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Design Sensitivity Analysis for the Optimization of the Injection Molding Process

  • F. Ilinca , J.-F. Hétu and D. Pelletier
Published/Copyright: April 30, 2013
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International Polymer Processing
From the journal International Polymer Processing Volume 20 Issue 1

Abstract

This paper presents an application of the Continuous Sensitivity Equation Method (CSEM) for the optimization of the injection molding process and its three-dimensional (3D) simulation by the finite element method. Finding the proper combination of process parameters such as injection speed, and melt and mold temperatures is critical to achieving a part that minimizes warpage and has the desired mechanical properties. Very often a successful design in injection molding comes at the end of a long trial and error process. Design Sensitivity Analysis (DSA) can help manufacturers improve their designs and can produce substantial savings in terms of both time and money. This work explores the ability of sensitivity analysis to predict the effects of design parameters on the performance of an injection molding process. The paper presents results of a 3D finite element solution of the filling stage of the injection molding process. Sensitivities of the solution with respect to different process parameters are computed using the continuous sensitivity equation method. Solutions are shown for the non-isothermal filling of a rectangular plate with a polymer melt behaving as a non-Newtonian fluid. The paper presents the equations for the sensitivity of the velocity, pressure and temperature and their solution by a finite element method. Sensitivities of the solution with respect to the injection speed, the melt and mold temperatures and to the heat transfer coefficient at the cavity/mold interface are shown.

∗ Mail address: F. Ilinca, Industrial Materials Inst., National Research Council, 75, de Mortagne, Boucherville, Québec, Canada, J4B 6Y4 E-mail:

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Received: 2004-11-3
Accepted: 2004-12-22
Published Online: 2013-04-30
Published in Print: 2005-03-01

© 2005, Carl Hanser Verlag, Munich

Articles in the same Issue

  1. Contents
  2. Contents
  3. Editorial
  4. New at International Polymer Processing
  5. Regular Contributed Articles
  6. Preparing of Homogeneous Solution of Ultrahigh Molecular Weight PAN
  7. Non-linear Viscoelastic Behavior of PVC Plastisol
  8. Algorithms for Two Gate Optimization in Injection Molding
  9. Viscoelastic Properties of Flexible Organic Fiber Composites
  10. Mold for Manipulation Microstructure Development
  11. Simultaneous Biaxial Stretching of PP Resins of Varying Tacticity
  12. Rotational Moulding of PVC Plastisol
  13. Drawability of As-spun PP Fibres
  14. Melt Fracture of Linear PE
  15. Investigation of the Cooling Jets Used in the Blown Film Process
  16. Non-linear Crystalline Spherulitic Growth Behavior for LLDPE
  17. Design Sensitivity Analysis for the Optimization of the Injection Molding Process
  18. Preparation and Characteristics of Reactive Blends of Phosphate-containing Maleimide and Epoxy
  19. Easy Tear Multilayer Film of Biaxially Oriented PA6/MXD6 by Double Bubble Tubular Film Process
  20. PPS News
  21. PPS News
  22. Seikei-Kakou Abstracts
  23. Seikei-Kakou Abstracts
https://doi.org/10.3139/217.1864

Articles in the same Issue

  1. Contents
  2. Contents
  3. Editorial
  4. New at International Polymer Processing
  5. Regular Contributed Articles
  6. Preparing of Homogeneous Solution of Ultrahigh Molecular Weight PAN
  7. Non-linear Viscoelastic Behavior of PVC Plastisol
  8. Algorithms for Two Gate Optimization in Injection Molding
  9. Viscoelastic Properties of Flexible Organic Fiber Composites
  10. Mold for Manipulation Microstructure Development
  11. Simultaneous Biaxial Stretching of PP Resins of Varying Tacticity
  12. Rotational Moulding of PVC Plastisol
  13. Drawability of As-spun PP Fibres
  14. Melt Fracture of Linear PE
  15. Investigation of the Cooling Jets Used in the Blown Film Process
  16. Non-linear Crystalline Spherulitic Growth Behavior for LLDPE
  17. Design Sensitivity Analysis for the Optimization of the Injection Molding Process
  18. Preparation and Characteristics of Reactive Blends of Phosphate-containing Maleimide and Epoxy
  19. Easy Tear Multilayer Film of Biaxially Oriented PA6/MXD6 by Double Bubble Tubular Film Process
  20. PPS News
  21. PPS News
  22. Seikei-Kakou Abstracts
  23. Seikei-Kakou Abstracts
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