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Conference Proceedings

Core-Shell Rubber Modified Microcellular Polymide-6 Composite
Andreas Winardi, Mingjun Yuan, Shaoqin (Sarah) Gong, Lih-Sheng Turng, May 2004

This paper presents the effects of processing parameters and sub-micron core-shell rubber particle filler on the mechanical properties and cell morphology of microcellular injection molded polyamide-6 (PA-6) composites. Three types of materials were studied, namely, neat PA-6 resin, and 0.5% and 3.1% core-shell rubber polybutylacrylate-polymethylmethacrylate filled PA-6 composites. This study showed that the addition of a small amount (0.5%) of core-shell rubber particles improved the ductility and impact strength of microcellular injection molded PA-6 samples. In comparison to the microcellular injection molded PA-6 polymer-clay nanocomposite, the samples with a small amount (0.5%) of core-shell rubber had much higher impact strength and ductility. The small addition of core-shell rubber also reduced cell size and increased cell density of the microcellular injection molded PA-6 parts, in comparison to their neat resin counterparts. On the other hand, at higher core-shell rubber loading, the cell size and density were found to be similar to that of the neat resin.

Crystallization Behavior of Polyamide 6 Micocellular Nanocomposites
Mingjun Yuan, Lih-Sheng Turng, Shaoqin Gong, Andreas Winardi, Daniel Caulfield, May 2004

The crystallization behaviors of polyamide-6 and its nanocomposites undergoing the microcellular injection molding process were studied using Transmission Electron Microscopy (TEM), X-ray Diffractometer (XRD), Polarized Optical Microscopy (POM), and Differential Scanning Calorimetry (DSC). The relationships among the morphology, the mechanical property of the molded parts, and the crystallization behavior were investigated. With the addition of nanoclays in microcellular injection molded parts, the growth of ? form crystal is suppressed and the formation of ? form crystals is promoted. Both nanoclay and dissolved gas have big influence on PA-6 crystalline structures. The existence of nanoclay increases the crystallization rate. But with extra addition of nanoclays in the polymer matrix, the crystallization rate is reduced. Nanocomposites with proper amount of nanoclays posses the maximum crystallization activation energy and produce finer and denser microcell structure which leads to better mechanical properties.

The Investigation of Flow Behavior of Polymeric Melts in the Water Assisted Injection Molding
R-Y. Chang, C-T. Huang, W-H. Yang, M-H. Tsai, K-I. Lu, S-J. Liu, May 2004

Water assisted injection molding (WAIM) is a pretty new way to fabricate hollow or more complicated parts. Basically, the process of WAIM is similar to gas assisted molding. If it is controlled correctly, WAIM can yield thinner, more uniform part walls. However, to obtain better products, a number of questions, regarding to the material properties and process conditions, need to be fully understood. In this study, the complex flow behavior of melts under the assistance of injected water is conducted by examining the coupling effects of the process conditions and the material properties numerically. Further, the verification is performed experimentally as well.

Fluid Assisted Polymer Processing in Extrusion and Injection Moulding: A Comparative Overview
L. Mulvaney-Johnson, M. Woodhead, M. Rose, A. Dawson, T.D. Gough, P.D. Coates, G.F. Smith, V. Goodship, Rui Magalhaes, Rob Hansell, May 2004

A programme of research is described to compare gas, cryogenically cooled gas, water and super-critical carbon dioxide assisted polymer processing. Results indicate apparent reductions in melt viscosity are possible by adding super critical carbon dioxide. The issues associated with implementing water assisted injection moulding are highlighted. Reductions in residual wall thickness are possible in the gas assisted injection moulding process when cryogenically cooled gas is used over the conventional implementation.

A New Technique of Super Critical CO2-Asisted Surface Coating Injection Molding
Masahiro Ohshima, May 2004

A brand-new technique of injection molding using supercritical CO2 is proposed so as to modify the surface of the solidified plastic products. The principle of the CO2-asisted surface coating injection-molding techniques is described in this paper. The technique utilizes the plasticization effect of CO2 on polymer, solubility of low molecular substance in super critical CO2 and diffusion mechanism of CO2/low molecule mixture into the surface of injected polymer. To confirm the principles, experiments using dye pigment as a low molecular solute is conducted. The experimental results of CO2-asisted surface coating injection-molding techniques are given at the end.

Three-Dimensional Simulation of Transient Temperature Distribution for Lens Mold Embedded with Heaters
Shia-Chung Chen, Shiu-Wu Chau, Ming-Cheng Lin, Yu-Wan Lin, May 2004

To avoid cost computation, the traditional simulation of mold temperature during the injection molding is usually conducted in a cycle-averaged approach plus one-dimensional transient variation. Boundary element method is frequent adopted as the major numerical scheme. In the present study, fully 3-D simulations of mold temperature variation based on both standard FEM in single CPU and VOF implemented in parallel computation scheme were executed for a lens mold embedded with heaters. Mold surface temperature distribution was measured by infrared thermal image system from which the temperature variations at interest locations can be obtained. Within steady state molding cycle, the predicted mold surface temperatures show a difference of 8° (cavity center), 6° (parting surface), and 18° (core cavity) after mold opening and part ejection. All simulations show quite precise predictions in accordance with experimental results.

A New Method for Simulation of Injection Molding
H. Yu, C. Kietzmann, P. Cook, S. Xu, F. Costa, Peter Kennedy, May 2004

Simulation of injection molding originally used the so-called Hele-Shaw approximation in which the part is represented as a mesh of triangles, located at the midplane of the component, each of which has a defined thickness. The time required to create appropriate models for this type of analysis increased with the rapid acceptance of 3D solid geometry modeling. Several approaches to reduce the time to create a model have been introduced and include automatic midplane determination, dual domain finite element analysis (2.5D) and true 3D analysis. Each of these approaches ignores the fact that a given injection molded part often comprises a variety of regions some of which are better analyzed with 2.5D analysis while other regions require 3D analysis. In this paper we introduce a new type of simulation which automatically decomposes a 3D model into 2D and 3D regions. The appropriate analysis type is then used. The approach shows improved accuracy over 2.5D analysis yet is more efficient than full 3D analysis.

Computational Prediction of PVC Degradation during Injection Molding Radial Flow
Liyong Yu, Jose L. Garcia, Guojun Xu, Kurt W. Koelling, James W. Summers, May 2004

Polyvinyl chloride (PVC) materials have been widely used because of their excellent weather ability, chemical resistance, and flame retardant properties. However, polymer degradation may occur, especially in high shear injection molding processes. A computational model has been developed to calculate the degradation of PVC during injection molding of discs. The effects of the injection speed, melt temperature, shot sizes, and material properties were examined. It was found that the injection speed is the most important factor influencing PVC degradation. Furthermore, the computational and experimental results were compared. The model could be used to help design the process to avoid degradation.

Numerical Simulation for Modeling Non-Isothermal Cell Growth in Microcellular Injection Molding
Andres Osorio, Lih-Sheng Turng, May 2004

This paper presents the mathematical modeling and numerical simulation of non-isothermal cell growth during the post-filling stage of microcellular injection molding. The model combines two numerical techniques, namely, finite-volume method to solve the transient heat transfer based on the equation of energy and finite-difference method to solve the continuity and momentum equations for the pressure field and the diffusion equation for the concentration of dissolved gas within the polymer-gas solution. The unit-cell" model employed in this study takes into account the effect of injection and packing pressures melt and mold temperatures and variable material properties for the polymer-gas solution. The numerical results in terms of cell size across the sprue diameter agree fairly well with the experimental data for microcellular injection molded polyamide 6 samples."

Prediction of Cooling Time in Injection Molding by a Simplified Semi-Analytical Equation
Dimitrios M. Zarkadas, Marinos Xanthos, May 2004

A semi-analytical equation, used successfully in food freezing/chilling time prediction, is proposed as a potential simple alternative for cooling time prediction in injection molding of polymer parts, amorphous or semi-crystalline. This equation is based on a convective boundary condition for the mold-part interface and requires information on the thermal contact resistance (TCR) at this interface. By incorporating a literature based heat balance method in the proposed equation, it is possible to use it as a standalone predictor of polymer cooling time. Its performance was tested against data generated with C-MOLD™ for four polymers, Polystyrene (PS), Polycarbonate (PC), Polypropylene (PP), and Polyethylene (PE). The % mean error and its SD calculated this way were respectively – 9.44 and 0.97 for PS, -9.44 and 0.83 for PC, -14.22 and 5 for PP and –20.12 and 1.38 for PE. The proposed equation can be used successfully to predict the cooling time of the selected semi-crystalline or amorphous polymers with the accuracy being higher for amorphous polymers and practically independent of the precise knowledge of the TCR, provided the latter is smaller than 0.001 m2K/W.

Shear Effects and Dimensional Stability in Injection Molding
C.A. Silva, J.C. Viana, A.M. Cunha, May 2004

A special mould (RCEM) was used to impose a controlled shear action on polypropylene molded discs. This was obtained by superimposing an external rotation to the pressure driven advancing flow front, during the molding filling stage. The resulting shear rate and stress were computed using a non-isothermal model that combines the simple and rotation shear components.The results evidence the importance of the magnitude and of the homogeneity of the imposed shear field on the material structure development and on the dimensional stability of the obtained moldings. This was evaluated quantitatively by the total shear stress level along the flow length and by the distortion angle for different rotating speeds.

Fabrication and Mechanical Properties of Textile Insert Injection Moldings
Tatsuro Fukui, Miyako Inoda, Asami Nakai, Hiroyuki Hamada, May 2004

In this study, in order to extend one-unity composites to injection molding field, textile insert injection molding was developed. Knitted fabric was chosen as reinforcement configuration, which is one of the textile configurations. PE/PE one-unity composites were prepared inserting knitted polyethylene (PE) fiber as reinforcement and PE was injected as matrix by using injection and injection-compression molding process. Tensile properties of PE/PE one-unity knitted composites were investigated. From these results, it was found that the tensile properties were dependent on resin impregnation state into fiber bundles. Tensile properties of injection-compression specimens were higher than that of injection specimens.

Effect of Material Velocities and Temperatures on the Morphology and Flexural Properties of Sandwich Parts: Statistical Study
D. Ait Messaoud, B. Sanschagrin, A. Derdouri, May 2004

Co-injection molding (or sandwich molding) is a process in which two or more dissimilar polymers are injected sequentially or simultaneously in a mold. Using a virgin polymer with a good surface aspect for the skin and fiber reinforced polymer for the core, one can obtain interesting final properties.In this study a statistical analysis of the relationship between processing parameters and final properties of co-injected molded plaques has been performed applying experimental design concepts. The plaques were co-injected with a virgin polypropylene (PP) as skin and a 40 % short glass fiber reinforced polypropylene (PP40) as core. Four co-injection molding parameters (independent variables), skin and core injection velocity and skin and core temperature were varied in two levels. Flexural tests and skin/core ratio measurements (dependent variables) were carried out on samples to investigate the effect of processing parameters. It has been found that the skin injection velocity has the most significant effect on the skin thickness distribution and on the mechanical properties studied.

Materials Distribution and Mechanical Properties of Incompatible Bi-Material Monosandwich Injection Moldings
J.C. Viana, N.G. Nikolay, D.B. Tchalamov, A.M. Cunha, May 2004

Rectangular plates were injection molded in two incompatible materials (polypropylene, PP, as the outer material and high density polyethylene, HDPE, in the core) by the monosandwich technique. The molding program included variations of the injection flow rate, the two materials ratio, and both melt temperatures, accordingly to a L8 Taguchi orthogonal array. The effect of processing on the materials distribution was analyzed, namely for common defects, such as incomplete molding, finger-like and break-through anomalies. The microstructure of the moldings was observed by polarized light microscopy, and the material ratio assessed. The mechanical behavior of the specimens was assessed at 50 mm/min and 23 °C. The experimental results were analyzed by ANOVA statistical tool, being identified the main processing parameters, their percentage of contribution and their effects on the materials distribution and molding mechanical properties.

Processing Characteristics of PSU/PC Blend Associated with Degradation in Injection Molding
Byung Hak Lee, May 2004

This study investigates the effect of degradation of the PSU/PC blend (SMA-8™) on quality characteristics of the molded parts. Experiments were conducted at two sets of melt temperatures - ‘normal’ temperature, where no severe degradation is expected (T-zone 1); and ‘elevated’ temperature, where significant degradation should occur (T-zone 2). ASTM D638 tensile bars were used for molding and measured for quality parameters of part weight, warpage, and tensile strength. Small fluctuations in the process variables were purposely introduced for Tzone 1 and T-zone 2. As the results, T-zone 1 provided more consistent shot-to-shot part properties and less process disturbances for all the parameters than T-zone 2. The subsequent baking of the molded parts rendered most of the parts excessively warped for T-zone 2. Back pressure was an important variable regarding shot-to-shot variations in all the parameters.

Advances in Injection Molding Process / Quality Control
Zhongbao Chen, Lih-Sheng Turng, May 2004

Injection molding process/quality control has been an active research area for many years, especially when part quality requirement is becoming more stringent due to increasing applications of plastics. This paper reviews the state-of-the-art research and developments in injection molding control. It has been found that all the prior studies can be organized into a multiple-level structure system, which consists of one feedforward loop (process setup) and three feedback loops (machine control, process control, and quality control). The three feedback loops are cascaded so that the output from the previous controller becomes the command to the next controller. Numerous variables, models, and control methods have been proposed and employed for different levels of control. However, the real on-line quality control without human's intervention has not been realized primarily due to lack of thorough understanding of the relationship among machine, process, and quality variables and lack of transducers for on-line quality measurement. Based on the research progress to date, it has been concluded that process/quality model and quality sensors are the two most important areas for further advancement in injection molding control.

Evaluation of Weldline Strength of Injection Molded Polystyrene by Surface Milling
Kohji Yamada, Kiyotaka Tomari, Toshihiko Harada, Hiroyuki Hamada, May 2004

Weldline strength of injection-molded polystyrene was evaluated using surface-milled specimens. The surface including a V-notch on an adjacent flow weldline occurring behind an obstructive pin was mechanically milled off and its tensile strength was measured. The strengths of specimens milled 1/5 of the thickness off from each surface were almost the same independent of the distance from the pin. On the other hand, the strengths of specimens without milling decreased once and then increased along the flow direction. It demonstrated that the strength of weldline was dependent on the properties of the surface layer of weldline influenced by stress concentration effect of V-notch and effect of flow stagnation at the area near the pin. The size of the surface layer could be evaluated by the variation of milling depth. The tensile strength increased with an increase of milling depth up to an intrinsic value and hence increased little despite the specimen was milled off deeper. It demonstrated that there was an area in which the bonding of the resin was insufficient at the weldline interface below the V-notch. The depth of the area was ten times larger than the V-notch depth at the area near the pin and decreased along the flow direction.

Mechanical Properties of Weldline in Injection Molded PC/ABS
Koji Yamada, Satoko Baba, Susumu Takashima, Hiroyuki Hamada, Machiko Mizoguchi, Takashi Kuriyama, May 2004

Relationship between morphology and mechanical properties of weldline in injection-molded PC/ABS blend was investigated by testing specimens sliced along the flow direction. The diameter of ABS particles at the weldline decreased along the direction from the center to the surface of the specimen. The most outside slice showed the lowest strength among all the slices due to stress concentration effect by surface v-notch. In contrast, the adjacent one exhibited the highest strength among all, then the strength decreased gradually toward the center. Thus, the decrease of the diameter of ABS particles coincided with the increase of the strength of the weldline.

The Effect of Processing Factors on Weld Lines in Injection Moulded Nylon 6 Nanocomposites
J. Tung, G.P. Simon, G.H. Edward, May 2004

The effect of process factors on weld lines of nylon 6 nanocomposites was investigated. Eight process factors were evaluated: injection pressure, holding pressure, holding time, back pressure, screw rotational speed, cooling time, melt and mould temperatures. A modified L16 orthogonal array of the Taguchi method with three levels was designed to run injection moulding experiments using a smaller number of samples to determine the most influential parameters. The experimental results were analysed by sensitivity test signal-to-noise (S/N) ratio and analysis of variance (ANOVA). The results show that the principal process factors for single end-gated tensile samples are different to those of double end-gated samples when the weld line occurs. The important process factors of the single end-gated samples are injection pressure and mould temperature, whilst for the double end-gated samples are mould temperature and melt temperature. The temperature factor plays an important role in processing to heal the weld strength by promoting the ability of polymer molecules to diffuse across the weld line boundary, enhancing interfacial strength at the weld region.

Internal Structure of PC/ABS Injection-Compression Moldings
Hiroyuki Hamada, Kengo Nodo, Susumu Takashima, Satoko Baba, Machiko Mizoguchi, Takashi Kuriyama, Kiyotaka Tomari, May 2004

The internal structures of injection-compression moldings were observed by using PC/ABS blends. Two different filling ratios of injected material were chosen. The internal structure at core had changed from round shape to very fine elongated shape due to additional melt flow during the compression process. This change of structure was strictly dependent on the additional flow. Therefore, in order to make similar internal structure through thickness direction, some amount of flow was needed especially at the core region.

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