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.

Influence of Processing Conditions on the Morphological Structure and Ductility of Water-Foamed Injection Molded PP/LDPE Blended Parts

2017 ◽  
Vol 36 (2) ◽  
pp. 51-74 ◽  
Author(s):  
Ying-Guo Zhou ◽  
Bei Su ◽  
Lih-Sheng Turng
Keyword(s):  
Injection Molding ◽  
Morphological Structure ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Processing Conditions ◽  
Injection Time ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Packing Time ◽  
Number Of Cells

Water-foamed injection molding (WFIM) uses conventional injection molding (CIM) with water as a physical foaming agent. Compared to CIM, WFIM is a much more complicated process. As such, it is critical to determine the processing conditions for fabricating quality parts using WFIM. We used the design of experiment (DOE) method based on the Taguchi method to determine the influence of the processing conditions on the morphological structure and ductility of PP/LDPE WFIM parts, which were investigated by tensile testing and scanning electron microscopy (SEM). Our research suggests that fabricating PP/LDPE super-ductile parts using WFIM is indeed feasible. Our research also indicates that there is a close relationship between the ductility and the foamed structures, both of which are deeply influenced by the processing conditions. The analysis of variance results shows further that the water content had the greatest influence on the ductility, followed by the melt temperature, packing time, packing pressure, and PP/LDPE ratio. However, the ductility was only slightly influenced by the mold temperature, injection pressure, and injection time in WFIM. As to the number of cells, the order of influence was melt temperature, water content, packing time, packing pressure, mold temperature, injection pressure, PP/LDPE ratio, and injection time, in that order. In addition, applying DOE is a quite effective method for deducing the optimal set of effective factors in WFIM to produce super-ductile parts with a maximum number of cells. To our knowledge, this is the first time that the relationship among the processing conditions, ductility, and foamed structure of PP/LDPE WFIM super-ductile parts has been investigated and reported.

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.

The simulation of the warpage rule of the thin-walled part of polypropylene composite based on the coupling effect of mold deformation and injection molding process

2018 ◽  
Vol 25 (3) ◽  
pp. 593-601 ◽  
Author(s):  
Jixiang Zhang ◽  
Xiaoyi Yin ◽  
Fengzhi Liu ◽  
Pan Yang
Keyword(s):  
Injection Molding ◽  
Coupling Effect ◽  
Mold Temperature ◽  
Injection Molding Process ◽  
Plastic Part ◽  
Molding Process ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Thin Walled ◽  
Packing Time

Abstract Aiming at the problem that a thin-walled plastic part easily produces warpage, an orthogonal experimental method was used for multiparameter coupling analysis, with mold structure parameters and injection molding process parameters considered synthetically. The plastic part deformation under different experiment schemes was comparatively studied, and the key factors affecting the plastic part warpage were analyzed. Then the injection molding process was optimized. The results showed that the important order of the influence factors for the plastic part warpage was packing pressure, packing time, cooling plan, mold temperature, and melt temperature. Among them, packing pressure was the most significant factor. The optimal injection molding process schemes reducing the plastic part warpage were melt temperature (260°C), mold temperature (60°C), packing pressure (150 MPa), packing time (2 s), and cooling plan 3. In this situation, the forming plate flatness was better.

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%.

Investigation of Mold Temperature Affecting on Shrinkage of Rapid Heat Cycle Molding Plastic Part

2011 ◽  
Vol 189-193 ◽  
pp. 2477-2481 ◽  
Author(s):  
Dong Lei Liu ◽  
Chang Yu Shen ◽  
Chun Tai Liu ◽  
Yong Xin ◽  
Ling Sun
Keyword(s):  
Deformation Temperature ◽  
Thermal Deformation ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Cooling Time ◽  
Melt Temperature ◽  
Heat Cycle ◽  
Temperature Conditions ◽  
Packing Pressure ◽  
Packing Time

In order to further investigate the influence of mold temperature in rapid heat cycle molding on shrinkage of plastic past, a self-developed vehicle-used blue-tooth front shell high-gloss mold and an auxiliary device for controlling the mold temperature were employed in experiments. And the effect of the other parameters on shrinkage of part with fixed or changed mold temperature conditions was also studied. Results reveal that the shrinkage of RHCM part is reduced obviously compared with a conventional one, decreasing as quasi-linear with mold temperature increased gradually. At same mold temperature conditions, packing pressure, followed by packing time, is the most significant parameter on shrinkage of part, while cooling time has almost no impact on it. Melt temperature and injection pressure effecting on shrinkage of part exists a critical value, near the thermal deformation temperature of plastic. When mold temperature is set below this temperature, injection pressure has more significant than melt temperature, but it is the opposite. With being elevated gradually of mold temperature, shrinkage of part shows a slight decrease trend under same melt temperature and injecting pressure. While it fluctuates as a “V” shape with a narrow range under same packing pressure, packing time and cooling time presumed conditions, and reaches the minimum near the thermal deformation temperature of plastic.

scholarly journals The simulation of volume shrinkage for double-injection molding with PC and ABS

2018 ◽  
Vol 192 ◽  
pp. 01053
Author(s):  
Pichai Leklong ◽  
Wipoo sriseubsai
Keyword(s):  
Injection Molding ◽  
Weld Line ◽  
Acrylonitrile Butadiene Styrene ◽  
Volume Shrinkage ◽  
Melt Temperature ◽  
Double Injection ◽  
Molded Part ◽  
Packing Pressure ◽  
Injection Molded ◽  
Plastic Injection

The objective of this paper was to study and analyze the plastic injection molding parameters to reduce the volume shrinkage of double injection molded part. The specimen was molded with Acrylonitrile-butadiene-styrene (ABS) after Polycarbonate was molded as a half part. The weld line occurred at the haft of the molded part. The simulation with Moldex 3D R13 and the design of experiment with Taguchi method was used to perform the experiments and analyze the data to get the optimum of volume shrinkage. The results showed that melt temperature and packing pressure was significant to the volume shrinkage. When using low melt temperature and high packing pressure, the shrinkage was low and related to the thermal expansion of the material. It would be one of the parameters to the design of double injection molding.

Fabrication of Supports for Solid Oxide Fuel Cells by Powder Injection Molding

2011 ◽  
Author(s):  
Ali Keshavarz Panahi ◽  
Hadi Miyanaji ◽  
Moein Taheri ◽  
Milad Janbakhsh
Keyword(s):  
Injection Molding ◽  
Weld Line ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Injection Rate ◽  
Powder Injection ◽  
Pressure Injection ◽  
Packing Pressure ◽  
Molded Parts ◽  
Short Shot

In this paper the processing steps for producing SOFC (Solid Oxide Fuel Cell) supports by means of PIM (Powder Injection Molding) technique were investigated. Injection molding parameters in this study were divided into pressure-related (injection pressure and packing pressure), temperature-related (nozzle temperature and mold temperature), and time-related (injection rate and holding time) parameters. Keeping the other parameters (pressure-related, temperature-related and time-related parameters) constant at an optimized value, the effects of each of the molding parameters above were investigated. The results show that the short shot, warpage, weld line and void are the most common defects in molded parts. According to the results the short shot could be seen in low values of injection pressure, injection rate, nozzle and mold temperature. Also, warpage could be seen in high values of mold temperature, injection and packing pressure. Poor weld line was another defect that could be seen in low values of injection pressure, injection rate, nozzle and mold temperature. Also the void was one of the most common defects that could be seen in high values of injection rate and nozzle temperatures. Finally, using optimized molding parameters, the molded parts underwent debinding and sintering processes. Based on the results of thermal shock tests and the porosity measurements of the sintered parts, these molded parts possessed relatively desirable characteristics.

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.

Influence of Process Parameters on Plastic Injection Molding of Automobile Interior Trim

2011 ◽  
Vol 189-193 ◽  
pp. 1675-1680
Author(s):  
Qing Qing Liu ◽  
Lin Hua ◽  
Wei Guo
Keyword(s):  
Mold Temperature ◽  
Process Conditions ◽  
Injection Time ◽  
Molding Process ◽  
Melt Temperature ◽  
Influence Of Process Parameters ◽  
Packing Pressure ◽  
Optimal Setting ◽  
Injection Molded ◽  
Packing Time

The influence of process conditions on the formability of injection-molded PX0034 (9% talc-filled PP) automobile B column mounting trim applied as a model has been studied in current work. This study has been focused on the interactive influence of melt temperature and mold temperature, the interactive influences of injection time and packing time and the influences of packing pressure. Weighting the effect of optimization is by formability including the values of pressure at V/P switchover, volumetric shrinkage differential at ejection, and maximum warpage. Aforementioned values were obtained by numerical simulation of the whole molding process using commercial dedicated code Moldflow. Results indicate that the combination of mold temperature at 25 °C, melt temperature at 220 °C, injection time at 2.2 s, packing time at 16 s and packing pressure at 90% of the filling pressure is the optimal setting for formability of this trim. The simulation results obtained under the optimized parameters are that the pressure at V/P switchover is 27.29 Mpa, the shrinkage differential at ejection is 6.55 %, and maximum warpage is 3.072 mm. Good correlation is highlighted between the experiments and the simulations by comparing effects of the global optimization in formability, which verifies the validity of the optimal combination.

Development of an Integrated Melt Modulation System to Manipulate Cold-Runner Injection Molding Processing Parameters and Their Effects on Final Product Physical and Optical Properties

2017 ◽  
Author(s):  
Majed E. Alsarheed
Keyword(s):  
Injection Molding ◽  
Processing Parameters ◽  
Optical Performance ◽  
Optical Polymers ◽  
Real Time Control ◽  
Time Control ◽  
Packing Pressure ◽  
Injection Molded ◽  
Melt Modulation ◽  
Packing Time

Packing processing parameters, including packing pressure and packing time, have significant impact on the internal molecular orientations, mechanical properties and optical performance of injection molded polymeric products. One of the limitations of cold-runner injection molding machines is the lack of real-time control of packing processing parameters during an injection molding cycle. As a result, a new melt modulation device has been developed and experimentally validated to control melt flow and manipulate processing parameters during cold-runner manufacturing. The use of the integrated melt modulation device has shown enhancement of physical properties and optical performance of injection molded polymeric products. Numerical simulations and experimental results of common thermoplastic optical polymers, such as PMMA, PC, and GPPS have been conducted and briefly demonstrated herein.

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