Factors determining the flow erosion/part deformation of film insert molded thermoplastic products
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Demei Lee
Abstract
Flow erosion and part deformation are unsolved molding problems that restrict the overall success of film insert molding. This work investigated, both experimentally and numerically, the factors that affect flow erosion and part deformation in film inset molded products. Three plate-with-thickness-variation geometries, namely flat, thin-to-thick, and thick-to thin, were molded for the products. Polystyrene films and polyethylene terephthalate (PET) resins were employed in the experiments. It was found that the thin-to-thick specimens exhibited the most severe flow erosion. Increasing the injection pressure or melt temperature worsened flow erosion. Meanwhile, for the processing parameters adopted in the experiments, part deformation generally increased with melt temperature and hold time, while it decreased with injection pressure and hold pressure. Additionally, a numerical software (Moldex® 3-D) was employed to simulate the temperature and shear stress distributions in molded products. The calculated results suggested that part deformation in insert molded products results mainly from the non-uniform temperature profile during the cooling stage, owing to the product configuration and the insert film, while flow erosion is induced by the high shear stress of the polymer melt in the filling stage.
Funding source: Ministry of Science and Technology, Taiwan
Award Identifier / Grant number: 111-2221-E-182-005-MY2
Funding source: Chang Gung Memorial Hospital
Award Identifier / Grant number: CMRPD2M0011
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Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
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Research funding: This work was sponsored by the Ministry of Science and Technology, Taiwan (Contract No. 111-2221-E-182-005-MY2), and Chang Gung Memorial Hospital (Contract No. CMRPD2M0011).
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Conflicts of interest: The authors declare no conflict of interest.
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Articles in the same Issue
- Frontmatter
- Editorial
- Special issue for John Vlachopoulos
- Review Article
- Calendering of thermoplastics: models and computations
- Special Issue Contributions
- Film casting of polycarbonate/multi-walled carbon nanotubes composites using ultrasound-assisted twin-screw extruder: experiment and simulation
- Effect of mixing conditions and polymer particle size on the properties of polypropylene/graphite nanoplatelets micromoldings
- Extrusion foaming of linear and branched polypropylenes – input of the thermomechanical analysis of pressure drop in the die
- Improving the thickness distribution of parts with hybrid thermoforming
- Synergistic material extrusion 3D-printing using core–shell filaments containing polycarbonate-based material with different glass transition temperatures and viscosities
- TPU-based porous heterostructures by combined techniques
- Surfactant-free oil-in-oil emulsion-templating of polyimide aerogel foams
- Factors determining the flow erosion/part deformation of film insert molded thermoplastic products
- The extrusion of EPDM using an external gear pump: experiments and simulations
- News
- PPS News
