scholarly journals Temperature Profile in Rubber Injection Molding: Application of a Recently Developed Testing Method to Improve the Process Simulation and Calculation of Curing Kinetics

Polymers ◽  
2021 ◽  
Vol 13 (3) ◽  
pp. 380
Author(s):  
Martin Traintinger ◽  
Roman Christopher Kerschbaumer ◽  
Bernhard Lechner ◽  
Walter Friesenbichler ◽  
Thomas Lucyshyn
Keyword(s):  
Injection Molding ◽  
Temperature Profile ◽  
Pressure Sensors ◽  
Simulation Software ◽  
Relative Degree ◽  
Actual State ◽  
Process Conditions ◽  
Inlet Temperature ◽  
Degree Of Cure ◽  
Mass Temperature

Injection molding of rubber compounds is an easily conducted yet sophisticated method for rubber processing. Simulation software is used to examine the optimal process conditions, identify failure scenarios, and save resources. Due to the complexity of the entire process, various aspects have to be considered in the numerical approach. This contribution focused on a comparison of process simulations with various definitions of the material’s inlet temperature, ranging from a stepwise increase, but constant temperature, to an exact axial mass temperature profile prior to injection. The latter was obtained with a specially designed, unique test stand consisting of a plasticizing cylinder equipped with pressure sensors, a throttle valve for pressure adjustments, and a measurement bar with thermocouples for the determination of the actual state of the mass temperature. For the verification of the theoretical calculations, practical experiments were conducted on a rubber injection molding machine equipped with the mold used in the simulation. The moldings, obtained at different vulcanization time, were characterized mechanically and the results were normalized to a relative degree of cure in order to enable comparison of the real process and the simulation. Considering the actual state of the mass temperature, the simulation showed an excellent correlation of the measured and calculated mass temperatures in the cold runner. Additionally, the relative degree of cure was closer to reality when the mass temperature profile after dosing was applied in the simulation.

Fiber energy efficiency Part I: Extended entropy model

2014 ◽  
Vol 29 (2) ◽  
pp. 322-331 ◽  
Author(s):  
Anders Karlström ◽  
Karin Eriksson
Keyword(s):  
Energy Efficiency ◽  
Temperature Profile ◽  
Dynamic Models ◽  
Fluid Dynamic ◽  
Multiscale Model ◽  
Process Conditions ◽  
Entropy Model ◽  
Refining Zone ◽  
Energy Balances ◽  
Flat Zone

Abstract This is the first in a series of papers presenting the development of a comprehensive multiscale model with focus on fiber energy efficiency in thermo mechanical pulp processes. The fiber energy efficiency is related to the defibration and fibrillation work obtained when fibers and fiber bundles interact with the refining bars. The fiber energy efficiency differs from the total refining energy efficiency which includes the thermodynamical work as well. Extracting defibration and fibrillation work along the radius in the refining zone gives information valuable for fiber development studies.Models for this process must handle physical variables as well as machine specific parameters at different scales. To span the material and energy balances, spatial measurements from the refining zone must be available. In this paper, measurements of temperature profile and plate gaps from a full-scale CD-refiner are considered as model inputs together with a number of process variables. This enables the distributed consistency in the refining zone as well as the split of the total work between the flat zone and the CD-zone to be derived. As the temperature profile and the plate gap are available in the flat zone and the CD-zone at different process conditions it is also shown that the distributed pulp dynamic viscosity can be obtained. This is normally unknown in refining processes but certainly useful for all fluid dynamic models describing the bar-to-fiber interactions. Finally, it is shown that the inclusion of the machine parameters will be vital to get good estimates of the refining conditions and especially the split between the thermodynamical work and the defibration/fibrillation work.

scholarly journals Minimum Number of Experimental Data for the Thermal Characterization of a Hot Water Storage Tank

Energies ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4741
Author(s):  
María Gasque ◽  
Federico Ibáñez ◽  
Pablo González-Altozano
Keyword(s):  
Experimental Data ◽  
Water Temperature ◽  
Temperature Profile ◽  
Storage Tank ◽  
Water Storage ◽  
Hot Water ◽  
Experimental Temperature ◽  
Inlet Temperature ◽  
Water Storage Tank ◽  
Minimum Number

This paper demonstrates that it is possible to characterize the water temperature profile and its temporal trend in a hot water storage tank during the thermal charge process, using a minimum number of thermocouples (TC), with minor differences compared to experimental data. Four experimental tests (two types of inlet and two water flow rates) were conducted in a 950 L capacity tank. For each experimental test (with 12 TC), four models were developed using a decreasing number of TC (7, 4, 3 and 2, respectively). The results of the estimation of water temperature obtained with each of the four models were compared with those of a fifth model performed with 12 TC. All models were tested for constant inlet temperature. Very acceptable results were achieved (RMSE between 0.2065 °C and 0.8706 °C in models with 3 TC). The models were also useful to estimate the water temperature profile and the evolution of thermocline thickness even with only 3 TC (RMSE between 0.00247 °C and 0.00292 °C). A comparison with a CFD model was carried out to complete the study with very small differences between both approaches when applied to the estimation of the instantaneous temperature profile. The proposed methodology has proven to be very effective in estimating several of the temperature-based indices commonly employed to evaluate thermal stratification in water storage tanks, with only two or three experimental temperature data measurements. It can also be used as a complementary tool to other techniques such as the validation of numerical simulations or in cases where only a few experimental temperature values are available.

The Use of Advanced Aluminum Alloys for Enhanced Productivity in Plastic Injection Molding

2000 ◽  
Author(s):  
Jim Nerone ◽  
Karthik Ramani
Keyword(s):  
Aluminum Alloys ◽  
Injection Molding ◽  
Wall Thickness ◽  
Simulation Software ◽  
Cooling Time ◽  
Coolant Temperature ◽  
Steel Mold ◽  
Cooling Channels ◽  
Injection Molding Simulation ◽  
Increased Strength

Abstract New aluminum alloys, QC-7® and QE-7®, have thermal conductivities four times greater than traditional tool steels, and have significantly increased strength and hardness compared to traditional aluminum materials. Molds were constructed of P-20 tool steel and QE-7® aluminum and were used to provide experimental data regarding thermal mold characteristic and confirm injection molding simulation predictions using C-Mold®. The relationships between cooling time reduction (using aluminum alloys) and polymer type, cooling channel depth, part wall thickness, and coolant temperature were explored both experimentally and using simulation software. It was shown that the potential reduction in cooling time varied from 5% to 25%. The most significant percentage improvements were observed in parts with part wall thickness of 0.05″ to 0.10″ and in molds with cooling channels at a depth ratio (D/d) of 2.0. The thermal pulses in the steel mold 0.10″ from the surface were approximately 63% larger than in aluminum mold.

Investigation of a Rotor Blade With Tip Cooling Subject to a Nonuniform Temperature Profile

2021 ◽  
Vol 143 (7) ◽  
Author(s):  
Harika S. Kahveci
Keyword(s):  
Temperature Profile ◽  
Turbine Blade ◽  
Numerical Study ◽  
Turbine Rotor ◽  
Inlet Temperature ◽  
Pressure Side ◽  
Engine Operation ◽  
Pressure Losses ◽  
Blade Tip ◽  
Temperature Levels

Abstract One of the challenges in the design of a high-pressure turbine blade is that a considerable amount of cooling is required so that the blade can survive high temperature levels during engine operation. Another challenge is that the addition of cooling should not adversely affect blade aerodynamic performance. The typical flat tips used in designs have evolved into squealer form that implements rims on the tip, which has been reported in several studies to achieve better heat transfer characteristics as well as to decrease pressure losses at the tip. This paper demonstrates a numerical study focusing on a squealer turbine blade tip that is operating in a turbine environment matching the typical design ratios of pressure, temperature, and coolant blowing. The blades rotate at a realistic rpm and are subjected to a turbine rotor inlet temperature profile that has a nonuniform shape. For comparison, a uniform profile is also considered as it is typically used in computational studies for simplicity. The effect of tip cooling is investigated by implementing seven holes on the tip near the blade pressure side. Results confirm that the temperature profile nonuniformity and the addition of cooling are the drivers for loss generation, and they further increase losses when combined. Temperature profile migration is not pronounced with a uniform profile but shows distinct features with a nonuniform profile for which hot gas migration toward the blade pressure side is observed. The blade tip also receives higher coolant coverage when subject to the nonuniform profile.

Three-Dimensional Finite Element Modeling of Drilling Processes

2006 ◽  
Author(s):  
T. D. Marusich ◽  
S. Usui ◽  
R. Aphale ◽  
N. Saini ◽  
R. Li ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Three Dimensional ◽  
Constitutive Models ◽  
Simulation Software ◽  
Process Conditions ◽  
Third Wave ◽  
Element Modeling ◽  
Drill Point ◽  
Three Dimensional Finite Element

The three dimensional (3D) finite element modeling (FEM) and experimental validation of drilling are presented. The Third Wave AdvantEdge machining simulation software is applied for the FEM. It includes fully adaptive unstructured mesh generation, thermo-mechanically coupling, deformable tool-chip-workpiece contact, interfacial heat transfer across the tool-chip boundary, and constitutive models appropriate for process conditions and finite deformation analyses. The workpiece is modeled with a predrilled cone-shape blind hole to enable the early full-engagement of the whole drill point region to reduce the simulation time. Drilling experiments are conducted on the Ti-6Al-4V using a twist drill geometry. The calculated cutting force and torque are compared with the results of experiments with good agreement. Effects of process parameters on the stress and temperature distributions of the drill and workpiece are investigated in detail using the FEM.

Optimization for Powder Yield of Spray-Dried Garlic Extract Powder Using Box-Behnken Experimental Design

2020 ◽  
Vol 859 ◽  
pp. 301-306
Author(s):  
Nattakanwadee Khumpirapang ◽  
Supreeya Srituptim ◽  
Worawut Kriangkrai
Keyword(s):  
Experimental Design ◽  
Spray Drying ◽  
Flow Rate ◽  
Interactive Effect ◽  
Garlic Extract ◽  
Process Conditions ◽  
Inlet Temperature ◽  
Feed Flow Rate ◽  
Air Inlet ◽  
Liquid Feed

Garlic exerts its pharmacological activities; antihyperglycemic, antihyperlipidemia, antihypercholesterolemic, and antihypertensive activity. Therefore, the aim of this study was to determine and optimize the influence of the individual and interactive effect of process conditions variables on the yield of garlic extract powders by three factors and three level-Box-Behnken design under response surface methodology. Spray drying processes the transformation of a garlic juice extract into a dried powder, where usually maltodextrin (MD) as a drying agent is used. According to experimental design, the mixing of garlic juice extract (85 – 95 %w/w) and MD (5 – 15 %w/w) were dried at an air inlet temperature 110°C - 150°C and liquid feed flow rate 5 – 35 rpm. The optimum spray-drying process conditions which maximized the yield of garlic extract powder (31%w/w) were found as follows: air inlet temperature of 150°C, the liquid feed flow rate of 16 rpm, and 5 %w/w MD. The experimental values slightly closed to the corresponding predicted values. Hence, the developed model was adequate and possible to use.

scholarly journals Design, Analysis and Fabrication of Safe Holder and Cam Dies in Injection Molding

2020 ◽  
Vol 8 (6) ◽  
pp. 4070-4077
Keyword(s):  
Injection Molding ◽  
Material Flow ◽  
Manufacturing Industry ◽  
Solid Material ◽  
Design Analysis ◽  
Simulation Software ◽  
Analysis Software ◽  
Flow Temperature ◽  
Mold Making ◽  
Temperature And Pressure

Injection molding is one of the very significant methodologies in the plastic manufacturing industry. Production of any shape in the injection molding, mold with cavity must require. For this mold making three phases were involved in this project starting from design, analysis, manufacturing respectively. The objective of this project is to introduce detailed steps on design mold and using the simulation software to analyze the material flow, temperature and pressure characteristics of the product. The product designed and analyzed for this project is SAFE HOLDER and CAM. The manufacturing of mold is done by using advanced machinery such as CNC. The design and analysis of this product and mold were made by the designing analysis software CATIA V5, ANSYS 15.0, which is then stimulated by the use of Fluid Flow (Fluent) tool. This project was very useful in knowing the fluid characteristic behavior subjected to flowing inside the mold and also observed the variation of values with respect to given values at each stage. In this project, the analysis performed with taking polypropylene as a fluid from propylene polymer and steel as solid material for the die with inlet values are 230℃ temperature and 15m/s velocity.

Effect of Processing Conditions on the Shrinkage and Warpage of Glass Fiber Reinforced PP Using Microcellular Injection Molding

2012 ◽  
Vol 501 ◽  
pp. 294-299 ◽  
Author(s):  
Zhi Bian ◽  
Peng Cheng Xie ◽  
Yu Mei Ding ◽  
Wei Min Yang
Keyword(s):  
Injection Molding ◽  
Glass Fiber ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Process Conditions ◽  
Fiber Reinforced ◽  
Injection Speed ◽  
Glass Fiber Reinforced ◽  
Microcellular Injection Molding ◽  
Molded Parts

This study was aimed at understanding how the process conditions affected the dimensional stability of glass fiber reinforced PP by microcellular injection molding. A design of experiments (DOE) was performed and plane test specimens were produced for the shrinkage and warpage analysis. Injection molding trials were performed by systematically adjusting six process parameters (i.e., Injection speed, Injection pressure, Shot temperature, SCF level, Mold temperature, and Cooling time). By analyzing the statistically significant main and two-factor interaction effects, the results showed that the supercritical fluid (SCF) level and the injection speed affected the shrinkage and warpage of microcellular injection molded parts the most.

Gate Location Optimization in Injection Molding Processing

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.

Sign in / Sign up

Export Citation Format

Share Document