Analysis of Influences of Processing Parameters on Filling Behavior in Microinjection Molding with a Hot Runner Nozzle

2012 ◽  
Vol 501 ◽  
pp. 117-121
Author(s):  
Gang Gou ◽  
Peng Cheng Xie ◽  
Wei Min Yang ◽  
Yu Mei Ding
Keyword(s):  
Injection Pressure ◽  
Polymer Melt ◽  
Mold Temperature ◽  
Processing Parameters ◽  
Simulation Software ◽  
Processing Parameter ◽  
Melt Temperature ◽  
Injection Speed ◽  
Microinjection Molding ◽  
Packing Pressure

The ability for polymer melt to flow into the microstructure is a crucial factor for successful molding in the microinjection molding of plastic parts. In this study, a simplified analytical model with a direct hot runner nozzle and was constructed to estimate the filling percentage of mold’s cavity. The filling behavior of polymer melt was observed by 3D simulation software Moldflow. The effects of the mold temperature, melt temperature, injection pressure, injection rate, and packing pressure on the filling behavior of polymer melt were investigated. Results revealed that the filling percentage increased with respect to the increase of mold temperature and melt temperature which didn’t exceed its degradation temperature. The injection pressure and packing pressure dramatically influence the filling percentage, and it made no sense to lift the injection speed to fill the cavity when the injection speed reached the relatively high values, and only processing parameter combined available could guarantee the perfect flow and filling for the microstructure.

Numerical Simulation of Shrinkage in the Microinjection Molding of Multi-Microparts Produced in one Mold

2011 ◽  
Vol 221 ◽  
pp. 649-656 ◽  
Author(s):  
Jian Wang ◽  
Wei Min Yang
Keyword(s):  
Numerical Simulation ◽  
Injection Molding ◽  
Plastic Material ◽  
Control Volume ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Processing Parameters ◽  
Injection Molding Process ◽  
Melt Temperature ◽  
Microinjection Molding

The aim of this paper is to verify the reliability of numerical results obtained by using MPI (Moldflow Plastic Insight) for predicting the shrinkage of multi-microparts produced in one mold in microinjection molding. 3D numerical simulation (control volume finite element method) was employed. Pure and 10-20 % GRF (glass fiber reinforced) POM materials were used for the plastic material. The injection molding process was used for different parameters (mold temperature, melt temperature and injection pressure). A DOE (Design of Experiments) technique was then used to plan the numerical simulation activity of the injection molding phase. Among injection processing parameters (mold temperature, melt temperature and injection pressure), the results showed that the mold temperature is the most important factor to affect the shrinkage of multi-microparts significantly for processing parameters. The results also indicated that the processing is very well for micro-injection molding by numerical simulation. In addition, properties of polymer composites with added fillers were systematically studied. Numerical simulation results showed that the numerical resulting composites with 10–20 wt% glass particles exhibited significant improvement in shrinkage, and showed good agreement with experimental results.

scholarly journals Cavity Air Flow Behavior During Filling in Microinjection Molding

2011 ◽  
Vol 133 (1) ◽  
Author(s):  
C. A. Griffiths ◽  
S. S. Dimov ◽  
S. Scholz ◽  
G. Tosello
Keyword(s):  
Flow Behavior ◽  
Air Flow ◽  
Polymer Melt ◽  
Mold Temperature ◽  
Quality Factors ◽  
Melt Temperature ◽  
Injection Speed ◽  
Microinjection Molding ◽  
Process Dynamics ◽  
Flow Length

Process monitoring of microinjection molding (μ-IM) is of crucial importance in understanding the effects of different parameter settings on the process, especially on its performance and consistency with regard to parts’ quality. Quality factors related to mold cavity air evacuation can provide valuable information about the process dynamics and also about the filling of a cavity by a polymer melt. In this paper, a novel experimental setup is proposed to monitor maximum air flow and air flow work as an integral of the air flow over time by employing a microelectromechanical system gas sensor mounted inside the mold. The influence of four μIM parameters, melt temperature, mold temperature, injection speed, and resistance to air evacuation, on two air flow-related output parameters is investigated by carrying out a design of experiment study. The results provide empirical evidences about the effects of process parameters on cavity air evacuation, and the influence of air evacuation on the part flow length.

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.

Molding and Optical Performance Simulations of a New Plastic Grating Lens for an Asymmetric LED Fog Lamp

2012 ◽  
Vol 253-255 ◽  
pp. 2223-2226 ◽  
Author(s):  
Yi Cheng Chen ◽  
Yen Chao Wang ◽  
Shi Chang Tseng
Keyword(s):  
Central Zone ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Stray Light ◽  
Optical Simulation ◽  
Melt Temperature ◽  
Injection Speed ◽  
3D Cad ◽  
Multi Stage ◽  
Test Distance

This research focuses on the effect manufacture factors about the brightness and uniformity of multi-stage reflector. Trace-pro and 3D CAD model were used for optical simulations. The optical simulation results of grating lens and reflector were done as well as successfully developed the LED fog lamp. The results meet the regulations, R19 CLASS F3, of Economic Commission for Europe (ECE) at the test distance of 25 meters, and central zone under line6 achieves average over 3200cd. The optimal design of reflector is of third-order paraboloidal one to improve the brightness and uniformity. The acuter the microstructure’s tip is(R below 0.1mm), the better the apparent improving of eliminating stray light. In accordance with microstructure of grating lens, Moldex-3D is used to help the mold flow filling simulation and mold design. The mold cavity with microstructure was manufactured by the wire cutting and polishing processing. And the molding plastic was optics level PC (Polycarbonate). Both Taguchi’s method applied in Moldex-3D and real injection molding experiments showed that high melt temperature, low injection speed and suitable holding time can reduce warpage; in addition, using higher melt temperature, mold temperature and injection pressure can achieve higher degree of replication of micro features.

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.

Optimization Design of Stack Package Warpage Based on Moldflow Software

2012 ◽  
Vol 605-607 ◽  
pp. 34-37
Author(s):  
Ming Xiang Zang ◽  
Ting Wang ◽  
Chen Liu ◽  
Yong Rui Zhao
Keyword(s):  
Optimization Design ◽  
Printed Circuit Board ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Simulation Software ◽  
Circuit Board ◽  
Melt Temperature ◽  
Factors Affecting ◽  
The Impact ◽  
Design Factors

Currently, 3D multi-chip stack assembly is becoming the future development direction of advanced manufacturing process for printed circuit board. However, during the process of Components stacked packages, Warpage control of chips in the reflow soldering is particularly important. By Combining Taguchi method and injection molding simulation software – Moldflow, this paper studied FBGA and PBGA warpage deformation in the POP, setted four design factors, such as the mold temperature, melt temperature, injection pressure and injection time , find out the minimum warpage combination of design and critical design factors affecting the warpage. Then the factors are ranked according to the degree of the impact of the above experiments. The best combination of levels for these factors is getted, the stacked package parameter is optimized. Experiments show that the value of warpage decreased significantly.

Simulation of Micro-Gear Manufactured by Differential Injection Molding Based on Moldex 3D

2012 ◽  
Vol 501 ◽  
pp. 269-273
Author(s):  
Peng Cheng Xie ◽  
Li Lei Miao ◽  
Pan Pan Zhang ◽  
Wei Min Yang
Keyword(s):  
Mold Temperature ◽  
Processing Parameters ◽  
Simulation Software ◽  
Injection System ◽  
Mechanical Transmission ◽  
Injection Time ◽  
Melt Temperature ◽  
The Core ◽  
Packing Time ◽  
Core Part

In this article, the structure of the differential pump is introduced, which is the core part of the differential injection system. The micro-gear with a shaft collar is simulated as it is an important micro-part and has great potential application in mechanical transmission. The Moldex 3D simulation software is used to investigate effects of processing parameters on the micro-gear such as melt temperature, mold temperature, injection time and packing time etc. By comparing the micro-gear's warpage under different processing parameters, it can be concluded that melt temperature has a greater impact on the molding quality than mold temperature. In addition, the effects of injection time and packing time on the micro-gear's molding quality are also investigated.

Study on Manufacturing Process Optimizing of Lightguiding Plate for Soft Computing

2007 ◽  
Vol 364-366 ◽  
pp. 43-47
Author(s):  
Yi Lin
Keyword(s):  
Genetic Algorithm ◽  
Simulated Annealing ◽  
Soft Computing ◽  
Liquid Crystal Display ◽  
Mold Temperature ◽  
Processing Parameters ◽  
Processing Parameter ◽  
Optimal Process ◽  
Injection Speed ◽  
Simulated Annealing Genetic Algorithm

This paper discusses the research of optimal process for lightguiding plate of backlight module of liquid crystal display. The PMMA material was used on lightguiding plate. This paper indicates that the different processing parameters (mold temperature, injection temperature, first period injection speed, second period injection speed, third period injection speed, packing pressure and packing time) are important for optimal research for lightguiding plate of backlight module. This paper introduces the extension engineering, simulated annealing and genetic algorithm on soft computing for optimal process and compares the results with experiment. The results show that the optimal process group is A1 B1C2 D3 E2 F2 G3 for extension engineering, simulated annealing, genetic algorithm or experiment. The mold temperature is the most important processing parameter of the flatness of lightguiding plate for soft computing and experiment. The calculation times for extension engineering, simulated annealing and genetic algorithm are less than experiment’s time.

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