Modeling and simulation of weld line location and properties during injection molding based on viscoelastic constitutive equation

Liu, Qingsheng; Liu, Youqiong; Jiang, Chuntao; Zheng, Shi-Yi

doi:10.1007/s00397-019-01182-8

Cited by 10 publications

(13 citation statements)

References 25 publications

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“…At one point of time, the mating angle between flow fronts is more than 135 , then the weldline becomes the meld-line which has the minimum impact on strength. 7,16,36,50 Before the experimental test, the specimens are required to be conditioned as plastic material has a tendency to absorb moisture. When moisture is absorbed by the part, its stiffness decreases while its ductility increases.…”

Section: Experimental Methodsmentioning

confidence: 99%

“…4,15,62 Taguchi method is widely used for the optimization of the process parameters and conducting designs of experiments. 16,63,64 The S/N ratio formula in Equation ( 19) is explaining largerthe-better characteristics, used to get optimized process parameters to maximize weld-line strength as…”

Section: Methods Of Reducing Weld-lines and Its Effectmentioning

confidence: 99%

“…The area of convergence has become a flowing weld‐line. When two or more gates are required to fill the cavity, then melt enters the cavity through the two different gates where melt streams meet each other while filling the cavity, and that meeting area of the melt flow‐front becomes a cold weld‐line or stagnation weld‐line 16,19,20 …”

Section: Introductionmentioning

confidence: 99%

“…When two or more gates are required to fill the cavity, then melt enters the cavity through the two different gates where melt streams meet each other while filling the cavity, and that meeting area of the melt flow-front becomes a cold weld-line or stagnation weld-line. 16,19,20 Figure 2 shows the formation of typical stagnation weld-line and flowing weld-line. Typically, in the case of stagnation weld-line, the center of the flow-fronts has a minimum mating angle, and it increases toward the surface however for the flowing weld-line mating angle is the minimum next to the obstacle and it increases when the distance from the obstacle increases.…”

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confidence: 99%

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Weld‐lines and its strength evaluation in injection molded parts: A review

Jadhav,

Gaval,

Solanke

et al. 2023

Polymer Engineering & Sci

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Injection molding manufacturing is immensely popular nowadays because of its excellent manufacturability for complex designs produced from a wide range of different engineering plastic materials. Weld‐line is a defect that arises in injection molding when two or more flow fronts collide. The weld‐lines are undesirable from both aesthetic and functional points of view and their effect is different for varied materials, process conditions, loadings, forms of weld‐line, etc. The presence of a weld‐line weakens components locally due to insufficient intermolecular diffusion, v‐notch formation, fiber anisotropy, insufficient process conditions, and so on. When a component is under load, crack propagation usually begins with a weak weld‐line area. Therefore, the designer should anticipate the presence of weld‐lines and their strength to avoid failure of components during operation. In this article, the review of published research work on weld‐line formation during injection molding has been summarized. The review focuses on the phenomenon of weld‐line formation, the type of weld‐lines, and the importance of weld‐line evaluations. The theoretical, experimental, and computational approaches to analyzing weld‐line and its strength are covered in detail. At last, methods for reducing weld‐lines and increasing the strength of weld‐line area have been discussed. This review also gathers data on weld‐line strength with respect to different materials.Highlights Details of weld‐line formation and its types. Importance of weld‐line evaluation. Methods of weld‐line strength evaluation. Methods of reduction of the number of weld‐line and its effect. Summary of weld‐line strength for different material.

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Section: Experimental Methodsmentioning

confidence: 99%

Section: Methods Of Reducing Weld-lines and Its Effectmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

mentioning

confidence: 99%

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Weld‐lines and its strength evaluation in injection molded parts: A review

Jadhav,

Gaval,

Solanke

et al. 2023

Polymer Engineering & Sci

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“…In addition to commercial software, many researchers have made great efforts to improve the accuracy of the simulation. Liu et al [ 9 ] developed a flow model based on Rolie‐Poly viscoelastic constitutive equation to describe the viscoelastic properties and simulate the formation and evolution process of weld lines. Quintana et al [ 10 ] used Moldex3D to simulate the fiber distribution pattern of injection products and results showed a clear correlation between the weld line strength factors and the orientation factor.…”

Section: Introductionmentioning

confidence: 99%

An integrated simulation method for analyzing mechanical properties of injection molded fiber‐reinforced polymers

Gao

Chen

et al. 2022

Polymer Composites

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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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Modeling and simulation of weld line location and properties during injection molding based on viscoelastic constitutive equation

Cited by 10 publications

References 25 publications

Weld‐lines and its strength evaluation in injection molded parts: A review

Weld‐lines and its strength evaluation in injection molded parts: A review

An integrated simulation method for analyzing mechanical properties of injection molded fiber‐reinforced polymers

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

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