scholarly journals Optimization for Reducing Warpage in Injection Moulding

2018 ◽  
Vol 2 (5) ◽  
pp. 25-31
Author(s):  
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Large Scale ◽  
Simulation Software ◽  
Optimum Process ◽  
Injection Molding Process ◽  
Molding Process ◽  
Melt Temperature ◽  
Product Cycles ◽  
Filling Time

Injection molding is a standout technique utilized for the fabrication of thermoplastic parts in industry due to short product cycles, high part quality, good mechanical properties and low cost for large scale manufacturing. In molded case circuit breaker (MCCB), Trip-bar is one of the most critical components as safety is concerned which is manufactured by injection molding process. To get it manufactured within the specified warpage and deformities free, number of mold flow simulations is carried out using Creo-MoldFlow. The outcomes of the simulation are used to design the mold tool and the process parameters for injection molding are optimized. For process parameter optimization Taguchi based experimental design and ANOVA analysis is done. The objective of this work is to optimize the injection molding process parameters such as filling time, melt temperature and mold temperature to minimize the warpage. CAE flow simulation software is used to simulate the process and Grey Relational Analysis (GRA) is used to find out optimum process parameters.

The Effect of Injection Molding Process Parameters on the Buckling Properties of PBT/Short Glass Fiber Composites

2011 ◽  
Vol 284-286 ◽  
pp. 550-556 ◽  
Author(s):  
Ming Hsiung Ho ◽  
Pin Ning Wang ◽  
Chin Ping Fung
Keyword(s):  
Injection Molding ◽  
Glass Fiber ◽  
Process Parameters ◽  
Injection Molding Process ◽  
Skin Area ◽  
Molding Process ◽  
Melt Temperature ◽  
Short Glass Fiber ◽  
Filling Time ◽  
Short Glass

This study investigates the effect of various injection molding process parameters and fiber amount on buckling properties of Polybutylene Terephthalate (PBT)/short glass fiber composite. The buckling specimens were prepared under injection molding process. These forming parameters about filling time, melt temperature and mold temperature that govern injection molding process are discussed. The buckling properties of neat PBT, 15 wt%, and 30 wt% are obtained using two ends fixed fixture and computerized closed-loop server-hydraulic material testing system. The fracture surfaces are observed by scanning electron microscopy (SEM). The global buckling forces are raised when increased the fiber weight percentage of PBT. Also, the fracture mechanisms in PBT and short glass fiber matrix are fiber pullout in skin area and fiber broken at core area. It is found that the addition of short glass fiber can significantly strengthen neat PBT.

Numerical Optimization of Shrinkage and Warpage on the Injection Molding Process Parameters of Electrical Connector

2017 ◽  
Vol 868 ◽  
pp. 183-191 ◽  
Author(s):  
Yun Wang ◽  
Li Yu Chen ◽  
Xia Ming Yang ◽  
Yan Zhao ◽  
Zhen Ying Xu ◽  
...  
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Mold Temperature ◽  
Influential Factors ◽  
Injection Molding Process ◽  
Molding Process ◽  
Melt Temperature ◽  
Influence Of Process Parameters ◽  
Filling Time ◽  
The Impact

Integrated with orthogonal design method and numerical simulation, injection molding process of the Y-type electrical connectors was conducted to study the influence of process parameters on volume shrinkage rate and maximum warpage, which are regarded as product quality indices. The multi-indices valuation model for the main influencing factors of the process is developed. The influencing sensitivity to the multi-objective of the processing parameters, such as melt temperature, mold temperature, injection time and holding pressure, is determined by range analysis. Through analyzing the diagrams of influential factors, the optimized process parameter diagram is obtained and verified by simulation. The optimum parameters minimizing the warpage defect and shrinkage are: melt temperature (528K), mold temperature (338K), filling time (0.6s), holding pressure (100%) and holding time (10s). The results show that it is effective to balance the impact of process parameters on the shrinkage and warpage. The work can provide optimal design and process reference for the quality control and assembly precision.

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.

Optimization of Injection Molding Process Parameters with Material Properties Based on GA and BP

2013 ◽  
Vol 345 ◽  
pp. 586-590 ◽  
Author(s):  
Xiao Hong Tan ◽  
Lei Gang Wang ◽  
Wen Shen Wang
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Mold Temperature ◽  
Injection Molding Process ◽  
Axial Deformation ◽  
Molding Process ◽  
Melt Temperature ◽  
Bp Network ◽  
Injection Parameters ◽  
Moldflow Simulation

To obtain optimal injection process parameters, GA was used to optimize BP network structure based on Moldflow simulation results. The BP network was set up which considering the relationship between volume shrinkage of plastic parts and injection parameters, such as mold temperature, melt temperature, holding pressure and holding time etc. And the optimal process parameters are obtained, which is agreed with actual results. Using BP network to predict injection parameters impact on parts quality can effectively reduce the difficulty and workload of other modeling methods. This method can be extended to other quality prediction in the process of plastic parts.Keyword: Genetic algorithm (GA);Neural network algorithm (BP);Injection molding process optimization;The axial deformation

scholarly journals ANALYSIS ON VOLUMETRIC SHRINKAGE OF PLASTIC FOOD CONTAINER MADE FROM AN INJECTION MOLDING PROCESS

2020 ◽  
Vol 8 (2) ◽  
pp. 22-31
Author(s):  
Rosidah Jaafar ◽  
◽  
Hambali Arep ◽  
Effendi Mohamad ◽  
Jeefferie Abd Razak ◽  
...  
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Food Packaging ◽  
Plastic Injection Molding ◽  
Volumetric Shrinkage ◽  
Injection Molding Process ◽  
Molding Process ◽  
Melt Temperature ◽  
Plastic Injection

The plastic injection molding process is one of the widely used of the manufacturing process to manufacture the plastic product with high productivity. Moreover, the food packaging manufacturing industry undergoes the trials and errors to obtain the optimal setting of the process parameters in order to minimize the quality issues and these trials and errors are time consuming and costly. The aim of this study is to improve the quality of the butter tub by minimizing the volumetric shrinkage. This study is to deal with the application of Moldflow integrating with the statistical technique to minimize the volumetric shrinkage the butter tub which depends on the process parameters of the plastic injection molding. For this purpose, the rectangular shape of butter tub is designed by utilizing the SolidWorks. Molflow is used to simulate the plastic filling of the single cavity mold of butter tub based on the Taguchi’s �!" orthogonal array table. In addition, the analysis of variance (ANOVA) is applied to investigate significant impact of the process parameters on the quality of the butter tub. Minitab is used to optimize the response of the volumetric shrinkage by selecting the most appropriate process parameters that maximizing the desirability value. Furthermore, the butter tub has a uniform thickness which was 1.2 mm and its factor of safety was 3.383 and the volumetric shrinkage response have optimized by 0.956 %. The melt temperature and mold temperature are found to be the most significant process parameters for the plastic injection molding process of butter tub and the volumetric shrinkage value obtained from the simulation is verified by the calculated volumetric shrinkage 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.

Viscosity Testing of Plastic Material PA6 with 15% of Glass Fibers

2018 ◽  
Vol 928 ◽  
pp. 133-138
Author(s):  
Karel Ráž ◽  
Martin Zahalka
Keyword(s):  
Injection Molding ◽  
Polymer Material ◽  
Process Parameters ◽  
Plastic Material ◽  
Glass Fibers ◽  
Injection Pressure ◽  
Injection Molding Process ◽  
Spiral Flow ◽  
Molding Process ◽  
Melt Temperature

The main aim of this paper was to describe the viscosity and injection mold filling behavior of PA6 with 15% of glass fibers. Injection molding is one of the most widely used processes for polymer products. The quality of these products is directly linked to correct choice of process parameters. It is necessary to understand the filling behavior of the polymer material during the injection molding process. The spiral flow test was carried out in this study to explore the effects of several injection process parameters. The resulting lengths of spiral flow were compared. The polymer material under test was Polyamide 6 with 15% of short glass fibers (trade name: Durethan BKV 15). Virtual testing as well as real testing was performed. A predominantly linear relationship between the flow length and the mold temperature, melt temperature and injection pressure is described here. A special mold was designed for this test.

scholarly journals Effects of Injection Molding Process Parameters on the Chemical Foaming Behavior of Polypropylene and Polystyrene

Polymers ◽  
2021 ◽  
Vol 13 (14) ◽  
pp. 2331
Author(s):  
Chen-Yuan Chung ◽  
Shyh-Shin Hwang ◽  
Shia-Chung Chen ◽  
Ming-Chien Lai
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Mold Temperature ◽  
Expansion Ratio ◽  
Injection Molding Process ◽  
Molding Process ◽  
Melt Temperature ◽  
Foaming Agent ◽  
Experimental Database ◽  
Injection Speed

In the present study, semi-crystalline polypropylene (PP) and amorphous polystyrene (PS) were adopted as matrix materials. After the exothermic foaming agent azodicarbonamide was added, injection molding was implemented to create samples. The mold flow analysis program Moldex3D was then applied to verify the short-shot results. Three process parameters were adopted, namely injection speed, melt temperature, and mold temperature; three levels were set for each factor in the one-factor-at-a-time experimental design. The macroscopic effects of the factors on the weight, specific weight, and expansion ratios of the samples were investigated to determine foaming efficiency, and their microscopic effects on cell density and diameter were examined using a scanning electron microscope. The process parameters for the exothermic foaming agent were optimized accordingly. Finally, the expansion ratios of the two matrix materials in the optimal process parameter settings were compared. After the experimental database was created, the foaming module of the chemical blowing agents was established by Moldex3D Company. The results indicated that semi-crystalline materials foamed less due to their crystallinity. PP exhibits the highest expansion ratio at low injection speed, a high melt temperature, and a low mold temperature, whereas PS exhibits the highest expansion ratio at high injection speed, a moderate melt temperature, and a low mold temperature.

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.

scholarly journals Experimental-Based Optimization of Injection Molding Process Parameters for Short Product Cycle Time

2020 ◽  
Vol 2020 ◽  
pp. 1-15 ◽  
Author(s):  
Saad M. S. Mukras
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Cycle Time ◽  
Optimization Problem ◽  
Extreme Values ◽  
Volumetric Shrinkage ◽  
Injection Molding Process ◽  
Product Cycle ◽  
Molding Process ◽  
Melt Temperature

This paper presents a framework for optimizing injection molding process parameters for minimum product cycle time subjected to constraints on the product defects. Two product defects, namely, volumetric shrinkage and warpage, as well as seven process parameters including injection speed, injection pressure, cooling time, packing pressure, mold temperature, packing time, and melt temperature, were considered. Injection molding experiments were conducted on specifically chosen test points and results were used to compute the volumetric shrinkage and warpage (at each test point). Thereafter, three relationships between the product cycle time (one relationship), the two product defects (two relationships), and the injection molding parameters were constructed using the kriging technique. An optimization problem to minimize the product cycle time (described by the first relationship) subject to constraints on the product defects (described by the latter two relationships) was then formulated. A combination set of points between the lower and upper extreme values of acceptable product defect was generated to serve as constraints for the two product defects. The optimization problem was then solved using the Fmincon function, available in the Matlab optimization toolbox. A plot of the optimization results revealed an appreciable tradeoff between the cycle time and the two product defects. To validate the optimization, an additional injection molding experiment was conducted for one of the optimization results. Results from the additional experiment showed reasonably close agreement with simulation optimization results differing in the cycle time, the warpage and volumetric shrinkage by 6.7%, 3.2%, and 8%, respectively.

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