scholarly journals Simplified optimal modeling of resin injection molding process

e-Polymers ◽  
2019 ◽  
Vol 19 (1) ◽  
pp. 369-376 ◽  
Author(s):  
Małgorzata Chwał ◽  
Aleksander Muc
Keyword(s):  
Theoretical Background ◽  
Injection Molding Process ◽  
Optimization Approach ◽  
Heating Regime ◽  
Molding Process ◽  
Design Variables ◽  
Resin Injection ◽  
Full Analysis ◽  
Simplified Procedure ◽  
Optimal Modeling

AbstractA simplified procedure has been developed to optimize the molding processes of thermosetting resins. The proposed methodology involves the classical finite element commercial package (NISA II v. 17). Here, the theoretical background and numerical implementation of the procedure are described. Various design variables that can describe the RIM are discussed. The solved example represents the influence of the heating regime on the curing process. The results are compared with the results obtained with the use of full analysis conducted with the aid of the finite volume analysis (filling and curing stages). They demonstrate the evident advantages of using the simplified optimization approach.

Runner Optimization for In-Mold Assembly of Multi-Material Compliant Mechanisms

2011 ◽  
Author(s):  
Wojciech Bejgerowski ◽  
Satyandra K. Gupta
Keyword(s):  
Optimization Problem ◽  
Compliant Mechanisms ◽  
Compliant Mechanism ◽  
Polymer Melt ◽  
Injection Molding Process ◽  
Optimization Approach ◽  
Assembly Process ◽  
Molding Process ◽  
Design Variables

The runner system in injection molding process is used to supply the polymer melt from injection nozzle to the gates of final part cavities. Realizing complex multi-material mechanisms by in-mold assembly process requires special runner layout design considerations due to the existence of the first stage components. This paper presents the development of an optimization approach for runner systems in the in-mold assembly of multi-material compliant mechanisms. First, the issues specific to the in-mold assembly process are identified and analyzed. Second, the general optimization problem is formulated by identification of all parameters, design variables, objective functions and constraints. Third, the implementation of the optimization problem in Matlab® environment is described based on a case study of a runner system for an in-mold assembly of a MAV drive mechanism. This multi-material compliant mechanism consists of seven rigid links interconnected by six compliant hinges. Finally, several optimization approaches are analyzed to study their performance in solving the formulated problem. The most appropriate optimization approach is selected. The case study showed the applicability of the developed optimization approach to runner systems for complex in-mold assembled multi-material mechanism designs.

scholarly journals Sensitivity Analysis of Conformal CCs for Injection Molds: 3D Transient Heat Transfer Analysis

2021 ◽  
Author(s):  
Hugo Miguel Silva ◽  
João Tiago Noversa ◽  
Leandro Fernandes ◽  
Hugo Luís Rodrigues ◽  
António José Pontes
Keyword(s):  
Sensitivity Analysis ◽  
Thermal Stresses ◽  
Cost Effective ◽  
Heat Transfer Analysis ◽  
Injection Molding Process ◽  
Optimization Approach ◽  
Molding Process ◽  
Ejection Time ◽  
Cooling Channels ◽  
Design Variables

Abstract Fabricating conformal cooling channels (CCCs) has become easier and more cost-effective because to recent advances in additive manufacturing. CCCs provide better cooling performance in the injection molding process than regular (straight drilled) channels. The main reason for this is that CCCs can follow the molded geometry's paths, but regular machining methods cannot. Thermal stresses and warpage can be reduced by using CCCs, which also improve cycle time and provide a more uniform temperature distribution. Traditional channels, on the other hand, have a more involved design technique than CCC. Computer-aided engineering (CAE) simulations are essential for establishing an effective and cost-effective design. The sensitivity analysis of design variables is the emphasis of this research, with the goal of establishing a design optimization approach in the future. The ultimate goal is to optimize the location of Cooling Channels (CCs) in order to reduce ejection time and increase temperature uniformity. It can be concluded that the parametrization performed in ANSYS Parametric Design Language (APDL), as well as the design variables used, can be applied in practice and could be relevant in future optimization approaches.

Design Sensitivity Analysis Applied to Injection Molding Process: Injection Pressure and Multi-Gate Location Optimization

2000 ◽  
Author(s):  
Kalonji K. Kabanemi ◽  
Jean-François Hétu ◽  
Abdessalem Derdouri
Keyword(s):  
Sensitivity Analysis ◽  
Injection Molding ◽  
Injection Pressure ◽  
Pressure Profile ◽  
Design Sensitivity ◽  
Design Sensitivity Analysis ◽  
Injection Molding Process ◽  
Molding Process ◽  
Filling Fraction ◽  
Design Variables

Abstract In this work, we develop a numerical simulation method to optimize the injection molding process using the design sensitivity analysis (DSA). The optimization concerns the filling stage and focuses on the number and location of gates in a mold cavity as well as the injection pressure, considered as one of the key processing parameters, in order to minimize the fill time. Since the problem to be solved involves transient flow with free surfaces, the direct differentiation method is used to evaluate the sensitivities of the Hele-Shaw, filling fraction and the energy equations with respect to the design variables used in the analysis. The mesh domain parameterization is coped with using B-spline functions. Sensitivity equations are solved by means of finite element method. The proposed numerical approach is combined with the sequential linear and quadratic programming method of the DOT optimization tools to find the new design variables at each iteration. Starting with any initial gate locations and injection pressure profile, the method enables us to find the optimal gate locations together with the optimal injection pressure profile. Finally, numerical results involving complex mold geometries are presented and discussed to assess the validity and robustness of the proposed method.

scholarly journals The Method for Optimum Design of Resin Injection Molding Process Conditions using Multivariate Analysis with Robust Parameter Design

2021 ◽  
Vol 8 (4) ◽  
pp. 1-21
Author(s):  
Eiji Toma
Keyword(s):  
Multivariate Analysis ◽  
Parameter Design ◽  
Injection Molding Process ◽  
Process Conditions ◽  
Robust Parameter Design ◽  
Design Development ◽  
Molding Process ◽  
Resin Injection ◽  
Robust Parameter ◽  
High Degree

In recent years, the demand for plastic products has increased, and along with the deepening of academics, mass production, weight reduction, and high precision are progressing. In the fields of design development and production technology, there are many issues related to quality assurance such as molding defects and product strength. In particular, in the resin molding process, there is a high degree of freedom in product shape and mold structure, and it is an important issue to create quality functions that apply analysis of complex multidimensional information. In this study, the important factors of the resin molding process related to the optimization of resin strength are extracted by applying the multivariate analysis method and robust parameter design. As a result of verification of the proposed method, it is clarified that uniformization of the resin filling density in the mold is extremely important for stabilizing the resin strength.

scholarly journals Multi-Objective Optimizations for Microinjection Molding Process Parameters of Biodegradable Polymer Stent

Materials ◽  
2018 ◽  
Vol 11 (11) ◽  
pp. 2322 ◽  
Author(s):  
Hongxia Li ◽  
Kui Liu ◽  
Danyang Zhao ◽  
Minjie Wang ◽  
Qian Li ◽  
...  
Keyword(s):  
Residual Stress ◽  
Injection Molding ◽  
Process Parameters ◽  
Optimization Method ◽  
Injection Molding Process ◽  
Kriging Surrogate Model ◽  
Adaptive Optimization ◽  
Molding Process ◽  
Microinjection Molding ◽  
Design Variables

Microinjection molding technology for degradable polymer stents has good development potential. However, there is a very complicated relationship between molding quality and process parameters of microinjection, and it is hard to determine the best combination of process parameters to optimize the molding quality of polymer stent. In this study, an adaptive optimization method based on the kriging surrogate model is proposed to reduce the residual stress and warpage of stent during its injection molding. Integrating design of experiment (DOE) methods with the kriging surrogate model can approximate the functional relationship between design goals and design variables, replacing the expensive reanalysis of the stent residual stress and warpage during the optimization process. In this proposed optimization algorithm, expected improvement (EI) is used to balance local and global search. The finite element method (FEM) is used to simulate the micro-injection molding process of polymer stent. As an example, a typical polymer vascular stent ART18Z was studied, where four key process parameters are selected to be the design variables. Numerical results demonstrate that the proposed adaptive optimization method can effectively decrease the residual stress and warpage during the stent injection molding process.

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

Pengembangan Mesin Pencacah Sampah/Limbah Plastik Dengan Sistem Crusher dan Silinder Pemotong Tipe Reel

2015 ◽  
Vol 10 (2) ◽  
pp. 66
Author(s):  
Junaidi - ◽  
Ichlas Nur ◽  
Nofriadi - ◽  
Rusmardi -
Keyword(s):  
Testing Machine ◽  
Engine Performance ◽  
Performance Testing ◽  
Injection Molding Process ◽  
Molding Process ◽  
Recycling Industry ◽  
Performance Improvements ◽  
Plastic Recycling ◽  
Technical Evaluation ◽  
Lower Frame

Waste plastic mounting, but can be recycled into other products in the form of granules before further processed into pellets and seed injection molding process produces products such as buckets, plates, bottles and other beverages. To be processed into the required form of granules of plastic thrasher. Though so small plastic recycling industry is still constrained in plastic enumeration process because the machine used was not optimal ability. The purpose of this research is the development of the system thrasher plastic crusher and cutter cylinder-type reel and technical evaluation. This study was conducted over two years, the first year the design and manufacture of machinery, the second year is a technical evaluation of the engine, engine performance improvements and economic analysis of granular plastic products.From the results obtained engine design capacity of the machine ± 350 kg / h, the engine size is 50 cm x 120 cm x 30 cm, power motor of 10 HP at 1450 RPM rotation with 3 phase. Some of the major components of the engine that is, counter crusher unit consists of two counter rotating cylinders opposite, counter shaft size Ø 4 cm x 58 cm, blade chopper Ø 17 cm x 2 cm with the number of teeth / blades 7 pieces and the number of blades along shaft 7 pieces, buses retaining Ø 10 cm x 2 cm. Counter-cylinder unit consists of a reel-type cutter counter shaft size Ø 4 cm x 90 cm, the middle shaft mounted cylinder with Ø 17 cm x 40 cm as the holder of the chopper blades. Chopper blade consists of 4 pieces with a size of 40 cm x 2 cm x 4 cm with ASSAB materials. Furthermore, as the blade retaining bedknife shear force of the blade chopper, upper frame, lower frame, strainer, funnel entry, exit funnel, and the drive unit consists of an electric motor, reducer, belts, pulleys and 2 pieces of gear transmission. The results of performance testing machine crusher round cylinder 75 RPM and 1450 RPM reel-type cutting machine capacity ± 300 kg / h on the filter hole Ø 1.5 cm, with a 80% grain uniformity.

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