Journal articles: 'Plastic injection moulding'

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Pfleging, W., T. Hanemann, M. Torge, and W. Bernauer. "Rapid fabrication and replication of metal, ceramic and plastic mould inserts for application in microsystem technologies." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 217, no. 1 (January 1, 2003): 53–63. http://dx.doi.org/10.1243/095440603762554613.

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The process strategy for the rapid fabrication of microcomponents made of polymers will be presented. Different fabrication routes have been developed at Forschungszentrum Karlsruhe GmbH within the microsystem technology programme focusig on replication techniques. Single prototypes can be generated by the direct patterning of plastics with excimer laser radiation. For the fabrication of very small series laser-assisted micromachining, neodymium-doped yttrium aluminium garnet (Nd:YAG) and krypton fluorine (KrF) excimer laser radiation allows for the rapid manufacturing of microstructured mould inserts made of plastics, steel, cemented carbide or ceramics. The applied mould insert material depends on the achievable low surface roughness values essential for the subsequent moulding process. Plastic replication such as hot embossing, injection moulding or reaction injection moulding of the generated microstructured mould inserts gives access to mouldings carrying structural details in the micrometre range and/or high aspect ratio microstructures.

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Singh, Gurjeet, Mohan Kumar Pradhan, and Ajay Verma. "A Review of the Effect of Process Parameters on the Performance of Plastic Injection Molding Process to Control the Warpage in Plastics." Materials Science Forum 830-831 (September 2015): 116–19. http://dx.doi.org/10.4028/www.scientific.net/msf.830-831.116.

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Quality control is important aspect of manufacturing process. The quality of product in injection moulding is influenced by injection moulding process parameter. A study of the influence of process parameters on the injection moulding process is presented. Statistically based model approach were studied. In this the process parameter that affect the injection moulding process are like injection time, injection pressure, packing pressure, packing time, cooling time, coolant temperature mold temperature, melt temperature are studied and compared. This paper deals with design of experiment approach to fine out optimal parameter setting. The comparison shows effect of parameters on injection moulding process.Key words: Plastic injection moulding, Orthogonal array, Cycle time

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Košík, Miroslav, Jozef Bílik, and Filip Polakovič. "Mechanical Benefits of Gas Assisted Injection Moulding Application in Design of Structural Parts." Materials Science Forum 862 (August 2016): 182–91. http://dx.doi.org/10.4028/www.scientific.net/msf.862.182.

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Due to of many advantages and specific properties plastics are gradually becoming the most widely used materials in the engineering industry. In the last years, more and more metal parts are converted to plastic, in the cases of mechanically loaded parts as well. However, the usage of plastic is limited by its mechanical properties and production possibilities. Conventional injection moulding as the most productive plastic part production technology mostly enables the manufacturing of thin-wall parts with uniform wall thickness, what restricts full-fledged utilization of plastics. In this study, the benefits of progressive gas assisted injection moulding is investigated in order to produce plastic parts with higher mechanical properties. The paper presents complex study with respect to structures generated in material during gas penetration state, orientation of reinforced short fibres, stress relaxation behaviour, notch effect of rough gas channel surface, producible cross-section profiles with high moment of inertia and undesirable production effects, which can occur during gas aided moulding technologies. Finally, the mechanical properties of specimen produced by conventional and gas-assisted injection moulding were compared using numerical analyses. For comparison, integration of two numerical solver - FVM for fluid analysis of plastic/gas injection and FEM for structural analysis of specimen strength/stiffness were used.

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Delafield, P. A. "Injection Moulding of Thermo-Plastic Compounds." Journal of the Society of Dyers and Colourists 53, no. 3 (October 22, 2008): 82–86. http://dx.doi.org/10.1111/j.1478-4408.1937.tb01951.x.

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Abd Aziz, Ahmad Aizuddin Bin, Shamsuddin Sulaiman, Aung Lwin Moe, and Aminudin bin Abu. "Investigation of Plastic Injecting Moulding Process Optimization in Complex Shape Product." Applied Mechanics and Materials 695 (November 2014): 260–64. http://dx.doi.org/10.4028/www.scientific.net/amm.695.260.

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Nowadays, plastic injection molding is widely used in the production of very complex parts and it enables to produce numerous parts within one cycle. Molding conditions or process parameters are crucial for productivity and quality of desired products. This research aims to investigate the state-of-the-art approach to find optimal parameters characteristics in plastic injection molding process. Fill time, average velocity, pressure, clamp force, cooling time and volumetric shrinkages are selected as process parameters in this research. Nokia 6680 model is used for revealing process optimization. Two case studies based on two plates and three plate moulding layout are conducted to suggest the plastic injection mold optimization process. The process parameters of two proposed layouts are compared based on Mold flow Plastics Insight (MPI) analysis results. Result show that three plate moulding satisfy not only the process quality but also the product quality characteristics in this injection moulding process.

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Wood, Stephen L., and David G. Ullman. "The functions of plastic injection moulding features." Design Studies 17, no. 2 (April 1996): 201–13. http://dx.doi.org/10.1016/0142-694x(95)00040-x.

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Hyland, Ian. "Robots used on plastic injection moulding machines." Industrial Robot: An International Journal 28, no. 2 (April 2001): 104–12. http://dx.doi.org/10.1108/01439910110382657.

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Huang, Chin-Yin, Wu-Lin Chen, Chia-Ming Cheng, and Chung-Yu Pan. "Product quality prognosis in plastic injection moulding." Production Engineering 5, no. 1 (September 28, 2010): 59–71. http://dx.doi.org/10.1007/s11740-010-0269-7.

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Kwak, S., T. Kim, S. Park, and K. Lee. "Layout and sizing of ejector pins for injection mould desian using the wavelet transform." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 217, no. 4 (April 1, 2003): 463–73. http://dx.doi.org/10.1243/095440503321628143.

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Injection moulding is one of the most prevalent technologies used in processing thermoplastic polymers. At the end of the injection moulding cycle, the plastic moulded part should be ejected when the injection mould opens. To eject complex mouldings with bosses, ribs and other features, ejector pins are generally used because they are economical and easy to install. However, the ejector pins can cause high local stresses and strains in the moulding at the stage of ejection, leading to part deformation and damage. Thus, the proper layout of ejector pins is very important in mould design. A method is proposed for determining the layout and size of the ejector pins required to eject thermoplastic mouldings, minimizing part deformation and damage. The proposed method computes the distribution of the necessary ejecting forces to overcome the friction between the part and its mould. Then, it transforms the ejecting forces into a certain number of representative forces by the wavelet transform. Finally, the location and size of the ejector pins that correspond to the discrete ejecting forces are obtained. The proposed method will help injection mould designers systematically to obtain ejector designs.

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Košík, Miroslav, Jozef Bílik, and Daynier Rolando Delgado Sobrino. "Reduction of Injection Moulded Plastic Part Warpage Using Advanced Gas Assisted Injection Moulding." Materials Science Forum 862 (August 2016): 200–209. http://dx.doi.org/10.4028/www.scientific.net/msf.862.200.

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Dimensional and shape accuracy are the basic quality criteria of almost every injection moulded plastic part, manufactured in the engineering industry. They are dependent on many production conditions as part and moulding tool design, material structure properties and injection parameters. Generally, it is very difficult to achieve high geometrical accuracy during injection moulding, therefore, dimensional tolerances for plastic parts are usually many times larger than in the case of metals. However, according to requirements of the engineering industry, demands for the plastic parts dimensional accuracy keep growing permanently, what also extends to the growing shape complexity of the produced parts. Due to this tendency, engineers must look for more and more advanced solutions to meet market requirements and keep the competitiveness of their product. In consonance with all this, this paper presents a case study where the progressive gas assisted injection moulding is used as a solution for the plastic part warpage reduction while any other conventional methods failed. The study is performed making use of part from the automotive industry, initially produced with unacceptable deformations. In the first step, the real manufacturing state was studied to determine the warp behaviour. Subsequently, the process parameters and cooling conditions were unsuccessfully modified while trying to reduce deformations. Nevertheless, these were effectively eliminated by the only application of internal gas support to the melt injection phase. A numerical modelling based on Finite Volume and Finite Element Method was also used in the case study in order to mathematically represent the fluid, thermal and mechanical processes during the process of injection moulding.

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Martinkovič, Maroš, and Lukáš Likavčan. "Estimation of Fibre Orientation in Injection Moulding Plastics Parts." Materials Science Forum 891 (March 2017): 55–59. http://dx.doi.org/10.4028/www.scientific.net/msf.891.55.

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Fibre orientation in short fibre reinforced thermoplastics depends on injection moulding parameters. There are a lot of different parameters that must be established and controlled to achieve proper injection moulding of a plastic part. These parameters fall within four major areas: pressure, temperature, time, and distance. The aim of this article is estimation of fibre orientation in injection moulding plastics parts and comparison of these results with numerical simulated ones. Stereological metallography was used for estimation of experimental orientation of fibres. The orientation of simple fibre may be defined by the two angles θ and Φ. In a Short Fibre Reinforced Thermoplastic (SFRT) component there are frequently millions of fibres, therefore each individual fibre orientation specifying is very impractical. The fibres orientation in space can be described by the probability distribution function (PDF), Ψ(θ, Φ). Numerical modelling of fibre orientation was realised using MOLDEX3D software. Moldex3D is the CAE product for the plastics injection moulding industry. This software allows to view results of fibre orientation as an orientation of the X direction, Y direction, Z direction, the total orientation and orientation at surface. These first three orientations are relevant for the establishment of second-order orientation tensor. They belong to tensor ́s values a11, a22 and a33. Utilization of stereological metallography for short fibre orientation in plastic matrix is very similar to its utilization for estimation of grain boundaries orientation in polycrystalline alloys cased by plastic deformation. In the case of short glass fibres reinforced thermoplastics it’s structure consist of thermoplastic matrix and reinforcing fibres, which has some preferred orientation in most of cases – the structure is anisotropy. The way of scalar measurement of structure anisotropy is determination of degree of orientation. The anisotropic microstructure is decomposed into isotropic, planar or linear oriented components using stereology methods.

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Whale, J., N. Fowkes, G. Hocking, and D. Hill. "A model of the injection moulding process." Journal of the Australian Mathematical Society. Series B. Applied Mathematics 37, no. 1 (July 1995): 1–15. http://dx.doi.org/10.1017/s0334270000007530.

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AbstractThis paper is concerned with the injection moulding process, in which hot molten plastic is injected under high pressure into a thin cold mould. Assuming that the velocity and temperature profiles across the mould maintain their shape, a simple steady state model to describe the behaviour of a Newtonian fluid during the filling stage is developed. Various phenomena of the process are examined, including the formation of a layer of solid plastic along the walls of the mould, and the relationship between the flux of liquid plastic through the mould and the average pressure gradient along the mould. In any given situation, it is shown that there is a range of pressures and injection temperatures which will give satisfactory results.

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Deng, Yi Min, Bao Shou Sun, Hua Bo He, and Fu Zhan Shangguan. "Towards Optimal Flow Uniformity: Stiffener Layout Design Evaluation of Injection Moulded Plastic Part." Advanced Materials Research 428 (January 2012): 33–37. http://dx.doi.org/10.4028/www.scientific.net/amr.428.33.

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Injection moulding is an important manufacturing method for plastic parts. There are however many moulding quality defects caused by inappropriate setting of moulding process conditions, as well as the poorly designed plastic part geometry. Often, stiffeners are used in a plastic part to increase its strength. However, if the stiffeners are not designed properly, they will introduce one or more moulding quality problems, which in turn will worsen the part strength rather than increasing it. Although there have been quite a lot of researches on optimising moulding quality, it is often difficult to minimize multiple quality defects simultaneously. In this paper, we propose to employ flow uniformity as the optimisation objective to address this problem. A number of stiffener layout designs are evaluated in terms of this objective to determine the best design, where standard deviations of filling times and pressures at the extremities of the plastic part are used to measure the uniformity of flow. A simple case study is also presented to demonstrate the applicability of the proposed methodology.

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Albert, André, Welf Guntram Drossel, Wolfgang Zorn, Wolfgang Nendel, and Dirk Raithel. "Process Combination of Hydroforming and Injection Moulding for the In Situ Manufacturing of Metal and Plastic Composite Structures." Materials Science Forum 825-826 (July 2015): 522–29. http://dx.doi.org/10.4028/www.scientific.net/msf.825-826.522.

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The use of lightweight structures is a major trend in the reduction of fuel consumption and CO2 emissions, especially in transport. Metal plastic hybrid structures are an efficient solution to use the best material at every point in the design space. In the state of the art production technologies, the metal parts are produced separately from the plastic parts. The injection moulding process is only used for forming the plastic parts and for joining. These process chains are very extensive. The article shows the development of new process combinations. The aim is a combination of metal forming and injection moulding in one die and one process. One part should be produced with every single stroke of the press.In the first step, deep drawing, injection molding and media based forming with the plastic melt were successfully merged in one tool and one process. It was possible to integrate the injection moulding process into a deep drawing machine. In the next step, it was possible to successfully combine hydroforming and injection molding. For this process combination the hydroforming process is integrated into an injection moulding press. Different surface structures of the metal tubes, such as sandblasting, knurling and laser structuring, were systematically tested regarding to their properties as an adhesion promoter. The target is to establish a purely mechanical connection between the hydroformed metal component and the injection moulded component from glass fibre reinforced plastic instead of the chemical bonding agents often used previously, such as Vestamelt®.

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Hopmann, Christian, Kirsten Bobzin, Roman Schoeldgen, Mehmet Oete, Johannes Wunderle, Thomas F. Linke, and Philipp Ochotta. "IMKS and IMMS: two methods for the production of plastic parts featuring metallic areas." Journal of Polymer Engineering 36, no. 6 (August 1, 2016): 549–56. http://dx.doi.org/10.1515/polyeng-2014-0281.

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Abstract The integration and combination of known technologies to one-step-processes is a promising way to implement enhancements to existing processes and products, as well as to new product developments. This approach is followed by two integrative process technologies that were developed by the Institute of Plastics Processing (IKV) at the RWTH Aachen University and the Surface Engineering Institute (IOT) at the RWTH Aachen University as part of the Cluster of Excellence “Integrative Production Technologies for High-Wage Countries”. In these processes, pure metals or metal alloys are joined to the injection moulded part, which potentially results in particular advantages referring to the electrical properties of the product. The integrated metal/plastic injection moulding (IMKS) represents the combination of injection moulding and metal die casting. The in-mould metal spraying (IMMS) combines the injection moulding with the thermal spraying of metal. In the following, the level of development of both methods is presented and future potentials are shown.

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Van Stappen, M., K. Vandierendonck, C. Mol, E. Beeckman, and E. De Clercq. "Practice vs. laboratory tests for plastic injection moulding." Surface and Coatings Technology 142-144 (July 2001): 143–45. http://dx.doi.org/10.1016/s0257-8972(01)01062-3.

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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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JUFRI, MOH. "OPTIMALISASI PROSES INJECTION MOULDING PADA NANOALUMINA." Jurnal Teknik Industri 12, no. 1 (March 30, 2012): 16. http://dx.doi.org/10.22219/jtiumm.vol12.no1.16-19.

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Composite is arranged from material with function as matrix that has weaker characteristic and material with fillerfunction that has a function to transfer force from load in matrix. Plastic has more advantages than other materials;those are, able to be formed finely, light in weight, easy to get and the price is cheaper relatively. However, the problem isthe filler that is involved here is still using fiberglass in which it will disturb human health. Alumina dust used here isMerck by particle size of > 0.063 mm, to get nano size then it would be mixed by Mixer Ball Mill for 50 hours and wouldbe measured for dust grain size with particle size analyzer (PSA), then it is dehydrated in the oven by temperature of 80° C. The percentage of nano alumina for each are 1%, 2%, 3%, 4% ,5%,6% and 7%. Furthermore, it is mixed with PP plastic grain that is conducted by internal mixer to ensure the material distribution evenly, then it is poured in hoper in injection moulding machine that is operated in the temperature of 170° C and is injected in sample test moulding. The result of characterization of tensile strength, modulus elasticity and tensile show the decrement by addition of 2–3% of nano alumina in polypropylene matrix.

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Haddad, Header, Syed H. Masood, and Abul B. M. Saifullah. "Gate Location and its Effects on Product Quality in Injection Moulding." Advanced Materials Research 32 (February 2008): 181–84. http://dx.doi.org/10.4028/www.scientific.net/amr.32.181.

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Design of gate location is a crucial factor in achieving product quality in injection moulding. It Influences the manner of plastic flow into the cavity. The optimum gate location improves quality and avoids products defects. This paper presents an investigation for the effects of gate location on product quality in injection moulding. Plastic advisor, simulation software embedded in Pro/Engineer package has been used for flow analysis of plastic product for selected gate locations. It has been shown that optimum gate location improves cooling quality resulting in a better product quality. The previous conventional experiences by individual credited engineers have been considered.

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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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Gelin, J.-C., T. Barriere, and B. Liu. "Improved mould design in metal injection moulding by combination of numerical simulations and experiments." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 216, no. 12 (December 1, 2002): 1533–47. http://dx.doi.org/10.1243/095440502321016297.

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Metal injection moulding combines thermoplastic injection moulding and powder metallurgy technologies to produce small and intricate metallic parts in a near net shape. The injection stage is of primary importance and the injection moulding of a metallic powder and plastic binder permits the desired shape to be obtained. A procedure is proposed for mould cavity design and optimal choice of injection parameters. This procedure is based on both numerical simulation by the finite element method and experiments allowing a primer choice and an update of injection moulding parameters. The powder segregation phenomena have been also investigated by experiments, moulding and simulation and an approach based on a biphasic flow approach has been proposed that permits powder segregation to occur during injection. Based on that approach, a three-dimensional finite element software has been developed and used for simulation. Experiments and numerical investigations on powder segregation have been carried out and results are presented that are in good agreement with experiments.

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Mehat, Nik Mizamzul, Shahrul Kamaruddin, and Abdul Rahim Othman. "Hybrid Integration of Taguchi Parametric Design, Grey Relational Analysis, and Principal Component Analysis Optimization for Plastic Gear Production." Chinese Journal of Engineering 2014 (January 14, 2014): 1–11. http://dx.doi.org/10.1155/2014/351206.

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The identification of optimal processing parameters is an important practice in the plastic injection moulding industry because of the significant effect of such parameters on plastic part quality and cost. However, the optimization design of injection moulding process parameters can be difficult because more than one quality characteristic is used in the evaluation. This study systematically develops a hybrid optimization method for multiple quality characteristics by integrating the Taguchi parameter design, grey relational analysis, and principal component analysis. A plastic gear is used to demonstrate the efficiency and validity of the proposed hybrid optimization method in controlling all influential injection moulding processing parameters during plastic gear manufacturing. To minimize the shrinkage behaviour in tooth thickness, addendum circle, and dedendum circle of moulded gear, the optimal combination of different process parameters is determined. The case study demonstrates that the proposed optimization method can produce plastic-moulded gear with minimum shrinkage behaviour of 1.8%, 1.53%, and 2.42% in tooth thickness, addendum circle, and dedendum circle, respectively; these values are less than the values in the main experiment. Therefore, shrinkage-related defects that lead to severe failure in plastic gears can be effectively minimized while satisfying the demand of the global plastic gear industry.

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Chaciński, Tomasz, and Paweł Sutowski. "Common defects in injection molding of plastic products and their influence on product quality." Journal of Mechanical and Energy Engineering 5, no. 1 (August 12, 2021): 7–14. http://dx.doi.org/10.30464/10.30464/jmee.2021.5.1.7.

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The article deals with issues related to quality management and quality assessment in production of plastic articles in injection moulding. Expert knowledge collected in textbooks and literature allows to get acquainted with the characteristics of plastic article production and product quality defects arising in such processes. The characteristics and technology of plastics processing are discussed, the most frequent quality defects occurring in the production of articles made of plastics by injection molding are listed. On the basis of expert knowledge collected in the literature, a series of actions leading to the elimination of each of the mentioned quality defects has also been proposed.

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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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Wang, Yun, Kai Zhang, Ya Chun Dai, Jiong Liu, and Yuan Yuan Zhang. "State-of-the-Art of Rotational Moulding Technique and its Application." Applied Mechanics and Materials 80-81 (July 2011): 980–84. http://dx.doi.org/10.4028/www.scientific.net/amm.80-81.980.

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With the rapid development of plastic products in the world and the increasingly sophistication of plastic technology, rotational moulding (RM), has become the most practical and irreplaceable way of producing the large and super large containers like tanks, tank, etc. Compared with injection moulding and blow moulding, RM has the characteristics of low cost and easy-to-use, and its application has been extended into many domains. The principle of rotational moulding and comparison of raw material by the requirement of rotational moulding is introduced. The paper emphasizes the introduction of state-of-the-art of RM equipment; also it points out the development of RM.

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Bang, Y.-B., and S. Ito. "Linear motor drive ultrahigh-speed injection moulding machine." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 216, no. 5 (May 1, 2002): 773–81. http://dx.doi.org/10.1243/0954405021520283.

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This paper presents a report on the development of a linear motor drive injection moulding machine for the attainment of ultrahigh-speed injection moulding. Until now it has been impossible to produce such a high speed with all-electric injection moulding machines, although the need for such ultrahigh-speed, electrically driven injection moulding machines has clearly existed. However, direct drive by linear motors may cause brief nozzle separation from the sprue bushing because of an inertia force as large as the total output thrust of the linear motors, and this momentary separation can cause molten plastic leakage. In this paper, two solutions are proposed for this inertia force problem. One is mechanical cancellation of the inertia force, the other is an increase in the nozzle contact force. Furthermore, a new nozzle contact mechanism is proposed that prevents the stationary platen bending caused by the nozzle contact force. Some experimental results on a manufactured all-electric, ultrahigh-speed injection moulding machine are presented.

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Saifullah, Abul B. M., and Syed H. Masood. "An Investigation on Warpage Analysis in Plastic Injection Moulding." Advanced Materials Research 264-265 (June 2011): 433–38. http://dx.doi.org/10.4028/www.scientific.net/amr.264-265.433.

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In an injection moulded part, warpage is the distortion caused by non-uniform shrinkage within the plastic part. When looking critically at the causes of warpage, it is found that several key parameters of the moulding process have some effect on the warpage. However, the two major categories that contribute to warpage include the part design and the mould design. In mould design, the gate location, runner/gate system and cooling system design are the major factors affecting not only the warpage and part quality but also the injection moulding cycle time. This paper presents an investigation of using different cooling system configuration on warpage and shrinkage of an industrial plastic part with the aim of determining which cooling configuration will provide minimum warpage and cycle time. As conventional injection mould cooling design is based on straight drilling, it limits the geometric complexity of the cooling design, especially curved shape cooling channels. Nowadays, new technology of advanced rapid tooling based on solid freeform fabrications can be been used to provide conformal cooling channels in injection moulds. In this paper, several type of cooling channels are analysed to compare the performance in terms of warpage and shrinkage and to determine which configuration is suitable for minimizing warpage. Autodesk Moldflow Insight (AMI) simulation software is applied to examine the results of the cooling performances and warpage analysis.

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Latif, Laith, and Hossein Saidpour. "Assessment of plastic mixture quality in injection moulding process." Polymer Testing 16, no. 3 (June 1997): 241–58. http://dx.doi.org/10.1016/s0142-9418(96)00045-1.

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Gurel, Baris, Osman Ipek, Yusuf Basogul, and Ali Kecebas. "Optimization of Nozzle Section in Plastic Injection Moulding Process." Hittite Journal of Science & Engineering 6, no. 2 (2019): 123–30. http://dx.doi.org/10.17350/hjse19030000137.

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Shi, F., Z. L. Lou, Y. Q. Zhang, and J. G. Lu. "Optimisation of Plastic Injection Moulding Process with Soft Computing." International Journal of Advanced Manufacturing Technology 21, no. 9 (June 1, 2003): 656–61. http://dx.doi.org/10.1007/s00170-002-1374-3.

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Ong, Huei Ruey, Ifwat Mohd Shah, Wan Mohd Eqhwan Iskandar, Md Maksudur Rahman Khan, Chi Shein Hong, Ridzuan Ramli, and Muhammad Khairul Anuar Mohamed. "Rejection Rate Reduction of the Automotive Thermoplastic Parts in Injection Moulding Using Response Surface Methodology." Key Engineering Materials 841 (May 2020): 225–31. http://dx.doi.org/10.4028/www.scientific.net/kem.841.225.

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Plastic injection moulding is widely used for manufacturing due to variety of plastic product. In this study, plastic part defects such as air bubble and gas mark defect are commonly occurs in thermoplastic part, specifically acrylonitrile butadiene styrene (ABS). In order to optimize the process parameters of injection moulding, design of experiment (DOE) with Response Surface Methodology (RSM) model was used. Process parameters such as melt temperature, mould temperature and injection pressure were selected for the DOE development. The experiments were conducted with melt temperature range from 200 °C to 240 °C, mould temperature from 60 °C to 80 °C and injection pressure from 90 to 99%. The result indicates that, all the selected parameters were significantly influence the rejection rate of the automotive ABS part. The optimum melt temperature, mould temperature and injection pressure were 220 °C, 70 °C and 98% respectively, in obtaining minimum rejection rate.

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Dobránsky, Jozef, Rastislav Mikuš, and Juraj Ružbarský. "Comparison of Cooling Variants by Simulation Software." Advanced Materials Research 801 (September 2013): 75–80. http://dx.doi.org/10.4028/www.scientific.net/amr.801.75.

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This paper deals with the verification of thermoplastic flowing when manufacturing plastic products by injection moulding used in the consumer industry. An analysis was performed by Plastic Insight, which is used for the determination of flow properties of thermoplastic materials. A good knowledge of flow properties of these materials enables a very good starting position for the design of thermoplastic products made by the injection moulding technology [1,2]. The task of this simulation was the comparison of injection parameters of a mould, with and without cooling of channels. Simulated thermoplastic material is used for the manufacture of ribs in washing machine drums. The tested material was polypropylene.

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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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Adam, Andrei, Cristian Cosma, and Andrei Pop. "Ultrasonic Activated Injection Used on Manufacturing Thin Wall Plastic Parts." Applied Mechanics and Materials 555 (June 2014): 524–29. http://dx.doi.org/10.4028/www.scientific.net/amm.555.524.

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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 set of experiments that focused on particular processing conditions of injection through narrow section, thin-wall injection and microinjection. In these cases, the ultrasonic activation does not play an important role as single influence factor but could amplify or strengthen the influence of classical setting parameters of the process: mould temperature, injection pressure and temperature

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Sun, Li Min, and Jing Chao Zou. "The Shell of Internal Combustion Tamping Pickax Injection Molding CAE Technology Research." Advanced Materials Research 415-417 (December 2011): 339–42. http://dx.doi.org/10.4028/www.scientific.net/amr.415-417.339.

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This article establish the physical and mathematic model of the plastic housing of the ND-5 internal combustion tamping pickax by plastic molding CAE, analyse the flow field in injection molding. We simulate many programs of the injection molding processing , analyze the mold-filling characteristic of the programs, study the defect situation and select the best injection molding program for the moulding.

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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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Godinho, J. S., A. Cunha, and R. J. Crawford. "Prediction of the mechanical properties of polyethylene parts produced by different moulding methods." Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 216, no. 3 (July 1, 2002): 179–91. http://dx.doi.org/10.1177/146442070221600303.

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The properties of moulded plastic products are dependent on the processing technology used in their manufacture and in particular on the structural morphology resulting from the thermomechanical environment experienced by the melt. This paper presents a unified approach to predict the mechanical properties of moulded parts. A linear medium-density polyethylene (LMDPE) was processed using injection moulding, rotational moulding and compression moulding in order to induce different thermomechanical conditions (i.e. shear rates and cooling rates). Two models were then developed to predict the mechanical properties of the parts produced by the quite different moulding methods. One model is based on laminate theory, in which the mechanical properties of the individual layers through the wall thickness are used to predict the tensile and flexural properties of the full-thickness moulding. The other approach is more generic in that it predicts the properties as a function of two thermomechanical indices. A good agreement is achieved between the experimental data and the values predicted by the models. It is also shown that the combined use of the thermomechanical indices concept and the laminate analysis permits good predictions to be made for the mechanical properties of plastic mouldings with complex microstructures. It is proposed that this approach could provide a very valuable addition to existing melt flow simulation packages. This would provide a valuable tool for designers in that not only would it be possible to optimize processing conditions but also the properties of the end product could be predicted.

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Huang, Ming-Shyan. "Design analysis of a standard injection screw for plasticising polycarbonate resins." Journal of Polymer Engineering 36, no. 5 (July 1, 2016): 537–48. http://dx.doi.org/10.1515/polyeng-2015-0275.

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Abstract The industrial use of plastic injection moulding machines is widespread. However, few studies have examined the injection screw, which is one of the key components of moulding machines. Studies have demonstrated that a properly designed injection screw improves both the moulding quality and the production rate. Factors that affect the plasticisation properties of conventional standard reciprocating screws include the screw geometry, the screw operation settings, and the processed resins. An ideal standard reciprocating screw exhibits a high plasticising capacity and excellent melt temperature homogeneity; however, these properties typically conflict. Through simulation analysis, this study investigated the optimal design of a standard reciprocating injection screw used for plasticising polycarbonate resins. First, the Taguchi method was integrated with a commercial simulation programme to identify the key control factors affecting the plasticising rate of a screw and the temperature uniformity of the melt. Simulation results revealed that the screw diameter, rotation speed, metering channel depth, ratio of the screw length to the screw diameter, and compression ratio substantially influence performance. Consequently, grey relational analysis was adopted to optimise the design of an injection screw that ensures sufficient quality according to the plasticisation rate and the homogeneity of molten plastic.

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Khomenko, Veligorskyi, Chakirov, and Vagapov. "An ANN-Based Temperature Controller for a Plastic Injection Moulding System." Electronics 8, no. 11 (November 1, 2019): 1272. http://dx.doi.org/10.3390/electronics8111272.

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This paper proposes an approach to an ANN-based temperature controller design for a plastic injection moulding system. This design approach is applied to the development of a controller based on a combination of a classical ANN and integrator. The controller provides a fast temperature response and zero steady-state error for three typical heaters (bar, nozzle, and cartridge) for a plastic moulding system. The simulation results in Matlab Simulink software and in comparison to an industrial PID regulator have shown the advantages of the controller, such as significantly less overshoot and faster transient (compared to PID with autotuning) for all examined heaters. In order to verify the proposed approach, the designed ANN controller was implemented and tested using an experimental setup based on an STM32 board.

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Janphuang, Pattanaphong, Mongkhol Laebua, Chanwut Sriphung, Phatsakon Taweewat, Anan Sirichalarmkul, Kasiphisan Sukjantha, Napatporn Promsawat, et al. "Polymer based microneedle patch fabricated using microinjection moulding." MATEC Web of Conferences 192 (2018): 01039. http://dx.doi.org/10.1051/matecconf/201819201039.

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This paper presents the development of a polymer based microneedle patch for transdermal drug delivery application using plastic microinjection moulding. Design and analysis of the microneedle cavities and mould insert used in the injection moulding process were carried out using Computer-Aided Engineering (CAE) software. A mould insert with low surface roughness was fabricated using Micro Electrical Discharge Machining (μ-EDM). The injection moulding parameters including clamping force, temperature, injection pressure and velocity were characterized in order to obtain the optimum reproducibility. Solid truncated cone microneedles, made of biocompatible polymethyl methacrylate (PMMA), with a round tip radius of 50 μm and 500 μm in height have been realized by microinjection moulding process demonstrating the potential of a low cost, high production efficiency, and suitable for mass production. In addition, a mould insert of cylindrical microneedles fabricated using X-ray LIGA has been proposed.

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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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Matsumori, Tadayoshi, and Koetsu Yamazaki. "Design improvement of cooling channel layout for plastic injection moulding." Engineering Optimization 43, no. 8 (August 2011): 891–909. http://dx.doi.org/10.1080/0305215x.2010.527004.

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Muhamad, Norhamidi, Javad Rajabi, Abu Bakar Sulong, Abdolali Fayyaz, and Muhammad Rafi Raza. "Micro Powder Injection Moulding Using Nanosized Powders." Advanced Materials Research 1024 (August 2014): 116–19. http://dx.doi.org/10.4028/www.scientific.net/amr.1024.116.

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Micro powder injection moulding (μPIM) is one of the micro-moulding technology applied today in high-volume fabrication of metal and ceramic micro-components. The current study presents the micro powder injection moulding (µPIM) of 316L Stainless Steel nanopowder-polymer mixtures. 316L SS powders have been blended with a binder system which consists of Polyethylene Glycol (PEG), Polymethyl Methacrylate (PMMA) and Stearic Acid (SA). All the feedstock prepared shows homogeneity and pseudo-plastic behaviour which is suitable for μPIM process. The results showed that increase in nano powder content would improve the powder loading, injection and sintering temperature. Moreover, high physical and mechanical properties of the sintered specimen have been achieved under vacuum atmosphere. The above results indicate that application of nano powder has the potential to provide micro powder injection moulded parts with nearly full density, fine microstructure. The binder system is environment-friendly, has low viscosity-temperature and suitable to prepare feedstock for μPIM.

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Chethan, K. N., V. Sabarinathan, R. Vivek Ram, and G. T. Mahesh. "Numerical Analysis and Fabrication of Battery Holder for Two Wheelers." Journal of Advanced Research in Fluid Mechanics and Thermal Sciences 78, no. 2 (December 10, 2020): 114–31. http://dx.doi.org/10.37934/arfmts.78.2.114131.

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The high-performance plastics usage is increasing in the automobile field because of its advantages over other metals and alloys. Corrosion resistance, light weight, low cost, flexibility in design are the major advantages of plastics above the conventional metallic materials. In this paper a metal version component converted into plastic version in order to increase efficiency, reduce the overall cost of a two-wheeler and to improve the production rate of component. Different types of material such as PP + 15% TALC, PP + 30% GF, PP + 30% TALC, Nylon 6 + 15% GF, Nylon 66 UF, Nylon 6 UF, Nylon 66 + 30% GF, ASA LI941 and ASA LI913 tested for 10,000km road test, vibration test and fitment test. An injection moulding used to produce the component and ‘Mouldx3D’ software was used for mould flow analysis and other simulation. The different parts of injection moulding tool made up of C45, P20 and D2 materials. Among different materials, ASA LI913 was selected since it has better weather resistance than others and the impact strength matched to metal version component. Finally, it was found that the cost of the component made of Plastic considerably less than same component made of metal.

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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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Kamaruddin, S., Zahid A. Khan, and S. H. Foong. "Application of Taguchi Method in the Optimization of Injection Moulding Parameters for Manufacturing Products from Plastic Blend." International Journal of Engineering and Technology 2, no. 6 (2010): 574–80. http://dx.doi.org/10.7763/ijet.2010.v2.184.

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Zhang, Nan, Jinghang Liu, Honggang Zhang, Nigel J. Kent, Dermot Diamond, and Michael D. Gilchrist. "3D Printing of Metallic Microstructured Mould Using Selective Laser Melting for Injection Moulding of Plastic Microfluidic Devices." Micromachines 10, no. 9 (September 10, 2019): 595. http://dx.doi.org/10.3390/mi10090595.

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A new method, a 3D printing technique, in particular, selective laser melting (SLM), has been used to fabricate moulds for the injection moulding of thermoplastic microfluidic chips that are suitable for prototyping and early stage scale-up. The micro metallic patterns are printed on to a pre-finished substrate to form a microstructured mould. The dimensional accuracy, surface morphology, bonding strength between the printed patterns and substrate, as well as the microstructure of micro features were all characterized. A microfluidic mould was successfully printed and used directly for injection moulding of cyclic olefin copolymer (COC) microfluidic chips, which were used subsequently to successfully monitor nitrite concentrations in environmental water. The characterization indicated that this new process can be used for fast fabrication of mould tools for injection moulding/hot embossing microfluidic devices. It is faster, more flexible and less expensive than conventional micro-machining processes, although the accuracy and finish are still needed to improve though process optimization and hybrid SLM and machining processes.

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Huang, Hai Bo, and Dong Hui Xue. "Topology Optimization on the Movable Platen of Plastic Injection Machine." Applied Mechanics and Materials 37-38 (November 2010): 1595–99. http://dx.doi.org/10.4028/www.scientific.net/amm.37-38.1595.

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Movable platen is key component of a plastic injection machine. In this paper the movable platen of HBT80X/1 plastic injection moulding machine is redesigned using topology optimization method. The SIMP method and OC method were applied as the optimization principle and Optimality Criteria. After given the topology structure, the refined structure is designed with experience. The results show that the weight and maximum placement of the new shape were 53Kg and 0.009mm less than the original design.

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Ter Maat, Johan, Claudia Cristea, and Ovidiu Cojocaru. "Current Trends in the Application of Powder Injection Moulding." Materials Science Forum 672 (January 2011): 12–16. http://dx.doi.org/10.4028/www.scientific.net/msf.672.12.

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Powder Injection Moulding (PIM) is a fast-growing manufacturing method, providing a cost efficient production route to complicated steel parts in highly stressed mechanical applications, but also to polished steel and ceramic parts fulfilling the most stringent aesthetical demands of design-dominated consumer products. The marriage between the two technologies plastic injection moulding and powder sintering is providing a valuable synergy, leading to a very efficient production of high density sintered steel and ceramic parts with a complex geometry. Reliable sources for PIM granulate; the use of standard injection moulding machines and the availability of mature furnace technology have each contributed to the credibility of in particular the Metal Injection Moulding (MIM) technology and have enabled in recent years the launch of mobile phone and automotive mass productions. While typical MIM parts in mobile phones are small and weigh around 1 g, the number of parts required is impressive and may reach several millions of parts per month. MIM parts in engineering applications, including automotive, are typically 5 - 50 g and have the advantage of long-lasting production runs, in some cases already approaching 10 years. Ceramic Injection Moulding (CIM) is not yet in the same stage of development as MIM due to the niche character of ceramic materials. Complex ceramic parts are not yet very common, but are also starting to appear in all segments.

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Kramar, D., and D. Cica. "Predictive model and optimization of processing parameters for plastic injection moulding." Materiali in tehnologije 51, no. 4 (July 27, 2017): 597–602. http://dx.doi.org/10.17222/mit.2016.129.

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Journal articles on the topic 'Plastic injection moulding'

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