ABSTRACT:A simplified semianalytical equation, used successfully in food freezing/chilling time prediction, is proposed as a potential simple alternative for cooling time prediction in injection molding of polymer parts, amorphous or semicrystalline. This equation is based on a convective boundary condition for the mold-part interface and requires information on the thermal contact resistance (TCR) or thermal contact conductance (TCC) at this interface, as well as information on the initial and final product temperatures, the mold surface temperature, and the thermal properties of the part. Eighty-five data points for four polymers, Polystyrene (PS), Polycarbonate (PC), Polypropylene (PP), and Polyethylene (PE) were generated with C-MOLD TM , a commercial injection molding design software, and the performance of the proposed equation was tested. The % mean error and its standard deviation (SD) in cooling time prediction were, respectively, −11.61 and 2.27 for PS, −6.04 and 2.13 for PC, −7.27 and 6.55 for PP, and −8.88 and 2.93 for PE. It was also shown that the accuracy of
PREDICTION OF COOLING TIME IN INJECTION MOLDINGthe proposed equation is not affected significantly by the exact knowledge of the TCC, provided that the latter is not smaller than 1000-2000 W m −2 K −1 . Since in this comparison all necessary temperatures were obtained from C-MOLD TM , methods of using the proposed equation independently were tested. The use of the inlet melt temperature as the initial product temperature increased the % mean error by mostly 1.5% while its SD remained practically the same. By incorporating a literature based heat balance method in the proposed equation, it was possible to use it as a stand-alone predictor of polymer cooling time. The % mean error and its SD calculated this way were, respectively, −9.44 and 0.97 for PS, −9.44 and 0.83 for PC, −14.22 and 5 for PP, and −20.12 and 1.38 for PE. The proposed equation, at least in a preliminary stage, can be used successfully to predict the cooling time of the selected semicrystalline or amorphous polymers with the accuracy being higher for amorphous polymers.