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.

On-Line Thermal Control for Injection Moulding Process

2013 ◽  
Author(s):  
Jaho Seo ◽  
Amir Khajepour ◽  
Jan P. Huissoon ◽  
Young-Jun Park
Keyword(s):  
Injection Moulding ◽  
Thermal Control ◽  
Production Quality ◽  
Modeling And Control ◽  
Moulding Process ◽  
Cycle Times ◽  
Plastic Injection Moulding ◽  
Injection Moulding Process ◽  
On Line ◽  
And Control

Thermal control is a key issue for injection moulding process due to its effects on production quality and rate. In this study, an on-line thermal control strategy is provided for effective thermal management in plastic injection moulding process. The strategy covers for methods in determining sensor locations as a prerequisite step for modeling and control, identifying a thermal dynamic model of a mould with uncertainties and designing a cavity wall temperature controller. A verification of the designed controller’s performance is carried out from the viewpoints of accuracy in on-line temperature tacking and response time under different injection moulding process with various cycle-times.

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.

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.

Influence of the Recycled Material Percentage on the Mechanical Behaviour of HDPE for Injection Moulding Process for an Ecologycal Design

2012 ◽  
Vol 445 ◽  
pp. 935-940 ◽  
Author(s):  
Carlos Javierre ◽  
Angel Fernandez ◽  
Victor Camanes
Keyword(s):  
Mechanical Behaviour ◽  
Material Properties ◽  
Injection Moulding ◽  
Plastic Material ◽  
Young Modulus ◽  
Raw Material ◽  
Moulding Process ◽  
Plastic Materials ◽  
Injection Moulding Process ◽  
Recycled Material

Nowadays plastic materials recycling aims most of the time to use the recycled material to manufacture products of less requirements than the original products, so the material is depreciated. It would be important to recycle plastic materials to use them for the same applications they were initially used. To make this possible it would be necessary to characterize the recycled material properties, design products taking into account that they are going to be produced with recycled material and to be able to recuperate the product at the end of its lifetime. An example of this designing philosophy is going to be presented in this work, applied to large trash containers produced withHDPE (RIGIDEX5740UA), where the product can be easily recovered at the end of its lifetime and also the amount of polymer material wasted during thermoplastic injection moulding is very high. Recycling mills convert parts into small pieces that are used as feed material for injection again, by mixing it in different percentages with raw material. This mixture of both raw and recycled material modifies material properties according to the percentage of recycled material introduced. Some of the properties affected by this modification are those related to mechanical behaviour. This paper analyzes the mechanical behaviour of material with different percentages of recycled material. Test parts have been injected with different percentage of recycled material and have been tested by a tensile machine. Results like; Stress at yield, Stress at break and Young Modulus have been calculated and analysed. The product of this work has been designed using only one plastic material, which is very helpful from the point of view of manufacturing and recycling.In these kinds of parts a very tight safety factor is used, thats why to know exactly material properties is very important during its design.

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.

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