Optimization of Injection Moulding Process from the View of Cavity Filling Time and Product Cooling Time

2014 ◽  
Vol 621 ◽  
pp. 208-213
Author(s):  
Katarina Monkova ◽  
Slavomir Hric
Keyword(s):  
Injection Moulding ◽  
3D Model ◽  
Cooling System ◽  
Moulding Process ◽  
Mould Filling ◽  
Injection Moulding Process ◽  
Filling Time ◽  
Moulding Machine ◽  
Mould Cavity ◽  
Cavity Filling

The article deals with the mould cooling system design. The goal of design presented in the article was to propose the mould form so to be achieved the shortest time for both mould filling and product cooling. Studied product is intended to serve as a stopper in the automotive spotlight. After filling of mould cavity, the melt has to cool at 100 ° C, only then it is possible to accede to the next phase, which is final pressure. So the cooling and filling time is directly proportional to the reduction of production cost. 3D model of the mould was created in Autodesk Inventor Proffesional software and then solidification of material was simulated in Autodesk Moldflow Insight software. There were considered four types of cooling system in the article and the best one from the view of time was manufactured and placed into the injection moulding machine Arburg Allrounder 320 C.

The Simulation as a Tool for Technical Devices Design and Optimization

2014 ◽  
Vol 718 ◽  
pp. 122-127
Author(s):  
Slavomir Hric ◽  
Dominika Lehocka ◽  
Jan Carach ◽  
Filip Murgas ◽  
Peter Pastucha
Keyword(s):  
Injection Moulding ◽  
3D Model ◽  
Cooling System ◽  
Moulding Process ◽  
Design And Optimization ◽  
Running System ◽  
Injection Moulding Process ◽  
Moulding Machine ◽  
Mould Cavity

The article deals with the research of the pressures originated inside the cooling system and also in the mould cavity during the injection moulding process. The simulations were realized for three designed types of running system and for four versions of cooling system. 3D model of the mould was created in Autodesk Inventor Proffesional software and then solidification of material was simulated in Autodesk Moldflow Insight software. The results were compared and the best version from the view of pressure was manufactured and placed into the injection moulding machine Arburg Allrounder 320 C.

Simulation of the micro-injection moulding process: effect of the thermo-rheological status on the morphology

2011 ◽  
Vol 225 (4) ◽  
pp. 224-238 ◽  
Author(s):  
T Nguyen-Chung ◽  
C Löser ◽  
G Jüttner ◽  
T Pham ◽  
M Obadal ◽  
...  
Keyword(s):  
Injection Moulding ◽  
Process Conditions ◽  
Transfer Coefficients ◽  
Moulding Process ◽  
Micro Injection Moulding ◽  
Mould Filling ◽  
Injection Moulding Process ◽  
Moulding Machine ◽  
Simulation Results ◽  
Micro Cavity

The software package Moldflow Plastics Insights was used to simulate the filling of a micro-cavity by considering precise material data and accurate boundary conditions. Experiments were carried out on an accurately controlled micro-injection moulding machine (formicaPlast) for providing important parameters to verify the simulation results and improve the accuracy of the simulation. Based on the relationship between the cavity pressure and the mould-filling ratio, the heat transfer coefficients can be appropriately determined for different process conditions. Finally, the transient thermo-rheological results were analysed with regard to their influence on the morphology of semi-crystalline (PP) micro-injection moulded parts, which not only give rise to the mechanisms of the morphological formation but also verify the quality of the simulation results.

Evaluation of Cadmould Software to Simulate the Filling Phase of a Natural Rubber Compound in Injection Moulding Process

2013 ◽  
Vol 747 ◽  
pp. 571-574 ◽  
Author(s):  
Zulkifli Mohamad Ariff ◽  
T.H. Khang
Keyword(s):  
Natural Rubber ◽  
Injection Moulding ◽  
Input Data ◽  
Cure Kinetics ◽  
Rubber Compound ◽  
Moulding Process ◽  
Related Data ◽  
Mould Filling ◽  
Injection Moulding Process ◽  
Material Input

The possibility of using Cadmould software to simulate the filling behaviour of a natural rubber compound during an injection moulding process was investigated. For the simulation process, the determination of required material input data involving the rheological and cure kinetics data of the designed rubber compound were conducted. It was discovered that the acquired data were able to function as reliable material input data as they were comparable with related data available in the Cadmould software materials database. Verification of the simulated filling profiles by experimental short shots specimens showed that the Cadmould Rubber Package was able to predict the realistic filling behaviour of the formulated natural rubber compound inside the mould cavity when the measured material data were utilized. Whereas, the usage of available material database from the software failed to model the mould filling progression of the intended natural rubber compound.

scholarly journals Optimisation of Mould Design for Injection Moulding – Numerical Approach

2021 ◽  
Vol 15 (2) ◽  
pp. 258-266
Author(s):  
Damir Godec ◽  
Vladimir Brnadić ◽  
Tomislav Breški
Keyword(s):  
Computer Simulation ◽  
Injection Moulding ◽  
Numerical Approach ◽  
Processing Parameters ◽  
Simulation Software ◽  
Moulding Process ◽  
Part Geometry ◽  
Injection Moulding Process ◽  
Mould Cavity ◽  
Mould Design

Computer simulation of injection moulding process is a powerful tool for optimisation of moulded part geometry, mould design and processing parameters. One of the most frequent faults of the injection moulded parts is their warpage, which is a result of uneven cooling conditions in the mould cavity as well as after part ejection from the mould and cooling down to the environmental temperature. With computer simulation of the injection moulding process it is possible to predict potential areas of moulded part warpage and to apply the remedies to compensate/minimize the value of the moulded part warpage. The paper presents application of simulation software Moldex 3D in the process of optimising mould design for injection moulding of thermoplastic casing.

Injection Moulding Simulation Analysis of Handle Shell

2013 ◽  
Vol 798-799 ◽  
pp. 286-289
Author(s):  
Wei Li
Keyword(s):  
Process Parameters ◽  
Injection Moulding ◽  
Simulation Analysis ◽  
Final Analysis ◽  
Moulding Process ◽  
Technical Requirements ◽  
Injection Moulding Process ◽  
Moulding Machine ◽  
Final Analysis Result

This thesis first made an introduction to the functional and technical requirements of this product, and then determined its moulding process. After that, the injection moulding process parameters of the selected injection moulding machine were set, besides, it applied Moldflow software to make simulation analysis to multiple schemes of injection moulding process, and finally, the best mold structure was determined according to the final analysis result.

Mould Filling and Pressure Distribution for Polymer Resins

2011 ◽  
Vol 264-265 ◽  
pp. 771-776
Author(s):  
A. Mohd ◽  
C. Hindle ◽  
W.A.Y. Yusoff
Keyword(s):  
Simulation Software ◽  
Cylindrical Shape ◽  
Moulding Process ◽  
Polymer Resin ◽  
Mould Filling ◽  
Packing Pressure ◽  
Injection Moulding Process ◽  
Mould Cavity ◽  
Mould Design ◽  
Market Needs

The application of simulation software packages for mould design and injection moulding process is becoming importance to optimizing the moulding quality and satisfy market needs. This paper presents the simulation of mould filling and packing for various polymer resin types. The filling and packing pressure phases for different type of polymer resins as well as the flow behaviour of molten resin in the mould cavity were investigated. Three common polymer resins which are amorphous and crystalline thermoplastics were used. Cylinder component cups with variation of wall thicknesses were designed. Two-cavity prototype moulds for cylindrical shape component were constructed by using AutoCAD 2006 including assembly and part drawings. The 3D model was produced by using Autodesk Inventor Professional. The result successfully revealed that polyamide resin required shorter time for filling the cavity and less pressure compared to PS and ABS.

Warpage Analysis of Different Number Cooling Channels for Dumbbell Plastic Part in Injection Moulding

2015 ◽  
Vol 761 ◽  
pp. 8-11 ◽  
Author(s):  
Mohd Amran ◽  
Siti Salmah ◽  
Raja Izamshah ◽  
Mohd Shahir ◽  
Mohd Amri ◽  
...  
Keyword(s):  
Injection Moulding ◽  
Simulation Analysis ◽  
Cooling System ◽  
Cooling Channel ◽  
Mould Temperature ◽  
Plastic Part ◽  
Melt Temperature ◽  
Moulding Process ◽  
Cooling Channels ◽  
Injection Moulding Process

Warpage deflection is one of the common pitfalls in plastic injection moulding which is always affected the quality and accuracy of the plastic products. It occurs due to the influences of mould temperature during injection moulding process and it is related to the number of cooling system existed in the mould. Therefore, this paper studies the effect of cooling channels on warpage of dumbbell plastic part having different number of cooling channel using Moldflow software. Warpage analysis was run using four and eight cooling channels. Parameters involved in this study are injection time, packing time, melt temperature and mould temperature. The result of warpage from simulation analysis was projected on the graphic having different colour which is presented the actual value of warpage. It is found from warpage simulation result that the maximum warpage for four cooling channels is 1.283mm and the maximum warpage for eight cooling channels is 1.280mm. It shows that the increasing of the number of cooling channel from four to eight channels in the injection mould reduces the warpage deflection about 0.2%. Thus, the result shows that the number of cooling system in the mould plays an important role on the quality of plastic part during injection moulding process.

scholarly journals Rheological characterization of polystyrene melts dissolved with supercritical nitrogen fluid during microcellular injection moulding

e-Polymers ◽  
2010 ◽  
Vol 10 (1) ◽  
Author(s):  
Shia-Chung Chen ◽  
Ming-Hsiu Chung ◽  
Yu-Wan Lin ◽  
Ping-Shun Hsu ◽  
Shyh- Shin Hwang ◽  
...  
Keyword(s):  
Injection Moulding ◽  
Rheological Behaviour ◽  
Rheological Characterization ◽  
Melt Temperature ◽  
Moulding Process ◽  
Foaming Process ◽  
Lower Viscosity ◽  
Injection Moulding Process ◽  
Mould Cavity ◽  
Moulding Pressure

AbstractThere are several benefits of using the supercritical fluid microcellular injection moulding process. The part weight, melt temperature, viscosity, moulding pressure, shrink/warpage, and cooling/cycle time are all significantly reduced. The purpose of this study is to investigate the rheological behaviour of PS melt dissolved SCF of nitrogen during Microcellular Injection Moulding process applied with Gas Counter Pressure (GCP) technology. The application of gas into the mould cavity prior to the melt filling provides a counter force against the melt front advancement, restricting the foaming process during the melt filling stage. A slit cavity is designed to measure the pressure drop of polystyrene mixed with 0.4wt% supercritical nitrogen fluid under different mould temperatures (185°C, 195°C, and 205°C), injection speeds (5, 10, and 15 mm/s) as well as counter pressures (0, 150, 300 bars). It was found that melt viscosity is reduced by up to 30% when GCP is increased from 50 to 150 bar as compared to conventional injection moulding. The non-nucleation mixture melt obtained by using a GCP of 300 bar has 32~49% lower viscosity. In addition, the glass transition temperature, Tg, was found to be reduced from 96 °C to 50 °C when the applied GCP is 300 bar.

scholarly journals Robust Part Quality by Controlling the Injection Moulding Process with 24 Fraction Factorial Design: A Case Study

2011 ◽  
Vol 383-390 ◽  
pp. 1032-1038 ◽  
Author(s):  
S. Rajalingam
Keyword(s):  
Factorial Design ◽  
Injection Moulding ◽  
Digital Camera ◽  
Moulding Process ◽  
Part Quality ◽  
Horizontal Length ◽  
Injection Moulding Process ◽  
Moulding Machine ◽  
Process Factors

The author wants to use a case study to investigate the injection moulding machine parameters which will affect the horizontal length dimension of a plastic component used in digital camera. Currently the injection moulding machine process setting caused variations in the diameter exceeding the specification limit. Therefore the experiment is needed to identify the process factors that could be set to maintain the horizontal length dimension closest to the target value and smallest possible variation. The experimental model is used to investigate four factors to identify the factors having large effect by using the Full Factorial Design of Experiment (DOE). The experiment has emphasized the use of these designs in identifying the subset of factors that are active and provide some information about the interaction.

Bio Inspired Algorithms for Injection Moulding Optimization

2013 ◽  
Vol 683 ◽  
pp. 771-774 ◽  
Author(s):  
Pedro Carreira ◽  
Nuno Alves ◽  
Carina Ramos ◽  
Paulo J. Bártolo
Keyword(s):  
Cycle Time ◽  
Injection Moulding ◽  
Optimization Strategy ◽  
Moulding Process ◽  
Injection Moulding Process ◽  
Filling Time ◽  
Living Organisms ◽  
Nature Inspired Algorithms ◽  
Optimum Solution ◽  
The Cost

Social behaviors of living organisms found in nature, like food searching, environment fitness and survival are inspiration for meta-heuristic mathematical models. Replicating these natural organism behaviors, several optimization algorithms have been developed and applied to technological processes. In this work, some nature inspired algorithms are applied to the injection problem in order to optimize the injection runners’ geometry, so that the overall cycle time is minimized. A key issue is the injection moulding process, as it strongly determines the cost per part. A global optimization strategy was implemented for the injection moulding cycle time, covering the main steps of process, filling time, cooling time, packing time and opening time. To achieve the optimum solution for each design variable and obtain the best time solution overall, it will enable to evaluate optimality, robustness, convergence, and variables dispersion for each used algorithm.

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