Robust Process Development and Scientific Molding

Kulkarni, Suhas

doi:10.3139/9783446433427.fm

Cited by 16 publications

(29 citation statements)

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“…As the melt polymer flows toward the end of the mold, the air inside the unfilled region of the mold is compressed, making an opposite pressure to the flow. If there are no vents in the mold, the pressure of the polymer flow might be unable to overcome the counter pressure, which hinders the flow of the molten polymer and result in an incomplete filling of the mold 30 . As mentioned by Kazmer, the lack of venting can form a short shot in the molded product and may cause the phenomenon known as "dieseling" and defects known as "burn marks" 1 .…”

Section: Simulation Results: Mold With No Venting Systemmentioning

confidence: 99%

“…Nevertheless, the decrease of the polymer viscosity due to a higher temperature along the cross section might compete with this phenomenon. Such behavior may lead to the arising of residual stresses in the polymer flow due to high shear rate values associated with the reduction of the molten polymer viscosity, as in the case of too high injection temperatures 29,30 . Another factor that should be considered in this analysis is the constant and slow cooling of the melt polymer.…”

Section: First Set Of Experimental Runs: Mold With No Venting Systemmentioning

confidence: 99%

“…In this way, the gas contained in the unfilled region of the cavity would be released outwards the mold as the polymer front advances toward the end of the cavity. Consequently, it was expected that the melt polymer flows easily inside the mold cavities up to their complete filling 1,30,33 . As the mathematical model used to simulate the behavior of the mold with no venting reproduced reasonably well the real process, the modifications were firstly executed in the virtual project of the mold using the software SolidWorks.…”

Section: Mold Considering a Venting System: Simulation And Experimentmentioning

confidence: 99%

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Simulation of an Injection Process Using a CAE Tool: Assessment of Operational Conditions and Mold Design on the Process Efficiency

Miranda

Nogueira

2019

Mat. Res.

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The present work developed an experimental and simulation study to evaluate the influence of some operational conditions and mold design on the efficiency of an injection process used to produce polystyrene parts. The software SolidWorks Plastic was used to simulate the injection process and assess the performance of the mold considering the absence and the presence of venting. Experimental results obtained by varying the injection pressure, injection temperature as well as the mold temperature were used to validate the simulation data generated considering both mold designs. The findings revealed air entrapment at the end of the mold cavity and low process efficiency when the mold was operated with no venting, regardless the processing conditions. Simulation results indicated a remarkable increase of the process efficiency when vents were included on the parting line of the mold. In addition, the range of processing conditions which led to the highest process efficiency was virtually identified and tested in the real modified mold (with venting system). The findings revealed that the injection cycle time reduced in approximately 35% and the waste generation diminished from 65% to less than 1% when venting was included in the mold design and the optimal operational conditions were used.

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Section: Simulation Results: Mold With No Venting Systemmentioning

confidence: 99%

Section: First Set Of Experimental Runs: Mold With No Venting Systemmentioning

confidence: 99%

Section: Mold Considering a Venting System: Simulation And Experimentmentioning

confidence: 99%

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Simulation of an Injection Process Using a CAE Tool: Assessment of Operational Conditions and Mold Design on the Process Efficiency

Miranda

Nogueira

2019

Mat. Res.

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“…From the calculated flow front velocity and the increase in melt pressure (together with information on the flow channel geometry h sim i ), based on the equation of Hagen–Poiseuille, machine‐independent parameters such as the wall shear stress τ i , the shear rate

{\dot{γ}}_{i},

and the melt viscosity η i expressed in Eqs . 5–7 , can be derived between the event points .

τ_{i} = \frac{{normalΔ p}_{i} ∙ h_{sim i}}{2 ∙ ((), x_{sim i + 1} - x_{sim i})}

{\dot{γ}}_{i} = 0,772 * \frac{6 ∙ v_{i}}{h_{sim i}}

η_{i} = \frac{{Δp}_{i} ∙ h_{sim i}^{2}}{12 ∙ ((), x_{sim i + 1} - x_{sim i}) ∙ v_{i}}

…”

Section: Proposition Of the New Methods For Determining The Flow Frontmentioning

confidence: 99%

A method for determining the flow front velocity of a plastic melt in an injection molding process

Mensler

Zhang

Win

2019

Polymer Engineering & Sci

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During the filling phase of an injection molding process, the flow front velocity of the plastics melt has a decisive influence on the form part quality. It has been believed that a constant flow front velocity of the melt leads to distortionfree and residual stress-free form parts. A process control strategy based on a constant flow front velocity of the melt, however, requires the full understanding of the flow front position as a function of the screw position of the injection molding machine. With current methods, this can only be achieved by direct measurements using a number of sensors inside the mold, which leads to complicated structure, great efforts, and high cost for the tooling equipment. This article proposes, designs, and develops an innovative method for determining the flow front velocity of a plastic melt in an injection molding using only one pressure sensor at the front of the screw and based on the idea of mapping a simulated filling process to a real injection molding process. The mapping ensues that the characteristic event points are identified and matched for both the simulated and real filling process. The results of the simulation analysis and experimental evaluation show that the proposed method can be used to determine the flow front position and the resulting flow front velocity of the melt within the cavity of the mold and provide evidence that the new method offers great potential to process control strategies based on machine independent parameters. POLYM. ENG.

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“…Optimal setting of injection moulding process variables plays a very important role in controlling the quality of the injection moulded products (Mathivanan, Nouby and Vidhya, 2010). Applying and using design of experiments (DOEs) in injection moulding are relatively simple as compared to its use in other manufacturing or production processes, because most responses to process changes are linear (Kulkarni, 2010).…”

Section: Introductionmentioning

confidence: 99%

Parametric design for quality improvement of injection-moulded product in a consumer electronics conglomerate

Rao¹,

Ravishankar²

2016

IJEDPO

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Current global market trends place an enormous amount of pressure on the process engineers to deliver functional products at the lowest possible cost. Taguchi's robust design methods provide a systematic and efficient method for developing improved products at reduced cost. This paper presents an application of Taguchi's parametric design methodology which is popularly known as robust design methodology to achieve improvements in product quality through process optimisation in a manufacturing context undertaken at the automation division of one of India's largest consumer electronics conglomerate. Plastic-moulded components are manufactured using automatic injection moulding machines to meet the needs of the entire group. During the preliminary investigation it was observed that sink mark on the surface of the moulded plastic component was the main contributor for rejection of the components and hence was selected as a measure for quality improvement. Taguchi's methods were applied and significant improvements in quality levels followed leading to an improvement of 84.95% reduction in current rejection rates. The authors advocate the need for manufacturing organisations to adopt Taguchi's robust design methodologies for process optimisation so as to achieve higher levels of quality on a continuing basis to sustain the intense global competitive pressures.

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Robust Process Development and Scientific Molding

Cited by 16 publications

References 0 publications

Simulation of an Injection Process Using a CAE Tool: Assessment of Operational Conditions and Mold Design on the Process Efficiency

Simulation of an Injection Process Using a CAE Tool: Assessment of Operational Conditions and Mold Design on the Process Efficiency

A method for determining the flow front velocity of a plastic melt in an injection molding process

Parametric design for quality improvement of injection-moulded product in a consumer electronics conglomerate

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