Experimental and Numerical Study Determining the Warpage Phenomenon of Thin-Wall Injection Molding

Huang, Yueh-Tzu; Huang, Chih-Wei; Peng, Bou Yue; Chang, Cheng-Chun; Cheng, Hsing-Chung; Lin, Yi; Shen, Yung-Kang; Wang, Hao

doi:10.1155/2020/2914801

Cited by 11 publications

(3 citation statements)

References 21 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The most conventional strategy is to reduce the warpage by optimising the process parameters, the idea being that process parameters impact the magnitude of the warpage and the shape of the warped part. The literature [4,6,11,14,15,29] identifies the following parameters as the most influential: melt temperature, injection and cooling time, and injection packing pressure. Changing the value of these process parameters causes a change in the material state during the moulding process, e.g., temperature and pressure field distribution in the material.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Correction of mould cavity geometry for warpage compensation

Kastelic

Starman²,

Cafuta³

et al. 2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Warpage is one of the most challenging defects occurring in plastic injection moulded parts. Various approaches to overcome this issue have been proposed in the literature, but they all provide only partial solutions to the problem. This paper proposes a new method for the compensation and minimisation of warpage. The method is based on Mould Cavity (MC) correction. In contrast to other similar methods, here the MC correction is accomplished through a direct comparison of the local deviations of the warped part's geometry to the desired geometry of the part. Modifying the MC shape accordingly yields parts with a lower shape discrepancy from the desired geometry compared to the nonadjusted shape. The key novelty of the paper is the development of software that iteratively adjusts the MC shape to minimise local deviations. In every iteration, the warped part is compared to the desired geometry and the MC geometry is adjusted accordingly. A curved thin-walled plate part case study demonstrates the method's capabilities. We show that the maximum warpage value of 0.005 mm (0.7% of the initial maximum warpage) was reached after three iterations of MC geometry correction and remained stable afterwards.

show abstract

Section: Introductionmentioning

confidence: 99%

“…Changing the value of these process parameters causes a change in the material state during the moulding process, e.g., temperature and pressure field distribution in the material. Many researchers have therefore studied the influence of each parameter extensively [6,7,14,15,27].…”

Section: Introductionmentioning

confidence: 99%

Correction of mould cavity geometry for warpage compensation

Kastelic

Starman²,

Cafuta³

et al. 2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…Taking the known equilibrium shape as input, the problems in the process of thermal expansion or contraction and nonlinear elastic deformation are analyzed, and the corresponding initial shape of the object is determined. Specifically, the numerical calculation of the part injection molding process is carried out with the help of CAE software [27]. The CAE analysis software mainly includes Moldex3D [28], Moldflow [29], etc.…”

Section: Introductionmentioning

confidence: 99%

A research method to improve the quality of box-type thin-walled parts by combining parameter optimization and i nverse-deformation design

Zhai

Chang²,

Li³

et al. 2022

Preprint

View full text Add to dashboard Cite

In this paper, a five-part study on the molding quality of box-type thin-walled injection molded parts with volume shrinkage and warpage deformation was conducted. In the first part, the molding parameters: filling time, plastic temperature, mold temperature (C), holding time (D), maximum holding pressure (E), and cooling time (F) were selected, and a six-factor, five-level L25 (5 6 ) orthogonal experimental design (OED) was designed. Then, the optimal combination of molding parameters was optimized by using gray correlation (GC) theory analysis. In the second part, the six molding parameters from the first part were further optimized based on the Box Behnken Design (BBD) response surface method (RSM) and BP neural network (BPNN) training, and the results showed that the fitted regression model after BPNN training had a smaller prediction error. In the third part, the regression models fitted with BBD and BPNN-BBD are further optimized globally. The optimization search method uses the NSGA-II genetic optimization algorithm. And comparing the above four optimization methods found that BPNN-BBD-NSGA-II prediction error < BPNN-BBD prediction error < BBD-NSGA-II prediction error < BBD prediction error. The fourth part is based on the anti-deformation design (ADD) theory. The NX/Moldex3D global optimization platform is created to finally almost completely eliminate warpage deformation of box-type thin-walled injection molded parts. In the last part, a trial mold verification analysis was performed, and the molding quality data was obtained by using optical scanning instruments, and the GOM software was used to compare and analyze the deviation values of each appearance surface and the flatness values.

show abstract

Numerical Simulation and Multi-objective Optimization of Injection Molding Parameters for Improving the Quality of Plastic Product

Nguyen

Manh

et al. 2022

Lecture Notes in Mechanical Engineering

View full text Add to dashboard Cite

Experimental and Numerical Study Determining the Warpage Phenomenon of Thin-Wall Injection Molding

Cited by 11 publications

References 21 publications

Correction of mould cavity geometry for warpage compensation

Correction of mould cavity geometry for warpage compensation

A research method to improve the quality of box-type thin-walled parts by combining parameter optimization and i nverse-deformation design

Numerical Simulation and Multi-objective Optimization of Injection Molding Parameters for Improving the Quality of Plastic Product

Contact Info

Product

Resources

About