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.

scholarly journals Towards Optimization of μ-Injection Molding Process for a New V-shaped Geometrical Component Using X-Ray CT-Based Quality Characterization

2019 ◽  
Vol 3 (1) ◽  
pp. 13
Author(s):  
Jitendra Rathore ◽  
Giovanni Lucchetta ◽  
Simone Carmignato
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Functional Performance ◽  
Quality Criteria ◽  
Mold Temperature ◽  
Process Window ◽  
Injection Molding Process ◽  
Molding Process ◽  
Melt Temperature ◽  
Injection Speed

The influence of micro-injection molding process parameters on a molded component’s quality is very prominent. Depending on the functional performance of the part, the desired quality is defined by several criteria which may include dimensional tolerances, shrinkage/warpage, fiber characteristics, and internal defects. A correlation of process parameters with the defined quality attributes needs to be investigated for a new geometrical component. In this work, a micro-component with a new V-shaped geometry is chosen, as this type of geometry finds potential applications in the medical industry. The parts are manufactured with polyoxymethylene resin with a full-factorial design of experimental plan with investigating parameters of mold temperature, melt temperature, injection speed, and packing pressure. The number of internal pores and amount of volumetric shrinkage are identified as the critical quality criteria and the effect of the process parameters is studied with respect to those criteria. The measurement results indicated that the presence of pores is inevitable within the chosen process window; however, the amount can be minimized with careful selection of process settings. Moreover, the statistical analyses demonstrated the significance levels of the process parameters.

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

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.

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.

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 The Study of Optimal Molding of a LED Lens with Grey Relational Analysis and Molding Simulation

2019 ◽  
Vol 63 (4) ◽  
pp. 278-294 ◽  
Author(s):  
Min-Wen Wang ◽  
Fatahul Arifin ◽  
Van-Hanh Vu
Keyword(s):  
Injection Molding ◽  
Mold Temperature ◽  
Injection Molding Process ◽  
Molding Process ◽  
Melt Temperature ◽  
Injection Speed ◽  
Relational Analysis ◽  
Total Displacement ◽  
Packing Pressure ◽  
Grey Relational

Injection molding technology is known as the most widely used method in mass production of plastic products. To meet the quality requirements, a lot of methods were applied in optimization of injection molding process parameter. In this study the optimization based on Taguchi orthogonal array and Grey relational analysis (GRA) is used to optimize the injection molding process parameters on a LED lens. The four process parameters are: packing pressure, injection speed, melt temperature and mold temperature. The multi-response quality characteristics are total displacement, volumetric shrinkage, and thermal residual stress. The optimal molding parameters are packing pressure (90 MPa), injection speed (300 mm/sec), melt temperature (270 °C) and mold temperature (90 °C). The luminous uniformity of the LED is 92.61 % and the viewing angle of the LED is 124.76°. Among the four factors, packing pressure plays the key role in reducing total displacement, volumetric shrinkage, and thermal residual stress.

Optimization of Warpage in Injection Molding Based on Simulated Annealing Algorithm

2010 ◽  
Vol 129-131 ◽  
pp. 931-935
Author(s):  
Jun Liu ◽  
Bao Shou Sun ◽  
Guo Fu Li
Keyword(s):  
Simulated Annealing ◽  
Injection Molding ◽  
Process Parameters ◽  
Simulated Annealing Algorithm ◽  
Random Search ◽  
Mold Temperature ◽  
Injection Molding Process ◽  
Molding Process ◽  
Melt Temperature ◽  
Annealing Algorithm

To make a simulated annealing algorithm(SA) to optimize the method of warping deformation of the purpose is to enable the optimal value of the warpage. Using ActiveX technology and VB programming tools will be SA and Moldflow combination. The optimal injection molding process parameters, such as mold temperature, melt temperature, gate location were determined by according to Metropolis criterion and following a route of Monte Carlo(MC) heuristic random search determined by SA. The results of the typical model show that the wargae is accurate and reliable, and the optimization efficiency is effectively improved by applying the SA method, therefore the combination of Moldflow and SA proposed in this paper is useful for the optimization of injection molding process parameters.

Injection Molding Process Parameters Analysis and Optimization Depending on Moldflow

2013 ◽  
Vol 401-403 ◽  
pp. 848-851
Author(s):  
Na Li ◽  
Hong Bin Liu
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Mold Temperature ◽  
Factorial Experiment ◽  
Injection Molding Process ◽  
Molding Process ◽  
Melt Temperature ◽  
Verification Process ◽  
Quality Of Products

t was carried out the simulation experiment for injection molding process by the factorial experiment method and the Moldflow software. The model was a computer panel. The responses target to experiment was the warpage. The data was used the ANOVA analysis which came from the factorial experiment. The effect levels of the parameters were got, such as the mold temperature, the injection time, the pressure, the melt temperature et .al. Through the analysis of the response figures, it obtained injection molding process parameters of the optimal combination plan, and the simulated verification process. The experiment proved that this method can reduce test times and guarantee the excellent quality of products.

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.

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.

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