Modeling and Experimental Studies on Polymer Melting and Flow in Injection Molding

Wilczyński, Krzysztof; Buziak, Kamila

doi:10.3390/polym14102106

Cited by 18 publications

(18 citation statements)

References 125 publications

(133 reference statements)

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“…An alternative coolant such as compressed gas, ultrafine bubble, or cold stream can also be employed to investigate the difference in the cooling performance. It should be noted that the fabricated injection mold can also be employed to plastic injection molding [ 26 , 27 ]. The heat transfer was affected significantly by the deposition of the limescale in the wall of the cooling channel during mass production using injection molding.…”

Section: Resultsmentioning

confidence: 99%

Characterization of Epoxy-Based Rapid Mold with Profiled Conformal Cooling Channel

Kuo

Zhu

2022

Polymers

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Based on the experience of the foundry industry, reducing the demolding time is the key for mass production of wax patterns with sophisticated geometries. Integration of numerical simulation and rapid tooling technology for decreasing the time to market is essential in advanced manufacturing technology. However, characterization of epoxy-based rapid molds with a profiled conformal cooling channel (PCCC) using computer-aided engineering simulation of the epoxy-based rapid mold with PCCC was not found in the literature. In this study, epoxy-based rapid molds with PCCC were characterized numerically and experimentally. The cooling performance of wax injection molds with two different kinds of cross-sections of the cooling channel was investigated. Four pairs of injection molds with PCCC were implemented using four different kinds of material formulations. It was found that the cooling performance of the PCCC was better than a circular conformal cooling channel (CCCC) since the PCCC maintained a more uniform and steady cooling performance of injection-molded product than CCCC. Epoxy resin added with 41 vol.% Cu powder seems to be a cost-effective empirical material formulation in terms of cooling time and material costs. This empirical material formulation provided an injection mold with low material cost and good cooling performance simultaneously compared to an injection mold fabricated with commercial material. The cooling performance could reach 88% of that of the injection mold fabricated with commercial material. The material cost of making the injection mold was only about 60% of that of the injection mold fabricated with commercial material. The coolant flow rate had no significant effect on the cooling time, whereas the cooling time of the wax pattern was affected by coolant temperature significantly.

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Section: Resultsmentioning

confidence: 99%

Characterization of Epoxy-Based Rapid Mold with Profiled Conformal Cooling Channel

Kuo

Zhu

2022

Polymers

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“…Cross-linked polyethylene (XLPE) with excellent mechanical, heat resistance and insulation performance has been extensively used as an insulating material for high-voltage (HV) cables [1][2][3]. XLPE is generally obtained after dynamic extrusion and crosslinking reaction of low-density polyethylene doped with additives (PEDA) [3,4].…”

Section: Introductionmentioning

confidence: 99%

Coupling Effect of LDPE Molecular Chain Structure and Additives on the Rheological Behaviors of Cable Insulating Materials

Shang

et al. 2023

Polymers

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The rheological behaviors of low-density polyethylene doped with additives (PEDA) determine the dynamic extrusion molding and structure of high-voltage cable insulation. However, the coupling effect of additives and molecular chain structure of LDPE on the rheological behaviors of PEDA is still unclear. Here, for the first time, the rheological behaviors of PEDA under uncross-linked conditions are revealed by experiment and simulation analysis, as well as rheology models. The rheology experiment and molecular simulation results indicate that additives can reduce the shear viscosity of PEDA, but the effect degree of different additives on rheological behaviors is determined by both chemical composition and topological structure. Combined with experiment analysis and the Doi–Edwards model, it demonstrates that the zero-shear viscosity is only determined by LDPE molecular chain structure. Nevertheless, different molecular chain structures of LDPE have different coupling effects with additives on the shear viscosity and non-Newtonian feature. Given this, the rheological behaviors of PEDA are predominant by the molecular chain structure of LDPE and are also affected by additives. This work can provide an important theoretical basis for the optimization and regulation of rheological behaviors of PEDA materials used for high-voltage cable insulation.

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“…Silva et al [14] compared the straight cooling channel with the conformal cooling channel and the concluded that conformal cooling channel (CCC) can obtain better cooling performance than the traditional (direct drilling) channel in the injection molding process. Wilczyrski et al [15] proposed and discussed the latest modeling and experiments of flow and melting in injection molding machines, and concluded that some mathematical models have no strong experimental basis. erefore, experimentation of the polymer flow and melting in the injection molding machine has been performed, and the effect of processing conditions such as the screw speed, the plasticating stroke, and the back pressure on the process course has been investigated.…”

Section: Introductionmentioning

confidence: 99%

Research on Optimization of Injection Molding Process Parameters of Automobile Plastic Front-End Frame

Yang

Tang

2022

Advances in Materials Science and Engineering

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The main objective of the present article is to obtain the optimum technological parameters of the automobile plastic front-end frame. Moldflow software was used to simulate the injection molding of the automobile plastic front-end frame bracket in this study. The uniformity experiment was designed and completed. Five injection molding process parameters, including mold temperature, melt temperature, packing pressure, injection time, and packing time, were selected as experimental factors. Volume shrinkage and warpage amount were selected as quality evaluation indexes. Statistical Product Service Solutions (SPSS) software was used to perform linear regression analysis on the test results, respectively, and the linear regression equation corresponding to the two evaluation indexes was obtained. Then, regression equation analysis was carried out to obtain the optimal process parameter combination of the volume shrinkage and the warpage amount. A back propagation (BP) neural network model with input as a process parameter and output as an evaluation index is established by MATLAB and optimized by a genetic algorithm (GA). Finally, the optimized neural network model was used to predict the combination of process parameters with the minimum volume shrinkage and warpage amount. Based on the performed simulations, the minimum volume shrinkage and the minimum amount of warping in the optimal design were 13% and 0.7062 mm, respectively. The corresponding combination of process parameters was the mold temperature of 75.5°C, the melt temperature of 285.32°C, the packing pressure of 42.32 MPa, the injection time of 3.45 s, and the packing time of 60 s. According to the optimal process parameters, the volume shrinkage and warpage amount of the automobile plastic front-end frame have reached the optimal state at the same time, which improves the quality of injection molding and reduces production and processing costs. It has a certain guiding significance.

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Modeling and Experimental Studies on Polymer Melting and Flow in Injection Molding

Cited by 18 publications

References 125 publications

Characterization of Epoxy-Based Rapid Mold with Profiled Conformal Cooling Channel

Characterization of Epoxy-Based Rapid Mold with Profiled Conformal Cooling Channel

Coupling Effect of LDPE Molecular Chain Structure and Additives on the Rheological Behaviors of Cable Insulating Materials

Research on Optimization of Injection Molding Process Parameters of Automobile Plastic Front-End Frame

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