Numerical Investigation on the Effect of Injection Pressure on Melt Front Pressure and Velocity Drop

Abstract:

Computational Fluid Dynamic (CFD) was used to simulate the injection molding process of a tray. The study focuses on pressure distribution and velocity drop during the injection process. CFD simulation software ANSYS FLUENT 14 was utilized in this study. The melt front pressure in the mold cavity shows that it was affected by the shape of mold cavity and filling stage. The melt front pressure will decrease as the flow move further than the sprue but it will increase rapidly when the mold was about to be fully filled. The slight pressure drop was detected when the molten flow meets the rib of the tray. The velocity of higher injection pressure was greater than the lower injection pressure but the velocity rapidly dropped when the melt front fully filled the cavity. The current predicted flow profile was validated by the experimental results, which demonstrates the excellent capability of the simulation tool in solving injection-molding problems.

• Periodical: Applied Mechanics and Materials (Volume 786)
• Pages: 210-214
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.786.210
• Online since: August 2015
• Authors: M.S. Rusdi, Mohd Zulkifly Abdullah, Abdus Samad Mahmud, C.Y. Khor, M.S. Abdul Aziz, Muhammad Khalil Abdullah*, H. Yusoff, S.M. Firdaus
• Keywords: Injection Molding, Injection Pressure, Melt Front, Velocity Drop

References

[1] M.K. Abdullah, M.Z. Abdullah, M.A. Mujeebu, S. Kamaruddin, Z.M. Ariff, Study on the effect of stack thickness during encapsulation of Stacked-Chip Scale Packages (S-CSP), Journal of Microelectronics and Electronic Packaging. 5: 2 (2008) 62-67.

DOI: 10.4071/1551-4897-5.2.62

[2] A.G. Smith, L.C. Wrobel, B.A. McCalla, P.S. Allan, P.R. Hornsby, A Computational Model for the Cooling Phase of Injection Moulding, J. Mater. Process. Technol., 195: 1–3 (2008) 305–313.

DOI: 10.1016/j.jmatprotec.2007.05.018

[3] A. Rudert, R. Schwarze, Experimental and Numerical Investigation of a Viscoplastic Carbopol Gel Injected into a Prototype 3D Mold Cavity, J. Nonnewton. Fluid Mech., 161: 1–3 (2009) 60–68.

DOI: 10.1016/j.jnnfm.2009.04.006

[4] M. Tutar, A. Karakus, Computational Study of the Effect of Governing Parameters on a Polymer Injection Molding Process for Single-Cavity and Multicavity Mold Systems, J. Manuf. Sci. Eng., 132: 1 (2010) 100-110.

DOI: 10.1115/1.4000620

[5] C. A. Hieber, H. H. Chiang, Shear-rate-dependence Modeling of Polymer Melt Viscosity, Polym. Eng. Sci., 32: 14 (1992) 931–938.

DOI: 10.1002/pen.760321404

[6] H. Hassan, N. Regnier, C. Pujos, E. Arquis, G. Defaye, Modeling the Effect of Cooling System on the Shrinkage and Temperature of the Polymer by Injection Molding, Appl. Therm. Eng., 30: 13 (2010) 1547–1557.

DOI: 10.1016/j.applthermaleng.2010.02.025

[7] C.Y. Khor, Z.M. Ariff, F.C. Ani, M.A. Mujeebu, M.K. Abdullah, M.Z. Abdullah, M.A. Joseph, Three-Dimensional Numerical and Experimental Investigations on Polymer Rheology in Meso-Scale Injection Molding, Int. Commun. Heat Mass Transfer, 37: 2 (2010).

DOI: 10.1016/j.icheatmasstransfer.2009.08.011