Design Sensitivity Analysis Applied to Injection Molding for Optimization of Gate Location and Injection Pressure
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K. K. Kabanemi
Abstract
In this work, we develop a numerical simulation method to optimize the injection molding process using the design sensitivity analysis (DSA). The optimization concerns the filling stage and focuses on the location of gates in the mold cavity as well as the injection pressure profile, in order to minimize the fill time. Since the problem to be solved involves transient flow with free surface (flow front), the direct differentiation method is used to evaluate the sensitivities of the Hele-Shaw, filling fraction and energy equations with respect to the design variables used in the analysis. The search domain parameterization is coped with using B-spline functions. Sensitivity and state equations are solved by means of finite element method. The proposed numerical approach is combined with the sequential linear and quadratic programming method of the design optimization tools (DOT) to find new design variables at the end of each complete filling simulation. Starting from any initial gate locations and injection pressure profile, the iterative optimization procedure enables us to find the optimal gate locations together with the optimal injection pressure profile. Finally, numerical results involving complex mold geometries are presented and discussed to assess the validity and robustness of the proposed method.
© 2002, Carl Hanser Verlag, Munich
Articles in the same Issue
- Editorial
- Touchstones of Polymer Processing
- Twin Screw Extrusion and Compounding
- Residence Time Distribution Curves of Screw Elements in Twin-Srew Extruder
- Rheological Effect of Zinc Surfactant on the TESPT-Silica Mixture in NR and S-SBR Compounds
- Optimization of Processing Conditions for Polymer Twin-Screw Extrusion
- Fibers and Film
- The Prediction of Sharkskin Instability Observed during Film Blowing
- Tensile Strength Characteristics of Polymer Melts
- Biaxially Oriented PP Films Using the Double Bubble Process
- Fiber and Film
- Crystallization and Orientation Development in Melt Spinning Isotactic PP of Varying Tacticity
- Extrusion Coating
- Extrusion Coating with Metallocene-Catalysed Polyethylenes
- Injection Molding
- Design Sensitivity Analysis Applied to Injection Molding for Optimization of Gate Location and Injection Pressure
- Three-dimensional Numerical Modeling of Co-injection Molding
- Residual Stress and Warpage Models for Complex Injection Molded Parts
- Blow Molding
- Investigation of Design Parameters and Novel Design of Petaloid PET Bottles
Articles in the same Issue
- Editorial
- Touchstones of Polymer Processing
- Twin Screw Extrusion and Compounding
- Residence Time Distribution Curves of Screw Elements in Twin-Srew Extruder
- Rheological Effect of Zinc Surfactant on the TESPT-Silica Mixture in NR and S-SBR Compounds
- Optimization of Processing Conditions for Polymer Twin-Screw Extrusion
- Fibers and Film
- The Prediction of Sharkskin Instability Observed during Film Blowing
- Tensile Strength Characteristics of Polymer Melts
- Biaxially Oriented PP Films Using the Double Bubble Process
- Fiber and Film
- Crystallization and Orientation Development in Melt Spinning Isotactic PP of Varying Tacticity
- Extrusion Coating
- Extrusion Coating with Metallocene-Catalysed Polyethylenes
- Injection Molding
- Design Sensitivity Analysis Applied to Injection Molding for Optimization of Gate Location and Injection Pressure
- Three-dimensional Numerical Modeling of Co-injection Molding
- Residual Stress and Warpage Models for Complex Injection Molded Parts
- Blow Molding
- Investigation of Design Parameters and Novel Design of Petaloid PET Bottles
