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Finite element analysis and experiemental verification of polymer melt temperature and product shrinkage in injection molding / Gan Teck Wan

It is not an easy task to control the final properties of the plastic product since there is a lot factors like mold design, processing parameters and behavior of the plastic material during injection molding have to be taken into consideration. Due to these factors, injection molded plastic part va...

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Main Author: Gan, Teck Wan
Format: Thesis
Published: 2012
Subjects:
T Technology (General)
TA Engineering (General). Civil engineering (General)
Online Access:http://studentsrepo.um.edu.my/8327/5/FINITE_ELEMENT_ANALYSIS_AND_EXPERIMENTAL_VERIFICATION_OF_POLYMER_MELT_TEMPERATURE_AND_PRODUCT_SHRINKAGE_IN_INJECTION_MOLDING.pdf
http://studentsrepo.um.edu.my/8327/
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record_format eprints
institution Universiti Malaya
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country Malaysia
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content_source UM Student Repository
url_provider http://studentsrepo.um.edu.my/
topic T Technology (General)
TA Engineering (General). Civil engineering (General)
spellingShingle T Technology (General)
TA Engineering (General). Civil engineering (General)
Gan, Teck Wan
Finite element analysis and experiemental verification of polymer melt temperature and product shrinkage in injection molding / Gan Teck Wan
description It is not an easy task to control the final properties of the plastic product since there is a lot factors like mold design, processing parameters and behavior of the plastic material during injection molding have to be taken into consideration. Due to these factors, injection molded plastic part varies accordingly with the parameter setting and results in different dimensional variation from part to part. For better quality control, the effect of these processing parameters on shrinkage must be known before manufacturing. In this study, finite element analysis was used to determine this effect by using one-way interaction approach and two-way interaction approach. In one-way interaction approach, three finite element analysis tools namely computational fluid dynamic, transient thermal analysis and static structural analysis were used to model the mold filling, mold cooling and product shrinkage after ejection as separate process. In the two-way interaction approach, a highly intelligent multi-physics architecture composed of both computational fluid dynamic and finite element analysis tools were proposed to study the injection molding shrinkage problem as a single process. Two test mold cavities namely mold cavity-I and mold cavity-II were used in this study. Marlex HDPE 9500 was injection molded in mold cavity-I and TOYOLAC 250 ABS was injection molded in mold cavity-II. Both cavities product shape were respectively rectangular in geometry with dimension of 100 mm × 50 mm × 2 mm and 67 mm × 40 mm × 4 mm. From analysis obtained from one-way interaction approach, it was found that the shrinkage of mold cavity-I increased from 4.7 - 4.8% to 4.9 – 5.0% when the melt temperature was adjusted from 220ºC to 240ºC. The packing pressure effect on shrinkage was relatively small compared with melt temperature effect since it was not taken into account in static structural analysis. The two-way interaction approach result showed that the shrinkage was high at the center location of the plastic part. No shrinkage was recorded when the mass flow rate was high. At low injection mass flow rate (0.05 kg/s), the shrinkage improved with melt temperature. Shrinkage was 1 - 10% when melt temperature was 220ºC and shrinkage was 0 - 4.5% when melt temperature used was 240ºC. One-way interaction approach simulation for mold cavity-II was compared with physical result obtained from experimental study. Both simulation and the physical results showed almost the same flow speed, temperature and thickness. Recorded experimental flow speed was 0.05 - 0.1 s faster than the simulation. The average recorded temperature obtained from the experimental result was about 9ºC higher than the simulation. Simulation over predicted the plastic product of mold cavity-II shrinkage by 1 - 4.8%. Taguchi method and analysis of variance (ANOVA) were used to optimize the processing parameter for minimum shrinkage of mold cavity-II product. According to the statistical result, melt temperature, mold cooling time and injection speed were the significant factors. Due to the small dimension of the injection gate, the material in this region cooled down and solidified very fast to the extent that the applied packing pressure and packing time had no significant effect on adding material into the cavity to reduce product shrinkage during packing phase. As a result, these two parameters were not significant according to Taguchi and ANOVA analysis.
format Thesis
author Gan, Teck Wan
author_facet Gan, Teck Wan
author_sort Gan, Teck Wan
title Finite element analysis and experiemental verification of polymer melt temperature and product shrinkage in injection molding / Gan Teck Wan
title_short Finite element analysis and experiemental verification of polymer melt temperature and product shrinkage in injection molding / Gan Teck Wan
title_full Finite element analysis and experiemental verification of polymer melt temperature and product shrinkage in injection molding / Gan Teck Wan
title_fullStr Finite element analysis and experiemental verification of polymer melt temperature and product shrinkage in injection molding / Gan Teck Wan
title_full_unstemmed Finite element analysis and experiemental verification of polymer melt temperature and product shrinkage in injection molding / Gan Teck Wan
title_sort finite element analysis and experiemental verification of polymer melt temperature and product shrinkage in injection molding / gan teck wan
publishDate 2012
url http://studentsrepo.um.edu.my/8327/5/FINITE_ELEMENT_ANALYSIS_AND_EXPERIMENTAL_VERIFICATION_OF_POLYMER_MELT_TEMPERATURE_AND_PRODUCT_SHRINKAGE_IN_INJECTION_MOLDING.pdf
http://studentsrepo.um.edu.my/8327/
_version_ 1738506128690511872
spelling my.um.stud.83272018-02-24T07:09:27Z Finite element analysis and experiemental verification of polymer melt temperature and product shrinkage in injection molding / Gan Teck Wan Gan, Teck Wan T Technology (General) TA Engineering (General). Civil engineering (General) It is not an easy task to control the final properties of the plastic product since there is a lot factors like mold design, processing parameters and behavior of the plastic material during injection molding have to be taken into consideration. Due to these factors, injection molded plastic part varies accordingly with the parameter setting and results in different dimensional variation from part to part. For better quality control, the effect of these processing parameters on shrinkage must be known before manufacturing. In this study, finite element analysis was used to determine this effect by using one-way interaction approach and two-way interaction approach. In one-way interaction approach, three finite element analysis tools namely computational fluid dynamic, transient thermal analysis and static structural analysis were used to model the mold filling, mold cooling and product shrinkage after ejection as separate process. In the two-way interaction approach, a highly intelligent multi-physics architecture composed of both computational fluid dynamic and finite element analysis tools were proposed to study the injection molding shrinkage problem as a single process. Two test mold cavities namely mold cavity-I and mold cavity-II were used in this study. Marlex HDPE 9500 was injection molded in mold cavity-I and TOYOLAC 250 ABS was injection molded in mold cavity-II. Both cavities product shape were respectively rectangular in geometry with dimension of 100 mm × 50 mm × 2 mm and 67 mm × 40 mm × 4 mm. From analysis obtained from one-way interaction approach, it was found that the shrinkage of mold cavity-I increased from 4.7 - 4.8% to 4.9 – 5.0% when the melt temperature was adjusted from 220ºC to 240ºC. The packing pressure effect on shrinkage was relatively small compared with melt temperature effect since it was not taken into account in static structural analysis. The two-way interaction approach result showed that the shrinkage was high at the center location of the plastic part. No shrinkage was recorded when the mass flow rate was high. At low injection mass flow rate (0.05 kg/s), the shrinkage improved with melt temperature. Shrinkage was 1 - 10% when melt temperature was 220ºC and shrinkage was 0 - 4.5% when melt temperature used was 240ºC. One-way interaction approach simulation for mold cavity-II was compared with physical result obtained from experimental study. Both simulation and the physical results showed almost the same flow speed, temperature and thickness. Recorded experimental flow speed was 0.05 - 0.1 s faster than the simulation. The average recorded temperature obtained from the experimental result was about 9ºC higher than the simulation. Simulation over predicted the plastic product of mold cavity-II shrinkage by 1 - 4.8%. Taguchi method and analysis of variance (ANOVA) were used to optimize the processing parameter for minimum shrinkage of mold cavity-II product. According to the statistical result, melt temperature, mold cooling time and injection speed were the significant factors. Due to the small dimension of the injection gate, the material in this region cooled down and solidified very fast to the extent that the applied packing pressure and packing time had no significant effect on adding material into the cavity to reduce product shrinkage during packing phase. As a result, these two parameters were not significant according to Taguchi and ANOVA analysis. 2012-06-14 Thesis NonPeerReviewed application/pdf http://studentsrepo.um.edu.my/8327/5/FINITE_ELEMENT_ANALYSIS_AND_EXPERIMENTAL_VERIFICATION_OF_POLYMER_MELT_TEMPERATURE_AND_PRODUCT_SHRINKAGE_IN_INJECTION_MOLDING.pdf Gan, Teck Wan (2012) Finite element analysis and experiemental verification of polymer melt temperature and product shrinkage in injection molding / Gan Teck Wan. Masters thesis, University of Malaya. http://studentsrepo.um.edu.my/8327/
score 13.211869

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