DYNAMIC TEMPERATURE CONTROL INFLUENCE ON PRESSURE DURING INJECTION MOLDING OF PLASTIC PARTS TO IMPROVE PART QUALITY

Injection molding has been increasing for decades its share in the production of polymer components, in comparison to other manufacturing processes, as it can assure a cost-efficient production while maintaining short cycle times. In any production line, the stability of the process and the quality of the produced components is ensured by frequently performed metrological controls, which require a significant amount of effort and resources. To avoid the expensive effect of an out of tolerance production, an alternative method to intensive metrology efforts to process stability and part quality monitoring is presented in this article. The proposed method is based on the extraction of process and product fingerprints from the process regulating signals and the replication quality of dedicated features positioned on the injection molded component, respectively. The features used for this purpose are placed on the runner of the moldings and are similar or equal to those actually in the part, in order to assess the quality of the produced plastic parts. For the purpose of studying the method’s viability, a study case based on the production of polymer microfluidic systems for bio-analytics medical applications was selected. A statistically designed experiment was utilized in order to assess the sensitivity of the polymer biochip’s micro features (μ-pillars) replication fidelity with respect to the experimental treatments. The main effects of the process parameters revealed that the effects of process variation were dependent on the position of the μ-pillars. Results showed that a number of process fingerprints follow the same trends as the replication fidelity of the on-part μ-pillars. Instead, only one of the two on-runner μ-pillar position measurands can effectively serve as product fingerprints. Thus, the method can be the foundation for the development of a fast part quality monitoring system with the potential to decrease the use of off-line, time-consuming detailed metrology for part and tool approval, provided that the fingerprints are specifically designed and selected.

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Process Control of Injection Molding Based on Multiscale Visualization Methodology - A Case Study

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.154-155.1839 ◽

2010 ◽

Vol 154-155 ◽

pp. 1839-1845

Author(s):

Jin Cheng ◽

Jian Rong Tan ◽

Jia Hong Yu

Keyword(s):

Injection Molding ◽

Optimal Process ◽

Part Quality ◽

Statistical Mathematics ◽

Injection Molded ◽

Plastic Parts ◽

Injection Molded Plastic ◽

Optimal Process Parameter

Multiscale visualization approaches are proposed to efficiently assist designers not familiar with statistical mathematics in determining the optimal process parameter schemes for achieving desired part quality in injection molding, based on which the parameters’ relative importance to part quality and their influence on either single quality index or comprehensive part quality can be visually described by the map of the sum of squared deviations, response surface diagram and distribution map of comprehensive part quality. The proposed visualization approaches are universal for analyzing the effects of process parameters on the quality of any injection-molded plastic parts although the mobile phone cover is utilized as an example in the presentation of our work.

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Influence of dynamic temperature control on the injection molding process of plastic components

Procedia Manufacturing ◽

10.1016/j.promfg.2020.01.155 ◽

2019 ◽

Vol 38 ◽

pp. 1338-1346 ◽

Cited By ~ 1

Author(s):

Cláudia Macedo ◽

Cláudia Freitas ◽

António M. Brito ◽

Gilberto Santos ◽

Luis Faria ◽

...

Keyword(s):

Injection Molding ◽

Temperature Control ◽

Injection Molding Process ◽

Molding Process ◽

Dynamic Temperature ◽

Plastic Components

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Study on External Gas-Assisted Mold Temperature Control with the Assistance of a Flow Focusing Device in the Injection Molding Process

Materials ◽

10.3390/ma14040965 ◽

2021 ◽

Vol 14 (4) ◽

pp. 965 ◽

Cited By ~ 1

Author(s):

Nguyen Truong Giang ◽

Pham Son Minh ◽

Tran Anh Son ◽

Tran Minh The Uyen ◽

Thanh-Hai Nguyen ◽

...

Keyword(s):

Injection Molding ◽

Temperature Control ◽

Mold Temperature ◽

Injection Molding Process ◽

Melt Flow ◽

Flow Focusing ◽

Molding Process ◽

Heating Efficiency ◽

Flow Length ◽

Insert Plate

In the injection molding field, the flow of plastic material is one of the most important issues, especially regarding the ability of melted plastic to fill the thin walls of products. To improve the melt flow length, a high mold temperature was applied with pre-heating of the cavity surface. In this paper, we present our research on the injection molding process with pre-heating by external gas-assisted mold temperature control. After this, we observed an improvement in the melt flow length into thin-walled products due to the high mold temperature during the filling step. In addition, to develop the heating efficiency, a flow focusing device (FFD) was applied and verified. The simulations and experiments were carried out within an air temperature of 400 °C and heating time of 20 s to investigate a flow focusing device to assist with external gas-assisted mold temperature control (Ex-GMTC), with the application of various FFD types for the temperature distribution of the insert plate. The heating process was applied for a simple insert model with dimensions of 50 mm × 50 mm × 2 mm, in order to verify the influence of the FFD geometry on the heating result. After that, Ex-GMTC with the assistance of FFD was carried out for a mold-reading process, and the FFD influence was estimated by the mold heating result and the improvement of the melt flow length using acrylonitrile butadiene styrene (ABS). The results show that the air sprue gap (h) significantly affects the temperature of the insert and an air sprue gap of 3 mm gives the best heating rate, with the highest temperature being 321.2 °C. Likewise, the actual results show that the height of the flow focusing device (V) also influences the temperature of the insert plate and that a 5 mm high FFD gives the best results with a maximum temperature of 332.3 °C. Moreover, the heating efficiency when using FFD is always higher than without FFD. After examining the effect of FFD, its application was considered, in order to improve the melt flow length in injection molding, which increased from 38.6 to 170 mm, while the balance of the melt filling was also clearly improved.

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Dynamic Temperature Control System for the Optimized Production of Liquid Metal Nanoparticles

ACS Applied Nano Materials ◽

10.1021/acsanm.0c01257 ◽

2020 ◽

Vol 3 (7) ◽

pp. 6905-6914 ◽

Cited By ~ 4

Author(s):

Hongda Lu ◽

Shi-Yang Tang ◽

Zixuan Dong ◽

Di Liu ◽

Yuxin Zhang ◽

...

Keyword(s):

Control System ◽

Liquid Metal ◽

Metal Nanoparticles ◽

Temperature Control ◽

Temperature Control System ◽

Dynamic Temperature

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A dynamic temperature control simulation system for FPGAs

2008 International Conference on Field Programmable Logic and Applications ◽

10.1109/fpl.2008.4630033 ◽

2008 ◽

Cited By ~ 2

Author(s):

Shilpa Bhoj ◽

Dinesh Bhatia

Keyword(s):

Temperature Control ◽

Simulation System ◽

Dynamic Temperature ◽

Control Simulation

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Gate Location Optimization in Injection Molding Processing

10.1115/imece2000-1234 ◽

2000 ◽

Author(s):

Baojiu Lin ◽

Won Gil Ryim

Keyword(s):

Injection Molding ◽

Simulation Software ◽

Innovative Technology ◽

Software Module ◽

Location Optimization ◽

Gate Location ◽

Part Quality ◽

Design Cycle ◽

Injection Molding Simulation ◽

Complex Models

Abstract Improvements in part quality and cost reduction are the primary objectives of CAE use in the injection molding industry. Engineers use advanced injection molding simulation software to analyze and verify their part designs. Traditionally, engineers have had to rerun simulations to verify the effects of changes in gate locations. For complex models, simulations are very time consuming. To reduce the design cycle time, a Design Optimization Module is developed by C-MOLD. One of the functions of this new software module is to automatically select optimal gate locations. This innovative technology is the result of close R&D collaboration between C-MOLD and LG-PRC in Korea. An overview of gate location optimization technology is presented in this paper, and several examples are also presented as illustration.

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Simultaneous Computer-Aided Design of Rotational Plastic Parts

13th Computers in Engineering Conference ◽

10.1115/cie1993-0018 ◽

1993 ◽

Author(s):

Colin Chong ◽

Kiyoshi Sogabe ◽

Kosuke Ishii

Keyword(s):

Injection Molding ◽

Dynamic Characteristics ◽

Computer Aided Design ◽

Critical Speed ◽

Dynamic Balance ◽

Cad System ◽

Compatibility Analysis ◽

Computer Aided ◽

Plastic Parts ◽

Aided Design

Abstract This paper addresses the problem of balancing rotational plastic parts during the early stages of design. The study develops an interactive methodology that uses a solid modeling CAD system and considers injection molding concerns simultaneously with static and dynamic balance. The Transfer Matrix Method evaluates the dynamic characteristics by predicting the approximate critical speed of the part. Design Compatibility Analysis (DCA) checks for injection molding guidelines. Using these evaluation modules interactively, designers can develop a functional and manufacturable part quickly.

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