Water-Assisted Injection Molding System Based on Water Hydraulic Proportional Control Technique

Water-assisted injection molding（WAIM）, an innovative process to mold plastic parts with hollow sections, is characterized with intermittent, periodic process and large pressure and flow rate variation. Energy savings and injection pressure control can not be .attained based on conventional valve control system. Moreover, the injection water can not be supplied directly by water hydraulic proportional control system. Poor efficiency and control performance are presented by current trial systems, which pressurize injection water by compressed air. In this paper, a novel water hydraulic system is developed applying an accumulator for energy saving. And a new differential pressure control method is proposed by using pressure cylinder and water hydraulic proportional pressure relief valve for back pressure control. Aiming at design of linear controller for injection water pressure regulation, a linear load model is approximately built through computational fluid dynamics（CFD） simulation on two-phase flow cavity filling process with variable temperature and viscosity, and a linear model of pressure control system is built with the load model and linearization of water hydraulic components. According to the simulation, model based feedback is brought forward to compensate the pressure decrease during accumulator discharge and eliminate the derivative element of the system. Meanwhile, the steady-state error can be reduced and the capacity of resisting disturbance can be enhanced, by closed-loop control of load pressure with integral compensation. Through the developed experimental system in the State Key Lab of Fluid Power Transmission and Control, Zhejiang University, China, the static characteristic of the water hydraulic proportional relief valve was tested and output pressure control of the system in Acrylonitrile Butadiene Styrene（ABS） parts molding experiments was also studied. The experiment results show that the dead band and hysteresis of the water hydraulic proportional pressure relief valve are large, but the control precision and linearity can be improved with feed-forward compensation. With the experimental results of injection water pressure control, the applicability of this WAIM system and the effect of its linear controller are verified. The novel proposed process of WAIM pressure control and study on characteristics of control system contribute to the application of water hydraulic proportional control and WAIM technology.

Simulation and Experiment Research on the Proportional Pressure Control of Water-assisted Injection Molding

Water-assisted injection molding（WAIM）,a newly developed fluid-assisted injection molding technology has drawn more and more attentions for the energy saving,short cooling circle time and high quality of products.Existing research for the process of WAIM has shown that the pressure control of the injecting water is mostly important for the WAIM.However,the proportional pressure control for the WAIM system is quite complex due to the existence of nonlinearities in the water hydraulic system.In order to achieve better pressure control performance of the injecting water to meet the requirements of the WAIM,the proportional pressure control of the WAIM system is investigated both numerically and experimentally.A newly designed water hydraulic system for WAIM is first modeled in AMEsim environment,the load characteristics and the nonlinearities of water hydraulic system are both considered,then the main factors affecting the injecting pressure and load flow rate are extensively studied.Meanwhile,an open-loop model-based compensation control strategy is employed to regulate the water injection pressure and a feedback proportional integrator controller is further adopted to achieve better control performance.In order to verify the AMEsim simulation results WAIM experiment for particular Acrylonitrile Butadiene Styrene（ABS） parts is implemented and the measured experimental data including injecting pressure and flow rate results are compared with the simulation.The good coincidence between experiment and simulation shows that the AMEsim model is accurate,and the tracking performance of the load pressure indicates that the proposed control strategy is effective for the proportional pressure control of the nonlinear WAIM system.The proposed proportional pressure control strategy and the conclusions drawn from simulation and experiment contribute to the application of water hydraulic proportional control and WAIM technology.

Evolution of stresses in metal injection molding parts during sintering

The evolution of stresses due to inhomogeneity in metal injection molding （MIM） parts during sintering was investigated. The sintering model of porous materials during densification process was developed based on the continuum mechanics and thermal elasto-viseoplastic constitutive law. Model parameters were identified from the dilatometer sintering experiment. The real density distribution of green body was measured by X-ray computed tomography （CT）, which was regarded as the initial condition of sintering model. Numerical calculation of the above sintering model was carried out with the finite element soRware Abaqus, through the user-defined material mechanical behavior （UMAT）. The calculation results showed that shrinkages of low density regions were faster than those of high density regions during sintering, which led to internal stresses. Compressive stresses existed in high density regions and tensile stresses existed in low density regions. The densification of local regions depended on not only the initial density, but also the evolution of stresses during the sintering stage.

Powder injection molding of pure titanium

An improved wax-based binder was developed for powder injection molding of pure titanium. A critical powder loading of 69 vol.% and a pseudo-plastic flow behavior were obtained by the feedstock based on the binder. The injection molding, debinding, and sintering process were studied. An ideal control of carbon and oxygen contents was achieved by thermal debinding in vacuum atmosphere （10^-3 Pa）. The mechanical properties of as-sintered specimens were less than those of titanium made by the conventional press-sintering process. Good shape retention and ±0.04 mm dimension deviation were achieved.

A strategy to obtain a high-density and high-strength zirconia ceramic via ceramic injection molding by the modification of oleic acid

Despite its unique high efficiency and good environmental compatibility, the water-soluble binder system still encounters problems achieving a desired sintered part via ceramic injection molding because of the poor compatibility and the powder-binder segregation between ceramic powders and binders. The objective of this study was to obtain a sintered part with excellent properties by introducing a small quantity of oleic acid to the surface of zirconia powders before the mixing process. As opposed to many previous investigations that focused only on the rheological behavior and modification mechanism, the sintering behavior and densification process were systematically investigated in this study. With the modified powders, debound parts with a more homogeneous and smaller pore size distribution were fabricated. Also, a higher density and greater flexural strength were achieved in the sintered parts fabricated using the modified powders.

NUMERICAL SIMULATION OF FEEDSTOCK MELT FILLING IN A CYLINDRICAL CAVITY WITH SOLIDIFICATION IN POWDER INJECTION MOLDING

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Structural Scheme Optimization Design for the Stationary Platen of a Precision Plastic Injection Molding Machine

The current development of precision plastic injection molding machines mainly focuses on how to save material and improve precision, but the two aims contradict each other. For a clamp unit, clamping precision improving depends on the design quality of the stationary platen. Compared with the parametric design of stationary platen, structural scheme design could obtain the optimization model with double objectives and multi-constraints. In this paper, a SE-160 precision plastic injection molding machine with 1600 kN clamping force is selected as the subject in the case study. During the motion of mold closing and opening, the stationary platen of SE-160 is subjected to a cyclic loading, which would cause the fatigue rupture of the tie bars in periodically long term operations. In order to reduce the deflection of the stationary platen, the FEA method is introduced to optimize the structure of the stationary platen. Firstly, an optimal topology model is established by variable density method. Then, structural topology optimizations of the stationary platen are done with the removable material from 50%, 60% to 70%. Secondly, the other two recommended optimization schemes are given and compared with the original structure. The result of performances comparison shows that the scheme II of the platen is the best one. By choosing the best alternative, the volume and the local maximal stress of the platen could be decreased, corresponding to cost-saving material and better mechanical properties. This paper proposes a structural optimization design scheme, which can save the material as well as improve the clamping precision of the precision plastic injection molding machine.

Fabrication and sintering behavior of high-nitrogen nickel-free stainless steels by metal injection molding

High-nitrogen nickel-free stainless steels were fabricated by the metal injection molding technique using high nitrogen alloying powders and a mixture of three polymers as binders.Mixtures of metal powders and binders with various proportions were also investigated, and an optimum powder loading capacity was determined as 64vol%.Intact injection molded compacts were successfully obtained by regulating the processing parameters.The debinding process for molded compacts was optimized with a combination of thermo-gravimetric analysis and differential scanning calorimetry analysis.An optimum relative density and nitrogen content of the specimens are obtained at 1360℃,which are 97.8%and 0.79wt%,respectively.

Injection molding of micro-porous titanium alloy with space holder technique

The powder space holder （PSH） and powder injection molding （PIM） methods have an industrial competitive advantage because they are capable of the net-shape production of micro-sized porous parts. In this study, micro-porous Ti6Al4V alloy （Ti64） parts were produced by the PSH-PIM process. Ti64 alloy powder and spherical polymethylrnethacrylate （PMMA） particles were used as a space holder material. After molding, binder debinding was performed by thermal method under inert gas. Debinded samples were sintered at 1250℃ for 60min in a vacuum （10-4 Pa）. Metallographic studies were conducted to determine densification and the corresponding microstructural changes. The surface of sintered samples was examined by SEM. The compressive stress and elastic modulus of the rificro-porous Ti64 samples were determined. The effects of fraction of PMMA on the properties of sintered micro-porous Ti64 alloy samples were investigated. It was shown that the fraction of PMMA could be controlled to affect the properties of the Ti alloy.

Simulation of Non-isothermal Injection Molding for a Non-Newtonian Fluid by Level Set Method

A non-isothermal injection molding process for a non-Newtonian viscous pseudoplastic fluid is simulated.A conservative interface capturing technique and the flow field solving method are coupled to perform a dynamic simulation.The validity of the numerical method is verified by a benchmark problem.The melt interface evolution versus time is captured and the physical quantities such as temperature,velocity and pressure at each time step are obtained with corresponding analysis.A"frozen skin"layer with the thickness increasing versus time during the injection process is found.The fact that the"frozen skin"layer can be reduced by increasing the injection velocity is numerically verified.The fountain flow phenomenon near the melt interface is also captured.Moreover,comparisons with the non-isothermal Newtonian case show that the curvatures of the interface arcs and the pressure contours near the horizontal mid-line of the cavity for the non-Newtonian pseudoplastic case is larger than that for the Newtonian case.The velocity profiles are different at different positions for the non-Newtonian pseudoplastic case,while in the case of Newtonian flow the velocity profiles are parabolic and almost the same at different positions.

The Simulation and Optimization of Aspheric Plastic Lens Injection Molding

For the purpose of reducing the volumetric shrinkage and volumetric shrinkage variation, the process in injection molding of aspheric plastic lens was simulated, and several process parameters which include holding pressure, melt temperature, mold temperature, fill time, holding pressure time and cooling time were optimized by using an orthogonal experimental design method. Finally, the optimum process parameters and the influence degree of process parameters on the average volumetric shrinkage and the volumetric shrinkage variation are obtained.

Fabrication of micro gear wheels by micropowder injection molding

The micropowder injection molding technology was investigated to fabricate the microsized gear wheels on a conventional injection molding machine. The feedstock comprised of carbonyl ferrum powder and a wax-based thermoplastic binder. Microinjection molding was fulfilled at about 423 K under 100 MPa. The heating system was applied to the die to improve the fluidity of the feedstock and subsequently the cooling system was used to enhance the strength of the green compacts after injection by decreasing the temperature of the die. The gear wheels were realized successfully with their addendum circle diameter ranging from 800 to 200 um and with the center hole as small as 60 um.

Preparation of Ti-Mo getters by injection molding

Ti-Mo getters have been fabricated via metal injection molding (MIM) using three kinds of Ti powders with different mean particle sizes of 46 μm,35 μm and 26 μm,respectively. The surface morphology,porosity,and hydrogen sorption properties of Ti-Mo getters formed by MIM using paraffin wax as a principal binder constituent were examined. It has been proven that the powder injection molding is a viable forming technique for porous Ti-Mo getters. The particle size of Ti powders and the powder loading influence...

Neural Network Approach to Predict Melt Temperature in Injection Molding Processes

Among the processing conditions of injection molding, temperature of the melt entering the mold plays a significant role in determining the quality of molded parts. In our previous research, a neural network was developed to predict the melt temperature in the barrel during the plastication phase. In this paper, a neural network is proposed to predict the melt temperature at the nozzle exit during the injection phase. A typical two-layer neural network with back propagation learning rules is used to model the relationship between input and output in the injection phase. The preliminary results show that the network works well and may be used for on-line optimization and control of injection molding processes.

Numerical simulation of the filling stage in injection molding based on a 3D model

Most injection molded parts are three-dimensional, with complex geometrical configurations and thick/thin wall sections. The change of the thickness of parts has significant influence on flow during injection molding. This paper presents a 3D finite element model to deal with the three-dimensional flow, which can more accurately predict the filling process than a 2.5D model. In this model, equal-order velocity-pressure interpolation method is successfully employed and the relation between velocity and pressure is obtained from the discretized momentum equation in order to derive the pressure equation. A 3D control volume scheme is employed to track the flow front. The validity of the model has been tested through the analysis of the flow in a cavity.

Antioxidation Study of Sm(Co, Cu, Fe, Zr)_z-Sintered Permanent Magnets by Metal Injection Molding

Antioxidation effects on Sm （Co, Cu, Fe, Zr）z-sintered magnets treated by different methods were studied through TGA and DTA. Microstructure of Sm（Co, Cu, Fe, Zr）z-sintered magnets was analyzed through SEM and EDS. The results indicate that the antioxidation effect of the alloy powder treated in silane solution is better than that of the other methods. The alloy powders treated in stearic acid （SA） solution and polymethyl methacrylate （PMMA） solution can prevent powders from oxidation for a short period of time. Silane solution is not suitable for metal injection molding （MIM） because it severely damages the magnetic properties and microstructure of Sm（Co, Cu, Fe, Zr）z-sintered magnets. SA solution can not only prevent powders from oxidizing in MIM, but also does not damage magnetic properties and microstructure of Sm（Co, Cu, Fe, Zr）z magnets. The oxygen content of Sm（Co, Cu, Fe, Zr）z-sintered magnets by MIM is 3300μg·g^-1.

Mechanical Properties of Carbon Epoxy Prepreg Insert Phenolic Resin Injection Moldings

This study focuses on the insert-injection molding process. The thermoset composite inserts in this study were carbon fiber/epoxy (CF/Epoxy) prepreg sheets. The injected molded part was glass fiber contained phenolic resin (GF/PF). The CF/Epoxy was placed in the mold cavity prior to injecting GF/PF onto the inserted injection molded CF/Epoxy specimens. The role of adhesion between the inserted part and injected resin on the mechanical properties was evaluated by 3 point bending and impact tests. In addition, the effect of prepreg orientation on the mechanical properties of the prepreg inserted-injection molding system was investigated. It was found that the prepreg with unidirectional orientation significantly improved flexural and impact strength of the inserted injection molding composites, providing better support and resistance to bending and impact loading. The main failure modes of the specimens were structural and adhesive failure.

Influence of the Compacts Homogeneity on the Incidence of Cracks during Thermal Debinding in Ceramic Injection Molding

During thermal debinding in ceramic injection molding, the inhomogeneity of green body is a key origin of cracks. In this study, the impact of low molecular weight binders on the homogeneity of the green body was investigated. Incidence of cracks during thermal debinding indicated that the volume ratio of wax to stearic acid should be out of high viscosity and incompletely wetting region. In these two formulation regions, typical inhomogeneous microstructures were observed. By mercury intrusion method, it was shown that pore size distribution of the debinded compacts was determined by thermal degradation of low molecular weight binders. A particle-rich region model was established to predict the nucleation of cracks caused by solid loading fluctuation. The criterion of cracks nucleation was that local capillary force from solid loading fluctuation was larger than the suction force from the surroundings.

Injection molding of micro patterned PMMA plate

A plastic plate with surface micro features was injection molded to investigate the effect of pressure rise of melt on the replication of the micro structures. Prism pattern, which is used in many optical applications, was selected as a model pattern. The prism pattern is 50 μm in pitch and 108° in the vertical angle. The overall size of the plate was 335 minx213 mm and the thickness of the plate varied linearly from 2.6 mm to 0.7 ram. The prism pattern was firstly machined on the nickel plated core block using micro diamond tool and this machined pattern core was installed in a mold for injection molding of prism patterned plate. Polymethyl methacrylate （PMMA） was used as a molding material. The pressure and temperature of the melt in the cavity were measured at different positions in the cavity and the replication of the pattern was also measured at the same positions. The results show that the pressure or temperature profile through the process depends on the shape and the size of the plate. The replication is affected by the temperature and pressure profiles at the early stage of filling, which is right after the melt reaches the position to be measured.

Injection molding of ultra-fine Si_3N_4 powder for gas-pressure sintering

The ceramic injection molding technique was used in the gas-pressure sintering of ultra-fine Si3N4 powder. The feedstock＇s flowability, debinding rate, defect evolution, and microstructural evolution during production were explored. The results show that the solid volume loading of less than 50vol% and the surfactant mass fraction of 6wt% result in a perfect flowability of feedstock; this feedstock is suitable for injection molding. When the debinding time is 8 h at 40°C, approximately 50% of the wax can be solvent debinded. Defects detected during the preparation are traced to improper injection parameters, mold design, debinding parameters, residual stress, or inhomogeneous composition distribution in the green body. The bulk density, Vickers hardness, and fracture toughness of the gas-pressure-sintered Si3N4 ceramic reach 3.2 g/cm^3, 16.5 GPa, and 7.2 MPa·m^1/2, respectively.