| Abstract: | The integrated knowledge of the injection molding process and the material changes induced by processing is essential to guarantee the quality of technical parts. In the case of parts with deep cavities, quite often the ejection phase of the molding cycle is critical. Thus, in the mold design stage, the aspects associated with the ejection system will require special consideration. In particular, the prediction of the ejection force will contribute to optimizing the mold design and to guarantee the integrity of the moldings. In this work, a simulation algorithm based on a thermomechanical model is described and their predictions are compared with experimental data obtained from a fully‐instrumented mold (pressure, temperature, and force). Three common thermoplastics polymers were used for the tubular moldings: a semicrystalline polypropylene and two amorphous thermoplastics: polystyrene and polycarbonate. The thermomechanical model is based on the assumption of the polymer behavior changing from purely viscous to purely elastic below a transition point. This point corresponds to solidification determined by temperature in the case of amorphous materials and by critical crystallinity for semicrystalline polymers. The model results for the ejection force closely agree with the experimental data for the three materials used. POLYM. ENG. SCI. 45:325–332, 2005. © 2005 Society of Plastics Engineers. |
