A review of current advancements in high surface quality injection molding: Measurement, influencing factors, prediction, and control

Gim, Jinsu; Turng, Lih‐Sheng

doi:10.1016/j.polymertesting.2022.107718

Cited by 47 publications

(16 citation statements)

References 128 publications

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“…A Conformal Cooling Channel (CCC), which is created along the surface of the product has been proposed as a solution to increase cooling efficiency for curved products, as well as the resulting quality of injection-molded parts [ 4 ]. Since CCC is not limited by its shape, it is difficult to manufacture using the traditional machining method.…”

Section: Introductionmentioning

confidence: 99%

A Novel Design Method of an Evolutionary Mold Cooling Channel Using Biomimetic Engineering

2023

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In this study, an evolutionary cooling channel, a new methodology for designing a conformal cooling channel, was proposed. This methodology was devised by imitating the way that a plant’s roots grow towards a nutrient-rich location. Additionally, Murray’s law was applied to increase the cooling efficiency through minimizing the pressure loss of the cooling water inside the cooling channel. The proposed method was applied to the specimen shape to verify the concept, and it was confirmed that efficient cooling was achieved by applying it to the headlamp lens cover part of an actual vehicle. When this methodology was applied, the temperature deviation of the part could be improved by about 46% in just third generations, and the pressure loss could be reduced by about 10 times or more compared to the result of applying the straight-line cooling channel.

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Section: Introductionmentioning

confidence: 99%

A Novel Design Method of an Evolutionary Mold Cooling Channel Using Biomimetic Engineering

2023

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“…This technology enhances the mechanical performance of the components and meets the requirements of lightweight design [ 19 ]. Microcellular foaming molding offers advantages, such as a unique structure, lightweight, and good sound, and thermal insulation properties [ 20 , 21 ]. It has broad application prospects in various fields, including automotive, construction, and aerospace [ 22 , 23 ].…”

Section: Introductionmentioning

confidence: 99%

Unveiling Sustainable Potential: A Life Cycle Assessment of Plant–Fiber Composite Microcellular Foam Molded Automotive Components

Feng

Guo

et al. 2023

Materials

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The development and utilization of new plant–fiber composite materials and microcellular foam molding processes for the manufacturing of automotive components are effective approaches when achieving the lightweight, low-carbon, and sustainable development of automobiles. However, current research in this field has mainly focused on component performance development and functional exploration, with a limited assessment of environmental performance, which fails to meet the requirements of the current green and sustainable development agenda. In this study, based on a life cycle assessment, the resource, and environmental impacts of plant–fiber composite material automotive components and microcellular foam molding processes were investigated. Furthermore, a combined approach to digital twinning and life cycle evaluation was proposed to conduct resource and environmental assessments and analysis. The research results indicate that under current technological conditions, resource and environmental issues associated with plant–fiber composite material automotive components are significantly higher than those of traditional material components, mainly due to differences in their early-stage processes and the consumption of electrical energy and chemical raw materials. It is noteworthy that electricity consumption is the largest influencing factor that causes environmental issues throughout the life cycle, especially accounting for more than 42% of indicators such as ozone depletion, fossil resource consumption, and carbon dioxide emissions. Additionally, the microcellular foam molding process can effectively reduce the environmental impact of products by approximately 15% and exhibits better overall environmental performance compared to chemical foaming. In future development, optimizing the forming process of plant–fiber composite materials, increasing the proportion of clean energy use, and promoting the adoption of microcellular foam injection molding processes could be crucial for the green and sustainable development of automotive components.

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“…The need for injection molding is growing with the increasing demand in various industries, such as automotive, medical, and electronic equipment 1,2 . Fiber‐reinforced composites are expected to replace wooden products such as chairs, tables, and furniture elements.…”

Section: Introductionmentioning

confidence: 99%

“…The need for injection molding is growing with the increasing demand in various industries, such as automotive, medical, and electronic equipment. 1,2 Fiber-reinforced composites are expected to replace wooden products such as chairs, tables, and furniture elements. For instance, Sathishkumar et al 3,4 evaluated a chair made of snake grass fiber-reinforced polymer and Sal wood regarding cost, weight, strength, and water absorption.…”

mentioning

confidence: 99%

Simulation‐based analysis of weld line strength of glass fiber‐reinforced polymer in injection molding

Kameya,

Ogata,

Tanohata

2023

Polymer Engineering & Sci

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The injection molding market is expected to grow with the increasing demand from various industries, such as automotive and furniture. However, weld lines in the injection molded part reduce the structural strength and affects its appearance. This study evaluates the effect of the weld line on the structure by shifting the position of the weld line outside the area where the load is applied by manipulating the opening time of the injection gates. We examined the effect of weld lines on the strength of a chair through coupled resin flow and structural analyses. The analysis revealed that the position of the weld lines is crucial for structural strength if the knockdown factor (KDF) is low. Additionally, controlling the opening time of the gate and shifting the position of the weld line improved the structure's appearance, number of weld line and avoid the lower meeting angle. However, depending on the material, the effect may be weak. For example, when the weld line location did not change much despite changing the gate timing, little change was observed in the number of weld lines. Hence, the improvement strategy of weld line should be considered for material types and strength.Highlights Injection molding growth driven by automotive, packaging, furniture demand. Weld lines impact structural strength and appearance. Shifting weld line position outside load area improves the structural appearance and strength. Effects of shifting weld line position depended on the material types. Weld line position is crucial for low knockdown factor and affects strength.

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A review of current advancements in high surface quality injection molding: Measurement, influencing factors, prediction, and control

Cited by 47 publications

References 128 publications

A Novel Design Method of an Evolutionary Mold Cooling Channel Using Biomimetic Engineering

A Novel Design Method of an Evolutionary Mold Cooling Channel Using Biomimetic Engineering

Unveiling Sustainable Potential: A Life Cycle Assessment of Plant–Fiber Composite Microcellular Foam Molded Automotive Components

Simulation‐based analysis of weld line strength of glass fiber‐reinforced polymer in injection molding

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