Cooling Process Window Development for Injection Molding
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B. Xie
Abstract
The great impact of the injection molding cooling process on both productivity and product quality makes it essential to optimize the cooling conditions as well as the cooling system design. The current practice in injection molding process development, to identify the final operating conditions, which is a time consuming iteration between model design and product line, is costly in both material and time. This defect in the process development also raises the necessity to establish a method, which can provide the manufacturer not only with an optimum but also with a window around the optimum for the operating conditions, so as to avoid this time with consuming process to determine the feasible operating conditions. This paper presents a methodology, which combines an optimization algorithm with a mold cooling analysis, to obtain an optimal cooling processing condition and a cooling window in the injection molding of plastics as an aid for mold designing and manufacturing. The cooling effect, which is characterized through uniform cooling and short cooling time, is quantified in terms of mold cooling simulation output. A mathematical model is then formulated based on semi-empirical criteria and solved numerically by implementing an optimization algorithm. Based upon the resultant final optimum cooling condition, a relaxation scheme scheme is developed by the authors and performed, followed by a sensitivity analysis to determine the cooling window. At last, the application of this method is demonstrated by two industrial molds: a drilling housing and a compact drill battery pack. This approach will help in designing a proper cooling system for a mold and in determining an operating range to achieve better part quality and higher productivity.
© 1995, Carl Hanser Verlag, Munich
Articles in the same Issue
- Contents
- Contents
- Editorial
- Sixteenth in a Series: Berstorff: Pioneer of Calenders and Screw Extruders
- Screw Extrusion/Continuous Mixing
- A Throughput Model for Grooved Bush Extruders
- Modeling of Polymer Devolatilization in a Multi-vent Screw Extruder
- Models of Flow and Experimental Studies on a Modular List/Buss Kokneter
- A Study of Distributive Mixing in Counterrotating Twin Screw Extruders
- Stress Controlled Simultaneous On-line Measurements of Viscosity, Flow Exponent, and Melt Index
- Film
- Microporous Film, Made from β-Crystalline Phase Polypropylene
- Analyses of Bowing Phenomena in Successive Transverse Stretching and Thermosetting Process for Biaxially Oriented Film
- Molding
- Comparative Wide-angle X-ray and Microscopical Studies on the Layered Structure in Injection Molded Polypropylene Disks
- Cooling Process Window Development for Injection Molding
- Modeling and Finite Element Analysis of Flow in SMC Compression Molding
- Reactive Processing
- Tool Heat Transfer Analysis in Resin Transfer Molding
Articles in the same Issue
- Contents
- Contents
- Editorial
- Sixteenth in a Series: Berstorff: Pioneer of Calenders and Screw Extruders
- Screw Extrusion/Continuous Mixing
- A Throughput Model for Grooved Bush Extruders
- Modeling of Polymer Devolatilization in a Multi-vent Screw Extruder
- Models of Flow and Experimental Studies on a Modular List/Buss Kokneter
- A Study of Distributive Mixing in Counterrotating Twin Screw Extruders
- Stress Controlled Simultaneous On-line Measurements of Viscosity, Flow Exponent, and Melt Index
- Film
- Microporous Film, Made from β-Crystalline Phase Polypropylene
- Analyses of Bowing Phenomena in Successive Transverse Stretching and Thermosetting Process for Biaxially Oriented Film
- Molding
- Comparative Wide-angle X-ray and Microscopical Studies on the Layered Structure in Injection Molded Polypropylene Disks
- Cooling Process Window Development for Injection Molding
- Modeling and Finite Element Analysis of Flow in SMC Compression Molding
- Reactive Processing
- Tool Heat Transfer Analysis in Resin Transfer Molding
