An Application of Computer Aided Engineering in Rubber Injection Mold With a Cold Runner System Design and Manufacturing

2007 ◽  
Author(s):  
Supasit Rodkwan ◽  
Rungtham Panyawipart ◽  
Chana Raksiri ◽  
Kunnayut Eiamsa-ard
Keyword(s):  
Injection Molding ◽  
Raw Material ◽  
Injection Molding Process ◽  
Molding Process ◽  
Actual System ◽  
Part Quality ◽  
Injection Process ◽  
Design And Manufacturing ◽  
Trial And Error Method ◽  
And Behavior

With a recent growth in the demand of the rubber products globally, the latest technology is adopted to improve the design and manufacturing of those rubber products in term of part quality and production lead time and cost. The cold runner system is one of the technologies which can assist in unfilling part problem and raw material saving. Nevertheless, with the lack of numerical tool with an ability to predict the behavior of rubber during the injection molding process, designers still need to use their experience and trial-and-error method to design the mold and the cold runner system. Therefore, in this research, the use of CAE and a cold runner system is applied to the design and manufacturing of rubber injection molding process with a gasket mold made of SBR as a case study. The empirical and simulated results agree well and the use of raw material in the actual system is decreased by 12% shot weight which can lead to the reduced cost of products. Finally, it can be seen that the use of CAE can assist the mold designers and manufacturers to get better understanding of flow pattern and behavior of rubber during the injection process so the better part quality can be obtained.

scholarly journals Effects of Injection Molding Process Conditions on Physical Properties of EPDM Using Design of Experiment Method

2018 ◽  
Vol 167 ◽  
pp. 02016 ◽  
Author(s):  
Young Shin Kim ◽  
Euy Sik Jeon ◽  
Eui Seob Hwang
Keyword(s):  
Injection Molding ◽  
Physical Properties ◽  
Raw Material ◽  
Injection Molding Process ◽  
Process Conditions ◽  
Process Variables ◽  
Molding Process ◽  
Test Pieces ◽  
Experiment Method ◽  
Major Factors

The process variables such as time and temperature during the EPDM-injection molding not only change the physical properties of the raw material but also affect the insertion and separations forces when a grommet product is molded and mounted on a car body. Using the design of experiments method, the major factors in the injection molding process were considered to analyze their effects on the physical properties of the obtained EPDM materials. Test pieces were prepared under different process conditions, tensile strength and elongation were measured, and their correlation was analyzed.

Numerical Investigation on the Effect of Injection Pressure on Melt Front Pressure and Velocity Drop

2015 ◽  
Vol 786 ◽  
pp. 210-214
Author(s):  
M.S. Rusdi ◽  
Mohd Zulkifly Abdullah ◽  
A.S. Mahmud ◽  
C.Y. Khor ◽  
M.S. Abdul Aziz ◽  
...  
Keyword(s):  
Injection Molding ◽  
Cfd Simulation ◽  
Fluid Dynamic ◽  
Injection Pressure ◽  
Simulation Software ◽  
Mold Cavity ◽  
Injection Molding Process ◽  
Flow Profile ◽  
Molding Process ◽  
Injection Process

Computational Fluid Dynamic (CFD) was used to simulate the injection molding process of a tray. The study focuses on pressure distribution and velocity drop during the injection process. CFD simulation software ANSYS FLUENT 14 was utilized in this study. The melt front pressure in the mold cavity shows that it was affected by the shape of mold cavity and filling stage. The melt front pressure will decrease as the flow move further than the sprue but it will increase rapidly when the mold was about to be fully filled. The slight pressure drop was detected when the molten flow meets the rib of the tray. The velocity of higher injection pressure was greater than the lower injection pressure but the velocity rapidly dropped when the melt front fully filled the cavity. The current predicted flow profile was validated by the experimental results, which demonstrates the excellent capability of the simulation tool in solving injection-molding problems.

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.

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.

scholarly journals Simple equipment for studying the injection molding process

2018 ◽  
Vol 178 ◽  
pp. 02001 ◽  
Author(s):  
Adelina Hriţuc
Keyword(s):  
Injection Molding ◽  
Injection Molding Process ◽  
Molding Process ◽  
Injection Equipment ◽  
Diagram Method ◽  
Constructive Solution ◽  
Injection Process ◽  
Plastic Parts ◽  
Experimental Researches

The injection molding process is largely applied to obtain plastic parts. The problem of finding a simple equipment able to allow the study of the injection process was addressed in the research presented in this paper. Aiming to solve the problem, the main requests valid for the proposed equipment were formulated. Considering some possible versions of the equipment subassemblies, the ideas diagram method and the method of imposed decision were applied to select the most convenient version of the injection equipment. As a result, a constructive solution for a simple injection molding equipment that could be used to develop some experimental researches was identified.

Improvement on the Technique for Production of Alkaline Battery Seal Ring

2012 ◽  
Vol 550-553 ◽  
pp. 464-467
Author(s):  
Jia Min Zhang ◽  
Yue Wen Li ◽  
Wen Qing Zhao
Keyword(s):  
Injection Molding ◽  
Processing Condition ◽  
Raw Material ◽  
Injection Molding Process ◽  
Seal Ring ◽  
Affecting Factors ◽  
Molding Process ◽  
Alkaline Batteries ◽  
Key Factor ◽  
Short Shot

Through studying technology of the seal ring production of alkaline storage battery, some products were often found to have defects, such as product short shot, yellow and transparence was not good. According to the to identify the causes of the defects, in order to find ways to solve these problems, production processes were reasonably optimized .Under the seal ring of the injection molding process, raw material preparation, injection molding and post-processing work pieces in three stages, combined with the affecting factors in producing the ring. From the key factor that choose and control of the processing condition of the molding material, molding equipment, injection molding process in the appropriate temperature, pressure, velocity and time conditions, to find performance parameters of producing high quality seal, giving countermeasures to defects emerged in the production of alkaline batteries seal ring.

Online pattern-based part quality monitoring of the injection molding process

1996 ◽  
Vol 36 (11) ◽  
pp. 1477-1488 ◽  
Author(s):  
Suzanne L. B. Woll ◽  
Douglas J. Cooper ◽  
Blair V. Souder
Keyword(s):  
Injection Molding ◽  
Quality Monitoring ◽  
Injection Molding Process ◽  
Molding Process ◽  
Part Quality

Influence of the Thermoplastic Type on the Thermal Evolution of a Piezoceramic Patch During the Manufacture of a Smart Thermoplastic Part by Injection Molding Process

2015 ◽  
Vol 137 (2) ◽  
Author(s):  
Louay Elsoufi ◽  
Khaled Khalil ◽  
Willy Charon ◽  
Remy Lachat
Keyword(s):  
Injection Molding ◽  
Comparative Study ◽  
Piezoelectric Properties ◽  
Thermal Evolution ◽  
Maximum Temperature ◽  
Injection Molding Process ◽  
Molding Process ◽  
Injection Process

The frame of the paper is the integration of PZT actuators and sensors within thermoplastic mechanical structures. The objective of the work reported here was to select the appropriate thermoplastic materials for the smart thermoplastic manufacturing. In order to reach this objective, a comparative study was realized between different thermoplastic materials taking into consideration the PZT patch maximum temperature, the overheat time of the PZT patch during injection process, and the PZT loss in piezoelectric properties due to its thermal fragility.

Study on Technology of Filter Made by Engineering Grade Thermoplastic Polyurethane

2011 ◽  
Vol 217-218 ◽  
pp. 746-751
Author(s):  
Jia Min Zhang
Keyword(s):  
Injection Molding ◽  
Raw Materials ◽  
Thermoplastic Polyurethane ◽  
Decomposition Temperature ◽  
Raw Material ◽  
Injection Molding Process ◽  
Polyurethane Elastomer ◽  
Molding Process ◽  
Thermoplastic Polyurethane Elastomer ◽  
Filter Housing

This paper introduced the different classifications and advantages of the project level thermoplastic polyurethane elastomer ,and according to the injection molding process of raw materials Isoplast 302EZ and thermoplastic polyurethane elastomer, from raw material preparation, injection machine selection, tooling selection, molding conditions, and introduced TPU injection molding process .The filter housing of TPU were briefly discussed from the design goals, technical characteristics, performance analysis. Combination of typical products, we studied the technology of the production of the thermoplastic polyurethane flexible filter housing. The results showed that the material should be pre-dried in a vacuum, and the time, temperature and pressure should be controlled properly. It should be pay attention that the specification of the waste and the raw materials should be the same, when recycling and on the other hand, the quality of the productions should be improved and no pollution should be ensure during the process; to avoid the decomposition temperature and the products aging, we should empty the material or stop the machine during it doesn’t work.

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