Injection Mold Design Handbook

Catoen, Bruce; Rees, Herbert

doi:10.3139/9781569908167.fm

Cited by 4 publications

(5 citation statements)

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“…These were mainly limited to modeling the flow in injection molds without considering the polymer flow and melting in the plasticating unit, e.g., by Manzione et al [ 82 ], Kennedy and Zheng [ 83 ], Kamal et al [ 84 ], Osswald et al [ 85 ] and Wang et al [ 86 ]. Other books have been devoted to the mold design, e.g., by Menges et al [ 87 ], Rees [ 88 ], Unger [ 89 ], Mennig and Stoeckhert [ 90 ], Kazmer [ 91 ], Turng and Chen [ 92 ], Beaumont [ 93 ] and Catoen and Rees [ 94 ], or to the injection molding machines by Johannaber [ 95 ]. An important review paper on modeling and optimization of injection molding was presented by Fernandes et al [ 96 ].…”

Section: Introductionmentioning

confidence: 99%

Modeling and Experimental Studies on Polymer Melting and Flow in Injection Molding

Wilczyński

Buziak

2022

Polymers

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Injection molding, in addition to extrusion, is the most important technology in the polymer processing industry. When modeling injection molding, the global approach is necessary to take into account the solid polymer transport, polymer melting and the polymer melt flow. The model of polymer melting is fundamental for the development of such a global injection molding model. In the paper, the state-of-the-art of modeling and experimentation of the flow and melting in injection molding machines has been presented and discussed. It has been concluded that the existing mathematical models have no strong experimental basis. Therefore, experimentation of the polymer flow and melting in the injection molding machine has been performed, and the effect of processing conditions: the screw speed, the plasticating stroke and the back pressure on the process course has been investigated. Starving in the beginning sections of the screw has been observed, which was not presented in the literature so far. The novel concepts of injection molding modeling have been discussed.

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Section: Introductionmentioning

confidence: 99%

Modeling and Experimental Studies on Polymer Melting and Flow in Injection Molding

Wilczyński

Buziak

2022

Polymers

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“…Different operating parameters were used to investigate their effect on material conveying and plasticizing in the injection-forming machine and the mold. The screw rotations were equal to N = 55 rpm, 110 rpm, 175 rpm, 240 rpm, and 310 rpm, the plasticizing stroke was constant at h plast = 1.5D, and the backpressures (hydraulic) were equal to P back = 17 MPa, 34 The process and material parameters [39] are collected in Table 1.…”

Section: Materials and Process Datamentioning

confidence: 99%

“…Some books referred to the tool design; for examp [28], Rees [29], Unger [30], Mennig et al [31], Turng et al [32], Beaumo al. [34], and Kazmer [35], or the injection-forming machines, such as Jo valuable review paper on the issues of the simulation of the injection-form written by Fernandes et al [37]. Nowadays, the most valuable program injection forming are the MOLDFLOW program [38], Moldex3D pr CADMOULD program [40], which were recently applied in [41,42].…”

Section: Introductionmentioning

confidence: 99%

“…These were mainly limited to modeling the flow in the molds and did not consider the material transport and plasticizing in the plasticizing system; for example, Manzione et al [23], Isayev et al [24], Osswald et al [25], Kennedy et al [26], and Wang et al [27]. Some books referred to the tool design; for example, Menges et al [28], Rees [29], Unger [30], Mennig et al [31], Turng et al [32], Beaumont [33], Catoen et al [34], and Kazmer [35], or the injection-forming machines, such as Johannaber [36]. A valuable review paper on the issues of the simulation of the injection-forming process was written by Fernandes et al [37].…”

Section: Introductionmentioning

confidence: 99%

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A Global Approach to Modeling Injection Molding

Narowski,

Wilczyński

2024

Polymers

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A problem of modeling plastic injection forming (molding) is presented, including both the plasticizing system of the injection-forming machine and the mold. When modeling the plastic flow in the mold, the input quantities are essentially unknown, e.g., the plastic melt temperature. Thus, a comprehensive (global) model of the injection-forming process is needed for the flow in the plasticizing system and in the mold. The process output quantities from the plasticizing system will be the input quantities for the mold. When modeling the plastic flow in the injection-forming machine, a comprehensive approach should be applied to consider the solid material conveying, material plasticizing, and the material melt flow. The model of material plasticizing is a basis for building such global models. In this research, the effect of the flow (including plasticizing) in the injection-forming machine on the flow in the mold is studied by simulation (using Moldex3D 2023R3OR 64-bit software) and experimentation. These studies are carried out for the injection forming of selected material using a specialized spiral mold. Simulations performed with the use of Moldex3D software for the plasticizing system significantly improved the accuracy of the simulation of the flow in the mold. However, the best results were obtained using experimental data (plastic melt temperature) as input quantities for mold filling simulations. The novel concepts of injection-forming process modeling based on our previous experimentations are also discussed.

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“…Efficient product development is responsible for the success of a company, especially in the injection molding industry [1]. Injection molding is the most important production process in the manufacture of plastic components (molded parts) and takes place in an injection mold on an injection molding machine, which can produce large quantities of molded parts until failure [2]. However, the conventional production of a mold is extremely time-consuming and costly, which creates a contradiction with the fast-moving market [2].…”

Section: Introductionmentioning

confidence: 99%

Review and Development of Design Guidelines for Additive Tooling of Injection Molds Using PolyJet Modelling

Junk,

Schrock,

Schmieder

2023

Industrializing Additive Manufacturing

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Due to globalization and the resulting increase in competition on the market, products must be produced more and more cheaply, especially in series production, because buyers expect new variants or even completely new products in ever shorter cycles. Injection molding is the most important production process for manufacturing plastic components in large quantities. However, the conventional production of a mold is extremely time-consuming and costly, which creates a contradiction to the fast pace of the market. Additive tooling is an area of application of additive manufacturing, which in the field of injection molding is preferably used for the prototype production of mold inserts. This allows injection molding tools to be produced faster and more cheaply than through the subtractive manufacturing of metal tools. Material Jetting processes using polymers (MJT-UV/P), also called Polyjet Modeling (PJM), have a great potential for use in additive tooling. Due to the poorer mechanical and thermal properties compared to conventional mold insert materials, e.g. steel or aluminum, the previously used design principles cannot be applied. Accordingly, new design guidelines are necessary, which are developed in this paper. The necessary information is obtained with the help of a systematic literature research. The design guidelines are mapped in a uniform design guide, which is structured according to the design process of injection molds. The guidelines do not only refer to the constructive design of the injection mold or the polymer mold insert, but to the entire design process and describe the four phases of planning, conception, development and realization. Particular attention is paid to the special geometric designs of a polymer mold insert and the thermomechanical properties of the mold insert materials. As a result, design guidelines are available that are adapted to the special requirements of additive tooling of molds inserts made of plastics for injection molding.

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Injection Mold Design Handbook

Cited by 4 publications

References 0 publications

Modeling and Experimental Studies on Polymer Melting and Flow in Injection Molding

Modeling and Experimental Studies on Polymer Melting and Flow in Injection Molding

A Global Approach to Modeling Injection Molding

Review and Development of Design Guidelines for Additive Tooling of Injection Molds Using PolyJet Modelling

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