The Influence of Processing Parameters on Gas Penetration in GAIM for Thick-Wall Parts

2010 ◽  
Vol 33 ◽  
pp. 669-673
Author(s):  
Hong Lei Shen ◽  
Liu Feng
Keyword(s):  
Quantitative Analysis ◽  
Process Parameters ◽  
Delay Time ◽  
Processing Parameters ◽  
Gas Pressure ◽  
Thick Wall ◽  
Melt Temperature ◽  
Computer Aided ◽  
Short Shot ◽  
Gas Penetration

In this paper, the auto door-handle was taken for an example, the quantitative analysis of the processing parameters (including melt temperature, shot size, delay time and gas pressure) on gas penetration in GAIM process was introduced using the method of orthogonality and computer-aided engineering. The effort in this article is aimed at the effect extent and trend of the four parameters on the molding result. Through the study, the main achievements are as follows: In short shot process for thick-wall parts, the shot size is the most significant factor on the molding result, the delay time is the second and the gas pressure is the last one. The length of gas penetration will increase with the reduction of shot size and delay time, or with the increasing of melt temperature and gas pressure. Then the optimization of the process parameters on the door handle was carried out.

An empirical study of gas penetration in full-shot gas-assisted injection moulded parts

2002 ◽  
Vol 216 (12) ◽  
pp. 1549-1559 ◽  
Author(s):  
S-J Liu ◽  
K-H Chang
Keyword(s):  
Injection Moulding ◽  
Bending Strength ◽  
Hold Time ◽  
Gas Injection ◽  
Processing Parameters ◽  
Melt Temperature ◽  
Relative Significance ◽  
Short Shot ◽  
Gas Penetration ◽  
Sink Mark

Full-shot gas-assisted injection moulding has increasingly become one of the most important methods used to produce plastic components. It has the advantage of eliminating the switchover mark, which usually occurs on the surface of short-shot gas-assisted injection moulded parts. This paper is devoted to an investigation of the effects of different processing parameters on the length of gas penetration in full-shot gas-assisted injection moulded parts. The first part of this report shows how the gas penetration of moulded parts is optimized. An L'18 experimental matrix design based on the Taguchi method was conducted to investigate the processing factors that affect the length of gas penetration in full-shot moulded parts. The second part of this paper identifies the relative significance of each processing parameter on the gas penetration of moulded products. The materials used were general-purpose polystyrene and polypropylene. Experiments were carried out on an 80 ton injection-moulding machine equipped with a high-pressure nitrogen gas injection unit. For the factors selected in the main experiments, melt temperature, gas injection delay time and gas hold time were found to be the key processing parameters affecting the length of gas penetration in full-shot gas-assisted injection moulded parts. In addition, the sink mark of full-shot moulded parts decreases with the length of gas penetration. Bending strength of full-shot gas-assisted injection moulded parts is higher than that of short-shot moulded parts.

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.

Warpage and Shrinkage Analysis and Optimization of Rapid Tooling Molded thin Wall Component Using Modified Particle Swarm Algorithm

2019 ◽  
Vol 18 (01) ◽  
pp. 85-102 ◽  
Author(s):  
Sagar Kumar ◽  
Amit Kumar Singh
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Simulation Analysis ◽  
Statistical Significance ◽  
Particle Swarm ◽  
Processing Parameters ◽  
Particle Swarm Algorithm ◽  
Thin Wall ◽  
Polybutylene Terephthalate ◽  
Melt Temperature

This paper presents a systematic methodology to determine optimal injection molding conditions for minimum warpage and shrinkage in a thin wall relay part using modified particle swarm optimization algorithm (MPSO). Polybutylene terephthalate (PBT) and polyethylene terephthalate (PET) were injected in a thin wall relay component for different processing parameters: melt temperature, packing pressure and packing time. Further, Taguchi’s L9 (3[Formula: see text] orthogonal array is used for conducting simulation analysis to consider the interaction effects of the above parameters. A predictive mathematical model for shrinkage and warpage is developed in terms of the above process parameters using regression analysis. ANOVA analysis is performed to establish statistical significance within the injection molding parameters. The analytical model is further optimized using a newly developed MPSO algorithm and the process parameters values are predicted for minimizing shrinkage and warpage. The predicted values of shrinkage and warpage using MPSO algorithm are improved by approximately 30% as compared to the initial simulation values and comparable to previous literature results.

Effects of Process Parameters on Shrinkage Uniformity and Birefringence of Injection-Compression Molded Parts

2008 ◽  
Author(s):  
Han-Xiong Huang ◽  
Can Yang ◽  
Kun Li
Keyword(s):  
Process Parameters ◽  
Delay Time ◽  
Mold Temperature ◽  
Compression Force ◽  
Melt Temperature ◽  
Compression Speed ◽  
Compression Time ◽  
Molded Parts ◽  
Injection Compression Molding ◽  
Conventional Injection Molding

Injection-compression molding (ICM) with greater flexibility than conventional injection molding (CIM) can produce parts with better quality. In this work, polystyrene (PS) parts were molded by ICM technology. The effects of seven dominating process parameters, including mold temperature, melt temperature, compression force, compression distance, compression speed, compression time, and delay time, on both shrinkage uniformity and birefringence of PS parts were investigated. The results showed that compression force is the most important parameter for part shrinkage uniformity. The position with a lowest shrinkage moved towards the gate with increased compression distance. There is a remarkable increase in birefringence with larger compression forces. There is certain relationship between shrinkage uniformity and birefringence results.

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.

Study on one Dimensional Numerical Simulation in Filling Stage of Water-Assisted Injection Molding

2011 ◽  
Vol 179-180 ◽  
pp. 1193-1198 ◽  
Author(s):  
Tang Qing Kuang
Keyword(s):  
Numerical Simulation ◽  
Injection Molding ◽  
Water Temperature ◽  
Water Pressure ◽  
Mold Temperature ◽  
Processing Parameters ◽  
Melt Temperature ◽  
Filling Stage ◽  
Short Shot ◽  
Temperature Water

Water assisted injection molding is a pretty novel way to fabricate hollow or more complicated parts. Its molding window and process control are more critical and difficult since additional processing parameters are involved. A simulation model for the filling stage of a pipe cavity during short-shot water assisted injection molding was proposed. The finite element/finite difference/control volume methods were adopted for the numerical simulation. A numerical study, based on the single factor method, was conducted to characterize the effect of different processing parameters on the short shot water-assisted injection-molding of thermoplastic composites, including short-shot size, melt temperature, mold temperature, water temperature and water pressure. For the factors selected in the simulations, short-shot size was found to be the principal parameters affecting the water penetration length while melt temperature, mold temperature, water temperature, water pressure were found to have little effect on the penetration of water.

scholarly journals Numerical Simulation during Short-Shot Water-Assisted Injection Molding Based on the Overflow Cavity for Short-Glass Fiber-Reinforced Polypropylene

2020 ◽  
Vol 2020 ◽  
pp. 1-13
Author(s):  
Zhong Yu ◽  
He-Sheng Liu ◽  
Tang-Qing Kuang ◽  
Xing-Yuan Huang ◽  
Wei Zhang ◽  
...  
Keyword(s):  
Injection Molding ◽  
Fiber Orientation ◽  
Delay Time ◽  
Flow Direction ◽  
Water Injection ◽  
Injection Pressure ◽  
Melt Flow ◽  
Melt Temperature ◽  
Short Shot ◽  
Main Cavity

Compared with water penetration condition of short-shot water-assisted injection molding with or without overflow cavity, it can be known from theory and common knowledge that short-shot water-assisted injection molding with overflow cavity has many advantages, such as it can save materials and energy. Then, the effects of melt short shot size, water injection delay time, melt temperature and water injection pressure on the penetration of water after penetration, and the orientation distribution of short fibers during water-assisted injection molding of the overflow cavity short-shot method were studied. It is found that the melt short shot size had the greatest influence on it, followed by water injection pressure, water injection delay time, and finally, melt temperature. With the increase of the melt short shot size, the thickness of the residual wall of the whole main cavity becomes thinner, the orientation of short fiber along the melt flow direction becomes higher, and the degree of fiber orientation changes becomes lower. In the front half of the main cavity, with the decrease of water injection pressure, the delay time of water injection, and the melt temperature, in the front part of the main cavity, the residual wall thickness becomes thinner, the fiber orientation along the melt flow direction becomes lower, and the fiber orientation changes degree becomes higher; in the latter half of the main cavity, the influence of the water penetration and the orientation distribution of short fibers along the melt flow direction are not significant.

scholarly journals Optimization of Residual Wall Thickness Uniformity in Short-Fiber-Reinforced Composites Water-Assisted Injection Molding Using Response Surface Methodology and Artificial Neural Network-Genetic Algorithm

2020 ◽  
Vol 2020 ◽  
pp. 1-10
Author(s):  
Haiying Zhou ◽  
Hesheng Liu ◽  
Tangqing Kuang ◽  
Qingsong Jiang ◽  
Zhixin Chen ◽  
...  
Keyword(s):  
Neural Network ◽  
Genetic Algorithm ◽  
Artificial Neural Network ◽  
Response Surface Methodology ◽  
Process Parameters ◽  
Delay Time ◽  
Short Fiber ◽  
Fiber Reinforced Composites ◽  
Reinforced Composites ◽  
Melt Temperature

This study aimed at improving the residual wall thickness uniformity (RWTU), which was closely related to the mechanical properties of plastic parts with a hollow cross-section, in short-fiber reinforced composites (SFRC) overflow water-assisted injection molding (OWAIM). The influences of five independent process parameters (melt temperature, mold temperature, delay time, water pressure, and water temperature) on RWTU were investigated through the methods such as central composite design, regression equation, and analyses of variance. Response surface methodology (RSM) and artificial neural network (ANN) optimized by genetic algorithm (GA) were employed to map the relationship between the process parameters and the standard deviation (SD) depicting the RWTU. Comparison assessments of three models (RSM, ANN, and ANN-GA) were carried out through some statistical indexes. It was concluded that the effect of melt temperature, delay time, and water temperature were significant to RWTU; the hybrid ANN-GA model had the best performance for predicting SD compared with RSM and ANN; the least SD obtained in optimization using ANN-GA as a fitness function was 0.0972.

scholarly journals Fused Deposition Modelling of Fibre Reinforced Polymer Composites: A Parametric Review

2021 ◽  
Vol 5 (1) ◽  
pp. 29
Author(s):  
Narongkorn Krajangsawasdi ◽  
Lourens G. Blok ◽  
Ian Hamerton ◽  
Marco L. Longana ◽  
Benjamin K. S. Woods ◽  
...  
Keyword(s):  
Process Parameters ◽  
Mechanical Performance ◽  
Fibre Length ◽  
Processing Parameters ◽  
Thermoplastic Composite ◽  
Fused Deposition Modelling ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Fibre Reinforced Polymer ◽  
Printing Parameters

Fused deposition modelling (FDM) is a widely used additive layer manufacturing process that deposits thermoplastic material layer-by-layer to produce complex geometries within a short time. Increasingly, fibres are being used to reinforce thermoplastic filaments to improve mechanical performance. This paper reviews the available literature on fibre reinforced FDM to investigate how the mechanical, physical, and thermal properties of 3D-printed fibre reinforced thermoplastic composite materials are affected by printing parameters (e.g., printing speed, temperature, building principle, etc.) and constitutive materials properties, i.e., polymeric matrices, reinforcements, and additional materials. In particular, the reinforcement fibres are categorized in this review considering the different available types (e.g., carbon, glass, aramid, and natural), and obtainable architectures divided accordingly to the fibre length (nano, short, and continuous). The review attempts to distil the optimum processing parameters that could be deduced from across different studies by presenting graphically the relationship between process parameters and properties. This publication benefits the material developer who is investigating the process parameters to optimize the printing parameters of novel materials or looking for a good constituent combination to produce composite FDM filaments, thus helping to reduce material wastage and experimental time.

scholarly journals Optimizing Laser Powder Bed Fusion Parameters for IN-738LC by Response Surface Method

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 4879
Author(s):  
Mireia Vilanova ◽  
Rubén Escribano-García ◽  
Teresa Guraya ◽  
Maria San Sebastian
Keyword(s):  
Response Surface ◽  
Response Surface Method ◽  
Process Parameters ◽  
Crack Density ◽  
Processing Parameters ◽  
Optimum Process ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Surface Method

A method to find the optimum process parameters for manufacturing nickel-based superalloy Inconel 738LC by laser powder bed fusion (LPBF) technology is presented. This material is known to form cracks during its processing by LPBF technology; thus, process parameters have to be optimized to get a high quality product. In this work, the objective of the optimization was to obtain samples with fewer pores and cracks. A design of experiments (DoE) technique was implemented to define the reduced set of samples. Each sample was manufactured by LPBF with a specific combination of laser power, laser scan speed, hatch distance and scan strategy parameters. Using the porosity and crack density results obtained from the DoE samples, quadratic models were fitted, which allowed identifying the optimal working point by applying the response surface method (RSM). Finally, five samples with the predicted optimal processing parameters were fabricated. The examination of these samples showed that it was possible to manufacture IN738LC samples free of cracks and with a porosity percentage below 0.1%. Therefore, it was demonstrated that RSM is suitable for obtaining optimum process parameters for IN738LC alloy manufacturing by LPBF technology.

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