Injection Mold Design Research Articles

Simultaneously enhancing the flow properties and mechanical strength of polyphenylene sulfide via in‐mold ultrasonic‐assisted injection molding

AbstractInjection molding is widely used for making intricate plastic products due to its precision, cost efficiency, and fast production. Industries like consumer electronics, aerospace, and medical, demand high mechanical properties from these parts. However, high‐performance polymers face challenges in flowability. Ultrasonic‐assisted injection molding offers a solution, but its impact on flowability and mechanical properties is not fully understood. We propose a novel injection mold design with in‐mold ultrasonic vibration to address this. By applying high‐frequency shear forces to the melt, it alters polymer chain alignment, enhancing flow and microstructure. Employing polyphenylene sulfide (PPS) resin as the primary material, this study systematically explores the impact of varying ultrasonic vibration durations and stages on melt filling behavior and product performance. Compared with conventional molds, ultrasonic‐assisted molds reduce melt viscosity by 38% and improve mechanical properties by 10.21%, with a 17.1% increase in crystallinity. This technology shows promise for improving flowability and mechanical properties in injection molding, with potential for wide industrial application.

Design and Analysis of Plastic Injection Mold for Hexagon Socket Head Cap Screw

Plastic is a majorly used material for making customer goods. It is appealing to customers as well as manufacturers. Properties like durability, light weight and moldability make it a suitable choice for consumer goods which are made by mass production. Plastic materials are soft, but they possess adequate strength to be utilized for different engineering applications. After the development of various grades of plastic, it has replaced metals from different engineering applications in the recent past. This article aims at analyzing the suitability of making Hexagon Socket Head Cap Screws (HSHCS) out of a plastic material by injection molding processes. These screws are widely used as threaded fasteners at different places. They are preferably made of ferrous metals and possess semi complex design. They are mass produced by following a series of manufacturing operations. This article will observe the manufacturability of HSHCS by injection molding process. Based on the observation a model mold will be prepared to make HSHCS. The software used for modeling the parts is Autodesk Fusion 360 and that for the simulation of process parameters is Autodesk Moldflow Adviser 2023. Index Terms: Hexagon Socket Head Cap Screws, plastic mold, manufacturability, threaded fasteners, injection molding, simulation.

Development and Validation of a 1D Dynamic Model of an Injection Moulding Process and Design of a Model-Based Nozzle Pressure Controller.

A 1D model describing the dynamics of an injection moulding machine and the injection process is presented. The model describes an injection cylinder actuated by a dual-pump electro-hydraulic speed-variable drive and the filling, holding and cooling phases of the injection moulding process utilising amorphous polymers. The model is suggested as the foundation for the design of model-based pressure controllers of, e.g., the nozzle pressure. The focus is on using material, mould and machine properties to construct the model, making it possible to analyse and design the dynamic system prior to manufacturing hardware or conducting experiments. Both the presented model and the developed controller show good agreement with experimental results. The proposed method is general in nature and enables the design, analysis and evaluation of the machine, material and mould dynamics for controller design based solely on the physical properties of the system.

Enhancing Complex Injection Mold Design Validation Using Multicombined RV Environments

Enhancing Complex Injection Mold Design Validation Using Multicombined RV Environments

Methodology of a thermal injection mold design with locally applied heating coatings on the cavity wall

AbstractThe thermal balance of injection molds is defined by the cooling channel layout. However, the fluid tempering of injection molds underlies certain restrictions concerning the thermal dynamic and the local limitation of the zone of influence. The optimal heat balance within the mold to minimize warpage cannot be solely achieved with conformal cooling channels. Ceramic heating coating systems applied by Thermal Spraying on the cavity wall are a novel tempering method for high heating rates and offer the possibility of a more local heat input. In terms of the thermal mold design, the position and size of local heating coating systems need to be determined. A methodology is proposed, which connects the optimization of part warpage by defining the necessary local heat flux within the mold with the determination of the heating coating placement. Due to the dependence of the coating placement on the heating time and the power, different decision criteria of these parameters are discussed with regard to the process efficiency. The developed methodology can calculate the necessary heating power distribution to homogenize the surface temperature and freeze time. A second step discretizes the heating power distribution to certain manufacturable heating zones.

A seamless CAD/CAM integration approach for venting system generation in injection mold design

A seamless CAD/CAM integration approach for venting system generation in injection mold design

Analysis of Plastic Injection Mold Design and Cooling System

Plastik malzeme, otomotivden beyaz eşyaya, kırtasiye malzemelerinden oyuncaklara, mutfak eşyalarından ofis malzemelerine kadar her sektörde yerini almıştır. Plastik enjeksiyon yöntemi, plastik parça üretiminde en çok kullanılan imalat yöntemidir. Üretimi talep edilen plastik malzemeler için, plastik enjeksiyon kalıpları tasarlanmaktadır. Bu kalıplar tasarlanırken, ilk aşamada ürün tasarımı göz önüne alınır. Üretime uygun, kısa sürede ve kaliteli bir imalat yapmak için en önemli faktör tasarlanan ürünün, üretilebilir olmasıdır.
 Bu çalışmada plastik bir kırtasiye-oyuncak sektörü diyebileceğimiz bir sulu boya paletinin ürün tasarımı ve kalıp tasarımı aşama aşama incelenecektir. Ürün, kalıplamaya uygun hale getirilip, kalıp tasarımı gerçekleştirilmiştir. Tasarımı biten ürün, daha üretimi yapılmadan yolluk ve soğutma sistemlerinde karşımıza çıkabilecek olası hataları gözlemlenmiştir. Yapılan analize göre yolluk giriş yerinin en iyi ürün merkezinden olacağı ama maliyeti arttırdığı tespit edilip soğuk yolluk sistemi kullanılarak bir tasarım gerçekleştirilmiştir. Hava birikecek yerler tespit edilmiştir, bu bölgelere hava çıkışını sağlayacak cepler kullanılması önerilmiştir. Soğutma kalitesiyle ilgili yapılan analiz ile ürünün et kalınlığının homojen olduğu ve erken donma ihtimalinin düşük olduğu tespit edilmiştir. Bu yüzden et kalınlığına müdahale edilmesine gerek görülmemiştir.

Mechanical Characterization and Corrosion Behavior of Magnesium/Boron Carbide Composites

“Product Design & Injection Mold Design Development of Car Chassis Upper Cover Part” This project fully concentrated on how to design of double impression injection Mold for wheel hub for the car sing the least economic processing and tooling method and it also helps to get the very deep knowledge about the “Split Activation Method”. Finally, the aim of the project is to estimation of the mold which should most economic and also detail about mention above things. It is all the transcendence of human race that people today reach the height of maximum, luxury upgrading from the days of their very ancient stone and cave age. What human being has achieved today was once only a dream out of reach. But man’s curiosity perhaps the most wonderful gift given to man by God was behind his quest leading to wholehearted efforts to convert all impossible dreams of yesteryears into reality. Today in the 21st century, men have reason enough to be proud for their unique achievements from stepping into the moon to cloning genes; there has been long list of tremendous success. Designing of product and mold for plastics is one of the important achievements in this century. This project is our sincere effort for the design of Bottom inlet valve components and their molds. This component has good aesthetics and optimum production cost which helps in withstanding the market competition.

Plastics Product & Injection Mold Design Development of Car Chassis Upper Cover

“Product Design & Injection Mold Design Development of Car Chassis Upper Cover Part” This project fully concentrated on how to design of double impression injection Mold for wheel hub for the car sing the least economic processing and tooling method and it also helps to get the very deep knowledge about the “Split Activation Method”. Finally, the aim of the project is to estimation of the mold which should most economic and also detail about mention above things. It is all the transcendence of human race that people today reach the height of maximum, luxury upgrading from the days of their very ancient stone and cave age. What human being has achieved today was once only a dream out of reach. But man’s curiosity perhaps the most wonderful gift given to man by God was behind his quest leading to wholehearted efforts to convert all impossible dreams of yesteryears into reality. Today in the 21st century, men have reason enough to be proud for their unique achievements from stepping into the moon to cloning genes; there has been long list of tremendous success. Designing of product and mold for plastics is one of the important achievements in this century. This project is our sincere effort for the design of Bottom inlet valve components and their molds. This component has good aesthetics and optimum production cost which helps in withstanding the market competition

Design of Injection Mould for Lithium Battery Heat Dissipation Device Connector Bottom Cover

The design process of the injection mould for the Lithium battery heat dissipation device connector bottom cover is described in detail. In the design process, the UG software is used to establish the three-dimensional model of the plastic part, and the mould flow analysis is carried out with the help of the moldflow software to determine the optimal gate position of the plastic part. By determining the injection process parameters of Lithium battery heat dissipation device connector bottom cover material, the design of the cavity layout of the plastic part is completed, and the basic size and mould structure of the mould base are determined. Then, the UG injection mould design guide module was used to carry out the parting design, and the structural design of the mould’s gating system, molding parts, lateral parting mechanism, core-pulling mechanism, ejection mechanism, exhaust system and cooling system was completed in turn. The whole design process improved the efficiency of mould design and saved a lot of time and cost.

A novel approach for automatic venting system generation on complex surfaces in injection mold design

A novel approach for automatic venting system generation on complex surfaces in injection mold design

Mold Design and Analysis for Multi-Component Plastic Injection Parts with Contrasting Functional Features: Case Study

The classical plastic injection method is based on the principle of injecting a single color of a single polymeric material into the mold cavity under high pressure. In cases where the products are expected to have contrasted functional features and different colors, the classic injection process and the conventional injection molds are not sufficient. This paper proposes a new design approach for multi-component injection molds required by products containing different polymeric materials or different colors of the same polymeric material at the same time. It also presents a case study including the design of the hot runner, electromechanical rotary-cross, cooling, and ejection systems of a two-component, eight-cavity toothbrush mold. The polymeric materials are polypropylene for the first component, and styrene based thermoplastic elastomer for the second component, which exhibit good bonding properties with each other. In addition, an analysis study covering the filling parameters and production defect generations is also provided. The adopted design approach provides a production rate of 1600 parts per hour, corresponding to 18 s cycle time and 200 cycles per hour, and makes it sufficient to rotate only the 80 kg core plate instead of 1120 kg entire core side. Compared to existing methods, the results show that the proposed multi-component injection mold design method eliminates the need for particular injection machines and robotic systems, shortens the cycle time, and reduces energy consumption.

Research on the Injection Mold Design and Molding Process Parameter Optimization of a Car Door Inner Panel

Numerical simulation of the injection molding of the inner panel of the car door and the optimization of its process parameters were completed. The inner panel and its injection mold were designed by UG software and simulated by the filling and cooling module of the Moldflow software. Different gate schemes were selected to compare quality indicators such as filling time, air pockets, and weld lines to obtain the optimal number of gates. We established the objective function model with gate position as the independent variable, and used a multi-population genetic algorithm to solve the optimal position of the function model to get the best gate position. The mold temperature, melt temperature, cooling time, holding pressure, and holding time were selected as the influencing factors, and volume shrinkage and warpage deformation were selected as the evaluation indicators to design and complete the orthogonal test. The test data were simulated by Moldflow, and the optimal combination of process parameters was determined by range and variance analysis. The BP neural network model related to the molding process parameters, volume shrinkage, and warpage deformation was built, and the trained network model was optimized with the ant colony algorithm. The optimal parameter combination was: mold temperature 76 ° C , melt temperature 205 ° C , cooling time 23.8s, holding pressure 54.7Mpa, and holding time 22.1s. The simulation results showed that volume shrinkage was 13.32% and warpage deformation was 4.315 mm. The design of an injection mold for the car door inner panel was completed and its molding process parameters were optimized.

Design of an Automobile Injection Mould Based on Automation Technology

At present, there are frequent occurrences in the industry of manufacturers only having products, but they have no product data, resulting in manufacturers unable to open molds to produce the products themselves and can only buy them at high prices. This article takes the rear case of an automobile generator produced by a company as an example, which aims to show the design of automobile injection molds through automation technology. This paper studies the use of automation technology to achieve the automatic model reconstruction of products, and uses the CAD technology to design injection molds based on the obtained digital models of products. This paper also uses the CAE technology to verify the feasibility and rationality of the designed mold, exploring the optimization method of the injection molding process of the mold. In this paper, a special product pouring system and demolding mechanism are designed according to the product process requirements. The design greatly simplifies the mold structure while fulfilling the product process requirements, which avoids the use of expensive hot runners and complex flip-chip mold structures, reducing the mold manufacturing cost. Secondly, the overall design of the injection mold is carried out, and the external dimensions and other main parameters of the mold are determined. Then, Moldflow software is used to simulate the injection molding process, verifying the feasibility and rationality of the designed mold. The optimization method of the injection molding process is also proposed, and the optimal injection process parameters are determined to ensure that the mold can produce qualified products and ensure high production efficiency. It can be seen from the analysis results that the maximum warpage deformation of the plastic part under all effects is 0.65 mm, which meets the product process requirements.

Design and Fabrication of Injection Molds to Manufacture Double Channel Laryngoscope for Effective Airway Management: Taguchi Method for Surface Roughness Optimization

The present work focuses on the mold design and production of the multifunctional device laryngoscope with surface quality through the injection molding process. A laryngoscope is a device used by anesthesiologists to lift the tongue that facilitates to fix the air pipe in the larynx. Demand still exists in the laryngoscope part to assist anesthesiologists to take care of the airway without causing chest compression and ensure visualization of vocal cords. Therefore, the present work aims at developing a laryngoscope with a double channeled device, wherein one for aligning the camera and another for the air pipe. The paper outlines the design parameters required for manufacturing a single cavity mold to produce a laryngoscope viz. injection molding machine. The mold has multiple plates with complex fluid channels which ensures effective thermal management in-mold system. The mold is manufactured using high-strength tool steel materials and the product laryngoscope (ABS: Acrylonitrile butadiene styrene) is fabricated from the designed mold. Taguchi L9 experimental array was used to determine the optimal conditions (injection pressure, injection velocity, mold and melt temperature) for desired surface finish in the laryngoscope parts. The designed mold and optimized injection molding conditions resulted in a lower surface roughness value equal to 0.214 µm. Thereby, injection-molded laryngoscope parts can be used for large-scale productions for the benefit of medical applications.

A Study on Injection Mold Design Using Topology Optimization

A Study on Injection Mold Design Using Topology Optimization

Properties of Liquid Crystal Injection Mouldings

Abstract The suitability of liquid crystal polymers for the injection moulding process was pointed out at the time of their discovery. However, up to now, it has been assumed that the unmodified liquid crystal polymers were less suited to processing by injection moulding due to their distinct anisotropies. The direction of developments in the application of liquid crystal polymers was done mainly in another direction. We, however, have been concerned for more than four years now with this subject [3, 4, 5], even when our practical experiments could not be as comprehensive as we would wish, due to the limited availability of the raw materials. We have also been able to use this time to develop CAE programs which support the constructor in the design of injection moulds, whereby these programs enable the flow process to be simulated and therefore enabling the orientation to be seen at every point in the injection moulded part [6]. This is naturally particularly important for those materials in which the orientation of the molecules plays such a large part for the respective properties, as these are caused by the direction of the flows in the flow process. A changed runner position causes other orientations. More details should therefore be reported about our investigations to date.

A Review on Machine Learning Models in Injection Molding Machines

One of the most suitable methods for the mass production of complicated shapes is injection molding due to its superior production rate and quality. The key to producing higher quality products in injection molding is proper injection speed, pressure, and mold design. Conventional methods relying on the operator’s expertise and defect detection techniques are ineffective in reducing defects. Hence, there is a need for more close control over these operating parameters using various machine learning techniques. Neural networks have considerable applications in the injection molding process consisting of optimization, prediction, identification, classification, controlling, modeling, and monitoring, particularly in manufacturing. In recent research, many critical issues in applying machine learning and neural network in injection molding in practical have been addressed. Some problems include data division, collection, and preprocessing steps, such as considering the inputs, networks, and outputs, algorithms used, models utilized for testing and training, and performance criteria set during validation and verification. This review briefly explains working on machine learning and artificial neural network and optimizing injection molding in industries.

ANALYSIS OF THE TEMPERATURE FIELD IN A MOLD CAVITY FOR POLYMER INJECTION PROCESS

A common situation in the design of injection molds is to achieve an efficient performance in terms of heat transfer, this will allow a higher production rate with better finished parts [1]. One of the most important factors in the design is the cooling time: about 80% of the processing time is determined by it [2]. Seeking to contribute with the increase of productivity, this work presents results of simulations through the finite volume method (MVF) of the injection molding process; those results are compared with an analysis of design of experiments (DOE) with different injection conditions, revealing the study variables that are fundamental to improve the process. Thus, a statistical analysis and a computer simulation analysis are presented to identify the variables inherent to the process and recommend their values.

Design and analysis of multi cavity injection mould using solidworks

Demand for Injection moldings components increased day by day. The injection molding process is one of the most versatile methods for mass production of plastics moldings with desired dimensional tolerances. The molds are the assembly of core, cavity, backplates, ejector pins, locating pins and stripper plates, etc. In the Injection Moulding Process, the design and fabrication of Mould is the most critical one. The present study reports the design consideration of multi-cavity mould for products using Polypropylene as material. The mould is designed with the SOLIDWORKS software to produce a fine quality component in consideration of ease of manufacturability and assembly.