Reducing service stress of the injection-molded polycarbonate window by optimizing mold construction and product structure

Wang, Xinyu; Zheng, Li; Gu, Junfeng; Ruan, Shilun; Shen, Changyu; Wang, Xicheng

doi:10.1007/s00170-015-8278-5

Cited by 24 publications

(8 citation statements)

References 27 publications

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“…The results clearly showed that both hardness and tensile strengths of the products were improved. Wang et al [ 11 ] employed optimization of mold with spiral conformal cooling system and product structure to reduce service stress of the injection molded parts. It was found that the common injection molding defects such as residual stress and warpage cannot be ignored.…”

Section: Introductionmentioning

confidence: 99%

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

et al. 2021

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Rapid tooling technology (RTT) provides an alternative approach to quickly provide wax injection molds for the required products since it can reduce the time to market compared with conventional machining approaches. Removing conformal cooling channels (CCCs) is the key technology for manufacturing injection mold fabricated by rapid tooling technology. In this study, three different kinds of materials were used to fabricate CCCs embedded in the injection mold. This work explores a technology for rapid development of injection mold with high cooling performance. It was found that wax is the most suitable material for making CCCs. An innovative method for fabricating a large intermediary mold with both high load and supporting capacities for manufacturing a large rapid tooling using polyurethane foam was demonstrated. A trend equation for predicting the usage amount of polyurethane foam was proposed. The production cost savings of about 50% can be obtained. An optimum conformal cooling channel design obtained by simulation is proposed. Three injection molds with different cooling channels for injection molding were fabricated by RTT. Reductions in the cooling time by about 89% was obtained. The variation of the results between the experiment and the simulation was investigated and analyzed.

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Section: Introductionmentioning

confidence: 99%

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

et al. 2021

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“…It was found that the solidification time was minimized appreciably keeping the same advantages of RT process. Wang et al [11] optimized the molds with spherical spiral conformal cooling system and product structure to reduce service stress of the injection molded parts. This work suggested that injection molding defects such as warpage and residual stress cannot be ignored, especially for the assembly edge.…”

Section: Introductionmentioning

confidence: 99%

Effects of Different Mold Materials and Coolant Media on the Cooling Performance of Epoxy-Based Injection Molds

Kuo

Zhu

et al. 2022

Polymers

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Metal additive manufacturing techniques are frequently applied to the manufacturing of injection molds with a conformal cooling channel (CCC) in order to shorten the cooling time in the injection molding process. Reducing the cooling time in the cooling stage is essential to reducing the energy consumption in mass production. However, the distinct disadvantages include higher manufacturing costs and longer processing time in the fabrication of injection mold with CCC. Rapid tooling technology (RTT) is a widely utilized technology to shorten mold development time in the mold industry. In principle, the cooling time of injection molded products is affected by both injection mold material and coolant medium. However, little work has been carried out to investigate the effects of different mold materials and coolant media on the cooling performance of epoxy-based injection molds quantitatively. In this study, the effects of four different coolant media on the cooling performance of ten sets of injection molds fabricated with different mixtures were investigated experimentally. It was found that cooling water with ultrafine bubble is the best cooling medium based on the cooling efficiency of the injection molded parts (since the cooling efficiency is increased further by about 12.4% compared to the conventional cooling water). Mold material has a greater influence on the cooling efficiency than the cooling medium, since cooling time range of different mold materials is 99 s while the cooling time range for different cooling media is 92 s. Based on the total production cost of injection mold and cooling efficiency, the epoxy resin filled with 41 vol.% aluminum powder is the optimal formula for making an injection mold since saving in the total production cost about 24% is obtained compared to injection mold made with commercially available materials.

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“…This work confirmed that the CCC provides a reduction in the warpage of plastic products. Wang et al [ 8 ] proposed a plastic injection mold with a spherical spiral conformal cooling system. Results suggested that defects of plastic products, such as residual stress or warpage, cannot be ignored.…”

Section: Introductionmentioning

confidence: 99%

Characterization of Epoxy-Based Rapid Mold with Profiled Conformal Cooling Channel

Kuo

Zhu

2022

Polymers

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Based on the experience of the foundry industry, reducing the demolding time is the key for mass production of wax patterns with sophisticated geometries. Integration of numerical simulation and rapid tooling technology for decreasing the time to market is essential in advanced manufacturing technology. However, characterization of epoxy-based rapid molds with a profiled conformal cooling channel (PCCC) using computer-aided engineering simulation of the epoxy-based rapid mold with PCCC was not found in the literature. In this study, epoxy-based rapid molds with PCCC were characterized numerically and experimentally. The cooling performance of wax injection molds with two different kinds of cross-sections of the cooling channel was investigated. Four pairs of injection molds with PCCC were implemented using four different kinds of material formulations. It was found that the cooling performance of the PCCC was better than a circular conformal cooling channel (CCCC) since the PCCC maintained a more uniform and steady cooling performance of injection-molded product than CCCC. Epoxy resin added with 41 vol.% Cu powder seems to be a cost-effective empirical material formulation in terms of cooling time and material costs. This empirical material formulation provided an injection mold with low material cost and good cooling performance simultaneously compared to an injection mold fabricated with commercial material. The cooling performance could reach 88% of that of the injection mold fabricated with commercial material. The material cost of making the injection mold was only about 60% of that of the injection mold fabricated with commercial material. The coolant flow rate had no significant effect on the cooling time, whereas the cooling time of the wax pattern was affected by coolant temperature significantly.

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Reducing service stress of the injection-molded polycarbonate window by optimizing mold construction and product structure

Cited by 24 publications

References 27 publications

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

Effects of Different Mold Materials and Coolant Media on the Cooling Performance of Epoxy-Based Injection Molds

Characterization of Epoxy-Based Rapid Mold with Profiled Conformal Cooling Channel

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