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Journal articles on the topic 'Injection moulding process simulation'

Author: Grafiati

Published: 4 June 2021

Last updated: 17 February 2022

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1

Białasz, Sebastian, and Tomasz Klepka. "Simulation of the medical syringe injection moulding process." MATEC Web of Conferences 252 (2019): 05016. http://dx.doi.org/10.1051/matecconf/201925205016.

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This paper contains a description of tests including the simulation of the injection moulding of thin-walled products. The simulation was designed to analyse the potential impact of processing conditions and cooling conditions on the defects of thin-walled products of the body of the syringe. In order to obtain the correct results, the analysis was based on a simulation comparison with the data obtained after the injection mouldings were produced. Four cases were considered - parameters with reduced injection pressure and absence of pressure push, with a reduced temperature of the injection mould. The test results were analysed in conditions compliant with the recommendations of the production card and with the parameters optimised by computational algorithms of the computer programme. Simulations were carried out using the Simcon CadMould 3D-F programme. The paper describes the construction of a thin-walled body, which is the main segment of a medical instrument - a medical syringe. Also described in the paper are the process of injection of polymer materials and the characteristics of the production of medical syringes. In addition the computer programme software for the simulation of production processes was presented.

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2

Nardin, B., K. Kuzman, and Z. Kampus. "Injection moulding simulation results as an input to the injection moulding process." Journal of Materials Processing Technology 130-131 (December 2002): 310–14. http://dx.doi.org/10.1016/s0924-0136(02)00734-3.

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3

Li, Wei. "Injection Moulding Simulation Analysis of Handle Shell." Advanced Materials Research 798-799 (September 2013): 286–89. http://dx.doi.org/10.4028/www.scientific.net/amr.798-799.286.

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This thesis first made an introduction to the functional and technical requirements of this product, and then determined its moulding process. After that, the injection moulding process parameters of the selected injection moulding machine were set, besides, it applied Moldflow software to make simulation analysis to multiple schemes of injection moulding process, and finally, the best mold structure was determined according to the final analysis result.

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4

Titomanlio, G., V. Speranza, and V. Brucato. "On the Simulation of Thermoplastic Injection Moulding Process." International Polymer Processing 10, no. 1 (March 1995): 55–61. http://dx.doi.org/10.3139/217.950055.

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5

Titomanlio, G., V. Speranza, and V. Brucato. "On the Simulation of Thermoplastic Injection Moulding Process." International Polymer Processing 12, no. 1 (March 1997): 45–53. http://dx.doi.org/10.3139/217.970045.

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6

Ding, D., P. Townsend, and M. F. Webster. "Finite element simulation of an injection moulding process." International Journal of Numerical Methods for Heat & Fluid Flow 7, no. 7 (November 1997): 751–66. http://dx.doi.org/10.1108/09615539710185884.

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7

Yanev, A. S., Gustavo R. Dias, and António M. Cunha. "Visualization of Injection Moulding Process." Materials Science Forum 587-588 (June 2008): 716–20. http://dx.doi.org/10.4028/www.scientific.net/msf.587-588.716.

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A special tool-transparent mould designed to visualize the melt flow inside the cavity is used in this research. The aim of the work is to assess the polymer melt behavior under different processing conditions-close to industrial, in conventional and two materials non-conventional injection moulding techniques. The mould is designed with two injection locations and has possibility to change the geometry of the cavity in order to investigate the melt behavior in differently shaped cavities. Visual access in the mould is allowed by the sapphire windows, surrounding the cavity. For image acquisition a high speed video camera NAC 1000 is used. Materials used in the research are three polypropylenes with different flow index. Results are obtained for conventional injection moulding, two material monosandwich and two material biinjection moulding. Apart from visualization, instrumentation of the mould allows to be obtained PT data for each processing condition. Results from conventional injection moulding are compared with MPI5.0 simulations.

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8

Palutkiewicz, Pawel. "Computer simulations of cellular injection moulding process." Polimery 60, no. 02 (February 2015): 132–43. http://dx.doi.org/10.14314/polimery.2015.132.

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9

Turng, L.-S., and M. Peić. "Computer aided process and design optimization for injection moulding." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 216, no. 12 (December 1, 2002): 1523–32. http://dx.doi.org/10.1243/095440502321016288.

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Sophisticated computer aided engineering (CAE) simulation tools for injection moulding have been available and are now widely used in industrial practices. As a result, the design and manufacturing of injection-moulded parts have been literally transformed from a ‘black art’ to an engineering discipline based on scientific principles. It is well recognized that computer simulation tools help engineers to gain process insight and to pinpoint blind spots and problems that are overlooked. Nevertheless, there remains a missing link in CAE, which lies in the ability to identify effectively the optimal design and process variables, as it is hampered by the sheer amount of computer-generated data and complex non-linear interactions among those input variables. This paper presents the system implementation and experimental verifications of an integrated CAE optimization tool that couples a process simulation program with optimization algorithms to determine intelligently and automatically the optimal design and process variables for injection moulding. In addition, this study enables evaluation and comparison of various local and global optimization algorithms in terms of computational efficiency and effectiveness for injection moulding, as presented in this paper.

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10

Virdhian, Shinta, Sina Jamilah, Sugeng Supriadi, and Bambang Suharno. "METAL INJECTION MOULDING PROCESS SIMULATION FOR ORTHODONTIC BRACKET APPLICATION." Jurnal Teknologi Bahan dan Barang Teknik 7, no. 2 (December 29, 2017): 51. http://dx.doi.org/10.37209/jtbbt.v7i2.94.

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Proses Metal Injection Moulding (MIM) merupakan salah satu proses yang efektif untuk pembuatan produk logam yang memiliki bentuk yang rumit dan skala produksi massal. Proses MIM telah digunakan pada banyak aplikasi seperti produk rumah tangga, otomotif, biomedikal dan lain-lain. Dalam penelitian ini, braket ortodontik dibuat melalui proses MIM. Sebelum proses manufaktur, simulasi injeksi dilakukan dengan menggunakan software komersial Sigmasoft untuk mengevaluasi desain dan optimasi parameter proses. Beberapa parameter proses dimasukkan ke dalam simulasi untuk mendapatkan kondisi proses yang optimum, antara lain temperatur injeksi,temperatur mold, waktu proses, dan tekanan selama proses injeksi. Dalam simulasi ini, temperatur injeksi 190 °C dan temperatur mold divariasikan 90-150 °C dan waktu pengisian dari 0,5-3 detik. Hasil simulasi menunjukkan temperatur mold optimum pada 90 °C dan feedstock masih bisa mengisi rongga dengan waktu pengisian 2,5 detik. Dari hasil simulasi aliran menunjukkan desain yang ada dapat dioptimalkan dengan mengurangi ukuran runner dan bentuk yang tajam.Kata kunci: braket ortodontik, metal injection moulding, simulasi, software Sigmasoft

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11

Zoetelief, W. F., G. W. M. Peters, and H. E. H. Meijer. "Numerical Simulation of the Multi-Component Injection Moulding Process." International Polymer Processing 12, no. 3 (September 1997): 216–27. http://dx.doi.org/10.3139/217.970216.

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12

Godec, Damir, Vladimir Brnadić, and Tomislav Breški. "Optimisation of Mould Design for Injection Moulding – Numerical Approach." Tehnički glasnik 15, no. 2 (June 9, 2021): 258–66. http://dx.doi.org/10.31803/tg-20210531204548.

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Computer simulation of injection moulding process is a powerful tool for optimisation of moulded part geometry, mould design and processing parameters. One of the most frequent faults of the injection moulded parts is their warpage, which is a result of uneven cooling conditions in the mould cavity as well as after part ejection from the mould and cooling down to the environmental temperature. With computer simulation of the injection moulding process it is possible to predict potential areas of moulded part warpage and to apply the remedies to compensate/minimize the value of the moulded part warpage. The paper presents application of simulation software Moldex 3D in the process of optimising mould design for injection moulding of thermoplastic casing.

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13

Arifin, Mohd Khairol A., Shamsuddin Sulaiman, B. T. Hang Tuah Baharudin, Tang Sai Hong, and S. Sreenivasan. "Simulation of Thermoset Injection for Bulk Moulding Compounds (BMC)." Key Engineering Materials 471-472 (February 2011): 1101–6. http://dx.doi.org/10.4028/www.scientific.net/kem.471-472.1101.

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This paper discusses about the simulation of the process of injection moulding for thermoset materials namely Bulk Moulding Compounds (BMC). BMC is a polyester resin based compound with glass fibre additives. In this paper a complex part was used to simulate and obtain the parameters for moulding BMC. Autodesk Moldflow Plastics Insight was used to run the simulation. Two main parameters i.e. Injection time and mould temperature were considered. Six different sets of parameters were used and the settings were optimized. The obtained optimized settings are 15.08 seconds and 145°C. The obtained parameters were then applied and the actual part was tested using an injection-moulding machine. After the simulation, changes were also made to the actual mould to improve the moulding conditions. Extra air vents were added at the problematic areas to ease the flow. There was an average variance of 7% which was thought to be acceptable as the simulation considers the ideal condition, where as there may be external factors such as the machine wear and tear during the actual moulding of the part. It can be said that the simulation was run successfully and tested during actual moulding.

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14

Azaman, M. D., S. M. Sapuan, Shamsuddin Sulaiman, E. S. Zainudin, and Abdan Khalina. "Numerical Simulation on Moulded Thin-Walled Parts via Injection Moulding Process." Applied Mechanics and Materials 575 (June 2014): 73–77. http://dx.doi.org/10.4028/www.scientific.net/amm.575.73.

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The current trend in the industry is to produce thin, light weight, and environmental products. In this project, flat or shallow thin-walled parts were designed and moulded lignocellulosic polymer composites (PP + 50 wt% wood) to visualize the processability via moulding simulation. This studied focused on the filling, shear stress at wall, and in-cavity residual stresses behaviors. The shallow thin-walled part is preferable in moulding PP + 50 wt% wood due to economically in processing, low shear stress distribution and low residual stresses than the flat thin-walled part.

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15

Cardozo, D. "A brief history of the filling simulation of injection moulding." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 223, no. 3 (December 1, 2008): 711–21. http://dx.doi.org/10.1243/09544062jmes986.

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Injection moulding is one of the most important manufacturing processes for mass production of complex plastic parts. The quality of injection moulded parts depends not only on the material, shape, and function of the part design, but also on how the material is processed during moulding. Traditional design approaches based on intuition, prior experience, and trial-and-error methodology have been becoming less efficient and effective. With advances in numerical modelling and computer simulation techniques, there have been tremendous efforts made to develop computer simulation tools to facilitate injection moulding design and process set-up. This paper reviews the history of research and development in the filling simulation of injection moulding. The existing models are classified into three categories: one-dimensional models, 2.5D models, and three-dimensional models. The basic features and relative key techniques about these models have been discussed. The techniques of tacking the moving flow front have also been presented. It is then followed by conclusions and discussions of these mentioned models.

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16

Iordan, Ionela, Constantin Dogariu, and Cristina Mohora. "Theoretical Contributions to the Accuracy of Parts by Moulding and Injection Moulding." Applied Mechanics and Materials 656 (October 2014): 270–79. http://dx.doi.org/10.4028/www.scientific.net/amm.656.270.

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The purpose of this study is to analyse, by simulation, the injection of ABS plastic parts and track results on piece deformations after the latter was removed from the mould. Injection Process. Analysis was performed using the Autodesk Moldflow professional package. The results of the theoretical analysis by numerical methods are used for optimal design of the die to reduce and eliminate the strains and defect parts.

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17

Zheng, Z. S., and X. H. Qu. "Numerical simulation of powder injection moulding filling process for intricate parts." Powder Metallurgy 49, no. 2 (June 2006): 167–72. http://dx.doi.org/10.1179/174329006x95329.

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18

Courbebaisse, Guy. "Numerical simulation of injection moulding process and the pre-modelling concept." Computational Materials Science 34, no. 4 (December 2005): 397–405. http://dx.doi.org/10.1016/j.commatsci.2004.11.004.

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19

Iwko, Jacek, Ryszard Steller, and Roman Wróblewski. "Experimentally Verified Mathematical Model of Polymer Plasticization Process in Injection Molding." Polymers 10, no. 9 (September 1, 2018): 968. http://dx.doi.org/10.3390/polym10090968.

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The mathematical model of the polymer plasticization in the reciprocating screw injection moulding machine is presented in this paper. Methods of calculation of the most important flow characteristics, such as the solid bed profile, the pressure and temperature profiles, the mass flow rate, the power demand, the screw torque and the energy consumption were analysed. According to the mathematical model, a computer program was developed. Based on the computer program, simulation studies of the injection moulding process were conducted. Thereafter, the experimental studies, evaluating the theoretical model from the accuracy and usefulness point of view, were carried out. Important output quantities, such as the temperature and pressure profiles, the power demand by the screw, the torque on the screw and the screw rotation time were measured. The studies were performed on a specially made research office. The simulation results were compared with the experimental data measured for the most popular polymers and different operating parameters of the injection machine. The experimental studies have indicated the need to introduce some corrections to the mathematical model. Several modifications have been made to the model, mainly related to the methods of stress determining in the polymer layer. Finally, the output characteristics of the plasticization process in the injection moulding are now correctly determined by the model with an average error less than 10%.

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20

Llewelyn, Gethin, Andrew Rees, Christian A. Griffiths, and Steffen G. Scholz. "Advances in microcellular injection moulding." Journal of Cellular Plastics 56, no. 6 (March 17, 2020): 646–74. http://dx.doi.org/10.1177/0021955x20912207.

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Injection moulding is a well-established replication process for the cost-effective manufacture of polymer-based components. The process has different applications in fields such as medical, automotive and aerospace. To expand the use of polymers to meet growing consumer demands for increased functionality, advanced injection moulding processes have been developed that modifies the polymer to create microcellular structures. Through the creation of microcellular materials, additional functionality can be gained through polymer component weight and processing energy reduction. Microcellular injection moulding shows high potential in creating innovation green manufacturing platforms. This review article aims to present the significant developments that have been achieved in different aspects of microcellular injection moulding. Aspects covered include core-back, gas counter pressure, variable thermal tool moulding and other advanced technologies. The resulting characteristics of creating microcellular injection moulding components through both plasticising agents and nucleating agents are presented. In addition, the article highlights potential areas for research exploitation. In particular, acoustic and thermal applications, nano-cellular injection moulding parts and developments of more accurate simulations.

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21

Ghazali, Wafiuddin Md, Daing Mohamad Nafiz Daing Idris, Azizul Helmi Sofian, Januar Parlaungan Siregar, and Mohamad Firdaus Basrawi. "Gate Location and Injection Analysis of a Spur Gear." MATEC Web of Conferences 225 (2018): 06012. http://dx.doi.org/10.1051/matecconf/201822506012.

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Injection moulding process is one of the common processes to produce plastic parts from simple to complicated parts. This paper focuses on the injection process analysis of a 25 tooth spur gear. Three runner system are proposed for the gear and each system will be analysed using Autodesk Simulation Moldflow Advisor. The most suitable design will then be chosen based on the results obtained from the simulation. The design undergoes cooling quality, sink mark, fill + pack, and warp analysis. Based on these analyses, Design 1 gave the better results compared to Design 2 and 3. From there, Design 1 runner system is chosen for the injection moulding mould which will be fabricated later in the research.

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22

Hric, Slavomir, Dominika Lehocka, Jan Carach, Filip Murgas, and Peter Pastucha. "The Simulation as a Tool for Technical Devices Design and Optimization." Applied Mechanics and Materials 718 (December 2014): 122–27. http://dx.doi.org/10.4028/www.scientific.net/amm.718.122.

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The article deals with the research of the pressures originated inside the cooling system and also in the mould cavity during the injection moulding process. The simulations were realized for three designed types of running system and for four versions of cooling system. 3D model of the mould was created in Autodesk Inventor Proffesional software and then solidification of material was simulated in Autodesk Moldflow Insight software. The results were compared and the best version from the view of pressure was manufactured and placed into the injection moulding machine Arburg Allrounder 320 C.

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23

Košík, Miroslav, Lukáš Likavčan, Jozef Bílik, and Maroš Martinkovič. "Diesel Effect Problem Solving During Injection Moulding." Research Papers Faculty of Materials Science and Technology Slovak University of Technology 22, no. 341 (December 1, 2014): 97–102. http://dx.doi.org/10.2478/rput-2014-0014.

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Abstract Study describes principles of diesel effect creation during thermoplastic injection moulding as a consequence of wrong injection conditions and poor venting system design. On real example, study shows sequence of all steps to eliminate this sort of material degradation with minimal costs in phase when mould is already made. As a first, process parameters were optimized by CAE simulation to minimize cavity internal gasses creation. Finally the specific mould modifications were suggested to improve the effectiveness of venting system.

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24

Garcia, David, Guy Courbebaisse, and Michel Jourlin. "IMAGE ANALYSIS DEDICATED TO POLYMER INJECTION MOLDING." Image Analysis & Stereology 20, no. 3 (May 3, 2011): 143. http://dx.doi.org/10.5566/ias.v20.p143-148.

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This work follows the general framework of polymer injection moulding simulation whose objectives are the mastering of the injection moulding process. The models of numerical simulation make it possible to predict the propagation of the molten polymer during the filling phase from the positioning of one point of injection or more. The objective of this paper is to propose a particular way to optimize the geometry of mold cavity in accordance with physical laws. A direct correlation is pointed out between geometric parameters issued from skeleton transformation and Hausdorff's distance and results provided by implementation of a classical model based on the Hele-Shaw equations which are currently used in the main computer codes of polymer injection.

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Li, Qiang, Jie Ouyang, Binxin Yang, and Tao Jiang. "Modelling and simulation of moving interfaces in gas-assisted injection moulding process." Applied Mathematical Modelling 35, no. 1 (January 2011): 257–75. http://dx.doi.org/10.1016/j.apm.2010.06.002.

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26

Zheng, Zhen Xing, Yuan Biao Wu, Wei Xia, and Wei Ping Chen. "Process Optimization of Mid-Density Tungsten Alloy for Injection Process in Metal Injection Molding Based on Numerical Simulation." Materials Science Forum 628-629 (August 2009): 599–604. http://dx.doi.org/10.4028/www.scientific.net/msf.628-629.599.

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In this paper, based on the CAE technology for MIM and fractional factorial design method, the simulation for the filling process was executed in different process conditions by the Moldflow software. And then it was realized that the extent of the effects of the single factor and pairwise interaction between the process parameters on quality of green parts were forecasted. According to that, the relationships of pressure, velocity and time and their optimal combination were researched by the experiments using a FC-80 plastic-Injection-Moulding machine. The experimental results suggested that the pressure, velocity and time have a obvious pairwise interaction which can have more effect on the product than single factor. It was shown that there was a good consistency between the numerical simulation and experiment. The CAE technique and the experiments are combined to optimize the process conditions and improve the part quality automatically by using smaller number of experiments.

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27

Hric, Slavomir, Alena Vagaska, Svetlana Radchenko, Filip Murgas, and Milan Micko. "Product Quality Improvement Using Simulation Tools." Applied Mechanics and Materials 718 (December 2014): 77–82. http://dx.doi.org/10.4028/www.scientific.net/amm.718.77.

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The article deals with the basic technological aspects of injection moulding, pointing to the importance of correct product geometry design. Large differences in the wall thickness of the mould result in uneven cooling, material shrinkage, and the formation of internal stress. This ultimately may give rise to deformations, such as those in form sink marks, and may affect the required quality of the mould. The article describes the application of a specific example of one of the ways of correction of the mould wall thickness used in technological practice of the injection moulding technology. This is a case of employing the method of the so-called relief pins. After the introduction of the proposed modification of the form, the mould quality has improved, thereby increasing the production efficiency in the process of shape optimization of manufacturing the product called Installation Box Series S-BOX 106 made of polyamide PA 66. In addressing the issue, simulation of cooling plastic and injection pressure in Cadmold 3D-f software was employed.

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28

Amran, Mohd, Siti Salmah, Raja Izamshah, Mohd Shahir, Mohd Amri, Effendi Mohamad, Mohd Sanusi, et al. "Warpage Analysis of Different Number Cooling Channels for Dumbbell Plastic Part in Injection Moulding." Applied Mechanics and Materials 761 (May 2015): 8–11. http://dx.doi.org/10.4028/www.scientific.net/amm.761.8.

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Warpage deflection is one of the common pitfalls in plastic injection moulding which is always affected the quality and accuracy of the plastic products. It occurs due to the influences of mould temperature during injection moulding process and it is related to the number of cooling system existed in the mould. Therefore, this paper studies the effect of cooling channels on warpage of dumbbell plastic part having different number of cooling channel using Moldflow software. Warpage analysis was run using four and eight cooling channels. Parameters involved in this study are injection time, packing time, melt temperature and mould temperature. The result of warpage from simulation analysis was projected on the graphic having different colour which is presented the actual value of warpage. It is found from warpage simulation result that the maximum warpage for four cooling channels is 1.283mm and the maximum warpage for eight cooling channels is 1.280mm. It shows that the increasing of the number of cooling channel from four to eight channels in the injection mould reduces the warpage deflection about 0.2%. Thus, the result shows that the number of cooling system in the mould plays an important role on the quality of plastic part during injection moulding process.

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29

Zhang, Haoyang, Fengzhou Fang, Michael D. Gilchrist, and Nan Zhang. "Precision replication of micro features using micro injection moulding: Process simulation and validation." Materials & Design 177 (September 2019): 107829. http://dx.doi.org/10.1016/j.matdes.2019.107829.

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30

Papadakis, Loucas, Stelios Avraam, Demetris Photiou, Simona Masurtschak, and Juan Carlos Pereira Falcón. "Use of a Holistic Design and Manufacturing Approach to Implement Optimized Additively Manufactured Mould Inserts for the Production of Injection-Moulded Thermoplastics." Journal of Manufacturing and Materials Processing 4, no. 4 (October 24, 2020): 100. http://dx.doi.org/10.3390/jmmp4040100.

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Injection moulding is one the most familiar processes for manufacturing of plastic parts by injecting molten thermoplastic polymers into a metallic mould. The cycle time of this process consists of the phases of injection, packing, cooling, and ejection of the final product. Shortening of cycle time is a key consideration to increase productivity. Therefore, in this manuscript the adoption of additively manufactured mould inserts with conformal cooling channels by means of selective laser melting (SLM) with the aim to reduce process cycles is presented. The design and manufacture of a mould insert with conformal cooling channels for producing pressure fitting thermoplastic parts is described. Numerical analysis of the injection process and simulation of shape distortions after SLM were conducted providing useful results for the design and manufacture of the mould insert. The results of the numerical analyses are compared with experimental 3D geometrical data of the additively manufactured mould insert. Temperature measurements during the real injection moulding process demonstrating promising findings. The adoption of the introduced method for the series production of injection moulded thermoplastics proves a shortening of cycle times of up to 32% and a final product shape quality improvement of up to 77% when using mould inserts with conformal cooling channels over the conventional mould inserts.

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31

Mehat, Nik Mizamzul, Shahrul Kamaruddin, and Abdul Rahim Othman. "Modeling and Analysis of Injection Moulding Process Parameters for Plastic Gear Industry Application." ISRN Industrial Engineering 2013 (June 11, 2013): 1–10. http://dx.doi.org/10.1155/2013/869736.

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The performance of plastic gears in wide variety of power and motion transmission applications is rather limited due to weak mechanical properties and divergent mechanism of failures. A methodical simulation is carried out to analyze the gear performance with various gating system types, gate locations, and processing parameters via grey-based Taguchi optimization method. With the obtained optimum results in simulation stage, the flow patterns of polymer melt inside the mould during filling, packing, and cooling processes are studied and the plastic gear failures mechanism related to processing parameters are predicted. The output results in the future can be used as guidance in selecting the appropriate materials, improving part and mould design, and predicting the performance of the plastic gear before the real process of the part manufacturing takes place.

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32

Bilovol, V. V., L. Kowalski, and J. Duszczyk. "Numerical Simulation of the Powder Injection Moulding Process for Optimization of Mould Design and Process Parameters." Advanced Engineering Materials 2, no. 3 (March 2000): 127–31. http://dx.doi.org/10.1002/(sici)1527-2648(200003)2:3<127::aid-adem127>3.0.co;2-9.

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33

Razak, Zakaria, Abu Bakar Sulong, Norhamidi Muhamad, Mohd Khairul Fadzly Md Radzi, Nur Farhani Ismail, Dulina Tholibon, and Izdihar Tharazi. "Numerical Simulation Analysis of Wood/PP Composites for Injection-Moulded Car Battery Trays." International Journal of Engineering & Technology 7, no. 3.17 (August 1, 2018): 15. http://dx.doi.org/10.14419/ijet.v7i3.17.16613.

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This research focused on the simulation analysis of wood polymer composites (WPCs) based on polypropylene (PP) for the injection moulding of automotive parts, namely car battery trays (CBTs). A plastic CBT, which is commonly used to support the battery in a car engine, is manufactured completely through the injection moulding process. The conventional design method is clearly unable to satisfy production requirements; however, with the application of the Moldflow software rational production process parameters, the filling time, injection pressure, clamping force, and others, can be formulated. A moulded CBT was designed using a computer-aided design tool, namely CatiaV5R20, before being imported to the finite element analysis tool, Moldflow. The use of the Moldflow software enabled a full analysis to be conducted of the material flow inside the mould cavity for the moulded CBT. Two types of gates, namely, the sprue and pinpoint gates, were used, through which the analyses were carried out by the Moldflow software to check the filling time, injection pressure, clamping force and warpage, by simulation in the sequential trials. The data on the wood fibre/PP composite, where 40 wt% of wood fibre loading was used. Finally, the use of the Moldflow simulation software was presented.

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34

Biglione, Jordan, Yves Bereaux, J. Y. Charmeau, Renaud G. Rinaldi, Jean Balcaen, and Sambor Chhay. "Injection Blow Moulding Single Stage Process – Approach of the Material Behaviour in Process Conditions and Numerical Simulation." Key Engineering Materials 651-653 (July 2015): 805–11. http://dx.doi.org/10.4028/www.scientific.net/kem.651-653.805.

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Single stage injection blow moulding process, without preform storage and reheat, could be run on a standard injection moulding machine, with the aim of producing short series of specific hollow parts. In this process, the preform is being blow moulded after a short cooling time. Polypropylene (Random copolymer) is a suitable material for this type of process. The preform has to remain sufficiently melted to be blown. This single stage process introduces temperature gradients, molecular orientation, high stretch rates and high cooling rates. These constraints lead to a small processing window, and in practice, the process takes place between the melting temperature and the crystallization temperature. To investigates the mechanical behaviour in conditions as close to the process as possible, we ran a series of experiments: First, Dynamical Mechanical Analysis was performed starting from the solid state at room temperature and ending in the vicinity of the melting temperature. Conversely, oscillatory rheometry was also performed starting this time from the molten state at 200°C and decreasing the temperature down to the vicinity of the crystallization temperature. The influence of the shear rate and of the cooling kinetics on the enhancement of the mechanical properties when starting from the melt is discussed. This enhancement is attributed to the crystallization of the material. The question of the crystallization occurring at such high stretch rates and high cooling rates is open. A viscous Cross model has been proved to be relevant to the problem. Thermal dependence is assumed by an Arrhenius law. The process is simulated through a finite element code (POLYFLOW software) in the Ansys Workbench framework. Thickness measurements using image analysis are performed and comparison with the simulation results is satisfactory.

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Othman, Mohd Hilmi, Shazarel Shamsudin, Sulaiman Hasan, and Mohd Norhafiz Abd Rahman. "The Effects of Injection Moulding Processing Parameters and Mould Gate Size towards Weld Line Strength." Advanced Materials Research 488-489 (March 2012): 801–5. http://dx.doi.org/10.4028/www.scientific.net/amr.488-489.801.

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Plastic moulded parts should have good mechanical properties and free from defects. Tensile behaviour of plastics plays an important role in defining the quality of injection-moulded products. In this study, numerical simulation (Cadmould) was employed to investigate the influence of gate sizes as well as the injection moulding parameters towards the occurrences of weld lines at Acrylonitrile Butadiene Styrene (ABS) specimens. This research begins from the simulation, fabrication of mould, practical injection process and tensile test. The double gates mould was used to present the weld line defects. The result shows that the smaller gate size produces less weld line in plastic parts, which was verified through simulation process. The optimal parameter setting that produced good tensile strength specimens was also validated experimentally in this research

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Amran, M. A. M., N. Idayu, K. M. Faizal, M. Sanusi, R. Izamshah, and M. Shahir. "Part weight verification between simulation and experiment of plastic part in injection moulding process." IOP Conference Series: Materials Science and Engineering 160 (November 2016): 012016. http://dx.doi.org/10.1088/1757-899x/160/1/012016.

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Atre, S. V., S. J. Park, R. Zauner, and Randall M. German. "Process simulation of powder injection moulding: identification of significant parameters during mould filling phase." Powder Metallurgy 50, no. 1 (March 2007): 76–85. http://dx.doi.org/10.1179/174329007x185607.

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Nguyen-Chung, T., C. Löser, G. Jüttner, T. Pham, M. Obadal, and M. Gehde. "Simulation of the micro-injection moulding process: effect of the thermo-rheological status on the morphology." Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering 225, no. 4 (October 3, 2011): 224–38. http://dx.doi.org/10.1177/0954408911415940.

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The software package Moldflow Plastics Insights was used to simulate the filling of a micro-cavity by considering precise material data and accurate boundary conditions. Experiments were carried out on an accurately controlled micro-injection moulding machine (formicaPlast) for providing important parameters to verify the simulation results and improve the accuracy of the simulation. Based on the relationship between the cavity pressure and the mould-filling ratio, the heat transfer coefficients can be appropriately determined for different process conditions. Finally, the transient thermo-rheological results were analysed with regard to their influence on the morphology of semi-crystalline (PP) micro-injection moulded parts, which not only give rise to the mechanisms of the morphological formation but also verify the quality of the simulation results.

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Othman, Mohd Hilmi, Sulaiman Hasan, and Muhammad Farid Shaari. "Development and Structural Analysis of Injection Moulding-Hydraulics Clamping Unit Testing System." Applied Mechanics and Materials 315 (April 2013): 156–60. http://dx.doi.org/10.4028/www.scientific.net/amm.315.156.

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This project is focusing on the development of a test unit for the hydraulically driven clamping system, typically used in injection moulding. The objectives of this project are to fabricate the model of clamping unit and to perform structural analysis based on the model design through simulation and by performing actual experiment on the real fabricated model. This actual test was conducted by compressing the load cell in between the two moulds halves in order to get the clamping force value through the data logger. The results obtained from simulation shows that the maximum stress of clamping unit with tie bar can achieve up to 11.2 MPa, with the safety value of 2.5. In the other hand, for the actual test experiment, the result the maximum clamping force produce is 3160N at 52bar of pressure. These values are important to be used as guidance in selecting the suitable injector part. As a conclusion, this clamping system has work properly and efficiently to be used for further research and a tool to understand more about the mechanism and the effects of clamping units in injection moulding process.

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Azaman, M. D., S. M. Sapuan, S. Sulaiman, E. S. Zainudin, and A. Khalina. "Numerical Simulation Analysis of Unfilled and Filled Reinforced Polypropylene on Thin-Walled Parts Formed Using the Injection-Moulding Process." International Journal of Polymer Science 2015 (2015): 1–8. http://dx.doi.org/10.1155/2015/659321.

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Thin-walled moulding technology has attracted increasing attention, particularly in electronic packing applications. The injection moulding of shallow, thin-walled parts with a thickness of 0.7 mm was performed using three types of materials from polypropylene, PP (PP, PP + 50 wt% wood composite, and PP + 10 wt% glass fibre composite). The highest deflection resulting from PP + 50 wt% wood does not occur in the critical area of the thin-walled part compared with PP + 10 wt% glass fibre. In addition, the results revealed that the warpage at the midpoint of the part surface injected using PP + 50 wt% wood is 0.04 mm lower than the value of 0.08 mm obtained when injected using PP + 10 wt% glass fibre. The warpage was hypothesised to result from the residual stress caused by nonuniform volumetric shrinkages formed during the solidification phase.

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Bikas, Athanasios, Nikos Pantelelis, and Andreas Kanarachos. "Computational tools for the optimal design of the injection moulding process." Journal of Materials Processing Technology 122, no. 1 (March 2002): 112–26. http://dx.doi.org/10.1016/s0924-0136(01)01248-1.

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Ahmad, Daniel, Nahiene Hamila, Khalid Lamnawar, and Philippe Boisse. "Mechanical Analysis and Simulation of the Thermoforming Process of Thin Polymer Sheets." Key Engineering Materials 504-506 (February 2012): 1111–16. http://dx.doi.org/10.4028/www.scientific.net/kem.504-506.1111.

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Most of industrial processes (thermoforming, injection moulding...) require the understanding of thermo-mechanical behaviour of polymeric sheets. Furthermore, the mastery of the deformation of the polymers becomes an important stake. In order to improve and complete the understanding of the deformation of thermoplastic polymer materials during their forming processes, the problem of modelling the thermoforming process for viscoelastic sheet under large strains is considered. The first step of the process that consists in heating the sheet using infrared lamps is taken into account by included a temperature field in viscoelastic behaviour laws under integral forms. The finite element simulation of the different steps will be presented

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Li, Qiang, Haifeng Niu, and Jinyun Yuan. "Macroscopic and mesoscopic simulation of viscoelastic free surface flow in gas‐assisted injection moulding process." Canadian Journal of Chemical Engineering 97, no. 8 (March 25, 2019): 2359–68. http://dx.doi.org/10.1002/cjce.23489.

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Bilovol, V. V., L. Kowalski, J. Duszczyk, and L. Katgerman. "Characterisation of 316L powder injection moulding feedstock for purpose of numerical simulation of PIM process." Powder Metallurgy 46, no. 3 (October 2003): 236–40. http://dx.doi.org/10.1179/003258903225005367.

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Nixon, J., S. Yan, and Gary H. Menary. "Analysis and Simulation of the Free-Stretch-Blow Process of PET." Key Engineering Materials 554-557 (June 2013): 1729–37. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.1729.

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This paper is concerned with understanding the behaviour of Polyethylene Terephthalate (PET) in the injection stretch blow moulding (ISBM) process where it is typically bi-axially stretched to form bottles for the packaging industry. Preforms which have been pre sprayed with a pattern and heated in an oil bath have been stretched and blown in free air using a lab scale ISBM machine whilst being monitored via high speed video. The images have subsequently been analysed using a digital image correlation system (VIC 3D). The results have been used to validate appropriate simulations of the free-blow process using ABAQUS®/Explicit FEA with a suitable viscoelastic material model, along with experimental process data obtained using an instrumented stretch rod.

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Jiang, Ning, and Chuan Yang Wang. "Design and Simulation of Injection Mold for the Digital Camera Shell Based on Moldflow." Applied Mechanics and Materials 741 (March 2015): 215–22. http://dx.doi.org/10.4028/www.scientific.net/amm.741.215.

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The camera shell is analyzed by using Finit Element Method (FEM) to judge reliability of the structure. Static structural and explicit dynamics analysis are conducted. The results provide valuable reference for the structural optimization design. Three schemes for injection mold are developed. Injection moulding process of the shell is simulated by applying Moldflow. The volumetric shrinkage, shrink mark index, total deformation, fill time and clamping force are analyzed. The results show that combining Moldflow with FEM method can not only shorten the construction period, but also ensure the molding quality.

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Kuppusamy, Raghu Raja Pandiyan, and S. Neogi. "Simulation of Air Entrapment and Resin Curing During Manufacturing of Composite Cab Front by Resin Transfer Moulding Process." Archives of Metallurgy and Materials 62, no. 3 (September 26, 2017): 1839–44. http://dx.doi.org/10.1515/amm-2017-0278.

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AbstractMould filling and subsequent curing are the significant processing stages involved in the production of a composite component through Resin Transfer Moulding (RTM) fabrication technique. Dry spot formation and air entrapment during filling stage caused by improper design of filling conditions and locations that lead to undesired filling patterns resulting in defective RTM parts. Proper placement of inlet ports and exit vents as well as by adjustment of filling conditions can alleviate the problems during the mould filling stage. The temperature profile used to polymerize the resin must be carefully chosen to reduce the cure time. Instead of trial and error methods that are expensive, time consuming, and non-optimal, we propose a simulation-based optimization strategy for a composite cab front component to reduce the air entrapment and cure stage optimization. In order to be effective, the optimization strategy requires an accurate simulation of the process utilizing submodels to describe the raw material characteristics. Cure reaction kinetics and chemo-rheology were the submodels developed empirically for an unsaturated polyester resin using experimental data. The simulations were performed using commercial software PAM RTM 2008, developed by ESI Technologies. Simulation results show that the use of increase in injection pressure at the inlet filling conditions greatly reduce the air entrapped. For the cab front, the alteration of injection pressure with proper timing of vent opening reduced the air entrapped during mould filling stage. Similarly, the curing simulation results show that the use of higher mould temperatures effectively decreases the cure time as expected.

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Adam, Andrei, Cristian Cosma, Adrian Ilie Dume, and Sorin Jadaneantu. "Integration of CAD CAM Techniques in the Development of an Injection Mould for Automotive Parts." Solid State Phenomena 216 (August 2014): 322–25. http://dx.doi.org/10.4028/www.scientific.net/ssp.216.322.

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Processing by injection is the technological process by that the thermoplastics material is injected, under pressure, in the cavity of a mould, where it cools down and solidifies. This process is the most common method for obtaining plastic materials. Injection moulding of thermoplastics has emerged as the premier vehicle for delivering high quality, value added commercial products. Continued global competitiveness has increased standards for product capability and quality while requiring reduced product development time and unit cost. Despite advanced design methods and new process technologies, it is becoming apparent that the injection moulding process is neither flexible nor robust. This paper presents a design process using CAD-CAM software applied to an injection mould for manufacturing a plastic component that is used in the automotive industry. The component was analyzed, measured and subjected to simulations that will certify the quality of the final product.

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Blest, D., B. R. Duffy, S. McKee, and M. F. Tome. "Two studies in process modelling: injection moulding and resin film infusion." IMA Journal of Management Mathematics 7, no. 1 (January 1, 1996): 23–27. http://dx.doi.org/10.1093/imaman/7.1.23.

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Liu, Xi Fen, Yi Hua Hu, and Wei Jian Huang. "Optimum Design of Plastic Injection Mould Gate Based on MoldFlow." Advanced Materials Research 239-242 (May 2011): 2541–44. http://dx.doi.org/10.4028/www.scientific.net/amr.239-242.2541.

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In view of the importance of proper gate location and size in mould design process, with the basic analog theory for simulating the filling process of plastic melts in the cavity of injection moulds, injection moulding CAE technology was proposed for the optimum design of gate location and size. Based on Moldflow software, the analysis process of the best gate location and size was stated. The gate location and size and injection moulding technical parameters were optimized in this paper by example. The optimal rectangular gate dimension was 5mm×2.5mm, filling state was fine, filling time was reduced from 0.72s to 0.69s. It was resulted in products of high previewed quality, reduced the cost of production and enhanced the competitive power of mould enterprises.

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