Feasibility Study of the Flatness of a Plastic Injection Molded Pallet by a Newly Proposed Sequential Valve Gate System

Filling-Balance-Oriented Parameters for Multi-Cavity Molds in Polyvinyl Chloride Injection Molding

PVC injection molding has constrained temperature and shear rate owing to its temperature sensitivity and high viscosity, as well as its low conductivity. Many challenges are associated with the PVC injection molding process used for producing PVC fittings with a multi-cavity mold. Once filling imbalance occurs, the gates and/or runner of the mold should be changed by machine tools, which is time- and cost-intensive. Using Moldex3D and the Taguchi method, this study reveals an approach to eliminate imbalanced filling of multi-cavity molds for PVC injection molding. The injection rate optimization of the filling stage is successfully verified to reduce the imbalance. Furthermore, the temperatures of the molded PVC fittings are only slightly increased by the change in injection rate. The temperatures of fittings in the filling and packing are lower than the degradation temperature of PVC. This approach may help technicians to obtain pilot-run samples for the optimization of molding parameters and ensure degradation-free PVC molding.

A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection Molding

Many challenges are associated with the injection molding process for forming a rib-structured pallet (1100 mm × 1100 mm × 140 mm, length × width × height) because greater flowing resistance through the rib channels within the pallet can induce insufficient filling. Essentially, multi-gate filling involves a sequential valve gate system, which helps to spread the filling front with fewer weld lines. Based on the presetting of the sequential scheme of the valve gates, actual measurements of pallet flatness using the ATOS scan system were compared to numerical warpage measurements of a pallet derived by Moldex3D 2020. In this study, we propose a sequential scheme by actuating the valve gates to open once the flow front spreads towards them; then, actual warpage measurements of a pallet are compared with numerical measurements. The results show that the warpage of the top surface of the pallet is 5.144 mm in actual measurements and 5.729 mm in simulation. The results all indicated small warpage with respect to the pallet size. The simulation and actual measurements of flatness are in excellent agreement; the difference in top flatness between the simulated and actual pallet is 0.59 mm, while the bottom flatness difference is 0.035 mm. By adjusting the cooling water temperature, increasing the mold temperature, and decreasing the material temperature, overall flatness and warpage displacement can be reduced.

Investigation of the Warpage of a High-Density Polyethylene Pallet by Plastic Injection Compression Molding: Part I—Numerical Approach

Many challenges are associated with the injection compression molding process for producing a half-pallet (1320 mm × 1110 mm × 75 mm, length × width × height), which is butt-welded to another one for enhancing its strength. This pooled high-density polyethylene (HDPE) pallet is able to endure the impacts of a heavy load and a low ambient temperature. Reducing the warpage of a half-pallet is, therefore, essential for reducing the residual internal stress within the welded portions. An advanced Moldex3D package helps to detail the temperature distribution and warpage of a half-pallet. The pre-setting molding parameters from a mass-production factory produce half-pallets with worse flatness. In this investigation on using appropriate cooling water temperatures within the core and cavity plates of the mold, the numerical results show that the warpage of the top surface of the half-pallet was 11.549 mm, low warpage with respect to this large-scale pallet. Furthermore, the compression speed of 50–60 mm/s may have produced a low flatness of the half-pallet in this study.