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EN
The objective of this study is to determine the different micro damages caused to the socket of an orthopedic prosthesis, during its drilling before and after static tensile test, in order to estimate the ultimate microscopic damage when drilling. For this, carbon-c-orthocryl composite material specimens were produced by infusion moulding, a mechanical test is carried static traction and charpy impact, to determine their mechanical performance. To quantify and compare the different damages caused by machining, SEM microscopy was carried out through deferent surfaces. The results Visualize that the material has undergone all the known Degradations including resin breakage, intralaminar, translaminar, and interlaminar delamination, decohesion, and fiber ruptures are consistent with those referenced in the bibliography., All these degradations were identified and quantified to determine their origins. Poor wetting between the fibers and the resin was identified, to address this, it was recommended to review the moulding technique by increasing the amount of retarder. Furthermore, the contribution of this study yield essential insights into the structural laminate and the resin composition, providing a pathway for enhancing carbon-c-orthocryl socket machinability to drilling.
EN
The EVOP (Evolutionary Operation) method was used to optimize the low-density polyethylene injection process under real-world production conditions. EVOP allows for small, controlled changes in key process parameters without the need to stop the process. Analysis of data collected during the injection process allowed us to determine the optimal injection and cooling times for injection molded parts, which translated into improved quality (tensile strength, elongation at break) and greater process stability. It was demonstrated that even small changes in the tested parameters can lead to significant quality improvements, making this method an effective tool for continuous improvement in industrial settings.
PL
Zastosowano metodę EVOP (Evolutionary Operation) do optymalizacji procesu wtryskiwania polietylenu małej gęstości w rzeczywistych warunkach produkcyjnych. EVOP umożliwia niewielkie, kontrolowane zmiany kluczowych parametrów procesu bez konieczności jego zatrzymywania. Analiza danych zbieranych podczas procesu wtryskiwania pozwoliła określić optymalny czas wtrysku i chłodzenia wyprasek wtryskowych, co przełożyło się na poprawę ich jakości (wytrzymałość na rozciąganie, wydłużenie przy zerwaniu) i większą stabilność procesu. Wykazano, że nawet niewielkie zmiany badanych parametrów mogą prowadzić do istotnej poprawy jakości, co czyni tę metodę skutecznym narzędziem ciągłego doskonalenia w warunkach przemysłowych.
EN
The results of the research project POIR.01.01.01-00-0760/18 implemented from the funds of the Smart Growth Operational Program in the years 2014-2020 entitled “Development of a new technology for manufacturing details from polymer materials with significantly improved mechanical and visual properties” at Splast Ltd. were presented. Atomic force microscopy (AFM) and scanning electron microscopy (SEM) were used to assess the structure of the composites. The strongest interactions at the composite-coating interface were observed in the case of the use of varnish (interphase boundary width). The composites were characterized by gloss in the range of 32.6-448 GU, which classifies them as semi-gloss or glossy materials. SEM micrographs confirmed the correctness of the selection of materials, as evidenced by good fiber dispersion in the polymer matrix, while maintaining a characteristic round shape.
PL
Przedstawiono wyniki badań projektu POIR.01.01.01-00-0760/18 realizowanego ze środków Programu Operacyjnego Inteligentny Rozwój w latach 2014-2020 pt. „Opracowanie nowej technologii wytwarzania detali z materiałów polimerowych o znacząco poprawionych właściwościach mechanicznych i wizualnych” w Splast Sp. z o.o. Do oceny struktury kompozytów użyto mikroskopię sił atomowych (AFM) i skaningową mikroskopię elektronową (SEM). Najsilniejsze oddziaływania na granicy faz kompozyt-powłoka zaobserwowano w przypadku zastosowania powłoki lakierniczej (szerokość granicy międzyfazowej). Kompozyty charakteryzowały się połyskiem w zakresie 32,6-448 GU, co klasyfikuje je jako materiały z półpołyskiem lub połyskiem. Mikrofotografie SEM potwierdziły poprawność doboru materiałów, o czym świadczy dobra dyspersja włókna w osnowie polimerowej, przy zachowaniu charakterystycznego okrągłego kształtu.
EN
Microporous products were obtained by injection molding. The effect of adding 1-5 wt% of a foaming agent (Expancel® FG92 MB 120) on selected properties of TPS/PBAT blend compatibilized with maleic anhydride-grafted PLA (MPLA) was investigated. The addition of a foaming agent did not significantly affect the wetting properties or the energetic character of the surface. SEM analysis showed that, unlike blow molding, injection molding, due to the high flow rate, high pressure, and rapid cooling, leads to the formation of closed but deformed pores. Significant structural variability and increased surface roughness occur along the flow direction, which is not fully correlated with internal porosity. This structure results in only minor changes in mechanical properties compared to the solid material. Density, hardness, tensile strength and elongation at break gradually decrease and moisture absorption increases with increasing foaming agent content.
PL
Mikroporowate wyroby otrzymano metodą formowania wtryskowego. Zbadano wpływ zawartości środka spieniającego (Expancel® FG92 MB 120), stosowanego w ilości 1, 3 i 5% mas., na wybrane właściwości mieszaniny TPS/PBAT kompatybilizowanej PLA szczepionym bezwodnikiem maleinowym (MPLA). Dodatek środka spieniającego nie wpłynął znacząco na właściwości zwilżające ani na charakter energetyczny powierzchni. Analiza SEM wykazała, że w przeciwieństwie do formowania z rozdmuchem, formowanie wtryskowe, ze względu na dużą szybkość przepływu, wysokie ciśnienie i szybkie chłodzenie, prowadzi do tworzenia się zamkniętych, ale zdeformowanych porów. Wzdłuż kierunku przepływu występuje duża zmienność struktury i większa chropowatość powierzchni, która nie jest w pełni skorelowana z porowatością wewnątrz materiału. Taka struktura powoduje jedynie niewielkie zmiany właściwości mechanicznych w stosunku do materiału litego. Gęstość, twardość, wytrzymałość na rozciąganie i wydłużenie przy zerwaniu stopniowo zmniejszają się, a chłonność wilgoci zwiększa wraz ze wzrostem zawartości środka spieniającego.
EN
The simulation of the thermoplastic injection process was carried out using the Autodesk Simulation Moldflow Insight software. The seven-parameter Cross-WLF rheological model was adopted for the tests. Knowledge of the pvT relationship is essential for simulating the pressing phase and for determining the residual stresses and deformation of the molded parts. For this purpose, the Tait equation was used in the numerical analysis. In the initial stage of the simulation, a solid model of the molded part was created using the Siemens NX software. In the subsequent step, the molded part model was imported, and the FEM mesh was applied. Then, the injection process parameters were entered into the program. This data included thermal, rheological, and mechanical properties of the injected thermoplastic. The recorded video sequences were compared with the results of numerical simulations, and the extent to which computer modeling of the injection process can be useful in practice was assessed.
EN
This study intended to investigate the impact of two distinct shaping methods, Injection molding and pellet additive manufacturing, on tensile and thermal properties of PLA based materials. It included comparisons of neat PLA and PLA reinforced with carbon nanoparticles derived from groundnut shells (GNSC) via pyrolysis at 800°C. These nanoparticles were characterized using FTIR, XRD, FESEM, and EDX analyses to assess their carbon content, morphology, and structure. The synthesized carbon was used as a reinforcement filler in the PLA matrix and biobased polymer nanocomposites were prepared by pellet 3D printing and injection molding. The mechanical and thermal characteristics of PLA/GNSC composite specimens with 0.25, 0.5, and 0.75 wt% of GNSC nanoparticles were compared. Reinforcing PLA with GNSC nanoparticles improved tensile properties in both shaping techniques. The PLA/GNSC_0.5 exhibited the greatest tensile strength, measuring 58.61 MPa for injection molded samples and 53.05 MPa for 3D printed samples, representing a 50% enhancement compared with neat PLA. The tensile modulus was also highest for PLA/GNSC_0.5, measuring 1.24 GPa for injection molded samples and 1.21 GPa for 3D printed samples, representing an improvement of 14% compared with neat PLA. The tensile characteristics showed a modest increase in tensile strength (9-13%) and a slight improvement in tensile modulus (2-3%) for injection molded samples compared to 3D printed samples. The thermal properties showed no substantial variation between the two shaping methods. These findings highlight the effectiveness of GNSC nanoparticles in enhancing the mechanical and thermal performance of PLA composites, regardless of the shaping technique.
EN
The article presents preliminary research on the influence of calcium phosphate (10–40 wt%) on the functional properties of ABS. Maleic anhydride grafted polyethylene was used as a compatibilizer (0.5 wt%). The mass flow rate, tensile properties and hardness were determined. The effect of the filler on the color change of the polymer matrix was also examined. For a composite containing 20 wt% calcium phosphate, the mechanical properties of samples obtained by 3D printing and injection molding were compared, with worse properties obtained by 3D printing. This can be explained by limited adhesion between the printed layers.
PL
W artykule przedstawiono wstępne badania wpływu fosforanu wapnia (10–40% mas.) na właściwości użytkowe ABS. Jako kompatybilizator użyto polietylen szczepiony bezwodnikiem maleinowym (0,5% mas.). Określono masowy wskaźnik szybkości płynięcia, właściwości mechaniczne przy rozciąganiu i twardość. Zbadano także wpływ napełniacza na zmianę barwy osnowy polimerowej. Dla kompozytu zawierającego 20 wt% fosforanu wapnia porównano właściwości mechaniczne próbek uzyskanych metodą druku 3D i formowania wtryskowego, przy czym gorsze właściwości uzyskano metodą druku 3D. Można to wyjaśnić ograniczoną przyczepnością pomiędzy drukowanymi warstwami.
EN
Influence of the height of the molding cavity and the injection speed for three PP grades with different mass melt flow rate (MFR) on the molded parts mass and longitudinal shrinkage, before and after UV aging, was investigated. It was shown that the mass of the molded parts depends on the flow rate of the material and the volume of the molding cavity, while shrinkage depends only on the volume of the mold cavity and is greater after aging.
PL
Zbadano wpływ wysokości gniazda formującego i prędkości wtrysku dla trzech odmian PP o różnym wskaźniku szybkości płynięcia (MFR) na masę wyprasek oraz skurcz wzdłużny, przed i po starzeniu UV. Wykazano, że masa wyprasek zależy od szybkości przepływu tworzywa i objętości gniazda formującego, skurcz tylko od objętości gniazda formy i jest większy po starzeniu.
EN
The purpose of this study is to determine the effect of manufacturing conditions on the mechanical properties and structure of ABS parts. Two sets of samples with the same geometric characteristics were produced by fused deposition modelling (FDM) and injection molding (IM). The molding pressure and cooling rate were found to have a significant effect on shaping the mechanical properties and structure of ABS products. The manufacturing method and adopted process parameters have a significant impact on the degree of packing of macromolecules in the volume of the product and thus determine its density. Selected mechanical properties were determined and compared with their specific gravity. The research was carried out using tools and machines, i.e. injection molds of unique design and standard measuring stations. Tensile and bending strengths and Young’s modulus were related to the density of products obtained under different process conditions and having gradient and solid structures. The results provide useful information for engineers designing products using FDM technology. Relating tensile and flexural strength and Young’s modulus to the specific gravity of the product. It was found that the value of product properties is closely related to various process conditions, which further provides a true description of the products.
EN
The paper shows the results of computer modeling of the polymer injection molding process. The influence of the gating system design on the warpage and volumetric shrinkage of the molded part was investigated. Particular attention was paid to the location of the gate. It has been proven that the selection of the place where the material is brought to the molding cavity has a significant impact on the final shape and quality of the molded part. The degree of compliance of its shape with the assumptions and dimensional accuracy was adopted as the criteria for assessing the quality of the molded part. The specialized software package Autodesk Moldflow Insight was used for numerical calculations. The obtained modeling results were related to the design recommendations of gating systems known from the literature.
EN
The most frequently used method for measuring surface roughness is profilographometry. However, with complex and non-homogeneous surfaces, this method may be subject to large errors because of its contact nature and limitations related to the geometry of the measuring head. In this study, the surface topography was examined on polypropylene injection moldings produced using an injection mold with a complex molding cavity surface. The moldings were modified using a Nd:YAG laser, and the obtained structures were examined using two measurement methods, i.e. contact (profilographometry) and optical (3D digital microscopy). Researchers performed a statistical analysis to determine the differences between the measurement results obtained for the two methods. Additionally, the impact of the laser parameters on the modified surface was determined. The obtained results showed significant differences between the values of measurements made using different methods, especially in the case of surfaces that were modified by the laser beam to the greatest extent (laser A parameters). In all cases where a statistically significant difference was found between the measurement results, the mechanical method showed lower roughness values than the optical method, and the average difference between these results was 15%.
EN
In recent years, a significant increase in the development of new composite materials with desirable mechanical, thermal or surface properties has been observed. One of the popular polymers on the market is polylactide. This article explores how to modify the polymer using steel fibres and organosilicon compounds (SSQ-SH, SSQ-SH-OCT, and SSQ-SH-OFP) to enhance its properties. Test samples were obtained by injection molding with varying concentrations of 0.5%, 1%, 1.5%, 2.5%, and 5% of steel fibres. Mechanical tests, including tensile strength, elongation at break, and impact strength, were conducted, along with an analysis of the contact angle. The modified samples showed higher impact strength values, with the PLA /steel fibres /SSQ-SH sample seeing an increase of 12%. The addition of modifiers with fluoroalkyl groups led to a contact angle increase of 8.5% compared to neat PLA. Thermal tests (TGA) were also carried out to determine the influence of fibres and organosilicon compounds on decomposition.
EN
The article describes the method of producing car parts using the Freeform method (FIM). The injection process into a mold obtained by 3D printing was simulated and the surface condition of the finished product made of high-strength PEEK was assessed.
PL
W artykule opisano sposób wytwarzania części samochodowych metodą Freeform (FIM). Przeprowadzono symulację procesu wtryskiwania do formy otrzymanej metodą druku 3D i dokonano oceny stanu powierzchni gotowego wyrobu z tworzywa o dużej wytrzymałości (PEEK).
EN
The effect of the chemical foaming on the structure (SEM) and selected properties of glass fi ber (30, 60 wt%) reinforced polyamide 6 (PA 6) was investigated. Density, tensile properties and Charpy impact strength were determined. Hydrocerol ITP 825 was used as a blowing agent in the amount of 2 wt%. The size of the pores and the foaming degree depended on the distance from the injection point. The smallest pore size (64 μm) was observed for 60 wt% glass fiber reinforced PA6.
PL
Zbadano wpływ procesu spieniania chemicznego na strukturę (SEM) oraz wybrane właściwości poliamidu 6 wzmocnionego włóknem szklanym (30, 60 % mas.). Oznaczono gęstość, właściwości mechaniczne przy rozciąganiu i udarność Charpy’ego. Jako porofor stosowano Hydrocerol ITP 825 w ilości 2% mas. Wielkość porów i stopień spieniania zależały od odległości od punku wtryskiwania. Najmniejszą wielkość porów (64 μm) stwierdzono w przypadku poliamidu zawierającego 60% mas. włókna szklanego.
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EN
The geometrical accuracy of injection-molded gears made of PA6, PA66 and PPA filled with glass fiber (30, 35 and 50%) were investigated. Using the AMI software, the injection mold cavity and the injection point distribution were simulated and the orientation of the glass fibers in the product was determined. The low accuracy class of injection-molded gears may indicate the need to optimize the injection process, which will be the subject of further research.
PL
Zbadano dokładność geometryczną formowanych wtryskowo kół zębatych wykonanych z PA6, PA66 i PPA napełnionych włóknem szklanym (30, 35 i 50%). Za pomocą oprogramowania AMI przeprowadzono symulację gniazda formy wtryskowej i rozmieszczenia punktu wtrysku oraz określono orientację włókna szklanego w wyrobie. Niska klasa dokładności formowanych wtryskowo kół zębatych może wskazywać na konieczność optymalizacji procesu wtryskiwania, co będzie przedmiotem dalszych badań.
EN
This paper describes a stability study of a plastic injection molding process. There is a need - underpinned by economic considerations - to continuously improve and lead to a maximum reduction in the level of deficiencies in production processes. One of the methods that can help to improve the process is SPC (Statistical Process Control). One of the SPC tools are proces capability indicators (Cp, Cpk) or performance indicators, such as Pp, Ppk. In this paper, on a mass measuring station, a study was conducted on three types of products manufactured in a company, and the measurements concerned each piece of the product manufactured during one work shift. The data collected were used to calculate the process capability and to evaluate these processes.
EN
This study presents an assessment of the effects of usage time for polypropylene (PP) experimental samples including those dyed with pigments of different UV resistance. A standard double cavity mold was used to create the samples by injection molding. Selected indices were analyzed in terms of color change (UV resistance of pigments), and UV radiation resistance of a PP polymer medium. The experiment revealed a significant impact of the accepted usage time and the type of dye concentrates on the indices characterizing the sample color change (CIELab) and a change in the structure and state of the PP medium surface.
PL
Oceniono wpływ czasu użytkowania próbek PP, w tym barwionych pigmentami o różnej odporności na UV, na wybrane wskaźniki użytkowe. Próbki doświadczalne wytworzono metodą wtryskiwania z zastosowaniem standardowej dwugniazdowej formy badawczej. Analizę wybranych wskaźników barwionych próbek przeprowadzono na podstawie: wyznaczonej zmiany barwy (odporność na UV pigmentów), a także odporności na promieniowanie UV nośnika polimerowego (PP). Wykazano istotny wpływ przyjętego w programie badań czasu użytkowania oraz rodzaju koncentratów barwiących na wartości wskaźników charakteryzujących barwę próbek (CIELab), a także strukturę i stan powierzchni tworzywa użytego jako nośnik (PP).
EN
Thin-walled plastic parts are susceptible to deformation during injection molding. Using the example of a notebook battery cover, optimization of the injection mold design and injection process parameters was performed with Moldflow software, which resulted in about 69% reduction of the deformations. Moreover, the uneven material shrinkage during the injection process has been shown to be the main cause of deformations of thin-walled plastic parts.
PL
Cienkościenne elementy z tworzyw polimerowych są podatne na odkształcenia podczas formowania metodą wtryskiwania. Na przykładzie pokrywy baterii notebooka dokonano optymalizacji konstrukcji formy wtryskowej oraz parametrów procesu wtrysku w programie Moldflow, co pozwoliło na zmniejszenie odkształceń o około 69%. Ponadto wykazano, że nierównomierny skurcz materiału podczas procesu wtryskiwania jest główną przyczyną deformacji cienkościennych elementów z tworzyw polimerowych.
EN
The article deals with issues related to quality management and quality assessment in production of plastic articles in injection moulding. Expert knowledge collected in textbooks and literature allows to get acquainted with the characteristics of plastic article production and product quality defects arising in such processes. The characteristics and technology of plastics processing are discussed, the most frequent quality defects occurring in the production of articles made of plastics by injection molding are listed. On the basis of expert knowledge collected in the literature, a series of actions leading to the elimination of each of the mentioned quality defects has also been proposed.
EN
Injection molding can undoubtedly be regarded as one of the most widely used manufacturing processes for polymers (Guevara-Morales & Figueroa-Lopez, 2014). Furthermore, injection molding has found its way into various branches of industry (Fernandez et al., 2018) since it has several essential advantages over other processing techniques in terms of good surface finish, the ability to process complex parts without the need for secondary operations, and low cost for mass production. In order to find optimal process settings, it is necessary to gain a deeper insight into the filling process and the underlying physical phenomena, as well as a thorough understanding of the complex material behavior. In this context, the numerical simulation of the injection molding process is increasingly important. Therefore, the current contribution is dedicated to present a thorough comparative numerical study for the mold filling of an exemplary thin-walled mold geometry, including a realistic non-Newtonian viscosity model for the polymer melt. For the numerical simulation, the authors employ the commercial CFD software packages Cadmould 3D-F and ANSYS CFX. While ANSYS CFX is a well-established CFD software for numerical modelling of multiphysical phenomena, Cadmould 3D-F is a highly specialized and computationally efficient alternative suitable for certain geometric configurations in the context of injection molding. The present study is new in the sense that it demonstrates the equivalence of the considered software packages for the simulation of the injection molding process in thin-walled mold geometries.
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