Relevant bibliographies by topics / Injection moulding tool

Contents

  1. Journal articles
  2. Dissertations / Theses
  3. Books
  4. Book chapters
  5. Conference papers

Academic literature on the topic 'Injection moulding tool'

Author: Grafiati
Published: 4 June 2021
Last updated: 14 February 2022

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Journal articles on the topic "Injection moulding tool"

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Kashouty, Rennie, and Ghazy. "Tool Life Performance of Injection Mould Tooling Fabricated by Selective Laser Melting for High-Volume Production." Materials 12, no. 23 (November 26, 2019): 3910. http://dx.doi.org/10.3390/ma12233910.

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Rapid Tooling processes are developing and proving to be a reliable method to compete with subtractive techniques for tool making. This paper investigates large volume production of components produced from Selective Laser Melting (SLM) fabricated injection moulding tool inserts. To date, other researchers have focused primarily on investigating the use of additive manufacturing technology for injection moulding for low-volume component production rather than high volume production. In this study, SLM technology has been used to fabricate four Stainless Steel 316L tool inserts of a similar geometry for an after-market automotive spare part. The SLM tool inserts have been evaluated to analyse the maximum number of successful injections and quality of performance. Microstructure inspection and chemical composition analysis have been investigated. Performance tests were conducted for the four tool inserts before and after injection moulding in the context of hardness testing and dimensional accuracy. For the first reported time, 150,000 injected products were successfully produced from the four SLM tool inserts. Tool inserts performance was monitored under actual operating conditions considering high-level demands. In the scope of this research, SLM proved to be a dependable manufacturing technique for most part geometries and an effective alternative to subtractive manufacturing for high-volume injection moulding tools for the aftermarket automotive sector.
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Glozer, G. R., and J. R. Brevick. "Laminate Tooling for Injection Moulding." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 207, no. 1 (February 1993): 9–14. http://dx.doi.org/10.1243/pime_proc_1993_207_056_02.

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The main goal of this research was to develop a method of prototyping injection moulded parts which produces a representation of the production part, including not only the part shape and functionality but the process as well. A prototyping method that meets all of these requirements could greatly aid in reducing the time required to bring a new product to the market by using the information gained from this prototype to manufacture a production tool that will be right the first time. Tooling constructed of laminations is appealing for prototyping or production because of the flexibility it affords in terms of rapidly altering mould geometry, gating or cooling passage design. This report summarizes a ‘proof of concept’ project which took a selected part geometry through the entire laminate tool manufacturing process. This report is divided into five sections: (1) introduction to the prototyping process, (2) background of current prototyping processes and description of the laminate tooling method, (3) description of the geometry selected for this work and the manufacturing details, (4) evaluation of the performance of the laminate injection mould and (5) conclusions.
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Harris, R. A., H. A. Newlyn, and P. M. Dickens. "Selection of mould design variables in direct stereolithography injection mould tooling." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 216, no. 4 (April 1, 2002): 499–505. http://dx.doi.org/10.1243/0954405021520193.

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Stereolithography (SL) can be used rapidly to produce injection moulding tools. The disadvantage of the technique is that it is capable of producing only a small number of parts before failure. Stereolithography tools may break under the force exerted by part ejection when the friction between a moulding and a feature of the tool is greater than the tensile strength of the tool, resulting in tensile failure. Very few justified recommendations exist concerning the choice of mould design variables that can lower the part ejection force experienced and reduce the risk of SL tool failure. This research investigates the ejection forces resulting from the injection moulding of polypropylene (PP), acrylonitrile-butadiene-styrene (ABS) and polyamide 66 (PA66) parts from SL tools that are identical in all respects except for their build layer thickness (a process variable when generating the SL tooling cavities) and incorporated draft angles (a tooling design variable). This work attempts to identify appropriate evidence for recommendations with respect to these variables and SL injection moulding. The results show that linear adjustment of draft angle results in a fairly minor linear change in part ejection force according to the moulding material. A linear adjustment of the build layer thickness results in a greater change in part ejection force as a more non-linear relationship. In both cases the greatest ejection forces were experienced by PA66, then ABS and then the PP parts. The results also show that the surface roughness of all tools remains unchanged after moulding a number of parts in all polymers. A mathematical model was used in an attempt to predict ejection forces according to the moulding material used. This model did reflect the experimental results in terms of relative values but not in absolute values, which may be due to the limitations imposed by the development of the expressions and uncertainty about some specific values.
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Kiatmanaroj, S., V. Goodship, and G. F. Smith. "Sandwich Injection Moulding of Thermosetting Materials Part II: Effects of Moulding Parameters." Progress in Rubber, Plastics and Recycling Technology 21, no. 1 (February 2005): 27–38. http://dx.doi.org/10.1177/147776060502100102.

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This paper describes experiments on the sandwich injection moulding of two thermosetting polyesters, a powder coating and a bulk moulding compound. The flow of the powder coating in the injection moulding machine at various tool temperatures was investigated in order to find the optimum conditions. The formation of the skin and core layers in the moulding component at various injection times is described and discussed.
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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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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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Hernández, P., S. Taboada, L. Suárez, M. D. Marrero, F. Ortega, and A. Benítez. "Interactive Learning Tool in Product Development for Injection Moulding." Procedia Engineering 132 (2015): 197–204. http://dx.doi.org/10.1016/j.proeng.2015.12.470.

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Ramos, Carina, Pedro Carreira, Paulo J. Bártolo, and Nuno Alves. "OPTIMALMOULD | Cooling System Influence in Injection Moulding Cycle Time Optimization." Advanced Materials Research 683 (April 2013): 544–47. http://dx.doi.org/10.4028/www.scientific.net/amr.683.544.

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Most works undertaken on injection moulding cooling time optimization aimed at reducing the time required to produce plastic parts, this way minimizing industrial costs. An optimal cooling system is proposed to improve the injection moulding design. A multi-objective genetic algorithm called NSGA-II is used, to obtain the optimal parameters in the optimal-mould design. This new design method is an efficient tool to get optimal parameters for injection moulding design. A real case study was carried out to test the optimization platform.
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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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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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Dissertations / Theses on the topic "Injection moulding tool"

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Fu, Tingrui. "PP/clay nanocomposites : compounding and thin-wall injection moulding." Thesis, Loughborough University, 2017. https://dspace.lboro.ac.uk/2134/24655.

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This research investigates formulation, compounding and thin-wall injection moulding of Polypropylene/clay nanocomposites (PPCNs) prepared using conventional melt-state processes. An independent study on single screw extrusion dynamics using Design of Experiments (DoE) was performed first. Then the optimum formulation of PPCNs and compounding conditions were determined using this strategy. The outcomes from the DoE study were then applied to produce PPCN compounds for the subsequent study of thin-wall injection moulding, for which a novel four-cavity injection moulding system was designed using CAD software and a new moulding tool was constructed based upon this design. Subsequently, the effects of moulding conditions, nanoclay concentration and wall thickness on the injection moulded PPCN parts were investigated. Moreover, simulation of the injection moulding process was carried out to compare the predicted performance with that obtained in practice by measurement of real-time data using an in-cavity pressure sensor. For the selected materials, the optimum formulation is 4 wt% organoclay (DK4), 4 wt% compatibiliser (Polybond 3200, PPgMA) and 1.5 wt% co-intercalant (erucamide), as the maximum interlayer spacing of clay can be achieved in the selected experimental range. Furthermore, DoE investigations determined that a screw speed of 159 rpm and a feed rate of 5.4 kg/h are the optimum compounding conditions for the twin screw extruder used to obtain the highest tensile modulus and yield strength from the PPCN compounds. The optimised formulation of PPCNs and compounding conditions were adopted to manufacture PPCN materials for the study of thin-wall injection moulding. In the selected processing window, tensile modulus and yield strength increase significantly with decreasing injection speed, due to shear-induced orientation effects, exemplified by a significantly increased frozen layer thickness observed by optical microscopy (OM) and Moldflow® simulation. Furthermore, the TEM images indicate a strong orientation of clay particles in the flow direction, so the PPCN test pieces cut parallel to the flow direction have 36.4% higher tensile modulus and 13.6 % higher yield strength than those cut perpendicular to the flow direction, demonstrating the effects of shear induced orientation on the tensile properties of thin-wall injection moulded PPCN parts. In comparison to injection speed, mould temperature has very limited effects in the selected range investigated (25-55 °C), in this study. The changes in moulding conditions show no distinctive effects on PP crystallinity and intercalation behaviour of clay. Impact toughness of thin wall injection moulded PPCN parts is not significantly affected by either the changes in moulding conditions or clay concentration (1-5 %). The SEM images show no clear difference between the fracture surfaces of PPCN samples with different clay concentrations. TEM and XRD results suggest that higher intercalation but lower exfoliation is achieved in PPCN parts with higher clay content. The composites in the thin sections (at the end of flow) have 34 % higher tensile modulus and 11 % higher yield strength than in the thicker sections, although the thin sections show reduced d001 values. This is attributed to the significantly enhanced shear-induced particle/molecular orientation and more highly oriented frozen layer, according to TEM, OM and process simulation results. In terms of the reduced d001 values in the thin sections, it is proposed that the extreme shear conditions in the thin sections stretch the PP chains in the clay galleries to a much higher level, compaction of clay stacks occurs as less interspacing is needed to accommodate the stretched chains, but rapid cooling allows no time for the chains to relax and expand the galleries back. Overall, data obtained from both actual moulding and simulation indicate that injection speed is of utmost importance to the thin-wall injection moulding process, development of microstructure, and thus the resulting properties of the moulded PPCN parts, in the selected experimental ranges of this research.
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Kuchař, Petr. "Aplikace CAD/CAM softwaru WorkNC při obrábění." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2019. http://www.nusl.cz/ntk/nusl-400955.

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The aim of this thesis was to design core and cavity part of the injection moulding tool with regard to the possibilities of SKD Bojkovice company. The structure of the thesis was divided into two main parts - the theoretical part, where the necessary theory for the elaboration of the second part, the practical one was briefly introduced. In the practical part own plastic component was designed, constructed an injection mold with emphasis on the core and cavity parts of the injection moulding tool and produced the necessary production documentation. Subsequently, the process of manufacturing these parts of the mold was described, and a brief technical-economic evaluation of the manufacturing process took place at the very end.
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Ilyas, Ismet Priana. "Production of plastic injection moulding tools using selective laser sintering and high speed machining." Thesis, University of Leeds, 2007. http://etheses.whiterose.ac.uk/4048/.

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Global manufacturing trend and competition challenge every industry to seek new manufacturing methods to improve their business processes and speed up the product development cycle [Conolly, 2004a and Knights, 2001]. Among the candidates, layer manufacturing (LM) technologies appear to be a potential solution [Plam, 2002, and Grimm, 2004]. Recent LM technologies have led to a demanding application for developing production tools to manufacture parts, known as rapid tooling (RT). Selective laser sintering (SLS) is one of the leading LM systems available today in RT to manufacture injection mould (core/cavity) inserts [Kruth, 1998, Chua, 1999, Dormal, 1999, and Grenda, 2005]. However, the current capabilities of the SLS in producing metal parts have not yet fulfil the requirements of the injection mould inserts, especially in dimensional accuracy and surface finish quality [Francis, 2002 and Dalgamo, 2001 a]. The aim of this research is to use indirect SLS and high speed machining (HSM) in developing production-quality plastic injection moulding (core/cavity) inserts. The idea is that the indirect SLS process is utilised to build a near-net-shape inserts, while HSM is then utilised to finish the inserts to production specifications. Benchmark studies have been carried out to characterise the capabilities of both SLS and HSM with reference to the typical requirements of injection mould inserts. Utilising the study results, new developments of the mould inserts have been implemented on three major industrial case studies. Their performances have been evaluated and measured by comparing them with its respective original inserts. Furthermore, a set of design rules has been derived from best practices of the case studies, and have been validated by developing a new design for each case studies inserts. The results have demonstrated that the indirect SLS process has a capability III manufacturing a near-net shape of the insert which requires further related finishing to achieve final production specifications. The insert performances in some case studies have indicated significant improvements in process productivity and energy consumption as well as economic benefits to using the inserts. Regarding the significant considerations in realising the design, a recommendation on further strategic design rules and manufacturing process are highlighted so that the development of the insert using the selected approach can be more effective and efficient. Moreover, a utilisation of computer analysis software and further durability trial is also highlighted in order to predict and evaluate the optimum overall performance.
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Ainsley, C. C. "An investigation into the use of slip casting of 316L stainless steel as a method of forming injection moulding tools." Thesis, University of Liverpool, 1997. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.263770.

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Cheng, Ching-Ming, and 鄭境明. "Surface finish of the injection moulding tool steel using ball burnishing , plating and polishing processes with machine tool." Thesis, 2004. http://ndltd.ncl.edu.tw/handle/83901275090315821412.

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碩士
國立臺灣科技大學
機械工程系
92
The objective of this study is to improve surface roughness of PX4 plastic injection mold steel using the ball burnishing, nickel-plating and ball polishing surface finish processes on a machining center. The test specimen was first burnished with the optimal burnishing process parameters, namely the combination of the tungsten carbide ball, the burnishing speed of 200mm/min, the burnishing force of 300N, the feed of 40μm, and the lubricant of grease. The surface roughness Ra of the specimen can be improved from about 1.0μm to 0.086μm after burnishing process. In order to protect the metal from corrosion, the burnished specimen was plated with nickel with the thickness of about 5~10μm. The surface roughness of the plated specimen was further improved with the ball polishing process. The optimal parameters were determined by the Taguchi’s method. Some dominant parameters, namely abrasive particle size, abrasive material, feed, step over distance, polishing force (depth of penetration) and the speed of the polishing ball were selected as the experimental factors. The optimal parameters have been determined after conducting the Taguchi’s L18 matrix experiments, analysis of variation (ANOVA), and the full factorial experiment. The optimal flat surface polishing parameters for the plastic injection mold steel PX4 were the abrasive of Al2O3 with grid no. 8000, the feed 20mm/min., step over distance 100μm, the polishing force 1.05N (depth of penetration 120μm) and the grinding speed 6000rpm. The surface roughness Ra of the burnished and plated specimen could be further improved from about 0.07μm. to 0.02μm based on the optimal polishing parameters. Applying the developed surface finish processes and their individual optimal parameters sequentially to a fine milled freeform surface mold cavity, the surface roughness Ra = 0.03μm was reachable on the freeform surface region of the test part.
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Books on the topic "Injection moulding tool"

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Rankin, I. M. Injection moulding tools: Specification, manufacturing techniques and sources : a technical and economic study with particular reference to small batch production requirements. Melton Mowbray: PERA, 1987.

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Book chapters on the topic "Injection moulding tool"

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Bobzin, K., W. Michaeli, N. Bagcivan, P. Immich, F. Klaiber, and S. Theiß. "Chromium Based PVD Coatings for Injection Moulding Tools." In Friction, Wear and Wear Protection, 737–43. Weinheim, Germany: Wiley-VCH Verlag GmbH & Co. KGaA, 2011. http://dx.doi.org/10.1002/9783527628513.ch97.

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Griffiths, C. A., S. S. Dimov, and D. T. Pham. "Micro injection moulding: the effects of tool surface finish on melt flow behaviour." In 4M 2006 - Second International Conference on Multi-Material Micro Manufacture, 373–76. Elsevier, 2006. http://dx.doi.org/10.1016/b978-008045263-0/50085-4.

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Dobrzanski, Leszek A., and Grzegorz Matula. "Powder Injection Moulding of Tool Materials and Materials Containing One-Dimensional Nanostructural Elements." In Powder Metallurgy - Fundamentals and Case Studies. InTech, 2017. http://dx.doi.org/10.5772/67353.

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Conference papers on the topic "Injection moulding tool"

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Iwan Halim Sahputra. "Comparison of two flow analysis software for injection moulding tool design." In 2007 IEEE International Conference on Industrial Engineering and Engineering Management. IEEE, 2007. http://dx.doi.org/10.1109/ieem.2007.4419261.

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Schonberg, T., K. Ruusuvuori, B. H. Christensen, K. Boivie, J. P. Berild, H. Ronkainen, and L. T. Gellein. "Surface embedded temperature sensor on tool part for real time injection moulding process monitoring." In 2013 Transducers & Eurosensors XXVII: The 17th International Conference on Solid-State Sensors, Actuators and Microsystems (TRANSDUCERS & EUROSENSORS XXVII). IEEE, 2013. http://dx.doi.org/10.1109/transducers.2013.6626715.

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Sonne, M. R., J. Cech, H. Pranov, G. Kofod, J. Garnæs, Y. C. Lam, J. H. Hattel, and R. Taboryski. "Modelling the deformation of nickel foil during manufacturing of nanostructures on injection moulding tool inserts." In ESAFORM 2016: Proceedings of the 19th International ESAFORM Conference on Material Forming. Author(s), 2016. http://dx.doi.org/10.1063/1.4963493.

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Trotta, Gianluca, Vincenzo Bellantone, Rossella Surace, and Irene Fassi. "Effects of Process Parameters on the Properties of Replicated Polymeric Parts." In ASME 2012 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. American Society of Mechanical Engineers, 2012. http://dx.doi.org/10.1115/detc2012-71049.

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The increasing demand for small and even micro scale parts is boosting the development of reliable micro system technologies. Micro-fabrication process capabilities should expand to encompass a wider range of materials and geometric forms, by defining processes and related process chains that can satisfy the specific functional and technical requirements of new emerging multi-material products, and ensure the compatibility of materials and processing technologies throughout these manufacturing chains. Micro injection moulding is the process of transferring the micron or even submicron precision of microstructured metallic moulds to a polymeric products. It represents one of the key technologies for micro manufacturing because its mass production capability and relatively low production cost. Polymers have relatively low cost, and offer good mechanical and thermal strength, electrical insulation, optical transparency, chemical stability and biocompatibility. In this work the authors investigate the micro injection moulding process parameters on the overall quality of a miniaturized dog-bone shaped specimen. The aim of the experimentation is to calibrate the process and set the machine for the correct filling of the component. A set of injection parameters are selected for study by experimental plan and simulation tool and then discussed. Simulation results are used to better understand the polymer flow behaviour during the filling phase. A commercial software is used and input data, collected during the micro injection moulding process, are included using as performance indicators flow front position and moulded mass. Process simulation can provide, at the present time, mostly qualitative input to the designer and process engineer. Two different polymers materials are tested and evaluated in relation to the process replication capability: Polyoxymethylene (POM) and Liquid Cristal Polymer (LCP). Finally, the moulding factors with significant statistical effects are identified. The holding pressure and holding time for POM and the holding pressure and injection velocity for LCP show the highest influence on achieving high part mass.
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Liew, W. Y. H., and X. Ding. "Wear of Coated Carbide Tools in the Ultra-Precision Machining of Stainless Steel." In World Tribology Congress III. ASMEDC, 2005. http://dx.doi.org/10.1115/wtc2005-63952.

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Ultra-precision machines are widely used to turn aspherical profiles on mould inserts for the injection moulding of optical lenses. During turning of a profile on a stainless steel mould insert, the cutting speed reduces significantly to 0 as the cutting tool is fed towards the center of the machined profile. This paper reports on experiments carried out to study the wear of uncoated, PVD-coated and CVD-coated carbide tools in the ultra-precision machining of STAVAX (modified AISI 420 stainless steel) at low speeds.
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Griffiths, C. A., S. S. Dimov, A. Rees, O. Dellea, J. Gavillet, F. Lacan, and H. Hirshy. "Nano Texturing of Micro Injection Moulding Tools with aC:H." In 10th International Conference on Multi-Material Micro Manufacture. Singapore: Research Publishing Services, 2013. http://dx.doi.org/10.3850/978-981-07-7247-5-336.

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Kampker, Achim, Johannes Triebs, Bruno Alves, Sebastian Kawollek, and Peter Ayvaz. "Potential analysis of additive manufacturing technologies for fabrication of polymer tools for injection moulding – A comparative study." In 2018 IEEE International Conference on Advanced Manufacturing (ICAM). IEEE, 2018. http://dx.doi.org/10.1109/amcon.2018.8614915.

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Todorov, Todor, Georgi Todorov, and Borislav Romanov. "Design and Simulation of Mould Tools with Multi-Material Structure for Plastic Injection Moulding Based on Additive Technology." In 2019 International conference on Creative Business for Smart and Sustainable Growth (CREBUS). IEEE, 2019. http://dx.doi.org/10.1109/crebus.2019.8840061.

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Boschetto, A., F. Veniali, and F. Miani. "Mass Finishing of Parts Produced by Direct Metal Laser Sintering." In ASME 7th Biennial Conference on Engineering Systems Design and Analysis. ASMEDC, 2004. http://dx.doi.org/10.1115/esda2004-58585.

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This paper presents some practical considerations on finishing of parts made by direct metal laser sintering (DMLS). The main process capabilities limitations of this promising rapid tooling technique are in fact in the surface roughness of the produced parts. This fact hinders the introduction of DMLS as a widely employed industrial process, especially for what concerns the production of moulds and inserts and allows their use only as preseries tools in injection moulding of plastics, since the requirements for preseries tools are worse than those needed during the process. Barrel finishing, in turn, is a well established technique to improve the roughness of parts of complicated shape by means of a soft mechanical action over the surface. The results herewith presented show that it is possible to achieve roughness of the order of 1 μm Ra even when starting from initial roughness of the order of 15 μm Ra, i.e. those typically attained by DMLS.
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Moguedet, M., J. Balcaen, Y. Be´reaux, and J. Y. Charmeau. "Modelling Processing of Unfilled and Long-Glass Fibre Reinforced Thermoplastics in a Screw-Barrel Unit." In ASME 2005 International Mechanical Engineering Congress and Exposition. ASMEDC, 2005. http://dx.doi.org/10.1115/imece2005-82740.

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In injection moulding, long glass fibre reinforced thermoplastics (LGFT) are an attractive way to produce large parts at low cost. The strength of the part depends chiefly on the average fibre length, fibres which are subjected to considerable attrition during processing in conventional three stage screws. First of all, in this study we have coupled a melting analysis in a conventional screw to a model of fibre breakage whereby a fibre anchored at one end in the solid bed is submitted, at its other end, to the intense shear stress of the molten polymer flowing in the film close to the barrel. As the melting of the solid bed progresses, more fibres are unlayered and submitted to bending which intensity is depending on both the fibre length and orientation. When the bending is too high, the fibre breaks. Bimodal fibre length distribution are obtained and compared to existing data. The sensibility of the model to main processing parameters such as screw rotation, initial fibre length, viscosity, barrel temperature and screw geometry are also investigated. Next, we present a new analytical solution for flow of a viscous fluid in a single screw channel that takes into account the torsion and curvature of the channel. Contrary to common knowledge in polymer processing based on the Parallel Plate Model, we found that, in the case of cross-sections with large aspect ratio, torsion effects can be significant. The implication of the model on velocity field, residence time and mixing efficiency is investigated and compared to the predictions of the classical Parallel Plate Model, to finite elements calculations, and to 3D experimental measurements. Indeed, an innovating device has been developed in our laboratory to visualize the flow of a viscous fluid in the channel of a screw. It consists of a transparent barrel and of a rotating screw, pumping a transparent viscous fluid at room temperature. A particle plunged in the flow is constantly monitored by four video-cameras placed around the barrel and recording its position in a frame. The 3D path lines are then computed.
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