混合气体在聚合物注射成型保压阶段中扩散的分子动力学模拟

构建了含有氧气、氮气分子和聚合物聚甲基丙烯酸甲酯（PMMA）高分子链的单元模型,并通过能量优化、退火等处理使其接近保压阶段状态,然后改变温度或压力进行分子动力学模拟,探讨微观尺度下混合气体（氧气和氮气）在聚合物PMMA中扩散的情况;并探讨了混合气体分子间相互作用的影响。模拟结果表明,随着温度或压力的增加,氧气和氮气在PMMA内的扩散系数增大;当温度或压力增大到一定程度时,扩散系数几乎不变,逐渐达到扩散平衡;模拟过程中发现气体分子在聚合物中的扩散过程中具有协同效应,混合气体的扩散系数大于纯气体的扩散系数。     

PMMA微流控芯片最佳注射成型工艺的实验研究

以聚甲基丙烯酸甲酯（PMMA）为原料,通过注塑加工的方式制备微流控芯片,经过多次注塑实验得出影响PMMA微流控芯片成型质量的主要因素是：模具温度、保压压力、熔体温度和注射速度。在其他参数不变的情况下,通过正交实验和极差分析确定了PMMA微流控芯片注射成型的最佳工艺：熔体温度260 ℃,模具温度50 ℃,保压压力60 MPa,注射速度400 mm/s,在该工艺条件下制得的单流道测试装置B的开口宽度、槽底宽度、槽深分别为：591.90、381.26、408.47 μm,这些参数所对应的设计值分别为：400、400、400 μm;在共聚焦显微镜下观察到芯片表面较为洁净、微结构比较完整,最后使用该微流控芯片完成了液体混合实验和液滴生成实验,表明最佳注塑工艺加工出的微流控芯片能满足正常使用,对于未来微流控芯片的批量化生产有着重要意义。     

注塑工艺对聚丙烯EP548N光学性能的影响

采用不同的工艺条件对无规共聚聚丙烯EP548N进行注塑成型,测试注塑件表面光泽度、黄色指数和透光率,分析了注塑成型条件对制品光学性能的影响。确定聚丙烯EP548N的最佳注塑工艺为:熔体温度200℃,模具温度40℃,注射速度210mm/s、保压压力4.6MPa、注射压力4.9MPa,注塑工艺条件改变对聚丙烯EP548N注塑件透光率影响较小。     

注塑工艺对聚碳酸酯制品环境应力开裂行为的影响

研究了不同注塑工艺下成型的聚碳酸酯（PC）平板制品的环境应力开裂行为。结果表明：在四氯化碳浸渍下,在制品侧壁位置出现分层开裂;熔体温度升高可以提升PC制品的耐环境应力开裂性;保压压力较大时,制品开裂现象较为明显。在分析分子取向和残余应力与制品环境应力开裂行为关系的基础上,探讨了注射成型工艺对PC注塑制品环境应力开裂行为的影响机理。     

注塑机使用与维护技术讲座（二）注塑成型原理

介绍了注射成型的基本原理及塑化计量、注射冲模及冷却定型三个注射成型过程的重要阶段。介绍了注射成型工艺与压力、温度、速度及成型工艺对性能的影响,注射压力根据注射阶段不同可以分为塑化压力、注射压力、型腔压力、注射压力与保压压力的切换、保压压力。注射成型过程中温度有料筒温度、喷嘴温度、熔体温度、液压油温度和模具温度。     

注射成型发泡过程中温度和剪切速率对CO2扩散行为影响的分子动力学研究

为研究临界CO₂辅助聚乳酸（PLA）注射成型发泡过程中,温度和剪切速率对CO₂扩散行为影响。应用分子动力学模拟方法,以PLA和CO₂为研究对象,基于周期性边界条件和SA算法,引入CAMPASS力场,构建PLA/CO₂扩散模型,对模型进行能量最小化处理。从温度和剪切速率两个方面研究在注射成型发泡过程中PLA主链活跃性、体系能量响应、均方回转半径对CO₂分子在PLA中扩散行为的影响。结果表明,CO₂扩散系数在不受剪切力作用时,随着温度升高而增大,温度达到388 K时,CO₂扩散系数达到0.219 8×10^-5 cm²/s;受剪切力作用时,随着剪切速率增大而增大;温度为378 K,剪切速率为1 ps^-1时,扩散系数达到17.743 6×10^-5 cm²/s;PLA分子链所处环境温度不断提高,分子链能量升高,活跃性提高,CO₂分子扩散路径增多,从而提高CO₂扩散速率;分子链所受剪切力不断增大,分子链能量升高,活跃性提高,单个分子链从缠结网络中剥离出来,沿剪切力方向形成流动取向,从而提高CO₂扩散速率。     

注射成型薄壁制品收缩与翘曲因素

介绍了薄壁注射成型的充填、保压、冷却和残余应力的数值模型,并将集成的模拟程序对收缩翘曲问题进行定量地模拟分析.采用Taguchi 实验优化设计理论,用L₂₇（3¹³）正交表设计实验并进行了统计分析.研究了因素如熔体温度、模具温度、保压时间、保压压力、浇口尺寸和注射速率对收缩与翘曲的影响的显著性.得出优化工艺参数如熔体温度、模具温度、保压时间和压力能减少残余热应力;保压压力和熔体温度是影响收缩与翘曲的最显著因素.     

玻璃纤维增强聚丙烯制品翘曲变形的研究

针对玻璃纤维增强聚丙烯(PP/GF)注射成型制品存在的翘曲变形缺陷,研究了注射工艺参数如模具温度、喷嘴温度、注射速率、保压压力和保压时间对制品成型收缩率及翘曲的影响。结果表明,随着模具温度、喷嘴温度和保压压力的降低,制品的翘曲减小;适当提高注射速率和减少保压时间也可减小制品翘曲。     

活性炭对氢气中O_2与N_2的吸附性能研究

研究测定了温度为77 K,压力0.1 MPa,流量分别为5、8、10 L·min-1时活性炭对O2、N2的饱和吸附量,考察了O2与N2双组分杂质在氢气中共存对活性炭吸附行为的影响,并采用Fick扩散模型分别对O2和N2在活性炭内的扩散行为进行了分析,求出了实验条件下O2与N2在活性炭内的扩散系数,确定了二者在活性炭内的扩散均属于晶体扩散。     

Cu/PEO/LDPE复合材料的制备工艺研究

采用熔融共混/注塑成型法制备了一种新型的用于制备含铜宫内节育器的聚合物合金基含铜复合材料,即铜/聚氧化乙烯/低密度聚乙烯(Cu/PEO/LDPE)复合材料。采用正交实验研究了加热温度、注射温度、注射压力、注射速率、保压压力和保压时间等对该复合材料Cu2+释放速率的影响。结果表明:注射压力对复合材料Cu2+释放速率的影响最大,其它工艺参数的影响相对较小,且影响大小的顺序依次为:注射压力保压时间注射温度注射速率加热温度保压压力,调控注塑工艺参数是调控该复合材料Cu2+释放行为的手段之一。获得了制备宫内节育器Cu/PEO/LDPE复合材料的最佳注塑工艺参数为:注射压力60bar、注射温度165℃、加热温度180℃、保压压力10bar、保压时间0.5s、注射速率70%。     

Mathematical modeling and numerical simulation of cell growth in injection molding of microcellular plastics

A mathematical formulation and numerical simulation for non‐isothermal cell growth during the post‐filling stage of microcellular injection molding have been developed. The numerical implementation solves the energy equation, the continuity equation, and a group of equations that describe the mass diffusion of dissolved gas and growth of micro‐cells in a microcellular injection molded part. The “unit‐cell” model employed in this study takes into account the effects of injection and packing pressures, melt and mold temperatures, and super‐critical fluid content on the material properties of the polymer‐gas solution and the cell growth. The material system studied is a microcellular injection molded polyamide 6 (PA‐6) resin. Two Arrhenius‐type equations are used to estimate the coefficients of mass diffusion and solubility for the polymer‐gas solution as functions of temperature. The dependence of the surface tension on the temperature is also included in this study. The numerical results in terms of cell size across the sprue diameter agree fairly well with the experimental observation. The predicted pressure profile at the sprue location has also been found to be in good agreement with the dynamics of the cell growth. Whereas for conventional injection molding the pressure of the system tends to decay monotonously, the pressure profile in microcellular injection molding exhibits an initial decay resulting from cooling and the absence of packing followed by an increase due to cell growth that expands the polymer‐gas solution and helps to pack out the mold uniformly. Polym. Eng. Sci. 44:2274–2287, 2004. © 2004 Society of Plastics Engineers.     

Analysis of filling,packing, and cooling stages in injection molding of disk cavities

This research tried to simulate three stages of injection molding cycles (filling, packing, and cooling) for polypropylene. The cavity used was a center-grated disk-shaped mold. During the filling stage, we assumed the polymer fluid obeyed the CEF equation and flowed nonisothermally. The packing stage was represented by isothermal flow of Newtonian fluid, and, during cooling stage, we took into account the effect of pressure drop on the energy balance. By finite difference method, we could solve the partial differential equations numerically. The results showed. (1) Elastic effect was not significant at the filling stage. (2) Pressure buildup in the cavity was very quick at the packing stage. (3) At the cooling stage, temperatures predicted by taking into account pressure drop were lower than those without considering pressure drop. In addition, the influences of mold temperature, flow rate, and inlet melt temperature on the three stages of injection molding process were discussed.     

Numerical modeling of injection/compression molding for center-gated disk: Part II. Effect of compression stage

In the accompanying paper, Part I, we have presented a physical modeling and the associated numerical analysis of the injection molding process with a compressible viscoelastic fluid model. In Part II, effects of the compression stage in the injection/compression molding process are presented. Numerical results showed that the injection/compression molding process reduced birefringence as compared with the injection molding process. In this respect, the injection/compression molding process seems to be more suitable for manufacturing precise optical products of good optical quality than the injection molding process. Effects of the packing stage on the birefringence distribution in the injection/compression molding process were found to be similar to those in the injection molding process. Our numerical results show that the birefringence becomes smaller as the melt temperature gets higher and the closing velocity of the mold gets smaller with the flow rate and the mold temperature affecting the birefringence insignificantly. As far as the density distribution is concerned, the flow rate, melt temperature, and mold closing velocity have insignificant effects on the density distribution in comparison with the mold temperature.     

Experimental investigation and molecular dynamics simulations of the effect of processing parameters on the filling quality of injection-molded micropillars

Microinjection molding has been attracting increasing attention and application in fabricating products with functional surface microstructures. The processing parameters, packing pressure, and melt temperature have important effects on the filling quality. In order to study the mechanisms of the packing pressure and melt temperature on the filling quality of micropillars, a simulation model of injection molding of nanopillars was constructed by molecular dynamics software and a series of injection molding experiments of micropillars were carried out in this paper. Subsequently, the mechanisms were analyzed qualitatively. The results showed that the frozen layers were formed at the interface between the polymer melt and mold under the action of heat transfer, which prevented effective filling of the polymer melt. The filling quality of the micropillars could be improved significantly via increasing the melt temperature and the packing pressure, but the mechanisms were different. To be specific, the increase of the packing pressure could make more polymer melts fill into the cavity fully. Thus, the density of the micropillars was increased and the filling quality could be improved. The forming rate of frozen layers could be slowed down by increasing the melt temperature. As a result, the purpose of improving the filling quality was achieved.     

注塑制品翘曲变形的最显著影响因素

采用Moldflow进行了塑料制品注塑过程模拟实验,分析了模具温度、熔体温度、保压时间、保压压力、冷却时间、注射时间和速度/压力控制转换（V/P转换）对注塑制品翘曲的影响,从中确定影响最显著的注塑过程参数。首先按一次因子法进行实验,根据因子效应,各因子影响权重顺序为：保压时间>冷却时间>熔体温度>注射时间> V/P转换>保压压力>模具温度,其中熔体温度、保压时间、冷却时间、注射时间对制品的翘曲有明显影响;再采用田口实验方法对这4个因素进行模拟实验,用L9（34）正交表设计实验,根据实验数据计算信噪比以评判影响因子的权重,由翘曲信噪比、体积收缩率信噪比和缩痕指数信噪比三方面分析,发现熔体温度对制品翘曲的影响最为显著。     

Birefringence and interface in sequential co‐injection molding of amorphous polymers: Simulation and experiment

Modelings of the interface distribution and flow‐induced residual stresses and birefringence in the sequential co‐injection molding (CIM) of a center‐gated disk were carried out using a numerical scheme based on a hybrid finite element/finite difference/control volume method. A nonlinear viscoelastic constitutive equation and stress‐optical rule were used to model the frozen‐in flow stresses in disks. The compressibility of melts is included in modeling of the packing and cooling stages and not in the filling stage. The thermally induced residual birefringence was calculated using the linear viscoelastic and photoviscoelastic constitutive equations combined with the first‐order rate equation for volume relaxation and the master curves for the relaxation modulus and strain‐optical coefficient functions of each polymer. The influence of the processing variables including melt and mold temperatures and volume of skin melt on the birefringence and interface distribution was analyzed for multilayered PS‐PC‐PS, PS‐PMMA‐PS, and PMMA–PC–PMMA molded disks obtained by CIM. The interface distribution and residual birefringence in the molded disks were measured. The measured interface distributions and the gapwise birefringence distributions in CIM disks were found to be in a fair agreement with the predicted interface distributions and the total residual birefringence obtained by the summation of the predicted frozen‐in flow and thermal birefringence. POLYM. ENG. SCI., 55:88–106, 2015. © 2014 Society of Plastics Engineers     

基于数值模拟的气体辅助注射成型工艺控制研究

基于广叉Hele-Shaw流动模型描述了气体辅助注射成型时气体的穿透过程。采用有限元／有限差分／控制体积法计算充填阶段的压力场、温度场,确定熔体前沿和气熔界面,并以实际产品为例分析工艺参数对气体辅助注射成型产品质量的影响。     

热力历史对PMMA残余应力和光学性能的影响

利用光弹测量对注射成型过程不同热力历史的聚甲基丙烯酸甲酯(PMMA)样件进行了残余应力的定量表征,并测试分析了样件的透光率和雾度。研究表明,成型过程中的工艺选择对样件的残余应力影响显著,提高熔体温度和模具温度、增大保压压力和注射速度、缩短保压时间和冷却时间都可以有效降低残余应力;退火温度升高可明显削弱成型过程热力历史的差异,降低残余应力并使之趋于一致,偏差最小为0.71 MPa。热力历史对光学性能的影响与残余应力相关性较大,总体上残余应力降低,透光率升高而雾度降低,可分别达到93.1%和1.1%。     

Study on the packing effects of external gas‐assisted injection molding on part shrinkage in comparison with conventional injection molding

Applying gas pressure on the reverse side of the part that called external gas‐assisted injection molding (EGAIM) has the potential to solve shrinkage‐related molding problems. We investigate the packing effects of EGAIM on part shrinkage and sink mark under various rib design and compare it to that of conventional injection molding (CIM). It was found that EGAIM has uniformly distributed packing pressure within the entire mold cavity. To achieve equivalent part shrinkage, CIM requires 100 MPa packing pressure from the molding machine, whereas EGAIM requires only 9 MPa. EGAIM can further reduce part shrinkage if the gas pressure and gas packing time are both increased. EGAIM can also eliminate sink marks for rib designs of an aspect ratio (rib width /part thickness) up to 1.2, whereas CIM can achieve the same sink mark level only at an aspect ratio of less than 0.5. POLYM. ENG. SCI., 2010. © 2010 Society of Plastics Engineers