Influence of Processing Conditions on the Morphological Structure and Ductility of Water-Foamed Injection Molded PP/LDPE Blended Parts

2017 ◽  
Vol 36 (2) ◽  
pp. 51-74 ◽  
Author(s):  
Ying-Guo Zhou ◽  
Bei Su ◽  
Lih-Sheng Turng
Keyword(s):  
Injection Molding ◽  
Morphological Structure ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Processing Conditions ◽  
Injection Time ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Packing Time ◽  
Number Of Cells

Water-foamed injection molding (WFIM) uses conventional injection molding (CIM) with water as a physical foaming agent. Compared to CIM, WFIM is a much more complicated process. As such, it is critical to determine the processing conditions for fabricating quality parts using WFIM. We used the design of experiment (DOE) method based on the Taguchi method to determine the influence of the processing conditions on the morphological structure and ductility of PP/LDPE WFIM parts, which were investigated by tensile testing and scanning electron microscopy (SEM). Our research suggests that fabricating PP/LDPE super-ductile parts using WFIM is indeed feasible. Our research also indicates that there is a close relationship between the ductility and the foamed structures, both of which are deeply influenced by the processing conditions. The analysis of variance results shows further that the water content had the greatest influence on the ductility, followed by the melt temperature, packing time, packing pressure, and PP/LDPE ratio. However, the ductility was only slightly influenced by the mold temperature, injection pressure, and injection time in WFIM. As to the number of cells, the order of influence was melt temperature, water content, packing time, packing pressure, mold temperature, injection pressure, PP/LDPE ratio, and injection time, in that order. In addition, applying DOE is a quite effective method for deducing the optimal set of effective factors in WFIM to produce super-ductile parts with a maximum number of cells. To our knowledge, this is the first time that the relationship among the processing conditions, ductility, and foamed structure of PP/LDPE WFIM super-ductile parts has been investigated and reported.

scholarly journals Optimization of Process Parameters for Vertical-Faced Polypropylene Bottle Injection Molding

2018 ◽  
Vol 2018 ◽  
pp. 1-9 ◽  
Author(s):  
Youmin Wang ◽  
Zhichao Yan ◽  
Xuejun Shan
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Dwell Time ◽  
Optimization Problem ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Orthogonal Test ◽  
Injection Molding Process ◽  
Injection Time ◽  
Melt Temperature

In order to obtain the optimal combination of process parameters for vertical-faced polypropylene bottle injection molding, with UG, the model of the bottle was drawn, and then, one module and sixteen-cavity injection molding system was established and analyzed using Moldflow. For filling and maintaining pressure during the process of infusion bottle injection molding, the orthogonal test table L25 (56) using CAE was designed for injection molding of the bottle, with six parameters such as melt temperature, mold temperature, injection pressure, injection time, dwell pressure, and dwell time as orthogonal test factors. By finding the best combination of process parameters, the orthogonal experiment was completed, the results were analyzed by range analysis, and the order of influence of each process parameter on each direction of optimization was obtained. The prediction dates of the infusion bottle were gained under various parameters, a comprehensive quality evaluation index of the bottle was formulated, and the multiobjective optimization problem of injection molding process was transformed into a single-objective optimization problem by the integrated weighted score method. The bottle parameters were optimized by analyzing the range date of the weighted scoring method, and the best parameter combination such as melt temperature 200°C, mold temperature 80°C, injection pressure 40 MPa, injection time 2.1 S, dwell pressure 40 MPa, and dwell time 40 S was gained.

The simulation of the warpage rule of the thin-walled part of polypropylene composite based on the coupling effect of mold deformation and injection molding process

2018 ◽  
Vol 25 (3) ◽  
pp. 593-601 ◽  
Author(s):  
Jixiang Zhang ◽  
Xiaoyi Yin ◽  
Fengzhi Liu ◽  
Pan Yang
Keyword(s):  
Injection Molding ◽  
Coupling Effect ◽  
Mold Temperature ◽  
Injection Molding Process ◽  
Plastic Part ◽  
Molding Process ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Thin Walled ◽  
Packing Time

Abstract Aiming at the problem that a thin-walled plastic part easily produces warpage, an orthogonal experimental method was used for multiparameter coupling analysis, with mold structure parameters and injection molding process parameters considered synthetically. The plastic part deformation under different experiment schemes was comparatively studied, and the key factors affecting the plastic part warpage were analyzed. Then the injection molding process was optimized. The results showed that the important order of the influence factors for the plastic part warpage was packing pressure, packing time, cooling plan, mold temperature, and melt temperature. Among them, packing pressure was the most significant factor. The optimal injection molding process schemes reducing the plastic part warpage were melt temperature (260°C), mold temperature (60°C), packing pressure (150 MPa), packing time (2 s), and cooling plan 3. In this situation, the forming plate flatness was better.

Warpage Measurement of a Micro Electrical Fan on Micro-Injection Molding

2012 ◽  
Vol 184-185 ◽  
pp. 1651-1654
Author(s):  
Jeou Long Lee ◽  
Y. Lin ◽  
Y.K. Shen
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Acrylonitrile Butadiene Styrene ◽  
Mold Temperature ◽  
Micro Injection Molding ◽  
Optimum Result ◽  
Suitable Material ◽  
Packing Pressure ◽  
Injection Molded ◽  
Packing Time

This study characterizes warpage of a micro-injection molded micro electrical fan using the Michelson interference method. This study conducts experiments to analyze different polymers-polypropylene (PP), polyamide (PA), acrylonitrile-butadiene styrene (ABS), ABS+ polycarbonate (PC), and polyoxymethylene (POM)-process parameters, such as mold temperature, injection temperature, injection pressure, injection time, packing time, and packing pressure, for a micro electrical fan. To obtain the optimum result (minimum warpage), this study assesses the effect (warpage) of each material on micro-injection molding. PA plastic is the very suitable material for micro electrical fan with Michelson interference analysis on micro-injection molding.

Reduction in Defect Rate by Taguchi Method in Plastic Injection Molded Components

2012 ◽  
Vol 488-489 ◽  
pp. 269-273 ◽  
Author(s):  
G.S. Dangayach ◽  
Deepak Kumar
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Processing Parameters ◽  
Process Conditions ◽  
Melt Temperature ◽  
Defect Rate ◽  
Packing Pressure ◽  
Optimal Injection ◽  
Packing Time ◽  
Plastic Injection

In the present era, competition gets tougher; there is more pressure on manufacturing sectors to improve quality and customer satisfaction while decreasing cost and increasing productivity. These can be achieved by using modern quality management systems and process improvement techniques to reduce the process variability and driven waste within manufacturing process using effective application of statistical tools. Taguchi technique is well known technique to solve industrial problems. This technique is fast and can pinpoint the chief causes and variations. Plastic injection molding is suitable for mass production articles since complex geometries can be obtained in a single production step. The difficulty in setting optimal process conditions may cause defects in parts, such as shrinkage and warpage. In this paper, optimal injection molding conditions for minimum shrinkage were determined by the Taguchi design of experiment (DOE) approach. Polypropylene (PP) was injected in circular shaped specimens under various processing parameters: melt temperature, injection pressure, packing pressure and packing time. S/N ratios were utilized for determining the optimal set of parameters. According to the results, 2400 C of melt temperature, 75 MPa of injection pressure, 50 MPa of packing pressure and 15 sec. of packing time gave minimum shrinkage of 0.951% for PP. Statically the most significant parameter was melt temperature for the PP. Injection pressure had the least effect on the shrinkage. The defect rate was reduced from 14% to 3%.

Investigation of Mold Temperature Affecting on Shrinkage of Rapid Heat Cycle Molding Plastic Part

2011 ◽  
Vol 189-193 ◽  
pp. 2477-2481 ◽  
Author(s):  
Dong Lei Liu ◽  
Chang Yu Shen ◽  
Chun Tai Liu ◽  
Yong Xin ◽  
Ling Sun
Keyword(s):  
Deformation Temperature ◽  
Thermal Deformation ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Cooling Time ◽  
Melt Temperature ◽  
Heat Cycle ◽  
Temperature Conditions ◽  
Packing Pressure ◽  
Packing Time

In order to further investigate the influence of mold temperature in rapid heat cycle molding on shrinkage of plastic past, a self-developed vehicle-used blue-tooth front shell high-gloss mold and an auxiliary device for controlling the mold temperature were employed in experiments. And the effect of the other parameters on shrinkage of part with fixed or changed mold temperature conditions was also studied. Results reveal that the shrinkage of RHCM part is reduced obviously compared with a conventional one, decreasing as quasi-linear with mold temperature increased gradually. At same mold temperature conditions, packing pressure, followed by packing time, is the most significant parameter on shrinkage of part, while cooling time has almost no impact on it. Melt temperature and injection pressure effecting on shrinkage of part exists a critical value, near the thermal deformation temperature of plastic. When mold temperature is set below this temperature, injection pressure has more significant than melt temperature, but it is the opposite. With being elevated gradually of mold temperature, shrinkage of part shows a slight decrease trend under same melt temperature and injecting pressure. While it fluctuates as a “V” shape with a narrow range under same packing pressure, packing time and cooling time presumed conditions, and reaches the minimum near the thermal deformation temperature of plastic.

The Application of Moldflow in Injection Molding of the Helmet

2015 ◽  
Vol 1096 ◽  
pp. 366-370
Author(s):  
Yong Cheng Huang ◽  
Hong Bin Liu ◽  
Hai Tao Wu
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Hold Time ◽  
Mold Temperature ◽  
Appropriate Technology ◽  
Injection Molding Process ◽  
Injection Time ◽  
Molding Process ◽  
Melt Temperature ◽  
Packing Pressure

Considering the importance of the reasonable injection molding technology.Based on the application of moldflow in injection molding of the helmet .By adjusting the mold temperature, melt temperature, injection time, packing pressure, hold time and so on the injection molding process parameters to develop appropriate technology methods to get the best injection molding parameters.

Influence of Process Parameters on Plastic Injection Molding of Automobile Interior Trim

2011 ◽  
Vol 189-193 ◽  
pp. 1675-1680
Author(s):  
Qing Qing Liu ◽  
Lin Hua ◽  
Wei Guo
Keyword(s):  
Mold Temperature ◽  
Process Conditions ◽  
Injection Time ◽  
Molding Process ◽  
Melt Temperature ◽  
Influence Of Process Parameters ◽  
Packing Pressure ◽  
Optimal Setting ◽  
Injection Molded ◽  
Packing Time

The influence of process conditions on the formability of injection-molded PX0034 (9% talc-filled PP) automobile B column mounting trim applied as a model has been studied in current work. This study has been focused on the interactive influence of melt temperature and mold temperature, the interactive influences of injection time and packing time and the influences of packing pressure. Weighting the effect of optimization is by formability including the values of pressure at V/P switchover, volumetric shrinkage differential at ejection, and maximum warpage. Aforementioned values were obtained by numerical simulation of the whole molding process using commercial dedicated code Moldflow. Results indicate that the combination of mold temperature at 25 °C, melt temperature at 220 °C, injection time at 2.2 s, packing time at 16 s and packing pressure at 90% of the filling pressure is the optimal setting for formability of this trim. The simulation results obtained under the optimized parameters are that the pressure at V/P switchover is 27.29 Mpa, the shrinkage differential at ejection is 6.55 %, and maximum warpage is 3.072 mm. Good correlation is highlighted between the experiments and the simulations by comparing effects of the global optimization in formability, which verifies the validity of the optimal combination.

Optimization of Process Parameters for Injection Molding Based on Taguchi Technique

2012 ◽  
Vol 538-541 ◽  
pp. 1170-1174
Author(s):  
Shi Jun Fu
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Orthogonal Design ◽  
Mold Temperature ◽  
Optimum Process ◽  
Process Conditions ◽  
Injection Time ◽  
Melt Temperature ◽  
Injection Process ◽  
Packing Pressure

In this paper, Taguchi and CAE technique are combined to study the influence of process conditions on the warpage of injection molding parts through twice orthogonal design experiments, and the injection process parameters are optimized according to the warpage. For the parameters selected, melt temperature and packing pressure have effects on the warpage of injection molding parts are highly significant, injection time is significant, other parameters have little effects. Within the range of experiments, the warpage decreased with the rise of the melt temperature and packing pressure. At last, the optimum process parameters of injection are that the mold temperature is 60°C, packing time is 10s, melt temperature is240°C, packing pressure is 115MPa and injection time is 0.4s.

Study on Optical Properties of Microstructure of Lightguiding Plate for Micro Injection Molding and Micro Injection-Compression Molding

2006 ◽  
Vol 505-507 ◽  
pp. 229-234 ◽  
Author(s):  
Yung Kang Shen ◽  
H.J. Chang ◽  
C.T. Lin
Keyword(s):  
Optical Properties ◽  
Injection Molding ◽  
Digital Camera ◽  
Mold Temperature ◽  
Compression Molding ◽  
Micro Injection Molding ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Injection Compression Molding ◽  
Better Than

The purpose of this paper presents the optical properties of microstructure of lightguiding plate for micro injection molding (MIM) and micro injection-compression molding (MICM). The lightguiding plate is applied on LCD of two inch of digital camera. Its radius of microstructure is from 100μm to 300μm by linearity expansion. The material of lightguiding plate uses the PMMA plastic. This paper uses the luminance distribution to make a comparison between MIM and MICM for the optical properties of lightguiding plate. The important parameters of process for optical properties are the mold temperature, melt temperature and packing pressure in micro injection molding. The important parameters of process for optical properties are the compression distance, mold temperature and compression speed in micro injection-compression molding. The process of micro injection-compression molding is better than micro injection molding for optical properties.

Using Taguchi Method to Optimize Molding Process Parameters of Chair Base

2012 ◽  
Vol 271-272 ◽  
pp. 1190-1194
Author(s):  
Hsueh Lin Wu ◽  
Ya Hui Wang
Keyword(s):  
Taguchi Method ◽  
Process Parameters ◽  
Simulation Analysis ◽  
Mold Temperature ◽  
Cooling Time ◽  
Injection Time ◽  
Molding Process ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Moldflow Simulation

In this study, volumetric shrinkage at ejection of the chair base in the injection process, application of the 3D CAD software pro/e to design the shape of the product, and then combines moldflow simulation analysis and Taguchi method with L25 Orthogonal Array to determine the optimal injection molding parameters combination. In the Taguchi L25 experimental design, the six controlling factors used are melt temperature, mold temperature, injection time, packing time, packing pressure and cooling time, the result of experiment revealed that the optimum combination of parameters was the A2 (melting temperature 265°C), B3 (mold temperature 40°C), C2 (injection time 1.7sec), D4 (packing pressure 95%), E5 (packing time20sec), F5 (cooling time 20sec). The results show that the combination of Taguchi method and Moldflow can not only improve the molding process parameters effectively, but also optimize the quality of the products.

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