[PDF] Computer Simulation Of The Injection Molding Process eBook
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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.
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.
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.
Given the importance of injection molding as a process as well as the simulation industry that supports it, there was a need for a book that deals solely with the modeling and simulation of injection molding. This book meets that need. The modeling and simulation details of filling, packing, residual stress, shrinkage, and warpage of amorphous, semi-crystalline, and fiber-filled materials are described. This book is essential for simulation software users, as well as for graduate students and researchers who are interested in enhancing simulation. And for the specialist, numerous appendices provide detailed information on the topics discussed in the chapters. Contents: Part 1 The Current State of Simulation: Introduction, Stress and Strain in Fluid Mechanics, Material Properties of Polymers, Governing Equations, Approximations for Injection Molding, Numerical Methods for Solution Part 2 Improving Molding Simulation: Improved Fiber Orientation Modeling, Improved Mechanical Property Modeling, Long Fiber-Filled Materials, Crystallization, Effects of Crystallizations on Rheology and Thermal Properties, Colorant Effects, Prediction of Post-Molding Shrinkage and Warpage, Additional Issues of Injection-Molding Simulation, Epilogue Appendices: History of Injection-Molding Simulation, Tensor Notation, Derivation of Fiber Evolution Equations, Dimensional Analysis of Governing Equations, The Finite Difference Method, The Finite Element Method, Numerical Methods for the 2.5D Approximation, Three-Dimensional FEM for Mold Filling Analysis, Level Set Method, Full Form of Mori-Tanaka Model
This practical introductory guide to injection molding simulation is aimed at both practicing engineers and students. It will help the reader to innovate and improve part design and molding processes, essential for efficient manufacturing. A user-friendly, case-study-based approach is applied, enhanced by many illustrations in full color. The book is conceptually divided into three parts: Chapters 1–5 introduce the fundamentals of injection molding, and how molding simulation methodology is developed, especially focusing on the effects on molding quality from the rheological, thermodynamic, thermal, mechanical, and kinetic properties of plastics, as well as curing kinetics for thermoset plastics. Chapters 6–11 introduce CAE verification on injection molding including design guidelines of part, gating, runner, and cooling channel systems. Temperature control in hot runner systems, prediction and control of warpage, and fiber orientation are also discussed. Chapters 12–17 introduce research and development in innovative molding, illustrating how CAE is applied to advanced molding techniques, including co-/bi-injection molding, gas-/water-assisted injection molding, foam injection molding, powder injection molding, resin transfer molding (RTM), and integrated circuit (IC) packaging. The 2nd edition contains many updates, including elaboration of material measurement data, connection of Smart Design and Smart Manufacturing, demonstration of the flow-induced fiber orientation effect, implementations of material characterization methods on PU reactive foaming and RTM, studies of dispensing control and creeping behaviors effects on IC underfill process, and much more. Several CAE case study exercises for execution in Moldex3D software are included to allow readers to practice what they have learned and test their understanding.
This book covers fundamental principles and numerical methods relevant to the modeling of the injection molding process. As injection molding processing is related to rheology, mechanical and chemical engineering, polymer science and computational methods, and is a rapidly growing field, the book provides a multidisciplinary and comprehensive introduction to the subjects required for an understanding of the complex process. It addresses the up-to-date status of fundamental understanding and simulation technologies, without losing sight of still useful classical approaches. The main chapters of the book are devoted to the currently active fields of flow-induced crystallization and orientation evolution of fiber suspensions, respectively, followed by detailed discussion of their effects on mechanical property, shrinkage and warpage of injection-molded products. The level of the proposed book will be suitable for interested scientists, R&D engineers, application engineers, and graduate students in engineering.