Analysis of the process influences on injection molded thermosets filled with hollow glass bubbles

2018 ◽  
Vol 38 (7) ◽  
pp. 695-701
Author(s):  
Christian Hopmann ◽  
Matthias Theunissen ◽  
Stefan Haase
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Processing Parameters ◽  
Injection Molding Process ◽  
Filler Materials ◽  
Molding Process ◽  
Molding Compound ◽  
Hollow Glass ◽  
Molding Compounds ◽  
Wide Range

Abstract Thermoset molding compounds have a wide range of beneficial properties such as easy handling, high temperature, chemical resistance, low shrinkage as well as low electrical conductivity. However, these properties come at the cost of a higher density than technical thermoplastic materials and thus the potential for lightweight applications is reduced. Due to the low viscosity of the resin within thermoset molding compounds a wide variety of filler materials can be used. The addition of low density hollow glass bubbles as a filler material in thermoset molding compounds offers the opportunity to decrease the density of the molding compound. At the same time the stiffness of the micro glass bubbles is expected to increase the stiffness of the material. In the present study, a thermoset molding compound was filled with different quantities of hollow glass bubbles and the effects of the filler content as well as the processing parameters were investigated regarding their effect on the weight and mechanical properties of the parts. Based on the results, significant weight reductions up to 5% were achieved. Furthermore, a significant impact of the process parameters on weight reductions was found. The results indicate that higher shearing reduces the weight. This can also contribute to damaging of the glass bubbles during the injection molding process. Similar results were found regarding the effect of process parameters on the mechanical properties.

Optimization of Injection Molding Process Parameters to Increase the Tensile Strength in Polyamide-Specimen Using the Taguchi Method

2011 ◽  
Vol 341-342 ◽  
pp. 395-399 ◽  
Author(s):  
S. Esmail Mirvar ◽  
Ramin Mohamadi Kaleybar ◽  
Ahmad Afsari
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Injection Molding ◽  
Process Parameters ◽  
Processing Parameters ◽  
Design Parameters ◽  
Injection Molding Process ◽  
Molding Process ◽  
Pressure Time ◽  
Injection Molded

Mechanical properties of plastic play an important role in defining the quality of injection molded products. Many studies have shown that mechanical properties of a product are influenced by the process parameters governing the injection-molding processes .This study employs Taguchi design parameters, to systematically investigate the influence of injection molding processing parameters on the tensile strength of Commercial grade Polyamide (PA-6). The result shows that the holding pressure time has main effect on the tensile strength, followed by cooling time, and holding pressure. Finally, a specimen produced according to the general form of the predictive equation of process parameters and verification test is performed on that. Test results show that the experimental value of tensile strength is very close to the estimated value.

Influence of Injection Molding Process Parameters on Sink Marks of Injection Parts Based on Moldflow

2013 ◽  
Vol 347-350 ◽  
pp. 1163-1167
Author(s):  
Ling Bai ◽  
Hai Ying Zhang ◽  
Wen Liu
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Mold Temperature ◽  
Processing Parameters ◽  
Injection Molding Process ◽  
Molding Process ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Sink Marks ◽  
Research Show

Moldflow software was used to obtain the best gate location and count. Influence of injection molding processing parameters on sink marks of injection-piece was studied based on orthogonal test. The effects of different process parameters were analyzed and better process parameters were obtained. Results of research show that decreasing melt temperature, mold temperature, the increasing injection time and packing pressure can effectively reduce the sink marks index.

Effect of Injection Molding Process on Electrical Conductivity and Mechanical Property of Nanoparticle Filled Polymer Composites

2012 ◽  
Vol 486 ◽  
pp. 34-38
Author(s):  
Jing Chao Zou ◽  
Ai Yun Jiang ◽  
Bao Feng Zhang ◽  
Hai Hong Wu ◽  
Ya Jun Zhou
Keyword(s):  
Mechanical Properties ◽  
Mechanical Property ◽  
Electrical Conductivity ◽  
Polymer Composites ◽  
Testing Machine ◽  
Injection Pressure ◽  
Processing Parameters ◽  
Injection Molding Process ◽  
Molding Process ◽  
Filled Polymer

Authors investigated the relationship among processing parameters, microstructures, electrical conductivity and mechanical property of injection molded nanoparticle filled polymer composites at present study. Standard tensile specimens were injected under different injecting pressures and packing pressures. The molded specimens were removing five layers from the surface to observe the microstructures at different positions of the moldings. The electrical properties were measured with a two-terminal standard resistor under DC condition at room temperature, and the mechanical properties of the moldings were measured by INSTRON 5580 Universal testing machine. The results showed that filled nanoparticles may form the best conductive path under the higher packing pressure matched with higher injection pressure. The mechanical properties of the molding depend on not only the concentration of the nanofiller, but processing conditions as well.

Application of Optimization Algorithms in Injection Molding Process Parameters

2011 ◽  
Vol 308-310 ◽  
pp. 3-8 ◽  
Author(s):  
Ze Hao Hu ◽  
Wei Wei ◽  
Juan Liu ◽  
Kun Liu
Keyword(s):  
Process Parameters ◽  
Quality Index ◽  
Processing Parameters ◽  
Injection Molding Process ◽  
Molding Process ◽  
Agent Model ◽  
Training Samples ◽  
The Neural Networks ◽  
Neural Networks Ensemble ◽  
Cae Simulation

The data of process parameters and quality index from CAE simulation orthogonal test is used as training samples, the BP neural network is trained and the neural networks ensemble approximate calculation agent model of the relations between processing parameters and the quality index of product are obtained. The agent model with a clear mathematical formula calculates quickly and accurately, so it can optimize globally by the genetic algorithm. The best group of process parameters is obtained and a multi-objective optimization of the quality index of products is realized.

scholarly journals Effect of Femtosecond-Laser-Structured Injection Molding Tool on Mechanical Properties of the Manufactured Product

Polymers ◽  
2021 ◽  
Vol 13 (13) ◽  
pp. 2187
Author(s):  
Krisztián Kun ◽  
Zoltán Weltsch
Keyword(s):  
Mechanical Properties ◽  
Injection Molding ◽  
Femtosecond Laser ◽  
Polymer Surface ◽  
Processing Parameters ◽  
Injection Molding Process ◽  
Mold Surface ◽  
Molding Process ◽  
Melt Temperature ◽  
Polymer Product

During the injection molding process, the melt travels with a flow due to friction. As the velocity of the layers next to the wall is less than that of those flowing in the middle of the channel, a fountain flow is formed at the melt front. The temperature of the polymer surface decreases from the melt temperature to the contact temperature after contacting the mold surface. Based on all this, a complex shell–core structure is formed in injection-molded products, which can be influenced by the processing parameters and the surface of the tool insert. This paper focuses on investigating the effect of the microstructures replicated from the insert to the polymer product on its mechanical properties. During the research, two microstructured surfaces were created, with different effects on the melt flow formed by the femtosecond laser. These were compared with a ground insert to analyze the effects. For examining the effect of technological variables on the mechanical properties, an experimental design was used. The structure created by the femtosecond laser on the surface of the tool influenced the mechanical properties of the polymer products. Recognizing the effect of microstructures on the melt front and, through this, the change in mechanical properties, a predefined polymer product property can be achieved.

scholarly journals Influence of Tool Geometry and Process Parameters on the Properties of Friction Stir Spot Welded Multiple (AA 5754 H111) Aluminium Sheets

Materials ◽  
2021 ◽  
Vol 14 (5) ◽  
pp. 1157
Author(s):  
Danka Labus Zlatanovic ◽  
Sebastian Balos ◽  
Jean Pierre Bergmann ◽  
Stefan Rasche ◽  
Milan Pecanac ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Spot Welding ◽  
Minimum Energy ◽  
Tool Geometry ◽  
Friction Stir ◽  
Minimum Energy Consumption ◽  
Punch Test ◽  
Wide Range ◽  
Lap Welding

Friction stir spot welding is an emerging spot-welding technology that offers opportunities for joining a wide range of materials with minimum energy consumption. To increase productivity, the present work addresses production challenges and aims to find solutions for the lap-welding of multiple ultrathin sheets with maximum productivity. Two convex tools with different edge radii were used to weld four ultrathin sheets of AA5754-H111 alloy each with 0.3 mm thickness. To understand the influence of tool geometries and process parameters, coefficient of friction (CoF), microstructure and mechanical properties obtained with the Vickers microhardness test and the small punch test were analysed. A scanning acoustic microscope was used to assess weld quality. It was found that the increase of tool radius from 15 to 22.5 mm reduced the dwell time by a factor of three. Samples welded with a specific tool were seen to have no delamination and improved mechanical properties due to longer stirring time. The rotational speed was found to be the most influential parameter in governing the weld shape, CoF, microstructure, microhardness and weld efficiency. Low rotational speeds caused a 14.4% and 12.8% improvement in joint efficiency compared to high rotational speeds for both tools used in this investigation.

scholarly journals Constant Temperature Approach for the Assessment of Injection Molding Parameter Influence on the Fatigue Behavior of Short Glass Fiber Reinforced Polyamide 6

Polymers ◽  
2021 ◽  
Vol 13 (10) ◽  
pp. 1569
Author(s):  
Selim Mrzljak ◽  
Alexander Delp ◽  
André Schlink ◽  
Jan-Christoph Zarges ◽  
Daniel Hülsbusch ◽  
...  
Keyword(s):  
Injection Molding ◽  
Glass Fiber ◽  
Process Parameters ◽  
Fatigue Properties ◽  
Injection Molding Process ◽  
Molding Process ◽  
Short Glass Fiber ◽  
Glass Fiber Reinforced ◽  
Molding Parameter ◽  
Short Glass

Short glass fiber reinforced plastics (SGFRP) offer superior mechanical properties compared to polymers, while still also enabling almost unlimited geometric variations of components at large-scale production. PA6-GF30 represents one of the most used SGFRP for series components, but the impact of injection molding process parameters on the fatigue properties is still insufficiently investigated. In this study, various injection molding parameter configurations were investigated on PA6-GF30. To take the significant frequency dependency into account, tension–tension fatigue tests were performed using multiple amplitude tests, considering surface temperature-adjusted frequency to limit self-heating. The frequency adjustment leads to shorter testing durations as well as up to 20% higher lifetime under fatigue loading. A higher melt temperature and volume flow rate during injection molding lead to an increase of 16% regarding fatigue life. In situ Xray microtomography analysis revealed that this result was attributed to a stronger fiber alignment with larger fiber lengths in the flow direction. Using digital volume correlation, differences of up to 100% in local strain values at the same stress level for different injection molding process parameters were identified. The results prove that the injection molding parameters have a high influence on the fatigue properties and thus offer a large optimization potential, e.g., with regard to the component design.

scholarly journals Optimization of injection molding process for car fender in consideration of energy efficiency and product quality

2014 ◽  
Vol 1 (4) ◽  
pp. 256-265 ◽  
Author(s):  
Hong Seok Park ◽  
Trung Thanh Nguyen
Keyword(s):  
Energy Efficiency ◽  
Energy Consumption ◽  
Injection Molding ◽  
Product Quality ◽  
Process Parameters ◽  
Optimization Problems ◽  
Computational Cost ◽  
Injection Molding Process ◽  
Molding Process ◽  
Nsga Ii

Abstract Energy efficiency is an essential consideration in sustainable manufacturing. This study presents the car fender-based injection molding process optimization that aims to resolve the trade-off between energy consumption and product quality at the same time in which process parameters are optimized variables. The process is specially optimized by applying response surface methodology and using nondominated sorting genetic algorithm II (NSGA II) in order to resolve multi-object optimization problems. To reduce computational cost and time in the problem-solving procedure, the combination of CAE-integration tools is employed. Based on the Pareto diagram, an appropriate solution is derived out to obtain optimal parameters. The optimization results show that the proposed approach can help effectively engineers in identifying optimal process parameters and achieving competitive advantages of energy consumption and product quality. In addition, the engineering analysis that can be employed to conduct holistic optimization of the injection molding process in order to increase energy efficiency and product quality was also mentioned in this paper.

The Effect of Heat Treatment on Mechanical Properties of Car Interior Fabric Used for Injection Molding

2012 ◽  
Vol 532-533 ◽  
pp. 234-237
Author(s):  
Wei Lai Chen ◽  
Ding Hong Yi ◽  
Jian Fu Zhang
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
High Temperature ◽  
Injection Molding ◽  
High Temperatures ◽  
Material Properties ◽  
Injection Molding Process ◽  
Molding Process ◽  
Composite Fabrics

The purpose of this paper is to study the effect of high temperature in injection molding process on mechanical properties of the warp-knitted and nonwoven composite fabrics (WNC)used in car interior. Tensile, tearing and peeling properties of WNC fabrics were tested after heat treatment under120, 140,160,180°C respectively. It was found that, after 140°C heat treatment, the breaking and tearing value of these WNC fabrics are lower than others. The results of this study show that this phenomenon is due to the material properties of fabrics. These high temperatures have no much effect on peeling properties of these WNC fabrics. It is concluded that in order to preserve the mechanical properties of these WNC fabrics, the temperature near 140°C should be avoided possibly during injection molding process.

Sign in / Sign up

Export Citation Format

Share Document