Numerical simulation on crystallization-induced warpage of injection-molded PP/EPDM part

Li, Xiaoyan; Qian, Wei; Li, Jun; Yang, Jian; Guan, Jiaxin; Qiu, Biwei; Xu, Jianjun; Wang, Xia

doi:10.1007/s10965-019-1869-3

Cited by 10 publications

(3 citation statements)

References 36 publications

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“…The quality is really important for each product that directly related to processes of product design, mold design, and manufacturing process. There are many defects formed during the injection molding process when the melt plastic filled into the mold cavity such as short shot, weld lines, shrinkage, and warpage [2][3][4][5]. So, it is crucial to control the melt plastic flow and injection molding process to improve product quality.…”

Section: Introductionmentioning

confidence: 99%

Application of digital simulation tool in designing of injection mold for sustainable manufacturing

Trinh

2024

Eureka: PE

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Gate location (GL) is one of the most important criteria in the injection molding technology to produce a good quality product. The best GL will bring many benefits to the manufacturing process such as reducing cycle time, minimizing defects of the product, and decreasing capital cost. In this study, an automatic gate location analysis tool (AGLA) is introduced to investigate the best gate location for designing the injection mold. EasyFill Advanced software was used to conduct experiments on analyzing the filling process of melting plastic material into the mold cavity. Acrylonitrile butadiene styrene (ABS) is the polymer material that is used in the study to produce the plastic product. The gate locations are located in different positions to analyze the product characteristics that will occur during the injection molding process such as weld lines, short shot, warpage, shrinkage, and air traps. Three simulation cases were set up and conducted including case 1 with the suggestion from EasyFill software, case 2 with the gate location located on the middle point of the long edge side, and case 3 with the gate location located on the middle point of the short edge side. The warpage defects are recorded with a minimum value of 0.464 mm belonging to case 1 smaller than that of 0.481 mm in case 2 and 0.482 mm in case 3, respectively. The method is a good solution for engineers in designing and developing a new mold for injection molding manufacturing

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Section: Introductionmentioning

confidence: 99%

Application of digital simulation tool in designing of injection mold for sustainable manufacturing

Trinh

2024

Eureka: PE

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“…Typically, increasing the crystallization rate significantly changed the solidification behaviour, and the oriented microstructure led to localized anisotropy in thermal and mechanical properties which can increase the shrinkage and warping of injection moulded parts (Derakhshandeh and Hatzikiriakos 2012). Also, crystallization could influence the warpage of semi-crystalline and its blend parts made by the injection moulding process (Li et al 2019). There is a direct relationship between crystal morphology and molecular orientation (Lellinger et al 2003; Janeschitz-Kriegl and Ratajski 2005).…”

Section: Introductionmentioning

confidence: 99%

Impact of multiple recycling on the dimensional stability of wood–plastic composite made by the injection moulding process

Salahshournejad

Saraeian

Shakouri

2023

International Wood Products Journal

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This study explored the effect of multiple recycling on the dimensional stability of woodplastic composite. For this purpose, the injection moulding parameters effective on dimensional stability were first optimized based on the response surface method. Optical scanning, melt flow index (MFI), and differential scanning calorimetry (DSC) tests were used to analyse the shrinkage and deformation of recycled samples. The obtained results revealed that some recycled samples were subjected to thermal changes during the grinding and injection moulding process. The MFI and DSC results showed that the highdensity polyethylene thermoplastic used in the wood-plastic composite was broken with long chains. Also, thermal changes occurred during the grinding and injection moulding process. The samples recycled three times had the highest dimensional instability (2.8% of shrinkage values). Finally, with the reduction of DSC, the semi-crystalline structure changed to amorphous, and the samples recycled four and five times had 2.7% and 2.5% shrinkage percentage, respectively.

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“…The prediction of warpage by computer will solve the issue of universality. Some methods have been introduced and developed to predict the warpage of CIM parts [ 18 , 19 , 20 ], and some of them have been introduced into commercial software, such as Moldflow and Moldex 3D. The large warpage is considered as the main defect of RHCM parts [ 21 ].…”

Section: Introductionmentioning

confidence: 99%

Warpage Prediction of RHCM Crystalline Parts Based on Multi-Layers

Bei

Liu

et al. 2021

Polymers

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Warpage is a typical defect for injection-molded parts, especially for crystalline parts molded by rapid heat cycle molding (RHCM). In this paper, a prediction method is proposed for predicting the warpage of crystalline parts molded by the RHCM process. Multi-layer models were established to predict warpage with the same thicknesses as the skin-core structures in the molded parts. Warpages were defined as the deformations calculated by the multi-layer models. The deformations were solved using the classical laminated plate theory by Abaqus. A model was introduced to describe the elastic modulus with the influence of temperature and crystallinity. The simulation process was divided into two procedures, before ejection and after ejection. Thermal stresses and thermal strains were simulated, respectively, in the procedure before ejection and after ejection. The prediction results were compared with the experimental results, which showed that the average errors between predicted warpage and average experimental warpage are, respectively, 7.0%, 3.5%, and 4.4% in conventional injection molding (CIM), in RHCM under a 60 °C heating mold (RHCM60), and in RHCM under a 90 °C heating mold (RHCM90).

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Numerical simulation on crystallization-induced warpage of injection-molded PP/EPDM part

Cited by 10 publications

References 36 publications

Application of digital simulation tool in designing of injection mold for sustainable manufacturing

Application of digital simulation tool in designing of injection mold for sustainable manufacturing

Impact of multiple recycling on the dimensional stability of wood–plastic composite made by the injection moulding process

Warpage Prediction of RHCM Crystalline Parts Based on Multi-Layers

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