Integrative Analysis of the Injection Molding Process and Mechanical Behavior of Plastic Part

Abstract:

For parts made of plastics, injection molding is a common manufacturing process. Warpage and residual stress induced during the injection molding process have very important influences on the mechanical performance of injection products. In this paper, an integrative analysis of the injection molding process and mechanical performance of plastic parts is proposed. This integrative approach incorporates the effects of the manufacturing process in the mechanical simulation: (a) firstly, the finite element package MoldFlow is used to simulate the injection molding process and obtain the warpage and residual stress results. (b) Then the finite element model of plastic part including the process induced warpage and residual stress is established. Explicit dynamic finite element program LS-DYNA is used to simulate the mechanical behaviors of the molded part. Based on the integrative analysis, the influences of injection molding process parameters on mechanical behavior of a PC windshield against impact loading are studied.

• Periodical: Advanced Materials Research (Volume 705)
• Pages: 181-186
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.705.181
• Online since: June 2013
• Authors: Qing Wen Zhang, Ying Jie Xu, Wei Hong Zhang, Jun Wang
• Keywords: Finite Element Method (FEM), Injection Molding, Integrative Analysis, Mechanical Behavior, Plastic Part

References

[1] G.U. Yuanxian, L.I. Haimei, S. Changyo, Numerical simulation of thermally induced stress and warpage in injection-molded thermoplastics, Adv. Polym. Technol. 20 (2001) 14-21.

DOI: 10.1002/1098-2329(200121)20:1<14::aid-adv1001>3.0.co;2-s

[2] S.J. Lui, Modeling and simulation of thermally induced stress and warpage in injection molded thermoplastics, Polym. Eng. Sci. 36 (1996) 807-818.

DOI: 10.1002/pen.10468

[3] B.H. Lee, B.H. Kim, Optimization of part wall thicknesses to reduce warpage of injection-molded parts based on the modified complex method, Polym. Plast. Technol. Eng. 34 (1995) 793-811.

DOI: 10.1080/03602559508009600

[4] T.J. Wang, C.K. Yoon, Shrinkage and warpage analysis of injection molded parts, in: SPE ANTEC Tech., 2000, pp.687-692.

[5] H. Ming-Chih, T. Ching-Chih, The effective factors in the warpage problem of an injection-molded part with a thin shell feature, J. Mater. Process. Technol. 110 (2001) 1-9.

[6] Y. Gao, X. Wang, Surrogate-based process optimization for reducing warpage in injection molding, J. Mater. Process. Technol. 209 (2009) 1302-1309.

DOI: 10.1016/j.jmatprotec.2008.03.048

[7] X.J. Wang, Z.Z. Feng, F.S. Wang, Z.F. Yue, Dynamic response analysis of bird strike on aircraft windshield based on damage-modified nonlinear viscoelastic constitutive relation, Chinese. J. Aeronaut. 20 (2007) 511-517.

DOI: 10.1016/s1000-9361(07)60075-2