Experimental and simulation studies on filling imbalance in geometrically balanced runner systems of multi-cavity injection molds

Wilczyński, Krzysztof; Narowski, Przemysław

doi:10.14314/polimery.2015.411

Cited by 7 publications

(5 citation statements)

References 8 publications

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“…Moreover, a flexible meshing was applied to provide high-resolution mesh for the runners and the cavity. Several simulation studies have confirmed this approach [22][23][24][25].…”

Section: Introductionmentioning

confidence: 89%

A Strategy for Problem Solving of Filling Imbalance in Geometrically Balanced Injection Molds

Wilczyński¹,

Narowski²

2020

Polymers

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Simulation and experimental studies were performed on filling imbalance in geometrically balanced injection molds. An original strategy for problem solving was developed to optimize the imbalance phenomenon. The phenomenon was studied both by simulation and experimentation using several different runner systems at various thermo-rheological material parameters and process operating conditions. Three optimization procedures were applied, Response Surface Methodology (RSM), Taguchi method, and Artificial Neural Networks (ANN). Operating process parameters: the injection rate, melt temperature, and mold temperature, as well as the geometry of the runner system were optimized. The imbalance of mold filling as well as the process parameters: the injection pressure, injection time, and molding temperature were optimization criteria. It was concluded that all the optimization procedures improved filling imbalance. However, the Artificial Neural Networks approach seems to be the most efficient optimization procedure, and the Brain Construction Algorithm (BSM) is proposed for problem solving of the imbalance phenomenon.

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“…Moreover, a flexible meshing was applied to provide high-resolution mesh for the runners and the cavity. Several simulation studies have confirmed this approach [22][23][24][25].…”

Section: Introductionmentioning

confidence: 89%

A Strategy for Problem Solving of Filling Imbalance in Geometrically Balanced Injection Molds

Wilczyński¹,

Narowski²

2020

Polymers

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“…Moreover, a flexible meshing comprising different element topologies was applied to provide high‐resolution mesh for the runner system and cavity. Several simulation studies have confirmed this simulation approach . Recently, the radial function method RFM was applied to model the flow and heat transfer in the runner systems.…”

Section: Introductionmentioning

confidence: 91%

“…The problem of filling imbalance has been studied by researchers for years . However, there are not solutions that would be universally accepted by engineers, producers, and researchers.…”

Section: Introductionmentioning

confidence: 99%

Experimental and theoretical study on filling imbalance in geometrically balanced injection molds

Wilczyński

Narowski

2018

Polymer Engineering & Sci

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Experimental and theoretical studies were performed on filling imbalance in geometrically balanced injection molds. Balancing the melt flow between cavities was investigated using several different runner systems at various operating conditions. Experiments indicate that injection rate, mold, and melt temperatures substantially affect the filling imbalance. It is strongly dependent on runners layouts geometry, and it has never been eliminated completely. It is most difficult to remove for high injection rates and low melt temperatures. Standard element geometry and circled element geometry cause positive imbalance which means that inner cavities fills faster, and it is opposite for one/two overturn element geometries which induce negative imbalance. A special modeling procedure is required to simulate properly the imbalance. This includes inertia effects, geometrical modeling of the nozzle where the imbalance starts, 3D tetrahedron meshing with minimum 12 layers. Simulations were consistent with experiment, however, when the imbalance increased, the discrepancies between simulation and experiment also increased. It can be stated that filling imbalance problem is still unsolved. There are serious thermo‐rheological aspects to explain for better understanding this phenomenon. Trends in modeling of injection molding are presented and new concepts solving the problem are discussed including simulation/optimization approach and a novel concept of global modeling of injection molding process. POLYM. ENG. SCI., 59:233–245, 2019. © 2018 Society of Plastics Engineers

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“…We have developed the composite models of this inverse computation approach for closely intermeshing counterrotating twin screw extruders, 35,36 as other researchers have done for corotating twin screw extruders. [37][38][39] However, those composite models using one-stage melting models were simpler in execution, and the melting regions were clearly specified in those cases.…”

Section: Computationsmentioning

confidence: 99%

A Global Model for Starve-Fed Nonconventional Single-Screw Extrusion of Thermoplastics

Lewandowski

Nastaj

Wilczyński

2015

Adv. Polym. Technol.

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ABSTRACT:A global computer model has been developed for starve-fed nonconventional single-screw extrusion. The model has been built by combining a new melt conveying model with recently developed melting models. Mixing screw equipped with dispersive mixing element of Maddock has been considered as an example for modeling. Extensive fully three-dimensional non-Newtonian Finite Element Method (FEM) computations have been performed to model the melt flow in mixing elements. Screw pumping characteristics have been computed and modeled for these elements at various power law indices. These characteristics have been implemented into the global model of the process. Computations were made for low-density polyethylene at various operating conditions. Fill factor, pressure, temperature, and melting profiles were simulated and validated experimentally. It has been confirmed by computation and experimentation that melting in starve-fed single-screw extruders is totally different compared with melting in flood-fed extruders. It is faster, and the screw length needed for melting extends with an increase of the flow rate. The screw is fully filled for some distance from the die only and starved beyond it. This distance is dependent on the flow rate and screw speed. C

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Experimental and simulation studies on filling imbalance in geometrically balanced runner systems of multi-cavity injection molds

Cited by 7 publications

References 8 publications

A Strategy for Problem Solving of Filling Imbalance in Geometrically Balanced Injection Molds

A Strategy for Problem Solving of Filling Imbalance in Geometrically Balanced Injection Molds

Experimental and theoretical study on filling imbalance in geometrically balanced injection molds

A Global Model for Starve-Fed Nonconventional Single-Screw Extrusion of Thermoplastics

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