scholarly journals Characteristic of micro injection molding process. Molds, optimization of the process, application with specification to automotive industry

2018 ◽  
Vol 19 (1-2) ◽  
pp. 48-51
Author(s):  
Grzegorz Janowski
Keyword(s):  
Injection Molding ◽  
Automotive Industry ◽  
Injection Molding Process ◽  
Fast Time ◽  
Technological Parameters ◽  
Molding Process ◽  
Micro Injection Molding ◽  
Plastic Properties ◽  
Wide Range ◽  
Plastic Parts

The growing needs for miniaturization of plastic parts motivates to the development of micro injection molding technology. Characteristic features of this process such as: low manufacturing costs, short process duration, the ability to produce details of various dimensions and a wide range of plastic properties allow to mass dissemination of this technology. Research on micro injection molding develops in a very fast time, which gives high hopes for a successful overcoming of the real limitations of this technology. This gives a great perspective on the development of the possibility of using micro injection parts e.g. in the automotive industry. This paper presents the possibilities of manufacturing molds for micro injection molding. The issue of process optimization has been discussed, taking into consideration the main technological parameters influencing the quality of micro-part. In addition, the possibility of using microdetals, including the automotive industry was presented.

scholarly journals Characteristic of micro injection molding process. Standard injection molding, material selection, micro injection molding machines

2017 ◽  
Vol 18 (12) ◽  
pp. 32-36
Author(s):  
Grzegorz Janowski
Keyword(s):  
Injection Molding ◽  
Material Selection ◽  
Injection Molding Process ◽  
Fast Time ◽  
Molding Process ◽  
Micro Injection Molding ◽  
Plastic Properties ◽  
Wide Range ◽  
Characteristic Features ◽  
Plastic Parts

The growing needs for miniaturization of plastic parts motivates to the development of micro injection molding technology. Characteristic features of this process such as: low manufacturing costs, short process duration, the ability to produce details of various dimensions and a wide range of plastic properties allow to mass dissemination of this technology. Research on micro injection molding develops in a very fast time, which gives high hopes for a successful overcoming of the real limitations of this technology. This gives a great perspective on the development of the possibility of using micro injection parts e.g. in the automotive industry, including the bus production process. This paper presents the conventional injection molding process – i.e. the process essence, the injection molding cycle and the construction of a conventional screw-type injection molding machine. The next part of this article focuses on the characteristics of micro injection molding technology. The essence of material selection and micro-part characteristics for the process were presented. Furthermore, injection molding machines for this process were characterized.

scholarly journals Vacuum Venting Enhances the Replication of Nano/Microfeatures in Micro-Injection Molding Process

2016 ◽  
Vol 4 (2) ◽  
Author(s):  
Seong Ying Choi ◽  
Nan Zhang ◽  
J. P. Toner ◽  
G. Dunne ◽  
Michael D. Gilchrist
Keyword(s):  
Injection Molding ◽  
Quantitative Study ◽  
Vacuum Pressure ◽  
Injection Molding Process ◽  
Anodized Aluminum ◽  
Molding Process ◽  
Micro Injection Molding ◽  
Sample Shape ◽  
Final Sample ◽  
Qualitative And Quantitative Study

Vacuum venting is a method proposed to improve feature replication in microparts that are fabricated using micro-injection molding (MIM). A qualitative and quantitative study has been carried out to investigate the effect of vacuum venting on the nano/microfeature replication in MIM. Anodized aluminum oxide (AAO) containing nanofeatures and a bulk metallic glass (BMG) tool mold containing microfeatures were used as mold inserts. The effect of vacuum pressure at constant vacuum time, and of vacuum time at constant vacuum pressure on the replication of these features is investigated. It is found that vacuum venting qualitatively enhances the nanoscale feature definition as well as increases the area of feature replication. In the quantitative study, higher aspect ratio (AR) features can be replicated more effectively using vacuum venting. Increasing both vacuum pressure and vacuum time are found to improve the depth of replication, with the vacuum pressure having more influence. Feature orientation and final sample shape could affect the absolute depth of replication of a particular feature within the sample.

Determination of Optimum Process Parameters in Gas-Assisted Injection Molding

2011 ◽  
Vol 143-144 ◽  
pp. 494-498
Author(s):  
Ke Ming Zi ◽  
Li Heng Chen
Keyword(s):  
Injection Molding ◽  
Delay Time ◽  
Optimization Design ◽  
Gas Pressure ◽  
Optimum Process ◽  
Injection Molding Process ◽  
Technological Parameters ◽  
Molding Process ◽  
Element Analysis ◽  
Melt Temperature

With finite element analysis software Moldflow, numerical simulation and studies about FM truck roof handle were conducted on gas-assisted injection molding process. The influences of melt pre-injection shot, gas pressure, delay time and melt temperature were observed by using multi-factor orthogonal experimental method. According to the analysis of the factors' impact on evaluation index, the optimized parameter combination is obtained. Therefore the optimization design of technological parameters is done. The results show that during the gas-assisted injection molding, optimum pre-injection shot is 94%,gas pressure is 15MPa,delay time is 0.5s,melt temperature is 240 oC. This study provided a more practical approach for the gas-assisted injection molding process optimization.

Polypropylene Based Piezo Ceramic Compounds for Micro Injection Molded Sensors

2017 ◽  
Vol 742 ◽  
pp. 807-814 ◽  
Author(s):  
Christoph Doerffel ◽  
Ricardo Decker ◽  
Michael Heinrich ◽  
Jürgen Tröltzsch ◽  
Mirko Spieler ◽  
...  
Keyword(s):  
Injection Molding ◽  
Ceramic Powder ◽  
Three Dimensional ◽  
Conductive Filler ◽  
High Sensitivity ◽  
Injection Molding Process ◽  
Molding Process ◽  
Ceramic Particles ◽  
Wide Range ◽  
Ceramic Compounds

Polymer matrix compounds based on piezo ceramic and electrically conducting particles within a thermoplastic matrix show distinctive piezoelectric and dielectric effects which can used for sensor applications. The electrical and mechanical properties can be adjusted in a wide range by varying the ratio of active filling particles and the matrix materials. The sensor effect of the compound is generated by the ceramic particles. A large ratio of piezo ceramic powder facilitates a high sensitivity. The electrical permittivity of the otherwise insulating matrix polymer can be adjusted by the amount of conductive filler. An aligned permittivity leads to a stronger electrical field in the ceramic particles. In contrast, too many conductive particles create a conductive network in the compound which short-circuits the sensors. The piezo ceramic compounds can be processed via micro injection molding for application as ceramic sensors. This offers a wide range of new sensor design variants, notably three-dimensional and highly complex geometries. However, there are two main demands for a highly sensitive sensor, which are conflicting. On the one hand the filler content of piezo ceramic particles in combination with electrical conductive carbon nanotubes must be very high, on the other hand the wall thickness should be as thin as possible. For filling cavities with a high aspect-ratio in an injection molding process, low viscosity polymer melts are necessary. These process characteristics conflict with the increasing viscosity by filling the melt with the particles. The sensor measuring area has to be designed as thin walled as possible. In order to overcome this obstacle a dynamically tempered mold design is applied to avoid solidification of the melt, before the mold is completely filled. The mold can be tempered by Peltier elements. The fully electric tempering is cleaner, more precise and more reliable than conventional water or oil tempering.

scholarly journals Electricity Consumption Estimation of the Polymer Material Injection-Molding Manufacturing Process: Empirical Model and Application

Materials ◽  
2018 ◽  
Vol 11 (9) ◽  
pp. 1740 ◽  
Author(s):  
Ana Elduque ◽  
Daniel Elduque ◽  
Carmelo Pina ◽  
Isabel Clavería ◽  
Carlos Javierre
Keyword(s):  
Environmental Impact ◽  
Injection Molding ◽  
Empirical Model ◽  
Electricity Consumption ◽  
Injection Molding Process ◽  
Molding Process ◽  
Polymer Injection ◽  
Wide Range ◽  
Molded Parts ◽  
Polymer Injection Molding

Polymer injection-molding is one of the most used manufacturing processes for the production of plastic products. Its electricity consumption highly influences its cost as well as its environmental impact. Reducing these factors is one of the challenges that material science and production engineering face today. However, there is currently a lack of data regarding electricity consumption values for injection-molding, which leads to significant errors due to the inherent high variability of injection-molding and its configurations. In this paper, an empirical model is proposed to better estimate the electricity consumption and the environmental impact of the injection-molding process. This empirical model was created after measuring the electricity consumption of a wide range of parts. It provides a method to estimate both electricity consumption and environmental impact, taking into account characteristics of both the molded parts and the molding machine. A case study of an induction cooktop housing is presented, showing adequate accuracy of the empirical model and the importance of proper machine selection to reduce cost, electricity consumption, and environmental impact.

Evaluation of a Piezoelectric Energy Extraction Device for Cavity Pressure Sensing in Injection Molding

2003 ◽  
Author(s):  
Charles B. Theurer ◽  
Li Zhang ◽  
David Kazmer ◽  
Robert X. Gao
Keyword(s):  
Injection Molding ◽  
Mechanical Strain ◽  
Piezoelectric Element ◽  
Polymer Melt ◽  
High Energy ◽  
Injection Molding Process ◽  
Molding Process ◽  
Transient Model ◽  
Piezoelectric Energy ◽  
Wide Range

This paper presents the design, analysis, and validation of a self-energized piezoelectric pressure sensor that extracts energy from the pressure differential of the polymer melt during the injection molding process. To enable a self-energized sensor design, an analytical study has been conducted to establish a quantitative relationship between the polymer melt pressure and the energy that can be extracted through a piezoelectric converter. Temperature and pressure are monitored during an injection molding cycle and the performance of the piezoelectric element is evaluated with respect to a mechanically static, electrically transient model. In addition to corroboration of the proposed model, valuable statistical information about the working temperature in the prototype sensor will prove very useful in the package design of molding cavity sensors. A linear model examining the energy conversion mechanism due to interactions between the mechanical strain and the electric field developed within the piezoelectric device is established. This model is compared to the functional prototype design to evaluate the relevance of the assumptions and accuracy. The presented design enables a new generation of self-energized sensors that can be employed for the condition monitoring of a wide range of high-energy manufacturing processes.

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.

In-Mold Monitoring of Temperature and Cavity Pressure During the Injection Molding Process

2014 ◽  
Author(s):  
Catalin Fetecau ◽  
Felicia Stan ◽  
Laurentiu I. Sandu
Keyword(s):  
Injection Molding ◽  
Pressure Sensors ◽  
Temperature Sensors ◽  
Injection Molding Process ◽  
Cavity Pressure ◽  
Molding Process ◽  
Shear Rates ◽  
Wide Range ◽  
Simulation Results ◽  
Two Temperature

This paper focuses on the in-mold monitoring of temperature and cavity pressure. The melt contact temperature and the cavity pressure along the flow path were directly measured using two pressure sensors and two temperature sensors fitted into the cavity of a spiral mold. Three melt temperatures and dies of different heights (1.0, 1.5 and 2 mm) were used to achieve a wide range of practically relevant shear rates. In order to analyze the extent to which the numerical simulation can predict the behavior of the molten polymer during the injection molding process, molding experiments were simulated using the Moldflow software and the simulation results were compared with the experimental data under the same injection molding conditions.

Study on Improving the Life of Stereolithography Injection Mold

2012 ◽  
Vol 468-471 ◽  
pp. 1013-1016 ◽  
Author(s):  
Hua Qing Lai
Keyword(s):  
Injection Molding ◽  
Injection Molding Process ◽  
Injection Mold ◽  
Molding Process ◽  
Molded Parts ◽  
Injection Molded ◽  
Plastic Parts ◽  
Assembly Operations ◽  
Conventional Injection Molding ◽  
Shape And Size

Molding is one of the most versatile and important processes for manufacturing complex plastic parts. It is a method of fabricating plastic parts by utilizing a mold or cavity that has a shape and size similar to the part being produced. Molten polymer is injected into the cavity, resulting in the desired part upon solidification. The injection-molded parts typically have excellent dimensional tolerance and require almost no finishing and assembly operations. But new variations and emerging innovations of conventional injection molding have been continuously developed to offer special features and benefits that cannot be accomplished by the conventional injection molding process. This study aims to improving the life of stereolithography injection mold.

Influence of Technological Parameters on Material Flow

2015 ◽  
Vol 1120-1121 ◽  
pp. 1194-1197 ◽  
Author(s):  
Michal Stanek ◽  
David Manas ◽  
Miroslav Manas ◽  
Vojtech Senkerik ◽  
Adam Skrobak ◽  
...  
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Polymer Processing ◽  
Injection Rate ◽  
Cavity Surface ◽  
Injection Molding Process ◽  
Technological Parameters ◽  
Molding Process ◽  
Processing Technologies

Injection molding is one of the most extended polymer processing technologies. It enables the manufacture of final products, which do not require any further operations. The tools used for their production – the injection molds – are very complicated assemblies that are made using several technologies and materials. Delivery of polymer melts into the mold cavity is the most important stage of the injection molding process. The fluidity of polymers is affected by many parameters Inc. mold design. Evaluation of set of data obtained by experiments in which the testing conditions were widely changed shows that the quality of cavity surface and technological parameters (injection rate, injection pressure and gate size) has substantial influence on the length of flow.

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