IE 337: Materials and Manufacturing Processes

Lab # 6

Injection Molding Simulation

Introduction: Injection molding is a manufacturing process for polymers and plastics. The growth of the polymer industry is due to the unique combination of properties of plastic products that include easy shaping and fabrication, low densities, resistance to corrosion, electrical and thermal insulation and favorable rigidity and toughness per unit weight. Synthetic polymers can be classified in two categories. Thermoplastics and Thermosets. Thermoplastics (by far the largest volume) can be melted by heating, solidified by cooling and remelted repeatedly. Major types are Polyethylene (PE), Polypropylene (PP), Polystyrene (PS), Polyvinyl Chloride (PVC), Polycarbonate (PC), Polymethyl Methacrylate (PMMA), Polyethylene Terephthalate (PET) and Polyamide (PA, Nylon). Thermosets are hardened by application of heat and pressure, due to crosslinking, i.e. the creation of permanent 3-D networks. They cannot be softened by heating for reprocessing. Ex: Bakelite, epoxies and polyurethanes. Processing of Thermoplastics: Thermoplastics are usually processed in the molten state. Molten polymers have very high viscosity values and exhibit non-Newtonian behavior. To put it in simple words, the viscosity of a Newtonian fluid (ex: water) never changes with temperature and pressure. However, for a non-Newtonian fluids (ex: polymers), the viscosity goes down with increase in temperature and shear. Such reduction in viscosity is also known as shear-thinning behavior. The most important polymer processing operations are extrusion and injection molding. Extrusion is material - intensive and injection molding is labor - intensive. Both these processes involve the following sequence of steps: (a) heating and melting the polymer, (b) pumping the polymer to the shaping unit, (c) forming the melt into the required shape and dimensions, (d) cooling and solidification. Other processing methods include calendering, blow molding, thermoforming, compression molding and rotational molding. There are more than 30000 grades of polymers processed by these methods. The question now will be How would I select a suitable processing method for a particular polymer? The answer is Melt Flow Index (MFI, also called Melt Flow Rate or MFR). This is an inverse measure of viscosity based on a rather crude test involving extrusion of a polymer through a die of standard dimensions under the action of a prescribed weight. MFI is the number of grams of polymer collected from the test apparatus in 10 minutes. Low MFI values mean high viscosity and high molecular weight, and low MFI values indicate the opposite. The following is the usual MFI range for some processes: Extrusion 0.01 - 10, Injection molding 1 100, Blow molding 0.01 1, Rotational molding 1.5 20. Basics of Injection Molding Process: An injection molding machine consists of two basic elements, the injection unit and the clamping unit. The process starts with a mold, which is clamped under pressure to accommodate the injection and cooling process. The pelletized polymers are fed into the machine, followed by the appropriate colorants (if required). The polymers then fall into an injection barrel, where they are heated slightly higher than their melting points, and then injected into the mold through either a screw or ramming device. 1 February 4, 2010

IE 337: Materials and Manufacturing Processes

Lab # 6

Injection Molding Simulation

Figure 1a: Exterior view of an injection-molding machine

Figure 1b: Exploded view of an injection-molding machine

An injection molding machine consists of two basic elements, the injection unit and the clamping unit. The process starts with a mold, which is clamped under pressure to accommodate the injection and cooling process. The pelletized polymers are fed into the machine, followed by the appropriate colorants (if required). The polymers then fall into an injection barrel, where they are heated slightly higher than their melting points, and then injected into the mold through either a screw or ramming device. Then comes the dwelling phase, in which the molten plastics are contained within the mold, and hydraulic or mechanical pressure is applied to make sure all of the cavities within the mold are filled. The plastics are then allowed to cool within the mold, which is then opened by separating the two halves of the mold. In the final step, the plastic part is ejected from the mold with ejecting pins. The completed part may contain extraneous bits called runners, which are trimmed off and recycled. The entire process is cyclical, with cycle times ranging from between ten and 100 seconds, depending on the required cooling time. Defects and remedies: Table 1 lists and defines the well-known defects encountered during the injection-molding step along with the possible cause and remedies. Figure 2 depicts the some of the defects experienced during the injection molding of thermoplastics.

February 4, 2010

IE 337: Materials and Manufacturing Processes

Lab # 6

Injection Molding Simulation

Table 1: Common Injection Molding Defects

Defects

Definition

Reason High injection pressure Poor clamp force Insufficient material supply

Remedy Lower the injection Pressure Increase the clamp force Check the back pressure Increase the injection speed Increase the melt temperature

Flashing

Melt seeping out of mold cavity

Short Shots

Incomplete product

Low injection speed Higher melt viscosity

Poor injection pressure Indentations on the product surface

Increase the injection pressure

Sink Marks

Non-uniform product thickness

Select products with uniform wall thickness

Warpage Cracking

Bending of the product Failure of product

Non-uniform cooling

Maintain uniform cooling

High ejection force Ejector Marks Indentation during part ejection

Lower the ejection force

Less cooling time Poor venting

Increase the cooling time Proper venting Increase the holding pressure Gate size and location Lower the injection speed Lower the melt temperature

Voids

Air pockets

Insufficient holding pressure and time Smaller gate Higher Injection speed Higher melt viscosity Poor weld line position

Jetting

Formation of flow patterns on the product surface V-shaped line that occurs at the point where two different flow fronts meet

Weld Lines

Gate size and location

February 4, 2010

IE 337: Materials and Manufacturing Processes

Lab # 6

Injection Molding Simulation

Figure 2: Defects during Injection Molding (a) Flashing (b) Short shot (c) Cracks (d) Voids (e) Ejection marks (f) Weld Line

Why do we need injection molding simulation software? When filling a new or unfamiliar mold for the first time, where shot size for that mold is unknown, a technician/tool setter usually starts with a small shot weight and fills gradually until the mold is 95 to 99% full. Once this is achieved a small amount of holding pressure will be applied and holding time will be increased. Solidification time is important as it determines cycle time, which itself is an important issue in the economics of the production process. Availability of a simulation software, thus help us play around the conditions including melt temperatures, injection pressure and in turn get the outputs including cycle time and possible defects. Objectives: Use Moldflow simulations of the injection molding process to develop a greater understanding of the key parameters in the injection molding process. Equipment & Materials: 1. A 3-D model of the mold in a format supported by Moldflow. 2. Moldflow software which is accessible in all MIME computer labs of OSU. Procedure: 1. Log in to your engineering account. 2. Select the Moldflow from all programs => MIME Apps => Autodesk => Moldflow. 3. After opening the program you may open an existing project or make a new project through the task menu on the left part of the page. 4. Choose the new project. Name the new project (as injection 1) and select a location for its storage. 5. Right click on your project name in task column and use import icon for importing your 3D model. Choose the type of mesh as 3D model. 6. Click on the 3D Mesh from the task column. 7. Click on the Mesh Now icon. Then close the pop-up. Detailed information for meshing will appear on the bottom part of the page. It takes a few seconds for meshing process to be completed and appears on the 3D model. 8. Wait until the message of mesh completed pops-up on the screen. Accept this message. 4 February 4, 2010

IE 337: Materials and Manufacturing Processes

Lab # 6

Injection Molding Simulation

9. Click on the fill from the task column and choose the fill from pop-up. Then press OK. 10. Click on the generic default from the task column to choose your material for filling the object. 11. Choose Eastman Chemicals from the manufacturer list. 12. Choose Tenite LDPE 1870 from the trade name list. a. In case you need to add a material to the list, Use the import icon to add the .udb file to this library. b. After import the new material to the library, choose it from the end of your manufacturer and the trade name menus. 13. Look at the details to see the material properties and the recommended process. 14. Press OK. 15. Click on the Set Injection Locations from the task column. 16. Set the injection points by clicking on the points A on your object. a. To remove an injection point, select it again and after its color change press the delete bottom on your keyboard. 17. Click on Process settings from the task column. 18. Enter 30C as the Mold Surface Temperature and 240C as the Melt Temperature. Consider that they cannot be out of the range that is suggested in recommended process available in Details of your material. 19. Press OK. 20. Click on the Start analysis from the task column. 21. Wait until the Analysis completed appears on the screen. 22. Press OK. 23. Look at the Results. 24. Start a new project (name as Injection 2)and repeat 4-18. 25. Enter 30C as the Mold Surface Temperature and 190C as the Melt Temperature. 26. Repeat 20-23. 27. Start a new project (name as Injection 3) and repeat 4-23 for Mold Surface Temperature of 70C and Melt Temperature of 190C. 28. Repeat 4-23 for injection spots at B (name it as Injection 4). 29. Start a new project (name as Injection 5) and repeat 4-8. 30. Click on the Fill from the task column and choose the Fill & Pack from pop-up. Then press OK. 31. Repeat 10-23. Lab Deliverables: 1. Prepare a report detailing the lab activity, observations, results and difficulties faced (follow the lab report instructions). In the laboratory report, please address the following requirements and questions: 2. Compare the filling times for all injection molding conditions that you used by applying Fill for filling the mold (injection 1-4). Explain how different parameters affect mold time. 5 February 4, 2010

IE 337: Materials and Manufacturing Processes

Lab # 6

Injection Molding Simulation

3. Compare the volumetric shrinkage and density uniformity in Injection 1 and 5. Explain the difference? 4. What is the relationship between temperature, shear rate and viscosity in polymers? Are polymers Newtonian fluids? What is the implication of this in injection molding? 5. Compare the air gap spots for the different injection molding conditions that you used. What is its implication for mold design? 6. What was the best condition that you used in this lab? Explain why? How could you improve it? 7. What are some benefits of using injection molding simulation within industry? Table 1: Required simulations: Simulation Injection positions Injection 1 Injection 2 Injection 3 Injection 4 Injection 5 A A A B A Mold Surface Temperature 30 30 70 30 30 Melt Temperature 240 190 240 240 240 Fill Fill Fill Fill Fill & Pack Filling method

Figure 1: Positions A and B for injection.

February 4, 2010