Influence of injection molding parameters on the morphology, mechanical and surface properties of ABS foams

Analysis and Validation of Varied Simulation Parameters in the Context of Thermoplastic Foams and Special Injection Molding Processes

The simulation solutions of different plastic injection molding processes are as multifaceted as the field of injection molding itself. In this study, the simulation of a special injection molding process, which generates partially foamed integral components, was parameterized and performed. This partial and physical foaming is realized by a defined volume expansion of the mold cavity. Using the injection molding simulation software Moldex 3D, this so-called Pull and Foam process was digitally reconstructed and simulated. Since the Pull and Foam process is a special injection molding technique for producing foamed components, the validity of the simulation results was analyzed and evaluated. With the use of Moldex 3D, varied settings such as different bubble growth models and mesh topologies were set, parameterized, and then analyzed, to provide differentiated numerical calculation solutions. Actual manufactured components represent the experimental part of this study and are produced for reference. Different evaluation methods were used to quantify morphological quantities such as porosities, local densities, and cell distributions. These methods are based on two-dimensional and three-dimensional imaging techniques such as optical microscopy and X-ray microtomography (µ-CT). Thus, this structural characterization of the manufactured samples serves as the validation basis for the calculated results of the simulations. According to the illustrated results, the adequate selection of bubble growth models and especially mesh topologies must be considered for valid simulation of specific core-back techniques, such as the Pull and Foam injection molding process.

Modelling and Simulation of MuCell®: The Effect of Key Processing Parameters on Cell Size and Weight Reduction

Microcellular injection moulding is an important injection moulding technique to create foaming plastic parts. However, there are no consistent conclusions on the impact of processing parameters on the cell morphology of microcellular injection moulded parts. This paper investigates the influence of the main processing parameters, such as melt temperature, mould temperature, injection pressure, flow rate, shot volume and gas dosage amount, on the average cell size and weight reduction of a talc-reinforced polypropylene square part (165 mm × 165 mm × 3.2 mm), using the commercial software Moldex 3D. The effect of each parameter is investigated considering a range of values and the simulation results were compared with published experimental results. The differences between numerical and experimental trends are discussed.

A Review on Microcellular Injection Moulding

Microcellular injection moulding (MuCell^®) is a polymer processing technology that uses a supercritical fluid inert gas, CO₂ or N₂, to produce light-weight products. Due to environmental pressures and the requirement of light-weight parts with good mechanical properties, this technology recently gained significant attention. However, poor surface appearance and limited mechanical properties still prevent the wide applications of this technique. This paper reviews the microcellular injection moulding process, main characteristics of the process, bubble nucleation and growth, and major recent developments in the field. Strategies to improve both the surface quality and mechanical properties are discussed in detail as well as the relationships between processing parameters, morphology, and surface and mechanical properties. Modelling approaches to simulate microcellular injection moulding and the mathematical models behind Moldex 3D and Moldflow, the two most commonly used software tools by industry and academia, are reviewed, and the main limitations are highlighted. Finally, future research perspectives to further develop this technology are also discussed.

A Design of Experiment Approach for Surface Roughness Comparisons of Foam Injection-Moulding Methods

The pursuit of polymer parts produced through foam injection moulding (FIM) that have a comparable surface roughness to conventionally processed components are of major relevance to expand the application of FIM. Within this study, 22% talc-filled copolymer polypropylene (PP) parts were produced through FIM using both a physical and chemical blowing agent. A design of experiments (DoE) was performed whereby the processing parameters of mould temperatures, injection speeds, back-pressure, melt temperature and holding time were varied to determine their effect on surface roughness, Young’s modulus and tensile strength. The results showed that mechanical performance can be improved when processing with higher mould temperatures and longer holding times. Also, it was observed that when utilising chemical foaming agents (CBA) at low-pressure, surface roughness comparable to that obtained from conventionally processed components can be achieved. This research demonstrates the potential of FIM to expand to applications whereby weight saving can be achieved without introducing surface defects, which has previously been witnessed within FIM.

Advances in Polymer Technology Application of Pareto-Based Genetic Algorithm in Determining Layout of Heating Rods for a Plastic Injection Mold

The Pareto-based genetic algorithm is an effective way to solve complex optimization design problems in engineering. In this study, first, the principles of Pareto optimal solutions and multiobjective genetic algorithm were presented. Second, to investigate the influence of the mold temperature on the products’ performances, a multicavity experiment injection mold was designed whose temperature could be controlled by the heating rods. To obtain a homogeneous temperature distribution across the multicavity surfaces after the heating stage, multiobjective optimization models for the heating rods layout were established based on the heat transfer process of the mold. Finally, the Pareto-based genetic algorithm and finite element method were combined to solve the optimized models to obtain the optimal solution. After a finite element analysis and experimental injection, it is proved that the optimized distribution of the heating rods in the mold is necessary for the experiment and production.

Five-Axis Tool Path Generation of Injection Mold Represented by T-Spline Surface

Injection molding is widely used in industries to produce polymeric products. At present, compound NURBS surfaces are commonly used to represent freeform surfaces in mold models. This work uses T-spline surface with extraordinary control points instead of NURBS to represent freeform surfaces in mold models. Compared with NURBS, T-splines’ higher-order continuity facilitates the mold quality control especially at the patch boundary. And, its patch layout information can be utilized for tool path planning. We propose an algorithm to determine the patch processing order and generate nonretraction tool path for T-spline surface models. The tool paths are generated patch by patch using isoparametric strategy. Actual machining and injection molding experiments have been conducted. The result shows the feasibility of the proposed method, and the final product is in good quality.