Design and Simulation of Injection Mold for the Shell of Switch

2010 ◽  
Author(s):  
Chuanyang Wang ◽  
Shuai Hu ◽  
Qiubo Qian ◽  
Xuanxuan Shen
Keyword(s):  
Simulation Analysis ◽  
Cooling System ◽  
Injection Pressure ◽  
3D Models ◽  
Injection Molding Process ◽  
Injection Mold ◽  
Molding Process ◽  
Development Cycle ◽  
Successful Probability ◽  
Filling Time

The 3D models of gating system, ejection mechanisms and cooling system of the swtich shell for injection mold are designed by using Pro/ENGINEER software. MOLDFLOW is utilized for CAE analysis. Three schemes are obtained by changing the gate location during the injection molding process. After comparing the volume shrinkage during injection, shrink marks index, filling time and the injection pressure, the best scheme is obtained. According to the optimal scheme, the injection mold is designed. The results showed that simulation analysis method can not only improve the successful probability of mold trial, but also shorten the production development cycle of developing product.

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.

Analysis and Optimization on Injection Molding Process of Double Helical Gear Based on Moldflow

2015 ◽  
Vol 1096 ◽  
pp. 376-380
Author(s):  
Chang Yong Jiang ◽  
Hong Lei Shen
Keyword(s):  
Numerical Simulation ◽  
Injection Molding ◽  
Simulation Analysis ◽  
Cooling System ◽  
Process Analysis ◽  
Electrical Equipment ◽  
Helical Gear ◽  
Injection Molding Process ◽  
Feed System ◽  
Molding Process

In view of a kind of a plastic double helical gear in some office electrical equipment, injection molding process analysis was done, by means of Moldflow,to create feed system and cooling system for Moldflow analysis of helical gear, to make numerical simulation analysis, verification and optimization of injection molding process, to obtain some major parameters such as temperature, pressure and time to meet molding requirements of injection molding process of double helical gear.

Performance Predictor for Thin-Wall Plastic Parts Produced by Injection Molding

2000 ◽  
Author(s):  
H. P. Wang ◽  
Sreeganesh Ramaswamy ◽  
Irene Dris ◽  
Erin M. Perry ◽  
Dominic Gao
Keyword(s):  
Injection Molding ◽  
Process Development ◽  
Injection Molding Process ◽  
Thin Wall ◽  
Molding Process ◽  
Melt Temperature ◽  
Shear Degradation ◽  
Development Cycle ◽  
Filling Time ◽  
Plastic Parts

Abstract The objective of this work was to develop a numerical simulation tool that is able to predict the processing window for thin-wall plastic parts made by the injection molding process. This performance predictor links the processing conditions (filling time, resin inlet melt temperature, and so on) to the mechanical properties and failure mechanisms of the part, using empirical data developed for the thermal and shear degradation behavior of the resin. Usage of such a performance predictor will help to expedite the long process development cycle time and to reduce the potentially expensive tooling costs associated with the thin-wall segment of the plastics business.

Design of Conformal Porous Structures for the Cooling System of an Injection Mold Fabricated by Additive Manufacturing Process

2019 ◽  
Vol 141 (10) ◽  
Author(s):  
Yunlong Tang ◽  
Zhengyang Gao ◽  
Yaoyao Fiona Zhao
Keyword(s):  
Cooling System ◽  
Design Method ◽  
Critical Role ◽  
Free Form ◽  
Injection Molding Process ◽  
Injection Mold ◽  
Mold Surface ◽  
Porous Structures ◽  
Molding Process ◽  
Free Form Surfaces

The cooling system of plastic injection mold plays a critical role during the injection molding process. It not only affects part quality but also its cycle time. Traditionally, due to the limitations of conventional drilling methods, the cooling system of the injection mold usually consists of simple paralleled straight channels. It seriously limits the mobility of cooling fluid, which leads to the low cooling efficiency for the parts with complex free-form surfaces. In this research, an innovative design method for the cooling system of an injection mold is proposed by using conformal porous structures. The size and shape of each cell in the conformal porous structure are varied according to the shape of an injection molded part. Design cases are provided at the end of this paper to further illustrate the efficiency of the proposed method. Compared with those existing design methods for the uniform porous structures, the proposed method can further reduce the nonuniformity of the mold surface temperature distribution and decrease the pressure drop of the cooling system.

scholarly journals Study on Stability of a Novel Binder System Based on Palm Stearin in Metal Injection Moulding Application

2007 ◽  
Vol 4 (2) ◽  
pp. 1
Author(s):  
Muhammad Hussain Ismail ◽  
Norhamidi Muhamad ◽  
Aidah Jumahat ◽  
Istikamah Subuki ◽  
Mohd Afian Omar
Keyword(s):  
Injection Molding ◽  
Flow Characteristics ◽  
Injection Pressure ◽  
Palm Stearin ◽  
Steel Powder ◽  
Metal Injection Molding ◽  
Injection Molding Process ◽  
Binder System ◽  
Molding Process ◽  
Flow Activation Energy

Metal Injection Molding (MIM) is a wellestablished technology for manufacturing a variety of complex and small precision parts. In this paper, fundamental rheological characteristics of MIM feedstock using palm stearin are theoretically analyzed and presented. The feedstock consisted of gas atomized 316L stainless steel powder at three different particle size distributions and the binder system of palm stearin (PS) and polyethylene (PE). The powder loading used was 60vol % for all samples (monosize 16 µm, monosize 45 µm, and bimodal 16 µm + 45 µm) and the binder system of 40vol %(PS/PE = 40/60). The viscosity of MIM feedstock at different temperatures and shear rates was measured and evaluated. Results showed that, the feedstock containing palm stearin exhibited suitable rheological properties by increasing the fluidity of feedstock in MIM process. The rheological results also showed a pseudoplastic flow characteristics, which poses higher value of shear sensitivity (n) and lower value of flow activation energy (E), that are both favourable for injection molding process. The green parts were successfully injected and exhibited adequate strength for handling by optimizing the injection pressure and temperature.

The Application of Moldflow in Injection Mold Design of Mobile Phone Cover

2011 ◽  
Vol 228-229 ◽  
pp. 542-547
Author(s):  
Wen Jian Zhang ◽  
Qi Zhang
Keyword(s):  
Mobile Phone ◽  
Simulation Analysis ◽  
Three Dimensional ◽  
Element Model ◽  
Mold Design ◽  
Injection Mold ◽  
Three Dimensional Model ◽  
Molding Process ◽  
Injection Mold Design ◽  
Cae Technology

Based the CAE technology, the paper introduced the application of Moldflow Insight in injection mold design of mobile phone cover. First, we must preprocess the finite element model, including importing three-dimensional model, meshing, and process setting. And then, we can use preliminary simulation analysis to determine the number and location of the gate. Finally to filling, cooling, packing and warpage analysis for part which can help us to find the causes from warpage generated. By optimizing the molding process parameters, adjusting the dwell pressure and the dwell time we can get less warpage, which can meet the precision demand of parts, consequently, the result can provide gist for the mold designers to design and for the injection molding technologist to process parameter adjustment.

Moldflow-Based Optimization Design of Gating System in Injection Mold for Automobile Bumper

2014 ◽  
Vol 1061-1062 ◽  
pp. 465-470 ◽  
Author(s):  
Bin Xu ◽  
Zhi Yuan Rui
Keyword(s):  
Design Optimization ◽  
Optimization Design ◽  
Weld Line ◽  
Injection Pressure ◽  
Optimization Method ◽  
Optimum Number ◽  
Injection Mold ◽  
Gating System ◽  
Filling Process ◽  
Filling Time

The gating system of an injection mold for car bumper was studied. A design optimization scheme is proposed to optimize both the number and locations of the gates by analyzing the filling process, in order to reduce the part war page and weld line, numerical simulation of injection mold filling process is combined with the design optimization method to find the optimum number of gates and their locations to achieve balanced f low and less weld lines while satisfying the limit of injection pressure. Moldflow software was applied to make analysis and comparison of various gating system in terms of their filling time, injection pressure and clamp force, weld line and distribution of air traps, and an optimized gating system was obtained. The result shows that this method can effectively reduce costs, shorten development cycle and improve the efficiency of molding design.

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.

The Effect of Injection Molding Process Parameters on the Buckling Properties of PBT/Short Glass Fiber Composites

2011 ◽  
Vol 284-286 ◽  
pp. 550-556 ◽  
Author(s):  
Ming Hsiung Ho ◽  
Pin Ning Wang ◽  
Chin Ping Fung
Keyword(s):  
Injection Molding ◽  
Glass Fiber ◽  
Process Parameters ◽  
Injection Molding Process ◽  
Skin Area ◽  
Molding Process ◽  
Melt Temperature ◽  
Short Glass Fiber ◽  
Filling Time ◽  
Short Glass

This study investigates the effect of various injection molding process parameters and fiber amount on buckling properties of Polybutylene Terephthalate (PBT)/short glass fiber composite. The buckling specimens were prepared under injection molding process. These forming parameters about filling time, melt temperature and mold temperature that govern injection molding process are discussed. The buckling properties of neat PBT, 15 wt%, and 30 wt% are obtained using two ends fixed fixture and computerized closed-loop server-hydraulic material testing system. The fracture surfaces are observed by scanning electron microscopy (SEM). The global buckling forces are raised when increased the fiber weight percentage of PBT. Also, the fracture mechanisms in PBT and short glass fiber matrix are fiber pullout in skin area and fiber broken at core area. It is found that the addition of short glass fiber can significantly strengthen neat PBT.

Comprehensive Online Control Strategies for Plastic Injection Molding Process

2014 ◽  
Vol 136 (4) ◽  
Author(s):  
Jaho Seo ◽  
Amir Khajepour ◽  
Jan P. Huissoon
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Thermal Control ◽  
Plastic Injection Molding ◽  
Injection Molding Process ◽  
Molding Process ◽  
Element Analysis ◽  
Thermal Dynamics ◽  
Uncertain Dynamics ◽  
Plastic Injection

This study proposes an effective thermal control for plastic injection molding (polymer: Santoprene 8211-45 with density of 790 kg/m3, injection pressure: 1400 psi (9,652,660 Pa)) in a laminated die. For this purpose, a comprehensive control strategy is provided to cover various themes. First, a new method for determining the optimal sensor locations as a prerequisite step for modeling and controller design is introduced. Second, system identification through offline and online training with finite element analysis and neural network techniques are used to develop an accurate model by incorporating uncertain dynamics of the laminated die. Third, an additive feedforward control by adding direct adaptive inverse control to self-adaptive PID is developed for temperature control of cavity wall (cavity size: 52.9 × 32.07 × 16.03 mm). A verification of designed controller's performance demonstrates that the proposed strategy provides accurate online temperature tracking and faster response under thermal dynamics with various cycle-times in the injection mold process.

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