Two methods are proposed for the control of part weight in injection molding. In the PT method, part weight control is achieved by controlling the temperature and pressure of the melt in the cavity at gate freeze time. This time is considered to occur when the cavity melt pressure starts to decrease from its peak value. For the purposes of control, the bulk melt temperature is estimated from measurements by surface thermocouples at strategic locations in the cavity. A cascade scheme is implemented for the control of bulk temperature from cycle to cycle. A self‐tuning algorithm, with an observer, is employed for controlling the cavity pressure‐time profile, to follow a set point trajectory during a cycle. In PWT control, the coolant temperature is controlled, while the peak cavity pressure is adjusted in a given cycle to compensate for bulk melt temperature deviations measured in the previous cycle. Both PT and PWT control reduce variance in part weight. PWT control appears to yield the best results.

A detailed study was carried out to understand the dynamics of pressure variations at different points in the injection-molding system. Thus, hydraulic, nozzle, and cavity pressures were evaluated, in addition to the pressure gradient in the cavity. Both steps and pseudorandom binary sequences (PRBS) were employed to obtain and compare dynamic models describing these variables. Subsequently, these models were employed to evaluate and select optimal controllers for the different variables.

Because of its versatility, cost effectiveness, and ability to produce intricate shapes to tight specifications, the injection molding process is widely used in plastics processing. Mold cavity pressure plays an important role in determining the quality of the molded articles. The dynamic behavior and control of cavity pressure were studied for the filling and packing phases. The dynamics of cavity pressure during filling were investigated and found to be both nonlinear and time-varying in relation to the hydraulic servo-valve opening, which is the manipulated variable. A self-tuning control system was designed and tested for a wide range of conditions. The transition from filling to packing was best detected by the change in the derivative of cavity pressure. The dynamics of cavity pressure during packing were studied and modeled similarly as for filling. The self-tuning technique was successfully extended and implemented in the packing phase.

The use of helical ribbon agitators to mix viscous non-Newtonian fluids has been investigated. A generalized model, based on an appropriate definition of effective viscosity, is proposed to predict power consumption. This model is most successful with fluids that do not have a high degree of elasticity.It was found that the efficiency of mixing of pseudoplastic fluids was about half of that of Newtonian fluids in the same mixer, while the efficiency of mixing viscoelastic fluids was still lower and approximately independent of the mixer geometry. Blade width was the primary variable affecting the mixing efficiency on inelastic fluids. SCOPEThe mixing of very viscous fluids can be efficiently accomplished with a helical ribbon agitator (HRA). A model to predict the power consumption of the HRA mixing Newtonian fluids has been reported by Patterson et al. (1979); however, very viscous fluids are often non-Newtonian or viscoelastic in nature.

The importance of the residence time distribution (RTD) in polymer extrusion has been recognized for a long time, however, it is very difficult to measure. In this project, an optical on-line RTD measurement technique based on extrudate transmi ttance changes was investigated. A He-Ne laser. beam was the light source, and carbon black was the tracer and detection was performed by a photomultiplier.