scholarly journals Analysis of Reactive Injection Compression Molding by Numerical Simulations and Experiments

2020 ◽  
Vol 2020 ◽  
pp. 1-8
Author(s):  
Giorgio Ramorino ◽  
Silvia Agnelli ◽  
Matteo Guindani
Keyword(s):  
Injection Molding ◽  
Experimental Tests ◽  
Curing Kinetics ◽  
Compression Molding ◽  
Computational Time ◽  
Injection Molding Process ◽  
Molding Process ◽  
Viscosity Models ◽  
Element Simulation ◽  
Injection Compression Molding

Injection compression molding is an injection molding process with the addition of a compression stage after the injection. This process is useful for the injection molding of precision parts. A stable and controlled manufacturing process is needed to guarantee reliability of complex products, and usually process optimization is achieved by experimental and time consuming approaches. However, for being competitive a minimal market time is a very important requirement and computer simulations can help to optimize the process at the only expense of computational time. This paper reports and discusses for the first time the results of a 3D finite element simulation of reactive injection compression molding (RICM) by commercial software for the production of rubber diaphragms. In particular, the stages of mold filling dynamics and material curing are analyzed and the results verified with experimental tests. To get an accurate representation of the process, the rheological behavior, thermal properties, and kinetic behavior during curing of the real rubber compound were described by mathematical models. A differential scanning calorimeter (DSC) and a capillary rheometer are employed to characterize the rubber material in order to achieve an appropriate curing reaction and viscosity models, respectively. The computations are found to be in good agreement with the experimental results, indicating that reliable information on material viscosity and curing kinetics can play a key role in making well-founded predictions and avoiding trial and error methods.

Numerical Simulation and Process Optimization of a 3D Thin-Walled Polymeric Part Using Injection Compression Molding

2021 ◽  
Vol 36 (4) ◽  
pp. 459-467
Author(s):  
D. Sönmez ◽  
A. A. Eker
Keyword(s):  
Numerical Simulation ◽  
Injection Molding ◽  
Process Parameters ◽  
Compression Molding ◽  
Injection Molding Process ◽  
Mold Surface ◽  
Clamping Force ◽  
Molding Process ◽  
Thin Walled ◽  
Injection Compression Molding

Abstract Injection compression molding (ICM) is a hybrid injection molding process for manufacturing polymer products with high precision and surface accuracy. In this study, a 3D flow simulation was employed for ICM and injection molding (IM) processes. Initially, the process parameters of IM and ICM were discussed based on the numerical simulations. The IM and ICM processes were compared via numerical simulation by using CAE tools of Moldflow software. The effect of process parameters of mold surface temperature, melting temperature, compression force and injection time on clamping force and pressure at the injection location of molded 3D BJ998MO Polypropylene (MFI 100) part was investigated by Taguchi analysis. In conclusion, it was found that the ICM has a relatively lower filling pressure than ICM, which results in reduced clamping force for producing a 3D thin-walled polymeric part.

Viscosity Measurement in Injection Molding Using a Multivariate Sensor

2012 ◽  
Author(s):  
N. Asadizanjani ◽  
R. X. Gao ◽  
Z. Fan ◽  
D. O. Kazmer
Keyword(s):  
Injection Molding ◽  
Polymer Melt ◽  
Experimental Tests ◽  
Injection Molding Process ◽  
Online Measurement ◽  
Cavity Pressure ◽  
Molding Process ◽  
Ir Detector ◽  
Melt Temperature

Online measurement of polymer melt properties during an injection molding process is a key to provide a high quality plastic product. In-situ cavity pressure and temperature sensors are used to observe the polymer states in the mold cavity during an injecting molding process. A new multivariate sensor is introduced to measure pressure, temperature, velocity, and viscosity of polymer melt as the key parameters of the melt to improve the controlling process. This paper presents the viscosity calculating method based on melt velocity and the slope of melt pressure. The velocity is inferred using the melt temperature ramping rate; the new multivariate sensor detects melt temperature through the installed IR detector in the sensor, and the pressure is measured via the mounted piezoelectric rings. Injecting molding process of polymer melt is simulated under a range of melt velocity and temperature and the related viscosity values are inferred from simulation results and also from a set of experimental tests for a real injection molding process. Results are well matched with the expected rheological behavior of polymer.

Shrinkage Analysis of Injection-Compression Molding for Transparent Plastic Panel by 3D Simulation

2010 ◽  
Vol 44-47 ◽  
pp. 1029-1033 ◽  
Author(s):  
Yi Chao Li ◽  
Yi Sheng Zhang ◽  
De Qun Li
Keyword(s):  
Injection Molding ◽  
High Efficiency ◽  
Flow Line ◽  
Compression Molding ◽  
Shrinkage Rate ◽  
Injection Molding Process ◽  
Transparent Plastic ◽  
Plastic Panel ◽  
Temperature And Pressure ◽  
Injection Compression Molding

Injection molding which is adopted to fabricate transparent plastic panel has merits such as high efficiency and low cost, and is being used widely. However, at the end of injection molding process, product may be affected by uneven shrinkage and as a result, bring defects such as warp to the final part. This can greatly damage its mechanical and optical quality. Injection-compression molding(ICM) can significantly minimize these defects. In the present paper, 3D model and coupled calculation method of flow, temperature and pressure are used to simulate the process of ICM for an irregular geometric transparent plastic panel. This method can not only reconstruct 3D flow front, temperature and pressure field of ICM process in a much more realistic way, but also more fully demonstrate the length of 3D fiber flow line(FFL) and the variation of shrinkage rate and its homogenize process. Due to such improved algorithm, great improvement has been made to accurately calculate the shrinkage rate in depth of the panel and predict its warp data, in comparison to the traditional temperature-volume contraction index method, which has important practical value to guide and design the technological process of ICM.

RHEOLOGICAL BEHAVIOR OF POWDER-POLYMER MIXTURES AND MODEL DESCRIPTION OF FEEDSTOCK VISCOSITY FOR NUMERICAL SIMULATION OF INJECTION MOLDING PROCESS

2021 ◽  
pp. 32-42
Author(s):  
A.A. Kutsbakh ◽  
◽  
A.N. Muranov ◽  
B.I. Semenov ◽  
A.B. Semenov ◽  
...  
Keyword(s):  
Injection Molding ◽  
Rheological Behavior ◽  
Polymer Composition ◽  
Powder Injection ◽  
Model Description ◽  
Injection Molding Process ◽  
Polymer Mixtures ◽  
Molding Process ◽  
Viscosity Models ◽  
Empirical Coefficients

The rheological behavior of the powder-polymer composition prepared for the application in the powder injection molding (PIM) technology has been studied. A review of models used to describe the rheological behavior of powder slips is presented. A viscosity study of MIM-4140 feedstock with a wax-polyolefin binder was carried out on a capillary rheometer with different capillary diameters. Empirical coefficients of viscosity models were determined. Verification of calculated viscosity values and experimental data for the studied feedstock is presented.

Filling Behavior of Polymer Material into Sub-^|^mu;m Structure in Injection Molding Process

2013 ◽  
Vol 133 (4) ◽  
pp. 105-111
Author(s):  
Chisato Yoshimura ◽  
Hiroyuki Hosokawa ◽  
Koji Shimojima ◽  
Fumihiro Itoigawa
Keyword(s):  
Injection Molding ◽  
Polymer Material ◽  
Injection Molding Process ◽  
Molding Process
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