Cavity pressure dynamics and self-tuning control for filling and packing phases of thermoplastics injection molding

Because of its versatility, cost effectiveness, and ability to produce intricate shapes to tight specifications, the injection molding process is widely used in plastics processing. Mold cavity pressure plays an important role in determining the quality of the molded articles. The dynamic behavior and control of cavity pressure were studied for the filling and packing phases. The dynamics of cavity pressure during filling were investigated and found to be both nonlinear and time-varying in relation to the hydraulic servo-valve opening, which is the manipulated variable. A self-tuning control system was designed and tested for a wide range of conditions. The transition from filling to packing was best detected by the change in the derivative of cavity pressure. The dynamics of cavity pressure during packing were studied and modeled similarly as for filling. The self-tuning technique was successfully extended and implemented in the packing phase.     

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.     

The process capability of multi-cavity pressure control for the injection molding process

Cavity pressure has been recognized as a critical process parameter for the injection molding of high quality thermoplastic parts. This Interest has led to the achievement of closed loop cavity pressure control, but only at one point in the mold cavity. A system has been recently described that extends this capability to provide simultaneous control of cavity pressure at multiple locations in the mold through the addition of dynamic valves in the melt delivery system, each of which can be independently controlled to meter flow and pressure to its portion of the mold. This paper describes the ability of the multi-cavity pressure control system to improve process capability and molded part quality. Experimental investigation has shown that the technology enables significant process flexibility to arbitrarily balance flow, move knit-lines, and control multiple part dimensions. In the presence of typical production process disturbances, moreover, closed loop multi-cavity pressure control was shown to increase the process capability index, Cp, from 0.52 for the conventional injection molding process to 1.5. After these capabilities have been discussed, several limitations of the process are described that lead to promising areas of future research.     

Adaptive model following control of the mold filling process in an injection molding machine

This paper is concerned with the practical application of the adaptive model following control (AMFC) theory on the cavity pressure control of the mold filling process in an injection molding machine. The experimental results indicate that the AMFC technique based on the modified Popov-Landau method is very useful for the cavity pressure control. Two kinds of control algorithms are implemented on a 16 bit microcomputer to control the cavity pressure. The results also show that the AMFC algorithm is superior to the classical PI control in this system when the acrylonitrile-butadiene-stryrene (ABS) is injected into a test specimen mold which is designed according to the ASTM code.     

A comparison of seven filling to packing switchover methods for injection molding

The effectiveness of seven methods for controlling switchover from the filling to packing stage were investigated, including: (1) screw position, (2) injection time, (3) machine pressure, (4) nozzle pressure, (5) runner pressure near the sprue, (6) cavity pressure near the gate, and (7) cavity temperature at the end of flow. The activation threshold for each of the seven switchover methods was iteratively determined so as to produce similar part weights relative to a standard process. A design of experiments was implemented for each of the seven switchover methods that perturbs the process settings by an amount equal to six standard deviations of the standard process so as to replicate the expected long‐term process variation. The results suggest that conventional switchover methods (e.g., screw position) had lower short‐term variation, but other methods were more robust with respect to rejecting long‐term process variation. The merits of different dimensional measurements for quality control are also discussed relative to the society of the plastics industry (SPI) standard tolerances. POLYM. ENG. SCI., 50:2031–2043, 2010. © 2010 Society of Plastics Engineers     

Modeling of mold filling process for powder injection molding

The mold filling process has been modeled for the injection molding of different polymer-based binders and powder-polymer mixtures. It is essentially a two dimensional non-Newtonian fluid flow analysis in a non-isothermal environment. A complete analysis is accomplished by combining a finite element method and control volume technique to describe an increment of flow front movement, whereas a finite difference method is used to solve the energy equation to characterize the temperature distribution. Numerical results are compared to exact solutions for a circular ring cavity using a power law fluid model under an isothermal condition. Comparison of computed results against published data for a simple circular disk shows good agreement between the two analysis methods. After making selected comparison studies, it is demonstrated that the filling process in Powder Injection Modeling with different combination of powder-polymer mixtures is markedly dependent on specific combinations of powder; and polymer based binders. Computed flow front results for a rectangular cavity also compared favorably against the data for a power law fluid model under non-isothermal conditions.     

Morphology evolution during injection molding: Effect of packing pressure

Injection molding is one of the most widely employed methods for manufacturing polymeric products. The final properties and then the quality of an injection molded part are to a great extent affected by morphology. Thus, the prediction of microstructure formation is of technological importance, also for optimizing processing variables. In this work, some injection molding tests were performed with the aim of studying the effects of packing pressure on morphology distribution. The resulting morphology of the moldings was characterized and it was compared with previous results gathered on samples obtained by applying a lower holding pressure. Furthermore, the molding tests were simulated by means of a code developed at University of Salerno. The results obtained show that on increasing holding pressure the molecular orientation inside the samples increases, and simulations show that this is due mainly to the increase of relaxation time caused by the higher pressures. On discussing the simulation results, some considerations are made on the effects of pressure on crystallization kinetics and on rheology.     

Advanced process control for injection molding

This paper deals with the application of advanced control strategies to an injection molding process. Of particular interest is the control of one variable during the cooling phase of the molding process. Due to the cyclic dynamic nature of injection molding, the controlled variable must be regulated over a short cycle; the full process is completed within 10 seconds. Therefore, a key control objective is rapid setpoint regulation. A closed-loop strategy has been implemented for the regulation of pressure within the mold during the cooling cycle. First order plus dead time models of the process have been identified from plant step responses. The performance of several control algorithms for this process are compared in simulation studies. These algorithms have given comparable regulatory and servo responses. Finally, the effectiveness of the closed loop controi system has been demonstrated experimentally using the PI algorithm. Simulated and experimental results are in excellent agreement.     

The process of cavity filling including the fountain flow in injection molding

This work deals with the simulation of the filling of a cavity utilizing the Marker-and-Cell numerical technique in solving the transient problem involved. The cavity is confined by two parallel plates, and is “end fed.” The flow was assumed isothermal and the fluid incompressible, obeying the power law model. Special attention was given to the flow region near the advancing melt front, in order to obtain a better insight of the “fountain effect,” during which the fluid flows from the center to the walls of the cavity. The results of the simulation of the front flow region are supported by and in qualitative agreement with experimental results involving “tracer resins” during cavity filling. Although the flows considered were slow and isothermal, this study has significant practical ramifications on industrial mold filling during injection molding.     

Dynamic modeling of the mold filling process in an injection molding machine

This paper presents the development of a nonlinear mathematical model for the study of the mold filling process in an injection molding machine. The model is formulated by the Reynolds transport theorem which is applied to describe the polymer flow dynamics. The mold filling process can be approximated by the transient phenomenon of the non-Newtonian fluids flowing through a closed conduit. The comparison between the experimental results and the theoretical simulation indicate that the nonlinear model is a reasonable representation of the mold filling dynamics when the acrylonitrile-butadiene-styrene (ABS) is injected into a disk shape mold. The actuation system dynamics of an injection molding machine are also investigated. The results indicate that the nonlinear model can also adequately predict the transient behavior of the actuation system.     

保压时间和保压压力对注塑制品厚度分布的影响

通过实验研究了保压压力和保压时间对制品厚度分布的影响,所得的结论可以指导塑件和模具的设计。     

注塑充模流动过程灵敏度数值分析

从注塑模充模过程控制方程出发,建立了注塑成型充模过程物理场对设计参数瞬态连续灵敏度分析理论,得到了充模过程压力场、温度场、速度场等物理场对设计参数的灵敏度控制方程.数值分析沿用了注塑模流动分析的基本思想,压力灵敏度采用有限元法、通过对时间和厚度方向的差分求解温度灵敏度,借助于控制体积的概念得到运动边界灵敏度分析.数值算例分析了注射压力对注射流率、熔体温度的设计灵敏度,与数值实验吻合良好.     

Visual analysis of cavity filling and packing process in injection molding of thermoset phenolic resin by the gate‐magnetization method

The Gate‐Magnetization method developed by Yokoi and coworkers for thermoplastics was used to investigate the flow behavior of glass‐fiber reinforced phenolic resin compound inside a mold cavity. Plug flow builds up in the cavity with a decrease of the local viscosity along the cavity wall due to the heat transfer from the wall and shear heating. Simultaneously, a high viscosity layer builds up from the crosslinking reaction along the cavity wall. The thickness of the high viscosity layer increased as the injection rate decreased. An unstable flow boundary formed between the reacted high viscosity layer along the wall and the low viscosity layer just under the layer.     

Analysis of the packing stage in injection molding

An unconditionally stable explicit finite difference numerical scheme is used to determine the pressure distribution during the packing stage of a rectangular mold cavity. Different initial conditions arising from both an isothermal and nonisothermal mold filling analysis are considered in relation to subsequent packing behavior. The packing stage is of short duration, may be assumed to be isothermal, and gives rise to a more uniform pressure distribution within the mold cavity.     

A numerical simulation of the cavity filling process with PVC in injection molding

Filling cold mold cavities with hot polymer melts at high pressures is of great practical interest. The transport approach to this process of solving the general equations of change with suitable equations of state to describe the flowing material has been largely ignored. No analytic solution is possible, and the non-steady state flow adds a dimension which makes digital computation discouraging because of the core storage and execution time requirements. The mold filled in this simulation is a disk which hot polymer melt enters through a tubular entrance located at the center of the top plate. The tube is 2.54 cm. long and has a radius of 0.24 cm. The plate separation and outer radius of the disk cavity may be varied. A constant pressure applied at the entrance of the tube causes the flow. The cavity walls are kept at various low temperatures. The reported results are for rigid polyvinyl chloride (PVC). The general transport equations, i.e. continuity, momentum, and energy, for a constant density power law fluid are used to solve the flow problem. Convergence to the differential solutions is guaranteed but since a lower limit was imposed on the time increment by the core storage limit of the computer facilities (27K) and long execution times, all results are semiquantitative for the problem as stated. Using the results obtained it is possible to predict “fill times”. The formation of a frozen polymer skin as the cavity fills may be followed via the velocity profiles. The temperature profiles which reflect cooling and the amount of viscous heat generated provide the basis for studying resin thermal degradation effects. Finally, because so much of the total pressure drop is disispated in the entrance tube, and so much viscous heat is generated there, this study indicates that the design of the gate and runner system is perhaps the most important facet of success in mold filling.     

Dynamics and control of pressure in the injection molding of thermoplastics

A detailed study was carried out to understand the dynamics of pressure variations at different points in the injection-molding system. Thus, hydraulic, nozzle, and cavity pressures were evaluated, in addition to the pressure gradient in the cavity. Both steps and pseudorandom binary sequences (PRBS) were employed to obtain and compare dynamic models describing these variables. Subsequently, these models were employed to evaluate and select optimal controllers for the different variables.     

Computer simulation and analysis of fountain flow in filling process of injection molding

The viscous flow in the filling stage of injection molding can be described in terms of an one-dimensional fully developed main flow and a complex two-dimensional flow near the advancing front, which is often termed the fountain flow. The transport characteristics in the front region of the mold flow are of increasing importance in injection process of composite materials such as resin injection molding (RIM). By using of finite element method, the simulation of non-isothermal viscous flow between two isothermal parallel plates with the generalized newtonian fluid is presented in detail. The un-folding of the fluid particles towards the mold wall directly affects transport characteristics such as the distribution of temperature, the orientation and the concentration of molecule near the front in filling stage.     

Modeling the packing stage in injection molding of thermoplastics

A model, for the packing stage In injection molding of thermoplastics is proposed. It allows one to calculate the time evolution of pressure and temperature fields and mass variations in simple geometries. The model holds for amorphous as well as for crystalline polymers if the kinetics of crystallization are known for temperatures far from the melting point, It applies after filling stage; initial temperature and pressure conditions are available from filling-simulating software. The principles rest on finite difference schemes computing simultaneously temperature and velocity of compressible non-Newtonian fluid in a filled cavity. The pressure field is determined from an equation of state at any time, owing to a mass balance in each gridmesh. The meaningful results of the simulation are local shrinkage and a good approximation of final weights of finished products. The algorithm is essentially checked for the influence of physical, thermal, and processing parameters on the cavity pressure for the injection of a polystyrene (Gedex 1541) into a rectangular mold cavity.     

General consequences of the packing phase in injection molding

The post-filling phase in injection molding was analyzed via simple heat-transfer and P-v-T models. An expression for the evolution of (volume-averaged) pressure in a molding cavity during the cooling phase of the process was derived from the empirical Tait model combined with the transient heat-conduction equation. This expression was used to establish general optimization criteria for the packing phase in injection molding, based on simple heuristics, and to assess the effects of various process and material parameters on the packing response of the system. The effects of gate geometry, part geometry, mold temperature, and melt temperature on the packing characteristics of a simple part are examined, and the general implications to the dimensional integrity of the part are discussed.     

Pressure losses in the packing stage of injection molding

The pressure loss between the mold and the nozzle in the injection molding of bar and box moldings has been monitored. The pressure drop observed during filling of the mold is reduced during the packing stage but remains finite. This has been attributed in the literature to solidification of polymer across the cavity transducer and to melt relaxation phenomena. Experiments have been carried out with hot molds to prolong the packing stage at the expense of the ‘cooling’ stage. Under these circumstances the pressure drop is reduced but not eliminated. The observed pressure drop may be related to the viscosity of the melt and its dependence on pressure and temperature although strain-induced crystallization and the pressure dependence of the melting point can confer effects similar to the cooling stage.