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13.11-2014
Warpage analysis verification between simulation and experimental of dumbbell plastic part in the injection mouldins
Mohd Amran, Siti Salmah, Zolkarnain Marjom, Umar Al-Amani, Raja Izamshah, Mohd Hadzley, Zulkeflee Abdullah, Mohd Sanusi
Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka
Injection moulding is widely used to produce a variety of plastic parts. Its process involvedvarious process parameters, which plays an important roles in influencing the quality and productivity of plastic parts. In this case, the application of Computer Aided Engineering (CAE) software is essential to enhance the quality of plastic parts in the injection moulding industry. This paper deals with the application of Moldflow Plastic Insight (MPI) intergrated with a statistical technique using Taguchi Method. The purpose of this application is to study the effect of process parameters on warpage deflection in dumbbell plastic part. Subsequently, the result of CAE simulation was validated with the aid of experimental data result…read more
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16.10-2014
Optimization of injection molding process parameters to improve the mechanical performance of polymer product against impact
Yingjie Xu, QingWen Zhang, Weihong Zhang, Pan Zhang
Engineering Simulation and Aerospace Computing (ESAC), Northwestern Polytechnical University, Xi’an, Shaanxi, China
Injection molding is the most widely used process in manufacturing polymer products. The warpage induced during injection molding process has an important influence on the mechanical performance of injection molded products. Therefore, how to optimize process parameters becomes the key issue in improving the mechanical performance of the product towards the expected service conditions. In this paper, a combined artificial neural network and particle swarm optimization (PSO) algorithm method is proposed to optimize the injection molding process. An integrated finite element analysis of the injection molding process, the warpage-induced residual stresses during assembly, and mechanical performance of serviced product is firstly proposed…read more
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24.09-2014
Analysis of the Influence of Microcellular Injection Molding on the Environmental Impact of an Industrial Component
Daniel Elduque,1 Isabel Clavería,1 Ángel Fernández,1,2 Carlos Javierre,1 Carmelo Pina,1 and Jorge Santolaria3
1 Department of Mechanical Engineering, University of Zaragoza EINA, Maria de Luna 3, 50018 Zaragoza, Spain; 2 AITIIP Foundation, Empresarium Industrial Park, C/Romero 12, 50720 Zaragoza, Spain; 3Department of Design and Manufacturing Engineering, University of Zaragoza EINA, Maria de Luna 3, 50018 Zaragoza, Spain
Microcellular injection molding is a process that offers numerous benefits due to the internal structure generated; thus, many applications are currently being developed in different fields, especially home appliances. In spite of the advantages, when changing the manufacturing process from conventional to microcellular injection molding, it is necessary to analyze its new mechanical properties and the environmental impact of the component. This paper presents a deep study of the environmental behavior of a manufactured component by both conventional and microcellular injection molding. Environmental impact will be evaluated performing a life cycle assessment…read more
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12.09-2014
Model Predictive Control of Cavity Pressure in an Injection Moulding Process
a Reiter, M.; a Stemmler, S.; bReßmann, A.; b Hopmann, Ch.; a Abel, D.
a Institute of Automatic Control, RWTH Aachen University, Aachen, Germany; b Institute of Plastics Processing (IKV) at RWTH Aachen University
Cavity pressure control is a means of improving repeatability and product quality in injection moulding processes. As the system behaviour is greatly dependent on the mould - which is interchangeable and typically designed and manufactured independently of the machine's control system - challenges arise in designing a controller that yields high performance and robustness to be suitable for universal use. A cavity pressure controller intended to be used for a wide variety of moulds will likely need some form of reparametrisation. In order to gain user acceptance, the process of manual or automatic parametrisation of the controller to a new mould needs to be simple enough to be performed and understood by…read more
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23.06-2014
A nondestructive online method for monitoring the injection molding process by collecting and analyzing machine running data.
Peng Zhao1, Huamin Zhou2, Yong He1, Kan Cai1, Jianzhong Fu1
1The State Key Lab of Fluid Power Transmission and Control, Zhejiang University; 2The State Key Lab of Material Processing and Die & Mould Technology, Huazhong University of Science and Technology
Nondestructive online monitoring of injection molding processes is of great importance. However, almost all prior research has focused on monitoring polymers in molds and damaging the molds. Injection molding machines are the most important type of equipment for producing polymeric products, and abundant information about actual polymer processing conditions can be obtained from data collected from operating machines. In this paper, we propose a nondestructive online method for monitoring injection molding processes by collecting and analyzing signals from injection molding machines. Electrical sensors installed in the injection molding machine, not in the mold, are used to collect physical signals...read more
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23.06-2014
Effect of reprocessing on shrinkage and mechanical properties of ABS and investugating of proper blend of virgin and recycled ABS in injection molding.
Mohammad Rahimia, Mohsen Esfahanianb, Mehran Moradib
aMechanical Engineering Department, Engineering Faculty, Islamic Azad University Najafabad Branch, Najafabad, Isfahan, Iran; bMechanical Engineering Department, Isfahan University of Technology, Isfahan, Iran
In this research, the effect of reprocessing of acrylonitrile–butadiene–styrene (ABS) on the mechanical properties of the polymer was studied through a five-stage reprocessing. To this end, the injection mold of the standard samples was manufactured. Then, using an injection molding machine, all of the virgin material was processed. After sampling, the rest of the parts were ground and then reprocessed under the same conditions. In order to get a proper combinational ratio of virgin and recycled ABS with respect to shrinkage and mechanical properties, another experiment was designed…read more
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23.06-2014
Multilayer injection moulding of thick-walled optical plastics parts
Ch. Hopmann, A. Neuss, M. Weber and P. Walach
Institute of Plastics Processing (IKV) at RWTH Aachen University, Pontstrasse 49, D-52062 Aachen, Germany
Optical components are often thick-walled. The cycle time of precise polymer optics with a wall thickness of more than 20 mm exceeds several minutes. The multilayer injection moulding or compression moulding lowers the cycle time and increases the quality of the moulded parts. For the production of multilayer moulded lenses the mould design plays an important role. An innovative mould concept is presented with the possibility to produce double or triple layer lenses…read more
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23.05-2014
Improvement of mechanical properties of recycled plastic blends via optimizing -processing parameters using the Taguchi method and Principal component analysis
Fu Gu, Philip Hall, , Nicholas J. Miles, Qianwen Ding, Tao Wu
Faculty of Science and Engineering, Nottingham University, No. 199, East Taikang Rd, Ningbo, Zhejiang, PR China
In this paper, the Taguchi method and principal component analysis(PCA) are used to improve the mechanical properties of recycled polypropylene (PP) blends in injection moulding procedure, with detailed assessments performed on each method and comparison was made based on results of both the methods. The experimental design was carried out by adopting a L9-34 Taguchi orthodoxy array (OA), which has four controllable factors (i.e., melt temperature, mould temperature, injection speed and packing pressure) at three levels…read more
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19.05-2014
Development of a heat-generable mold insert and its application to the injection molding of microstructures
A.C. Liou, R.H. Chen, C.K. Huang, C.H. Su, P.Y. Tsai
Department of Mechanical Engineering, National Chiao Tung University, Taiwan, Republic of China
This work presents a heat-generable mold insert for micro injection molding that solves the problem of de-molding destruction. This mold insert is constructed from silicon wafer by silicon micro-fabrication. Micro electrical heating lines were formed in the wall of the micro mold cavity to control the temperature distribution and the sequence of local solidification of the filled plastic during injection molding. This design reduces the shrinking stress of the plastic filled in the mold…read more
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19.05-2014
Measurement of the visual perceptibility of sink marks on injection molding parts by a new fast processing model
Dieter P. Grubera, Johannes Machera, Dietmar Habaa, Gerald R. Bergerb, Gernot Pachera, Walter Friesenbichlerb
aPolymer Competence Center Leoben GmbH, Roseggerstrasse 12, A-8700 Leoben, Austria; bMontanuniversitaet Leoben, Chair of Injection Molding of Polymers, Otto Gloeckel-Strasse 2, A-8700 Leoben, Austria
The aim of this work is to present a novel methodology for fast evaluation of the visual perceptibility of sink marks on surfaces of injection molded parts. Based on previous research work on the detection of surface defects, a new model for the calculation of the visibility of sink marks from CCD-images was developed…read more
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04.01-2014
Ultra-thin tool heating for injection molding
Research News, Jan 02, 2014
If you have ever tried to make waffles then you are bound to be familiar with the following problem: You only get good waffles if the iron is heated to the correct temperature. The same principle applies to the manufacture of plastics parts, such as displays, facings, covers and instrument panels, using injection molding techniques. A liquid plastic melt is injected into a steel forming tool which is heated just like a waffle iron. The point is to produce a perfect cast of the tool’s surface, which may be smooth like a mirror or feature a functional structure…read more