Improving the Melt Flow Length of Acrylonitrile Butadiene Styrene in Thin-Wall Injection Molding by External Induction Heating with the Assistance of a Rotation Device

Minh, Pham Son; Le, Minh Tai

doi:10.3390/polym13142288

Cited by 16 publications

(10 citation statements)

References 40 publications

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“…Therefore, with the design shown in Figure 1 , the water mold temperature controller is the same as in the traditional injection molding process. As compared with other mold heating methods such as external induction heating [ 23 ] or external gas-assisted mold temperature control [ 29 ], this has the advantage of using an In-GMTC.…”

Section: Experimental Methodsmentioning

confidence: 99%

“…These issues can be addressed by directly heating the cavity surface. There are several methods that can support a high heating rate and good predictability without heating the entire cavity volume, for example, induction heating [ 22 , 23 , 24 , 25 ], high-frequency proximity heating [ 26 , 27 ], and gas-assisted mold temperature control (GMTC) [ 28 , 29 , 30 , 31 , 32 ]. The induction heating method has a very fast heating rate, which is a great advantage.…”

Section: Introductionmentioning

confidence: 99%

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Internal Gas-Assisted Mold Temperature Control for Improving the Filling Ability of Polyamide 6 + 30% Glass Fiber in the Micro-Injection Molding Process

2022

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In micro-injection molding, the plastic filling in the cavity is limited by the frozen layer due to the rapid cooling of the hot melt when it comes into contact with the surface of the cavity at a lower temperature. This problem is more serious with composite materials, which have a higher viscosity than pure materials. Moreover, this issue is also more serious with composite materials that have a higher weight percentage of glass filer. In this article, a pre-heating step with the internal gas heating method was used to heat the cavity surface to a high temperature before the filling step to reduce the frozen layer and to improve the filling ability of the composite material (polyamide 6 + 30% glass fiber) in the micro-injection molding process. To heat the cavity surface, an internal gas-assisted mold temperature control (In-GMTC) system was used with a pulsed cooling system. We assessed different mold insert thicknesses (t) and gaps between the gas gate and the heating surface (G) to achieve rapid mold surface temperature control. The heating process was observed using an infrared camera, and the temperature distribution and the heating rate were analyzed. Thereafter, along with the local temperature control, the In-GMTC was used for the micro-injection molding cycle. The results show that, with a gas temperature of 300 °C and a gas gap of 3.5 mm, the heating rate reached 8.6 °C/s. The In-GMTC was also applied to the micro-injection molding process with a part thickness of 0.2 mm. It was shown that the melt flow length had to reach 24 mm to fill the cavity completely. The results show that the filling ability of the composite material increased from 65.4% to 100% with local heating at the melt inlet area when the gas temperature rose from 200 to 400 °C with a 20 s heating cycle.

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Section: Experimental Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Internal Gas-Assisted Mold Temperature Control for Improving the Filling Ability of Polyamide 6 + 30% Glass Fiber in the Micro-Injection Molding Process

2022

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“…The original material shapes for the AM method are powder or wire, and they are melted and adhered to generate the designed forms. Powder materials require a laser beam or electron beam, which are expensive and high-energy consumption devices, despite the fact that they could build high-resolution parts [4][5][6][7][8]. Compared to powder materials, wire shapes have the merits of saving fusion energy and time during the additive process.…”

Section: Introductionmentioning

confidence: 99%

Conformal Cooling Channel Design for Improving Temperature Distribution on the Cavity Surface in the Injection Molding Process

et al. 2023

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Mold heating is an essential process in plastic injection molding. Raising the temperature of the mold before injecting liquefied plastic can ease the mold-filling process. A cooling channel can be used to transport high-temperature fluids for this purpose, such as hot water or oil. This dual purpose is a cost-effective solution for heating the mold because the target temperature is easily achieved using this method. In addition, a conformal cooling channel (CCC) can provide more efficient mold heating than a straight cooling channel. This study used the response surface methodology to determine the optimum CCC shape for heat distribution in a mold, and the simulation results confirmed its optimization. The average temperature of the mold using a CCC was better than that using a straight cooling channel, and the heat zone was uniform across the mold surface.

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“…Additionally, according to Barad et al [ 21 ], reducing the channel thickness can decrease the distance of the weld line’s influence on the ultimate tensile strength (UTS). Additionally, it may be necessary to use specialized equipment, such as twin-screw extruders or mixing screws, to ensure proper mixing and dispersion of the composite materials or some unique molding process as mold pre-heating [ 22 ], gas-assisted injection molding [ 23 ], over-molding [ 24 ], or thin wall injection molding [ 25 ]. Overall, the injection molding process for composite materials requires careful attention to processing parameters, material selection, and equipment to ensure that the resulting parts meet the desired specifications for strength, durability, and appearance.…”

Section: Introductionmentioning

confidence: 99%

Influences of TPU Content on the Weld Line Characteristics of PP and ABS Blends

Do,

Nguyen,

Song Toan

et al. 2023

Polymers

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This study aims to explore the effects of Thermoplastic Polyurethane (TPU) content on the weld line properties of Polypropylene (PP) and Acrylonitrile Butadiene Styrene (ABS) blends. In PP/TPU blends, increasing the TPU content results in a significant decrease in the PP/TPU composite’s ultimate tensile strength (UTS) and elongation values. Blends with 10 wt%, 15 wt%, and 20 wt% TPU and pure PP outperform blends with 10 wt%, 15 wt%, and 20 wt% TPU and recycled PP in terms of UTS value. The blend with 10 wt% TPU and pure PP achieves the highest UTS value of 21.85 MPa. However, the blend’s elongation decreases due to the poor bonding in the weld line area. According to Taguchi’s analysis, the TPU factor has a more significant overall influence on the mechanical properties of PP/TPU blends than the recycled PP factor. Scanning electron microscope (SEM) results show that the TPU area has a dimple shape on the fracture surface due to its significantly higher elongation value. The 15 wt% TPU sample achieves the highest UTS value of 35.7 MPa in ABS/TPU blends, which is considerably higher than other cases, indicating good compatibility between ABS and TPU. The sample containing 20 wt% TPU has the lowest UTS value of 21.2 MPa. Furthermore, the elongation-changing pattern corresponds to the UTS value. Interestingly, SEM results present that the fracture surface of this blend is flatter than the PP/TPU blend due to a higher compatibility rate. The 30 wt% TPU sample has a higher rate of dimple area than the 10 wt% TPU sample. Moreover, ABS/TPU blends gain a higher UTS value than PP/TPU blends. Increasing the TPU ratio mainly reduces the elastic modulus of both ABS/TPU blends and PP/TPU blends. This study reveals the advantages and disadvantages of mixing TPU with PP or ABS to ensure that it meets the requirements of the intended applications.

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Improving the Melt Flow Length of Acrylonitrile Butadiene Styrene in Thin-Wall Injection Molding by External Induction Heating with the Assistance of a Rotation Device

Cited by 16 publications

References 40 publications

Internal Gas-Assisted Mold Temperature Control for Improving the Filling Ability of Polyamide 6 + 30% Glass Fiber in the Micro-Injection Molding Process

Internal Gas-Assisted Mold Temperature Control for Improving the Filling Ability of Polyamide 6 + 30% Glass Fiber in the Micro-Injection Molding Process

Conformal Cooling Channel Design for Improving Temperature Distribution on the Cavity Surface in the Injection Molding Process

Influences of TPU Content on the Weld Line Characteristics of PP and ABS Blends

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