[PDF] Computer Simulation Of A Ceramic Core Injection Molding Process eBook

Author : Huamin Zhou
Publisher : John Wiley & Sons
Page : 40 pages
File Size : 15,44 MB
Release : 2013-03-04
Category : Technology & Engineering
ISBN : 0470602996

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This book covers a wide range of applications and uses of simulation and modeling techniques in polymer injection molding, filling a noticeable gap in the literature of design, manufacturing, and the use of plastics injection molding. The authors help readers solve problems in the advanced control, simulation, monitoring, and optimization of injection molding processes. The book provides a tool for researchers and engineers to calculate the mold filling, optimization of processing control, and quality estimation before prototype molding.

Author : B.C. Mutsuddy
Publisher : Springer Science & Business Media
Page : 386 pages
File Size : 38,67 MB
Release : 1994-11-30
Category : Technology & Engineering
ISBN : 9780412538100

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This book provides a comprehensive overview of the steps involved in the ceramic injection molding process. It provides the reader with a convenient and authoritative source of information and guidance on the use of materials, equipment and testing procedures to produce satisfactory ceramic products.

Author : Kyaw Lin
Publisher : GRIN Verlag
Page : 85 pages
File Size : 45,86 MB
Release : 2009-10
Category : Technology & Engineering
ISBN : 3640445554

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Research Paper (postgraduate) from the year 2008 in the subject Engineering - Mechanical Engineering, University of South Australia, language: English, abstract: Determining optimal values of process control factors is critical in injection moulding process because of their influences on product quality, productivity and cost of production. In the past, many researchers exploited traditional and artificial methods but the limitations of different methods prevented to achieve optimal level of process design variables for multiple-input multiple-output (MIMO) injection moulding process. To bridge the gap, this study aims to develop a computer integrated optimisation system (CIOS). In this research, virtual reality (VR) technology is employed, in the first phase, for simulation purpose and combination of design of experiments (DOE) and SAPSO-based ANN method is used for optimising the simulation results in order to achieve global optimal solution for the control parameters. Apparently, the proposed approach is a new integration system that can help the users determine optimal parameter settings to accomplish the MIMO injection moulding process with competitive benefits of cost and production efficiency.

Author : Jaime N. Castaneda
Publisher :
Page : 60 pages
File Size : 22,21 MB
Release : 2006
Category :
ISBN :

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To reduce costs and hazardous wastes associated with the production of lead-based active ceramic components, an injection molding process is being investigated to replace the current machining process. Here, lead zirconate titanate (PZT) ceramic particles are suspended in a thermoplastic resin and are injected into a mold and allowed to cool. The part is then bisque fired and sintered to complete the densification process. To help design this new process we use a finite element model to describe the injection molding of the ceramic paste. Flow solutions are obtained using a coupled, finite-element based, Newton-Raphson numerical method based on the GOMA/ARIA suite of Sandia flow solvers. The evolution of the free surface is solved with an advanced level set algorithm. This approach incorporates novel methods for representing surface tension and wetting forces that affect the evolution of the free surface. Thermal, rheological, and wetting properties of the PZT paste are measured for use as input to the model. The viscosity of the PZT is highly dependent both on temperature and shear rate. One challenge in modeling the injection process is coming up with appropriate constitutive equations that capture relevant phenomenology without being too computationally complex. For this reason we model the material as a Carreau fluid and a WLF temperature dependence. Two-dimensional (2D) modeling is performed to explore the effects of the shear in isothermal conditions. Results indicate that very low viscosity regions exist near walls and that these results look similar in terms of meniscus shape and fill times to a simple Newtonian constitutive equation at the shear-thinned viscosity for the paste. These results allow us to pick a representative viscosity to use in fully three-dimensional (3D) simulation, which because of numerical complexities are restricted to using a Newtonian constitutive equation. Further 2D modeling at nonisothermal conditions shows that the choice of representative Newtonian viscosity is dependent on the amount of heating of the initially room temperature mold. An early 3D transient model shows that the initial design of the distributor is sub-optimal. However, these simulations take several months to run on 4 processors of an HP workstation using a preconditioner/solver combination of ILUT/GMRES with fill factors of 3 and PSPG stabilization. Therefore, several modifications to the distributor geometry and orientations of the vents and molds have been investigated using much faster 3D steady-state simulations. The pressure distribution for these steady-state calculations is examined for three different distributor designs to see if this can indicate which geometry has the superior design. The second modification, with a longer distributor, is shown to have flatter, more monotonic isobars perpendicular to the flow direction indicating a better filling process. The effects of the distributor modifications, as well as effects of the mold orientation, have also been examined with laboratory experiments in which the flow of a viscous Newtonian oil entering transparent molds is recorded visually. Here, the flow front is flatter and voids are reduced for the second geometry compared to the original geometry. A horizontal orientation, as opposed to the planned vertical orientation, results in fewer voids. Recently, the Navier-Stokes equations have been stabilized with the Dohrman-Bochev PSPP stabilization method, allowing us to calculate transient 3D simulations with computational times on the order of days instead of months. Validation simulations are performed and compared to the experiments. Many of the trends of the experiments are captured by the level set modeling, though quantitative agreement is lacking mainly due to the high value of the gas phase viscosity necessary for numerical stability, though physically unrealistic. More correct trends are predicted for the vertical model than the horizontal model, which is serendipitous as the actual mold is held in a vertical geometry. The full, transient mold filling calculations indicate that the flow front is flatter and voids may be reduced for the second geometry compared to the original geometry. The validated model is used to predict mold filling for the actual process with the material properties for the PZT paste, the original distributor geometry, and the mold in a vertical orientation. This calculation shows that voids may be trapped at the four corners of the mold opposite the distributor.

Author : Sumit Banerjee
Publisher :
Page : 214 pages
File Size : 15,4 MB
Release : 1983
Category : Computer simulation
ISBN :

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A numerical technique is proposed for the simulation of cavity filling process during injection molding of glass-bead filled polypropylene. The mold cavity is of cylindrical shape. Marker And Cell (MAC) method is utilized for solving the transient flow phenomena, after a mathematical simulation of the flow model is carried out by using the relevant continuity and-momentum equations governing the system. The complexity of the equations involved, results in the simplifying assumption of incompressible and isothermal flow process. A computer program is written on the basis of finite-difference equations developed during the application of MAC method under the prevailing conditions. The numerical results yield significant data on the progression of the melt front, the velocity profiles in both axial and transverse directions and the pressure distributions at different times and positions in the cavity.