Abstract
The mathematical model of the polymer plasticization in the reciprocating screw injection moulding machine is presented in this paper. Methods of calculation of the most important flow characteristics, such as the solid bed profile, the pressure and temperature profiles, the mass flow rate, the power demand, the screw torque and the energy consumption were analysed. According to the mathematical model, a computer program was developed. Based on the computer program, simulation studies of the injection moulding process were conducted. Thereafter, the experimental studies, evaluating the theoretical model from the accuracy and usefulness point of view, were carried out. Important output quantities, such as the temperature and pressure profiles, the power demand by the screw, the torque on the screw and the screw rotation time were measured. The studies were performed on a specially made research office. The simulation results were compared with the experimental data measured for the most popular polymers and different operating parameters of the injection machine. The experimental studies have indicated the need to introduce some corrections to the mathematical model. Several modifications have been made to the model, mainly related to the methods of stress determining in the polymer layer. Finally, the output characteristics of the plasticization process in the injection moulding are now correctly determined by the model with an average error less than 10%.
Highlights
One of the main factors that minimizes the production costs is the optimal choice of the processing equipment and processing conditions
The mathematical model of the plasticization process in the injection moulding predicts values of of the following characteristics: the following characteristics: (a). the pressure profile of the polymer in the screw channel, (a) the pressure profile of the polymer in the screw channel, (b). the temperature profile of the polymer in the screw channel, (b)(c).the of the polymer in the screw channel, thetemperature profile of theprofile solid polymer bed width in the screw channel, (c)(d).the profile of the solid polymer bed width in the screw channel, the power demanded by the screw in the plasticizing system, (d)(e).the by the screw in the plasticizing system, thepower torquedemanded on the screw, (f)
The paper presents the comprehensive model of the plasticization process during the injection moulding
Summary
One of the main factors that minimizes the production costs is the optimal choice of the processing equipment and processing conditions. The theoretical approach has been having the increasing importance It relies on using mathematical models for the plasticization process on the basis of the law of mass, momentum and energy conservation and the characteristics of a material. The models join the output characteristics of the plasticization process, such as pressure and temperature distribution, throughput, power demand and so forth, with the geometry of the plasticizing system, the adjustable process parameters and the material data, allowing thereby the optimization of the equipment design [1]. Many models can be found in the literature They describe, in less or more complex way, the plasticization of polymers in single-screw extruders. These models commonly use similar principles but differ in detailed assumptions. The extruder is divided into three main functional zones—the zone of solid
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