scholarly journals Fabrication of Micro-Structured Polymer by Micro Injection Molding Based on Precise Micro-Ground Mold Core

Micromachines ◽  
2019 ◽  
Vol 10 (4) ◽  
pp. 253 ◽  
Author(s):  
Yanjun Lu ◽  
Fumin Chen ◽  
Xiaoyu Wu ◽  
Chaolan Zhou ◽  
Yan Lou ◽  
...  
Keyword(s):  
Injection Molding ◽  
Mass Production ◽  
Injection Pressure ◽  
Machining Accuracy ◽  
Filling Rate ◽  
Micro Structure ◽  
Micro Injection Molding ◽  
Melt Temperature ◽  
Array Structures ◽  
Micro Structures

Precise micro-grinding machining was proposed to fabricate regular and controllable micro-grooved array structures on the surface of mold cores to realize the mass production and manufacturing of micro-structured polymer components by micro injection molding in this paper. First, the 3D topographies and section profiles of micro-ground mold cores and micro-formed polymers with different micro-structure parameters were presented. Then, the surface roughness of mold cores and polymers were compared. Next, the relationships between machining accuracy of mold core ground by micro-grinding and filling rates of micro-structured polymer formed by micro injection molding were investigated. Finally, the influences of micro injection molding parameters on the filling rate of micro-structures polymer were investigated. It is shown that the micro-structured polymer can be effectively and rapidly fabricated using the proposed method. The experimental results indicate the highest form accuracy of the micro-grooved mold core and the filling rate of micro-structured polymer can reach to 4.05 µm and 99.30%, respectively. It is found that the filling rate of the micro-structured polymer roughly increased with increasing machining accuracy of the mold core. The injection pressure had the greatest influence on the filling rate of the injection formed polymer, while the melt temperature had the least influence.

Study on Micro-Feature of Backlight Module for Micro Injection Molding Technology

2007 ◽  
Vol 364-366 ◽  
pp. 53-57 ◽  
Author(s):  
Yung Kang Shen ◽  
Yi Lin ◽  
Jeou Long Lee ◽  
Fwu Hsing Liu ◽  
Chih Wei Wu ◽  
...  
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Mold Insert ◽  
Mold Temperature ◽  
Processing Parameters ◽  
High Viscosity ◽  
Injection Velocity ◽  
Parameter Method ◽  
Micro Injection Molding ◽  
Melt Temperature

This research first indicates the melt front delay of wedge-shaped lightguiding plate of backlight module on micro injection molding. This research fabricated the patterns of mold insert of lightguiding plate by photo etching process. The micro-facture of lightguiding plate was manufactured by micro injection molding. The lightguiding plate of backlight module was used for the PMMA material. The single parameter method was used to discuss the flatness and replication properties for different processing parameters (mold temperature, melt temperature, packing pressure, packing time and injection pressure). The results show that there are melt front delays due to the slow injection velocity, the low temperature induced by the little effect of shear heating, the high viscosity, the large flow resistance and the slow flow velocity. The mold temperature is the most important factor for the flatness and the replication of micro-feature of liughtguiding plate. Lower mold temperature induces better flatness properties. The surface roughness of micro-facture of lightguiding plate is 8.8 nm on micro injection molding for this work.

Study on Optical Properties of Microstructure of Lightguiding Plate for Micro Injection Molding and Micro Injection-Compression Molding

2006 ◽  
Vol 505-507 ◽  
pp. 229-234 ◽  
Author(s):  
Yung Kang Shen ◽  
H.J. Chang ◽  
C.T. Lin
Keyword(s):  
Optical Properties ◽  
Injection Molding ◽  
Digital Camera ◽  
Mold Temperature ◽  
Compression Molding ◽  
Micro Injection Molding ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Injection Compression Molding ◽  
Better Than

The purpose of this paper presents the optical properties of microstructure of lightguiding plate for micro injection molding (MIM) and micro injection-compression molding (MICM). The lightguiding plate is applied on LCD of two inch of digital camera. Its radius of microstructure is from 100μm to 300μm by linearity expansion. The material of lightguiding plate uses the PMMA plastic. This paper uses the luminance distribution to make a comparison between MIM and MICM for the optical properties of lightguiding plate. The important parameters of process for optical properties are the mold temperature, melt temperature and packing pressure in micro injection molding. The important parameters of process for optical properties are the compression distance, mold temperature and compression speed in micro injection-compression molding. The process of micro injection-compression molding is better than micro injection molding for optical properties.

scholarly journals Optimization of Process Parameters for Vertical-Faced Polypropylene Bottle Injection Molding

2018 ◽  
Vol 2018 ◽  
pp. 1-9 ◽  
Author(s):  
Youmin Wang ◽  
Zhichao Yan ◽  
Xuejun Shan
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Dwell Time ◽  
Optimization Problem ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Orthogonal Test ◽  
Injection Molding Process ◽  
Injection Time ◽  
Melt Temperature

In order to obtain the optimal combination of process parameters for vertical-faced polypropylene bottle injection molding, with UG, the model of the bottle was drawn, and then, one module and sixteen-cavity injection molding system was established and analyzed using Moldflow. For filling and maintaining pressure during the process of infusion bottle injection molding, the orthogonal test table L25 (56) using CAE was designed for injection molding of the bottle, with six parameters such as melt temperature, mold temperature, injection pressure, injection time, dwell pressure, and dwell time as orthogonal test factors. By finding the best combination of process parameters, the orthogonal experiment was completed, the results were analyzed by range analysis, and the order of influence of each process parameter on each direction of optimization was obtained. The prediction dates of the infusion bottle were gained under various parameters, a comprehensive quality evaluation index of the bottle was formulated, and the multiobjective optimization problem of injection molding process was transformed into a single-objective optimization problem by the integrated weighted score method. The bottle parameters were optimized by analyzing the range date of the weighted scoring method, and the best parameter combination such as melt temperature 200°C, mold temperature 80°C, injection pressure 40 MPa, injection time 2.1 S, dwell pressure 40 MPa, and dwell time 40 S was gained.

Effects of process parameters on the formability of sheet metal during plastic injection forming

2020 ◽  
Vol 62 (5) ◽  
pp. 535-543
Author(s):  
Mirigul Altan ◽  
Bora Sener ◽  
Mirigul Altan
Keyword(s):  
Injection Molding ◽  
Sheet Metal ◽  
Injection Pressure ◽  
Industrial Applications ◽  
Effective Parameter ◽  
Melt Temperature ◽  
Injection Speed ◽  
Aluminum Sheets ◽  
Plastic Injection ◽  
Thinning Rate

Abstract Plastic injection forming (PIF) is an alternative sheet metal forming method for complex geometrical parts with dimensions in low tolerance. This method is a combination of injection molding and hydroforming in which a molten polymer material has been injected over a sheet metal via a plastic injection molding machine. In this study, aluminum sheets 1.5 mm thick were shaped by PIF at various injection pressures, melt temperatures and injection speed. The effects of these parameters on the formability of the sheet metal were investigated using the experimental design technique. The thinning rate, flange radius and the hardness values of the shaped sheets were considered in the experimental study. Injection pressure was found to be the most effective parameter and melt temperature was the second degree effective parameter for the thinning rate. The usability of the PIF process in industrial applications as an alternative method was emphasized by comparing PIF with conventional hydroforming by means of the finite element method (Ls-Dyna). A 2.07 % deviation was observed between the FE results for hydroforming and the experimental results for PIF.

Warpage Measurement of a Micro Electrical Fan on Micro-Injection Molding

2012 ◽  
Vol 184-185 ◽  
pp. 1651-1654
Author(s):  
Jeou Long Lee ◽  
Y. Lin ◽  
Y.K. Shen
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Acrylonitrile Butadiene Styrene ◽  
Mold Temperature ◽  
Micro Injection Molding ◽  
Optimum Result ◽  
Suitable Material ◽  
Packing Pressure ◽  
Injection Molded ◽  
Packing Time

This study characterizes warpage of a micro-injection molded micro electrical fan using the Michelson interference method. This study conducts experiments to analyze different polymers-polypropylene (PP), polyamide (PA), acrylonitrile-butadiene styrene (ABS), ABS+ polycarbonate (PC), and polyoxymethylene (POM)-process parameters, such as mold temperature, injection temperature, injection pressure, injection time, packing time, and packing pressure, for a micro electrical fan. To obtain the optimum result (minimum warpage), this study assesses the effect (warpage) of each material on micro-injection molding. PA plastic is the very suitable material for micro electrical fan with Michelson interference analysis on micro-injection molding.

Reduction in Defect Rate by Taguchi Method in Plastic Injection Molded Components

2012 ◽  
Vol 488-489 ◽  
pp. 269-273 ◽  
Author(s):  
G.S. Dangayach ◽  
Deepak Kumar
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Processing Parameters ◽  
Process Conditions ◽  
Melt Temperature ◽  
Defect Rate ◽  
Packing Pressure ◽  
Optimal Injection ◽  
Packing Time ◽  
Plastic Injection

In the present era, competition gets tougher; there is more pressure on manufacturing sectors to improve quality and customer satisfaction while decreasing cost and increasing productivity. These can be achieved by using modern quality management systems and process improvement techniques to reduce the process variability and driven waste within manufacturing process using effective application of statistical tools. Taguchi technique is well known technique to solve industrial problems. This technique is fast and can pinpoint the chief causes and variations. Plastic injection molding is suitable for mass production articles since complex geometries can be obtained in a single production step. The difficulty in setting optimal process conditions may cause defects in parts, such as shrinkage and warpage. In this paper, optimal injection molding conditions for minimum shrinkage were determined by the Taguchi design of experiment (DOE) approach. Polypropylene (PP) was injected in circular shaped specimens under various processing parameters: melt temperature, injection pressure, packing pressure and packing time. S/N ratios were utilized for determining the optimal set of parameters. According to the results, 2400 C of melt temperature, 75 MPa of injection pressure, 50 MPa of packing pressure and 15 sec. of packing time gave minimum shrinkage of 0.951% for PP. Statically the most significant parameter was melt temperature for the PP. Injection pressure had the least effect on the shrinkage. The defect rate was reduced from 14% to 3%.

Optimization and Design for Parameter in Injection Molding Technology of Cell Shell of Polypropylene

2011 ◽  
Vol 189-193 ◽  
pp. 537-540
Author(s):  
Jia Min Zhang ◽  
Ming Yi Zhu ◽  
Zhao Xun Lian ◽  
Rong Zhu
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Injection Molding Process ◽  
Technological Parameters ◽  
Molding Process ◽  
Melt Temperature ◽  
Injection Speed ◽  
Technical Parameters ◽  
High Degree

The use of L27 (35) orthogonal to the battery shell injection molding process is optimized. The main factors of technical parameters were determined mould temperature, melt temperature, the speed of injection, injection pressure, cooling time.On the basis of actual production, to determine the factors values of different process parameters.Combination of scrapped products in key (reduction and a high degree of tolerance deflated) tests were selected in the process parameters within the scope of the assessment. Various factors impact on the product of the total height followed by cooling time, mold temperature, melt temperature, injection pressure, injection speed from strong to weak .The best products technological parameters were determined.Good results were obtained for production.

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.

Design and Motion Simulation of the Clamping Mechanism of Micro-Structure Injection Molding Machine

2014 ◽  
Vol 945-949 ◽  
pp. 670-675 ◽  
Author(s):  
Bai Ge Chou ◽  
Heng Zhi Cai ◽  
Gang Zhou ◽  
Ya Jun Zhang ◽  
Jian Zhuang
Keyword(s):  
Injection Molding ◽  
Kinetic Characteristic ◽  
Clamping Force ◽  
Molding Machine ◽  
Micro Structure ◽  
Injection Molding Machine ◽  
Micron Size ◽  
Lqr Controller ◽  
And Control ◽  
Micro Structures

Micro-structure injection molding machine is mainly used for processing the plastic products in micron-size or with micro-structures. This paper focuses on the design and control of the clamping mechanism of micro-structure injection molding machine. Firstly, the deformation of the clamping mechanism was analyzed. The simulation results shows that the clamping force is 5.0051×105N, and it’s bigger than the design value 500kN. Secondly, the kinetic characteristic of the clamping was simulated by ADAMS software. The curves of the displacement, velocity, clamping force of moving platen were analyzed. Thirdly, the control model of clamping mechanism was established. And the LQR controller was designed and simulated by Matlab. The rise time is 0.010s, the settling time is 0.026s and the steady-state is 0.307m.

The Applied Study Based on the Injection Molding Mechanism of Microcellular Foamed Plastics (MCFP)

2014 ◽  
Vol 709 ◽  
pp. 374-379
Author(s):  
Yi Jun Huang
Keyword(s):  
Injection Molding ◽  
Engineering Application ◽  
Injection Pressure ◽  
Injection Molding Process ◽  
Injection Time ◽  
Molding Process ◽  
Melt Temperature ◽  
Applied Study ◽  
Foamed Plastics ◽  
Plastics Injection Molding

Injection molding is one of several molding technology of microcellular foamed plastics. This paper mainly discusses the injection molding mechanism and applications of microcellular foamed plastics here, and analyzes the influence of microcellular foamed plastics injection molding process parameters, including injection pressure, melt temperature, injection time, etc.; At the same time, this paper makes a more systematic discussions for the injection molding technology of microcellular foamed plastics, and the typical cases of microcellular foamed plastics in engineering application are introduced in detail.

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