Characteristics analysis and mold design for ultrasonic-assisted injection molding
-
Yi-Jen Yang
,
Chung-Ching Huang
Abstract
This study investigated the use of ultrasonic technology in assisted injection molding (AIM) and mold design. An ultrasonic device installed in a mold was employed to vibrate a melt, thereby converting kinetic energy into thermal energy. This method enabled maintaining the desired temperature in the melt flow, preventing a high level of shear and the formation of a thick frozen layer surrounding the skin layer; thus, the injection molding efficiency was enhanced and the residual stress inside the injection-molded component was reduced. In this study, a flat sample (75 mm×47 mm×1 mm) of an ultrasonic-assisted injection mold was developed. An ultrasonic oscillation device 45 mm in diameter was placed in the center of the cavity and used to vibrate a polycarbonate melt at a frequency of 20 KHz. In addition, cavity pressure sensors were positioned at the front and rear of the vibration region to analyze the melt flow behavior under ultrasonic-AIM (UAIM) conditions. The results showed that ultrasonic oscillations can reduce the amount of melt pressure lost through the cavity. The pressure loss of the flat sample used in UAIM was approximately 29% lower than that of the sample used in conventional injection molding (CIM; nonultrasonic-assisted injection); the power of UAIM did not yield substantial effects. Direct ultrasonic oscillations destroyed the melt flow and thermal stresses, therefore, the region exhibited a low stress distribution. Compared with using CIM, using UAIM reduced the average residual stress by 27%. Ultrasonic oscillation affected the surface roughness during melt solidification. When the ultrasonic power was <70%, no substantial increase in surface roughness was observed; however, when the ultrasonic power >70%, the surface roughness was 10 times higher compared with that observed using CIM.
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©2014 by De Gruyter
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Artikel in diesem Heft
- Frontmatter
- Editorial
- Editorial improvements at the Journal of Polymer Engineering
- Original articles
- Cationic copolymerization of 1,3-pentadiene with α-pinene
- In vitro degradation of polyglycolic acid synthesized by a one-step reaction
- Synthesis of a novel class of mixed-type surfmers and their properties in water
- Unique viscosity mutation of multi-generation hyperbranched waterborne polyurethane
- Preparation and characterization of oxidized starch-graft-poly(styrene-butyl acrylate) latex via emulsion polymerization
- Peroxide vulcanization of natural rubber. Part I: effect of temperature and peroxide concentration
- The stimuli-response characters of hydrogels prepared using ultrasound
- A new conductometric biosensor based on horseradish peroxidase immobilized on chitosan and chitosan/gold nanoparticle films
- A new approach for the development of textile waste cotton reinforced composites (T-FRP): laminated hybridization vs. coupling agents
- Effects of the surface treatment of wollastonite on the tensile and flow properties for reinforced polypropylene composites
- Effect of the quenching temperature on the mechanical and thermophysical properties of polycarbonate pigmented with titanium dioxide
- Processing and characterization of poly(lactic acid) blended with polycarbonate and chain extender
- Characteristics analysis and mold design for ultrasonic-assisted injection molding
