Computer Simulation of Warpage Formation in Polymer Injection Molding of a Step Pad

2006 ◽  
Author(s):  
Sridhar P. Ramamurthy ◽  
Lyle Steenson ◽  
Zhong Hu
Keyword(s):  
Injection Molding ◽  
Cooling System ◽  
Three Dimensional ◽  
Nonlinear Material ◽  
Injection Molding Process ◽  
Molding Process ◽  
Element Analysis ◽  
Polymer Injection ◽  
Fea Model ◽  
Polymer Injection Molding

Warpage is one of the most common defects of a plastic product in the polymer injection molding process. It is attributed to the differential shrinkage after the part is ejected from the die cavity due to the nonlinear material property of the polymer, improper design of the cooling system, geometry of the part and the related process parameters. In this paper, the warpage formation of a plastic part, Step Pad of polypropylene copolymer, in the cooling stage of the polymer injection molding process was simulated by finite element analysis (FEA). A three-dimensional FEA model, taking into account the nonlinear material (polypropylene copolymer) properties, with a thermal-structural sequential coupled approach of higher computing efficiency was developed. The effects of mold closed time and layout of cooling system on the dimension and shape of the part were investigated. Industrial experiments for the different mold closed times (25s, 30s, 35s, 40s, 45s, 50s, and 55s) were conducted. The simulation results were compared with the experimental results. The approach is effective in predicting warpage in the polymer injection molding processes.

scholarly journals Electricity Consumption Estimation of the Polymer Material Injection-Molding Manufacturing Process: Empirical Model and Application

Materials ◽  
2018 ◽  
Vol 11 (9) ◽  
pp. 1740 ◽  
Author(s):  
Ana Elduque ◽  
Daniel Elduque ◽  
Carmelo Pina ◽  
Isabel Clavería ◽  
Carlos Javierre
Keyword(s):  
Environmental Impact ◽  
Injection Molding ◽  
Empirical Model ◽  
Electricity Consumption ◽  
Injection Molding Process ◽  
Molding Process ◽  
Polymer Injection ◽  
Wide Range ◽  
Molded Parts ◽  
Polymer Injection Molding

Polymer injection-molding is one of the most used manufacturing processes for the production of plastic products. Its electricity consumption highly influences its cost as well as its environmental impact. Reducing these factors is one of the challenges that material science and production engineering face today. However, there is currently a lack of data regarding electricity consumption values for injection-molding, which leads to significant errors due to the inherent high variability of injection-molding and its configurations. In this paper, an empirical model is proposed to better estimate the electricity consumption and the environmental impact of the injection-molding process. This empirical model was created after measuring the electricity consumption of a wide range of parts. It provides a method to estimate both electricity consumption and environmental impact, taking into account characteristics of both the molded parts and the molding machine. A case study of an induction cooktop housing is presented, showing adequate accuracy of the empirical model and the importance of proper machine selection to reduce cost, electricity consumption, and environmental impact.

Solution of Three-Dimensional Transient Heat Transfer During Polymer Injection Molding

2001 ◽  
Author(s):  
Florin Ilinca ◽  
Jean-François Hétu
Keyword(s):  
Heat Transfer ◽  
Injection Molding ◽  
Operator Splitting ◽  
Three Dimensional ◽  
Free Surface Flow ◽  
Surface Flow ◽  
Element Analysis ◽  
Polymer Injection ◽  
Prandtl Numbers ◽  
Polymer Injection Molding

Abstract This paper presents a three-dimensional transient finite element analysis code for solving the flow and heat transfer during polymer injection molding. The problems of interest present important challenges for both the physical modeling and the solution algorithm. The free surface flow of molten polymer moving inside the filling cavity has to be computed as well as the heat transfer between the polymer and the mold. During filling, heat transfer occurs at high Prandtl numbers because of the low material conductivity, resulting in sharp temperature gradients close to the walls. In this work the momentum, energy and front tracking equations are solved in a segregated manner. The energy equation is solved in an operator splitting approach. The methodology is robust and effective in solving three-dimensional industrial parts.

scholarly journals Study of Injection Molding Process Simulation and Mold Design of Automotive Back Door Panel

2021 ◽  
Author(s):  
Huiwen Mao ◽  
Youmin Wang ◽  
Deyu Yang
Keyword(s):  
Injection Molding ◽  
Cooling System ◽  
Production Cycle ◽  
Injection Molding Process ◽  
Mold Design ◽  
Molding Process ◽  
Element Analysis ◽  
Suitable Material ◽  
Door Panel ◽  
Back Door

Abstract Numerical simulation of the injection molding process of the outer panel of the automotive plastic rear door and mold design is presented here. CATIA is used to design the original automotive steel structure. In order to efficiently design the panels; finite element analysis is used to verify whether the designed parts meet the mechanical properties requirements such as light weight, low fuel consumption, short production cycle, strong modeling design, high corrosion resistance and good recovery. To simulate the injection molding process, CAE software such as ANSYS and HYPERWORKS are used to analyze the back door of the selected material. After the numerical analysis, suitable material is selected, so that the modal and thermodynamic properties of the product could be satisfied as well as improved. In this paper, UG is used to design the convex and concave mold for the injection molding of the automobile’s plastic back door panel. Combined with the characteristics of the parts and the design requirements of the injection mold, the multi-scheme design of the pouring and cooling system is carried out. By comparing the effects of different gating and cooling systems on injection molding, the best gating and cooling system is selected.

CAE of Mold Cooling in Injection Molding Using a Three-Dimensional Numerical Simulation

1992 ◽  
Vol 114 (2) ◽  
pp. 213-221 ◽  
Author(s):  
K. Himasekhar ◽  
J. Lottey ◽  
K. K. Wang
Keyword(s):  
Heat Transfer ◽  
Heat Exchange ◽  
Injection Molding ◽  
Cooling System ◽  
Three Dimensional ◽  
Ambient Air ◽  
Injection Molding Process ◽  
Analysis Tool ◽  
Molding Process ◽  
Dimensional Boundary

In recent years, increased attention has been paid to the design of cooling systems in injection molding, as it became clear that cooling affects both productivity and part quality. In order to systematically improve the performance of a cooling system in terms of rapid, uniform, and even cooling, the designer needs a CAE analysis tool. For this, a computer simulation has been developed for three-dimensional mold heat transfer during the cooling stage of an injection molding process. In this simulation, mold heat transfer is considered as cyclic-steady, three-dimensional conduction; heat transfer within the melt region is treated as transient, one-dimensional conduction; heat exchange between the cooling channel surfaces and coolant is treated as steady, as is heat exchange with the ambient air and mold exterior surfaces. Numerical implementation includes the application of a hybrid scheme consisting of a modified three-dimensional, boundary-element method for the mold region and a finite-difference method with a variable mesh for the melt region. These two analyses are iteratively coupled so as to match the temperature and heat flux at the mold-melt interface. Using an example, the usefulness of the simulation developed here in the design of a cooling system for an injection molding process is amply demonstrated.

Optimal Sensor Locations for Polymer Injection Molding Process

2014 ◽  
Vol 611-612 ◽  
pp. 1724-1733
Author(s):  
David Garcia ◽  
Ronan Le Goff ◽  
Maxime Gasse ◽  
Alexandre Aussem
Keyword(s):  
Injection Molding ◽  
Physical Phenomenon ◽  
Sensor Data ◽  
Injection Molding Process ◽  
Molding Process ◽  
Virtual Sensor ◽  
Polymer Injection ◽  
Sensor Configuration ◽  
Data Driven Modeling ◽  
Polymer Injection Molding

The subject discussed in this article concerns the determination of optimal sensor (pressure & temperature) configurations for polymer injection moulds. A sensor configuration is considered optimal when it is able to predict the product quality (dimension, warpage, etc.) with a good accuracy (from experimental data provided by these sensors). Initially, plastic engineers integrated sensors in moulds to acquire knowledge about their processes and to have better understanding of physical phenomenon. This article presents a numerical methodology to identify optimal combinations of sensors. The methodology is firstly based on polymer injection molding simulation to collect virtual sensor data. In a second step, virtual sensor data are analyzed by modern data-driven modeling techniques to identify optimal sensor configurations.

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