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.

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.

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.

Warpage Analysis of Single and Dual Gates Designed for Injection Moulding Using Response Surface Methodology

2015 ◽  
Vol 754-755 ◽  
pp. 775-783 ◽  
Author(s):  
S.M. Nasir ◽  
Khairul Azwan Ismail ◽  
Z. Shayfull ◽  
M.A. Fairuz
Keyword(s):  
Injection Moulding ◽  
Variable Parameter ◽  
Acrylonitrile Butadiene Styrene ◽  
Inlet Temperature ◽  
Melt Temperature ◽  
Mould Material ◽  
Moulding Process ◽  
Packing Pressure ◽  
Injection Moulding Process ◽  
Mould Design

This study focuses on the analysis of plastic injection moulding process simulation using Autodesk Moldflow Insight (AMI) software in order to correlate between process parameters as an input and warpage as an output for single and dual gates mould design. Nessei NEX 1000 injection moulding machine and P20 mould material details are incorporated in this study on top of Acrylonitrile Butadiene Styrene (ABS) as a moulded thermoplastic material. Coolant inlet temperature, material melt temperature, packing pressure and packing time are selected as a variable parameter. Design Expert software is obtained as a medium for analysis and optimization of input variables in order to minimize the warpage. RSM method as well as Analysis of Variance (ANOVA) has been applied in this study. The results of ANOVA show that some interactions between factors are significant towards warpage existence, which is coolant inlet temperature, material melt temperature and packing pressure. Furthermore, the model created using RSM can be used for warpage prediction and improvement due to a minimum value of error. From this study, the dual gate is the best solution which able to improve the warpage up to 80% instead of single.

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 Viscoelastic Characterization of Short Fibres Reinforced Thermoplastic in Tension and Shearing

2010 ◽  
Vol 24-25 ◽  
pp. 419-423 ◽  
Author(s):  
A. Andriyana ◽  
Luisa Silva ◽  
Noelle Billon
Keyword(s):  
Mechanical Response ◽  
Polymer Matrix Composites ◽  
Mechanical Analysis ◽  
Integrated Modelling ◽  
Matrix Composites ◽  
Moulding Process ◽  
Permanent Strain ◽  
Mould Filling ◽  
Injection Moulding Process

The present work can be regarded as a first step toward an integrated modelling of mould filling during injection moulding process of polymer matrix composites and the resulting material behaviour under service loading conditions. More precisely, the emphasis of the present research is laid on the development of a mechanical model which takes into account the processing-induced microstructure and is capable to predict the mechanical response of the material. In the Part I, a set of experiments which captures the mechanical behaviour of an injection moulded short fibre reinforced under different strain histories is described. Three mechanical testing are conducted: Dynamic Mechanical Analysis (DMA), uniaxial tension and simple shear. Tests show that the material exhibits complex responses mainly due to non-linearity, anisotropy, time/rate-dependence, hysteresis and permanent strain. Moreover, the relaxed state of the material is characterized by the existence of a so-called anisotropic equilibrium hysteresis independently of the prescribed strain rate.

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.

Investigating the Effects of Injection Moulding Process Parameters on Multiple Tensile Characteristics of Plastic Spur Gear via Experimental Approach

2013 ◽  
Vol 748 ◽  
pp. 544-548 ◽  
Author(s):  
Nik Mizamzul Mehat ◽  
Shahrul Kamaruddin ◽  
Abdul Rahim Othman
Keyword(s):  
Process Parameters ◽  
Injection Moulding ◽  
Experimental Approach ◽  
Low Cost ◽  
Spur Gear ◽  
Melt Temperature ◽  
Moulding Process ◽  
Packing Pressure ◽  
Injection Moulding Process ◽  
State Of Tension

This paper presents the original development of an experimental approach in studying the multiple tensile characterizations as key quality characteristics for several different plastic gear materials related to various parameters in injection moulding process. In this study, emphases are given on a new low-cost mechanism for the testing of the injection moulded plastic spur gear specimens with various teeth module. The testing fixture are developed and validated to provide uniform state of tension with series of plastic gear specimens produced in accordance with the systematically designed of experiment. The effects of changes in the process parameters including melt temperature, packing pressure, packing time and cooling time at three different levels on the elongation at break and ultimate strength of plastic gear is evaluated and studied through the proposed experimental approach.

Optimizing Flow for the Two Color Injection Mould Design

2013 ◽  
Vol 441 ◽  
pp. 627-630
Author(s):  
Yan Fang Yin ◽  
Zhen Hui Tian
Keyword(s):  
Analytical Solutions ◽  
Material Behavior ◽  
Governing Equations ◽  
Window Frame ◽  
Moulding Process ◽  
Injection Moulding Process ◽  
Cad Cam ◽  
Pros And Cons ◽  
Mould Design ◽  
Cam Systems

Commercial CAD/CAM systems provide semi-automatic tools to assist the designer in the dimensioning process. Analytical solutions to injection molding problems are very rare due to thecomplexities of the governing equations, the material behavior and the cavity geometry. Study of window frame fabrication by injection moulding process was carried out with the aid of Moldflow® software. Ejector plate designs were created to compare the pros and cons of each design. The investigations were carried out on flowing, packing, cooling and costing of injection moulded window frame. Using the method, good results have been obtained for several basic geometric models.

scholarly journals Modeling and Analysis of Injection Moulding Process Parameters for Plastic Gear Industry Application

2013 ◽  
Vol 2013 ◽  
pp. 1-10 ◽  
Author(s):  
Nik Mizamzul Mehat ◽  
Shahrul Kamaruddin ◽  
Abdul Rahim Othman
Keyword(s):  
Polymer Melt ◽  
Optimization Method ◽  
Processing Parameters ◽  
Taguchi Optimization ◽  
Modeling And Analysis ◽  
Moulding Process ◽  
Real Process ◽  
Injection Moulding Process ◽  
Mould Design ◽  
Plastic Gears

The performance of plastic gears in wide variety of power and motion transmission applications is rather limited due to weak mechanical properties and divergent mechanism of failures. A methodical simulation is carried out to analyze the gear performance with various gating system types, gate locations, and processing parameters via grey-based Taguchi optimization method. With the obtained optimum results in simulation stage, the flow patterns of polymer melt inside the mould during filling, packing, and cooling processes are studied and the plastic gear failures mechanism related to processing parameters are predicted. The output results in the future can be used as guidance in selecting the appropriate materials, improving part and mould design, and predicting the performance of the plastic gear before the real process of the part manufacturing takes place.

The Effect of Thermo-Mechanical Environment on the Shrinkage and Warpage in Thermoplastic Parts

2008 ◽  
Vol 587-588 ◽  
pp. 558-562 ◽  
Author(s):  
P.S. Alves ◽  
A.J. Pontes
Keyword(s):  
Material Properties ◽  
Injection Moulding ◽  
Data Acquisition System ◽  
Monitoring And Control ◽  
Process Variables ◽  
Mechanical Environment ◽  
Moulding Process ◽  
Injection Moulding Process ◽  
Mould Design ◽  
And Control

During the injection moulding process, the material is subjected to successive transformations, being submitted to a thermo-mechanical environment that determines the final dimensions of the part. This environment is characterized by several parameters which are related to material properties, the mould design, equipment and process variables. As a result, deviations of the dimensions of the moulded parts from the dimensions of the cavity cannot be avoided. If differences on shrinkage occur, caused for example by anisotropies of the material or non-uniform cooling, distortions will happen. In order to predict this two effects on the injection cycles is require one strategy to monitoring and control the process variables. The aim is to achieve highest quality control of all manufacture parts. This paper presents the effect of different holding pressures and mould temperatures on shrinkage and warpage in two different materials, one amorphous (PC) and another semi crystalline (PP). An instrumented mould was manufactured. During the injection moulding process sensors signals were continuously monitored by a Data Acquisition System. The experimental results were compared with predictions made by commercial software.

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