Molding simulation : theory and practice / Maw-Ling Wang, Rong-Yeu Chang, and Chia-Hsiang Hsu.

Format:

Book

Author/Creator:

Wang, Maw-Ling, author.

Chang, Rong-Yeu, author.

Hsu, Chia-Hsiang (David), author.

Language:

English

Subjects (All):

Injection molding of plastics--Data processing.

Injection molding of plastics.

Molding (Chemical technology).

Plastics--Molds--Computer-aided design.

Plastics.

Physical Description:

1 online resource (622 pages)

Edition:

2nd ed.

Place of Publication:

Munich : Hanser Publishers, [2022]

Summary:

This practical introductory guide to injection molding simulation is aimed at both practicing engineers and students. It will help the reader to innovate and improve part design and molding processes, essential for efficient manufacturing. A user-friendly, case-study-based approach is applied, enhanced by many illustrations in full color.

Contents:

Intro

Acknowledgments

Preface

Contents

1 Overview of Plastics Molding

Che-Ping (Barton) Lin

1.1 Introduction to Injection Molding

1.1.1 The Systems of Injection Molding

1.1.1.1 The Cycle of Injection Molding

1.1.1.2 Injection Machine

1.1.2 Defects in Injection Molded Products

1.1.2.1 Short Shot

1.1.2.2 Warp

1.1.2.3 Flash

1.1.2.4 Sink Mark and Void

1.1.2.5 Air Trap

1.1.2.6 Burn Mark

1.1.2.7 Delamination

1.1.2.8 Fish Eye

1.1.2.9 Flow Mark

1.1.2.10 Stress Mark

1.1.2.11 Hesitation

1.1.2.12 Jetting

1.1.2.13 Splay

1.1.2.14 Weld Line

1.2 Core Values of Molding Simulation

1.2.1 Application of CAE Technology in Injection Molding

2 Material Properties of Plastics

Chen-Chieh (Jye) Wang

2.1 Overview

2.2 Rheological Properties

2.2.1 Viscosity

2.2.1.1 Effects of Non-Newtonian and Molecular Conformation

2.2.1.2 Effects of Shear Rate

2.2.1.3 Effects of Temperature

2.2.1.4 Effects of Pressure

2.2.1.5 Theoretical Models

2.2.1.6 Viscosity Properties of Plastics

2.2.2 Viscoelastic Fluids

2.2.2.1 Viscoelastic Behavior

2.2.2.2 Theoretical Models

2.2.2.3 Measurement of Viscoelasticity

2.3 Thermodynamic and Thermal Properties

2.3.1 Specific Heat Capacity

2.3.2 Melting Point and Glass Transition Temperatures

2.3.3 PVT Equation of State

2.3.3.1 Definition

2.3.3.2 Data Interpretation

2.3.3.3 Theoretical Models

2.3.3.4 Effects of Non-Equilibrium State on PVT

2.3.4 Thermal Conductivity and Heat Transfer Coefficient

2.3.4.1 Definition

2.3.4.2 Theoretical Models

2.3.4.3 Data Interpretation

2.3.4.4 Mold-Melt Contact and Heat Transfer Coefficient (HTC)

2.4 Mechanical Properties

2.4.1 Stress and Strain of Plastics

2.4.2 Solid-Like Viscoelasticity

2.4.3 Theoretical Model

2.4.4 Data Interpretation.

2.5 Kinetic Properties

2.5.1 Crystalline

2.5.2 Theoretical Models

2.5.3 Effects of Cooling Rate on Crystallization

2.6 Curing Kinetics

2.6.1 Curing Phenomenon

2.6.2 Theoretical Models

2.6.3 Curing Effect on Viscosity

2.6.4 Data Interpretation

3 Part and Mold Design

Tsai-Hsin (Sam) Hsieh, Yao-Chen (Cloud) Tsai, Yao-Wei (Willie) Chuang

3.1 Part Design

3.1.1 Golden Rule: Uniform Wall Thickness

3.1.2 Wall Thickness versus Flow Length

3.1.3 Radius/Fillets and Chamfer Angle

3.1.4 Rib and Boss

3.1.5 Draft Angle

3.1.6 Design for Manufacturing (DFM)

3.1.7 Summary

3.2 Mold Design

3.2.1 Basics

3.2.2 Gate Design

3.2.2.1 Gate Number

3.2.2.2 Gate Location

3.2.2.3 Gate Types

3.2.3 Runner Design

3.2.3.1 Runner Shape and Dimension

3.2.3.2 Multi-Cavity Runner Design

3.2.4 Cooling Design

3.2.5 Others

3.2.5.1 Ejector System

3.2.5.2 Venting Design

4 Process Conditions

Chuan-Wei (Arvid) Chang

4.1 Introduction to the Injection Molding Cycle

4.1.1 Brief Introduction to Injection Molding Machine Units

4.1.2 Injection Molding Cycle

4.1.3 Molding Window

4.1.4 PVT Variations during Injection Stages

4.2 Plasticizing Conditions

4.2.1 Nozzle Temperature and Cylinder Temperatures

4.2.2 Back Pressure, Screw rpm, Suck Back, and Metering Stroke

4.3 Filling Conditions

4.3.1 Filling Time versus Injection Velocity

4.3.2 Injection Pressure

4.3.3 VP Switch

4.4 Packing Conditions

4.5 Cooling Conditions

4.5.1 Cooling Time

4.5.2 Coolant Flow Rate

4.5.3 Mold Temperature

4.6 Connecting Smart Design to Smart Manufacturing

4.6.1 Machine Characterization

4.6.2 The CAE Setting Mode in Combination with Injection Machine on Site

4.6.3 Case Study

5 Molding Simulation Methodology

Hsien-Sen (Ethan) Chiu.

5.1 The Goal of Molding Simulation

5.1.1 Design Verification and Optimization

5.1.1.1 Overview of Design for Manufacture (DFM)

5.1.1.2 CAE and DFM: A Practical Case Study

5.1.2 Process Conditions Optimization

5.1.2.1 Molding Stability

5.1.2.2 Real Case

5.2 Basics of Simulation Equations

5.2.1 Governing Equations

5.2.2 Numerical Approximation

5.2.2.1 Finite Difference Method (FDM)

5.2.2.2 Finite Volume Method (FVM)

5.2.2.3 Finite Element Method (FEM)

5.3 What Is Molding Simulation

5.3.1 Brief History of Molding Simulation

5.3.2 Simulation Workflow

6 Flow Consideration versus Part Features

Wen-Hsin (Debbie) Weng

6.1 Basics

6.1.1 Flow Behavior of Plastic Melt in the Cavity

6.1.2 Effects of Filling Time

6.1.3 Flow Rate versus Injection Pressure

6.1.3.1 Flow Rate Curve Setting

6.1.3.2 Relationship of Injection Rate and Injection Pressure

6.1.4 VP Switch and Cavity Pressure

6.1.5 Effects of Part Thickness

6.1.6 Material Viscosity an Flow Behaviour

6.1.7 Summary

6.2 Practical Applications

6.2.1 CAE Solution to Stress Mark in a Phone Shell

6.2.2 Flow Rate Effect on Injection Pressure of Laptop Product

6.3 CAE Case Study

7 Runner and Gate Design

Yao-Chen (Cloud) Tsai, Yao-Wei (Willie) Chuang

7.1 Basics

7.1.1 General Design Guide of Runners

7.1.2 General Design Guide of Gates

7.1.3 Gate Sealing

7.1.4 Flow Balance

7.2 Practical Applications

7.2.1 CAE Verification on MeltFlipper Design

7.2.2 CAE Verification of Multi-Cavity Systems

7.3 CAE Case Study

8 Cooling Optimization

Hung-Chou (Kent) Wang

8.1 Basics

8.1.1 Heat Transfer Mechanism

8.1.2 Design Golden Rule: Uniform Mold Temperature

8.1.3 General Design Guide of Cooling Channel

8.1.4 Cooling Efficiency: Coolant Flow Consideration

8.1.5 Cooling Time Estimate.

8.1.6 Use CAE Cooling Analysis

8.1.7 Conformal Cooling Application

8.2 Practical Applications

8.2.1 Digital Camera Cover

8.2.2 Cartridge

8.3 CAE Case Study

9 Warpage Control

Shih-Po (Tober) Sun, Wen-Hsin (Debbie) Weng

9.1 Basics

9.1.1 The Causes of Warpage

9.1.2 Material Effects

9.1.3 Geometrical Effects

9.1.4 Process Condition Effects

9.1.5 Criteria of CAE Warp Analysis

9.1.6 Methods to Minimize Warpage

9.2 Practical Applications

9.3 CAE Case Study

10 Fiber Orientation Control

Huan-Chang (Ivor) Tseng

10.1 Basics

10.1.1 Process Principle

10.1.2 Theory Models

10.1.3 Advantages and Challenges

10.2 Practical Applications

10.2.1 Using the iARD-RPR Model for an Injection Molded Center-Gated Disk with Fiber-Reinforced Thermoplastics

10.2.2 Comparison of iARD-RPR Models under GNF Decoupling and IISO Coupling

10.2.3 The Influences of Material Flow and Fiber Interaction on Fiber Orientation and Product Quality during Injection Molding

10.3 CAE Case Study

11 Hot Runner Optimization

Tsai-Hsin (Sam) Hsieh

11.1 Basics

11.1.1 Process Principle

11.1.2 Temperature Control in a Hot Runner System

11.1.3 Advantages and Challenges

11.2 Practical Applications

11.2.1 CAE Verification on a Single-Gate Hot Runner System

11.2.2 CAE Pin Movement Control of Valve Gate

11.3 CAE Case Study

12 Co-/Bi-Injection Molding

Chih-Chung (Jim) Hsu, Yu-Sheng (Tim) Chou

12.1 Basics

12.1.1 Process Principle

12.1.2 Advantages and Challenges

12.1.3 Theory Models

12.2 Practical Applications

12.2.1 Co-Injection Molding of Fork Model

12.2.2 Co-Injection Molding: Core Breakthrough and Flow Imbalance

12.2.3 Co-Injection Molding: Fiber Orientation Predictions

12.2.4 CAE Case of Bi-Injection Molding

12.3 CAE Case Study.

13 Gas-/Water-Assisted Injection Molding

13.1 Basics

13.1.1 Process Principle

13.1.1.1 Short-Shot Process

13.1.1.2 Full-Shot Process

13.1.2 Advantages and Challenges

13.2 Practical Applications

13.2.1 CAE Verification on GAIM

13.2.2 CAE Verification on WAIM

13.2.3 CAE Verification on GAIM: Fingering Effect

13.3 CAE Case Study

14 Foam Injection Molding

Yuan-Jung (Dan) Chang, Li-Yang (Robert) Chang, Chih-Wei (Joe) Wang

14.1 Basics

14.1.1 Microcellular Process Principle

14.1.2 Advantages and Challenges

14.1.3 Theory Models

14.2 Practical Applications

14.2.1 CAE Verification on Microcellular Injection Molding: Case 1

14.2.2 CAE Verification of Microcellular Injection Molding: Case 2

14.2.3 CAE Verification on Chemical Foaming Injection Molding

14.2.4 CAE Verification of Polyurethane Reactive Foaming Molding

14.2.5 Summary

14.3 CAE Case Study

15 Powder Injection Molding

15.1 Basics

15.1.1 Process Principle

15.1.2 Advantages and Challenges

15.1.3 Theory Models

15.2 Practical Applications

15.3 CAE Case Study

16 Resin Transfer Molding

Hsun (Fred) Yang, Yu-He (Zoe) Chen

16.1 Basics

16.1.1 Process Principle

16.1.2 Advantages and Challenges

16.2 Theory Models

16.2.1 2.5D Analysis

16.2.2 3D Analysis

16.2.3 Measurement of Permeability

16.2.4 Porosity

16.2.5 Measurement of Chemorheological Properties

16.2.6 Simulation Parameters

16.3 Practical Applications

16.3.1 CAE Verification on Edge Effects

16.3.2 CAE Verification on Thickness-Direction Flow

16.3.3 CAE Verification on a Wind Turbine Blade

16.3.4 CAE Verification on Mat Effects

16.3.5 CAE Verification on Flybridge

16.4 CAE Case Study

17 Integrated Circuit Packaging.

Chih-Chung (Jim) Hsu, Chia-Peng (Victor) Sun, Chen-An (Jennan) Wang, Yu-En (Joseph) Liang.

Notes:

Description based on print version record.

Other Format:

Print version: Wang, Maw-Ling Molding Simulation: Theory and Practice

ISBN:

1-56990-885-0