 (6) ◽  
pp. 557-562 ◽  
Author(s):  
Christian Hopmann ◽  
Malte Röbig
Keyword(s):  
Optical Properties ◽  
Injection Molding ◽  
Mold Temperature ◽  
Injection Molding Process ◽  
Molding Process ◽  
Optical Components ◽  
Considerable Potential ◽  
Cycle Times ◽  
Molded Part ◽  
Injection Molded

Abstract Nowadays, the injection molding of optical components is becoming more and more important. A process which constructs the injection-molded part in layers offers considerable potential for productivity increases in the manufacturing of thick-walled optical components. The so-called multilayer injection molding, also known as overmolding technology enables a considerable reduction of the normally long cycle times and improves the optical properties. It is even possible to increase the molding accuracy due to the lower shrinkage potential of the single layers. Contrary to experience, the influence of the mold temperature on the bonding strength is very low. So, the temperature control of the mold can be adapted to the process consideration in regard to optical characteristics.

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.

Feedstock Formulation of Open-Pore Cell Copper Foam via Metal Injection Molding

2016 ◽  
Vol 1133 ◽  
pp. 290-294
Author(s):  
Noorsyakirah Abdulah ◽  
Mazlan Mohamad ◽  
Mohd Afian Omar ◽  
Muhammad Jabir Suleiman @ Ahmad ◽  
Ahmad Aswad Mahaidin ◽  
...  
Keyword(s):  
Injection Molding ◽  
Metal Injection Molding ◽  
Injection Molding Process ◽  
Molding Process ◽  
Powder Morphology ◽  
Space Holder ◽  
Copper Foam ◽  
Vertical Injection ◽  
Injection Molded ◽  
Feedstock Preparation

Feedstock preparation is one of the most crucial steps that will influence the metal injection molding process. In this study, the properties of Cu and space holder powder were determined. Powder morphology was captured using Scanning Electron Microscopy (SEM). Three different ratios of feedstocks were premixed with potassium carbonate as space holder using Turbulence Shaker mixer prior to mixing with constant binder system consist of waste rubber (WR). Mixes of three feedstocks with from 40, 50 and 60 wt. % were carried out in Brabender Plasticoder. All feedstocks were mixed at constant powder loading. The feedstocks were successfully injection molded using Vertical Injection Molding machine at 200°C.

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