In injection molding, the pressure in the cavity usually reaches the atmospheric pressure before the ejection, therefore the thermal contact between polymer and mold is modified. This paper aims to evaluate the nature of the thermal contact between the polymer and the mold during the holding and cooling phase. An experimental plate mold has been designed to study this phenomenon. Thermal sensors facing each other and pressure sensors have been set in the mold. An inverse method is used to determine the heat flux density crossing the polymer mold interface, and the mold surface temperature. Then, a second inverse algorithm allows to determine the temperature profile at the end of the filling and the time evolution of the thermal contact resistance (TCR). Finally, the polymer temperature distribution in the thickness is determined between the thermal sensors. The results of this study show that the TCR between the polymer and the mold is not negligible and not constant with time. The polymer temperature at the surface can be 20°C higher than the mold surface temperature. Moreover, asymmetric air gaps have been observed when cavity pressure becomes equal to atmospheric pressure, therefore asymmetric temperature profile in the thickness are generated.

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The main objective of this paper is to numerically investigate the use of fiber-dependent viscosity models in injection molding simulations of short fiber reinforced thermoplastics with a latest commercial software. We propose to use the homogenization-based anisotropic rheological model to take into account flowfiber coupling effects. The 4th-order viscosity tensor is approximated by an optimal scalar model and then implemented in the Moldflow Insight API framework. Numerical simulations are performed for a test-case rectangular plate with three fiber orientation models. The resulting coupled flow kinematics and fiber evolutions are then compared to the standard uncoupled simulations. Interpretations are given based on detailed post-processing of the field results. Certain deformation conditions are expected to be better taken into account, which may also in return lead to an improved fiber orientation prediction. Preliminary confrontation between flow-fiber coupled simulations and existing experimental data is then presented at the end of the paper.

In injection molding of thermoplastic parts, high hold pressures are set during the packing phase to generate a post-filling, which compensates the shrinkage of polymer due to its cooling. The polymer pressure in mold cavity leads to a cavity deformation due to mold and machine compliance. Then, the increase in cavity thickness can m o d e the post-filling and consequently the pressure history, the volumetric shrinkage and the part mass. The first goal of this paper is to present a simple method to locally determine mold rigidities: over-packed slabs are injected and local deflections are determined from measurements of the local residual pressure, the local in-plane shrinkages and the plate thickness. In the studied plate mold, which can be considered as stiff compared to some industrial molds, a rigidity of more than 1 pm/MPa has been measured close to the center of the plate. The second goal of this paper is to show the influence of mold deflection on dimensional properties. If the cavity thickness is small as for our 1-mm-thick plate mold, considering an infinitely rigid mold cannot do realistic predictions of polymer pressure history, volumetric shrinkages and part mass. Nevertheless, in-plane shnnkage seems to be less affected by mold deflection. It means that the additional polymer mass due to mold deflection is mainly distributed in the part thickness.

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