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DESIGN PROCESS
FEEDING SYSTEM (Sprue, Runner, Gates) COOLING SYSTEM (Channel, Coolant, Temp) EJECTION SYSTEM (Pins, Stroke, Actuation)
Mold Types
Different types of molds:
(a) the cold-runner two-plate mold (b) the cold-runner three-plate mold (c) the hot-runner mold (d) the insulated hot-runner mold (e) the hot-manifold mold ( f ) the stacked mold.
Parting Lines
UNDERCUT
Multiple-Cavity MOLDS
Melt
Insulated
Internally Heated
Externally Heated
G(g)
500 400
300
200
S=1 1.5 3 3.5 2 2.5
100 0
4 4.5
Gate Effects
Melt front progression during injection molding of the part. The part is one of the two covers for a 3.5 inch computer floppy disk. The illustration shows the melt front just before the cavity is filled. Before the availability of molding CAE, the short shot was the molding engineers favorite diagnostic tool.
MOLDFLOW RESULTS
Air traps
Weld lines
Orientation at skin
Fill time
MOLDFLOW RESULTS
MOLDFLOW RESULTS
Temperature at flow front
Fill time
Air traps
FILLING SIMULATION
Mold-Cooling Design
Differing temperatures on opposite sides of the mold causes the part to be concave towards the hot side
Cooling Design
How Cooling Time Affects Cycle Time How Wall Thickness Impacts Cooling Time Considerations for a Good Cooling Design
Proper Cooling
Poor Cooling
Part temperature distribution at ejection shows that initial cooling system does not provide even cooling of the part.
Volumetric shrinkage distribution across the molded part at the time of ejection.
Walls close to the intersection of the rib and the base structure are warmer than other areas. Shrinkage will be higher there.
Cooling line layout with manifolds. The flow rate in each cross channel is different, ranging from 4 liters per second at the channel closest to the inlet and outlet, to half that for the channel farthest from the inlet.
Fiber Orientation
Tensile stress/strain behavior of a 30% carbon fiber reinforced polycarbonate parallel and perpendicular to the flow direction.
Gate Positions
Warpage
differential shrinkage on a
flat fiber-filled part that is center-gated
Warpage Tendency
Warpage from the central gate, with the reference plane changes to the nodes at one end
Warpage predicted for the center gated radiator end cap. The upper left window shows the model. The upper right widow shows the warpage referenced to a plane defined by the user to be near the end of the cap. The lower right shows the shrinkage in the X-axis direction due to differential area shrinkage. The lower left window shows the shrinkage from orientation.
Center gate flow directions as the melt front passes each element. These can be correlated with the fiber orientation.
Resulting flow directions and fiber orientation for a part with an end gate
Melt front temperature from a mold filling simulation, showing effects of the melt hesitating in the thin region.
Figure 10.10:
Finite element mesh of the part, automatically generated from CAD solids model.
Volumetric shrinkage distribution demonstrates potential different shrinkage that can cause stresses between different regions of the part. Red areas represent regions of high shrinkage; cooler colors represent regions of lower shrinkage.
Distribution of process-induced shrinkage of the molded part. Process-induced warpage includes the effects of both non-uniform shrinkage and uneven cooling of the cavity faces.
Pressure distribution at the end of the packing phase shows over packing near the gate. This will also result in lower volumetric shrinkage in this area. Since the time is at the end of the packing phase, pressure at these points indicate a residual pressure that time.
Fiber orientation on the skin of a molded part. The short lines follow the direction of fiber or molecular orientation on the surface of the part. This layer is oriented by shear stresses between the layers of the plastic as the cavity is filling. As the plastic touches the cold cavity wall, it is frozen with the orientation effects in place.
Comparing a mold filling simulation to an actual filling pattern in an 8-cavity mold. The error in the simulation results from the use of simplified 1D beams, which are standard with most of todays state of the art injection molding simulation programs.
Hybrid Composites
Hybrid composite materials, incorporating both fiber and flake reinforcements, have mold shrinkage values that tend to be more isotropic than conventional fiber-reinforced polymers
SIMULATION
Mold Flow
simulated model
Fill Time
FILLING SIMULATION
Fiber Effects
Comparison between flow and crossflow shrinkage and the effect of fiber type on shrinkage
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