Warpage reduction through optimized process parameters and annealed process of injection-molded plastic parts

Sudsawat, Supattarachai; Sriseubsai, Wipoo

doi:10.1007/s12206-018-0926-x

Cited by 25 publications

(12 citation statements)

References 22 publications

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“…in the injection molding machine [41,42], which is also an effective approach to avoid warpage. (c) Adjust process parameters [43], such as the mold temperature, holding pressure, cooling time and so on, according to the actual production situation. Among those methods, the designs of products and injection machines are usually determined in the initial stage of product manufacture, which cannot be easily changed.…”

Section: The Role Of Process Parameters In Influencing Warpage and Sh...mentioning

confidence: 99%

Recent progress in minimizing the warpage and shrinkage deformations by the optimization of process parameters in plastic injection molding: a review

Zhao

Lian

Wang

et al. 2022

Int J Adv Manuf Technol

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The quality control of plastic products is an essential aspect of the plastic injection molding (PIM) process. However, the warpage and shrinkage deformations continue to exist because the PIM process is easily interfered with by several related or independent process parameters. Thus, great efforts have been devoted to optimizing process parameters to minimize the warpage and shrinkage deformations of products during the last decades. In this review, we begin by introducing the manufacturing process in PIM and the cause of warpage and shrinkage deformations, followed by the mechanism about how process parameters, like mold temperature, melt temperature, injection rate, injection pressure, holding pressure, holding and cooling duration, affect those defects. Then, we summarize the recent progress of the design of experiments and four advanced methods (artificial neural networks, genetic algorithm, response surface methodology, and Kriging model) on optimizing process parameters to minimize the warpage and shrinkage deformations. In the end, future perspectives of quality control in injection molding machines are discussed.

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Section: The Role Of Process Parameters In Influencing Warpage and Sh...mentioning

confidence: 99%

Recent progress in minimizing the warpage and shrinkage deformations by the optimization of process parameters in plastic injection molding: a review

Zhao

Lian

Wang

et al. 2022

Int J Adv Manuf Technol

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show abstract

“…In recent years, various approaches have been presented and introduced to monitor process parameters of injection molding in real-time and furthermore to reduce common quality defects such as warpage or shrinkage [46][47][48][49]. Many sensor-supported monitoring systems for measuring pressure and temperature are used for process monitoring of injection molding in order to obtain an insight into the injection molding process [50,51].…”

Section: Use-case Injection Moldingmentioning

confidence: 99%

Tooling systems with integrated sensors enabling data based process optimization

Bleicher¹,

Ramsauer²,

Leonhartsberger³

et al. 2021

Journal of Machine Engineering

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Sensor integration into machining equipment has become an important factor for gaining deep process insights mainly driven by increasingly smaller and cheaper sensors and transmitters. Due to advances in microelectronics and communication technology, a broader field of applications in production processes and machine tools can be addressed using sensing devices and their implementation potentials. Ensuring a sensitive but robust data stream from close to the actual process allows not only reliable monitoring but also process and quality control based on sensor information. This paper provides an overview of the utilization of sensor data for the purpose of condition monitoring, model fitting and real-time control coping with stochastic effects. Examples of sensor integration in fields of injection molding, roll forming and heavy-duty milling comprise the state of the art of sensor implementation, data evaluation and possible feedback loops in the respective application scenarios.

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“…The complex crystallization will introduce more complicated shrinkage and greater warpage [6,7]. Some researchers have discussed the influences of the processing parameters on the warpage of CIM parts through experiments [8][9][10][11][12], and the warpage has been optimized based on experimental results [13][14][15][16][17]. These works have provided guidance to reduce the warpage of injection-molded parts.…”

Section: Introductionmentioning

confidence: 99%

Warpage Prediction of RHCM Crystalline Parts Based on Multi-Layers

Bei

Liu

et al. 2021

Polymers

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Warpage is a typical defect for injection-molded parts, especially for crystalline parts molded by rapid heat cycle molding (RHCM). In this paper, a prediction method is proposed for predicting the warpage of crystalline parts molded by the RHCM process. Multi-layer models were established to predict warpage with the same thicknesses as the skin-core structures in the molded parts. Warpages were defined as the deformations calculated by the multi-layer models. The deformations were solved using the classical laminated plate theory by Abaqus. A model was introduced to describe the elastic modulus with the influence of temperature and crystallinity. The simulation process was divided into two procedures, before ejection and after ejection. Thermal stresses and thermal strains were simulated, respectively, in the procedure before ejection and after ejection. The prediction results were compared with the experimental results, which showed that the average errors between predicted warpage and average experimental warpage are, respectively, 7.0%, 3.5%, and 4.4% in conventional injection molding (CIM), in RHCM under a 60 °C heating mold (RHCM60), and in RHCM under a 90 °C heating mold (RHCM90).

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Warpage reduction through optimized process parameters and annealed process of injection-molded plastic parts

Cited by 25 publications

References 22 publications

Recent progress in minimizing the warpage and shrinkage deformations by the optimization of process parameters in plastic injection molding: a review

Recent progress in minimizing the warpage and shrinkage deformations by the optimization of process parameters in plastic injection molding: a review

Tooling systems with integrated sensors enabling data based process optimization

Warpage Prediction of RHCM Crystalline Parts Based on Multi-Layers

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