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Expectation of the parts quality on the ground the simulation of the injection moulding process

Nabialek J., Koszkul J., Gnatowski A.

Archives of Materials Science and Engineering

2008

Vol. 32, nr 2

109-112

Purpose: The aim of this paper was to present results of researches concerned to predestining quality of polymer parts created by injection moulding method. The estimation of structural solution quality was made on the grounds of the injection moulding computer simulation. Results of studies were compared with predictions presented in professional literature. Design/methodology/approach: Series of injection moulding computer simulations were carried out for different structural solutions of chosen polypropylene part. Supported by taken results predicted quality of part was evaluated. Next literature studies were carried out to compare taken results with instances happened in industrial practice. The analysis of computer simulations usability in designing process of polymer products was made. For the simulation investigations a professional computer software Moldflow Plastics Insight ver. 6.1. has been employed. Findings: Modern computer programs for injection moulding process simulation allow us to predict the quality of final product. Applied algorithms and calculation methods makes elimination of structural defects possible, on the stage of production process designing. Using computer methods to design and optimization of structural conclusions of parts, cut down time and costs of initiating to production. Research limitations/implications: Authors didn’t have the possibility to inject part in every considered in the article structural versions. In the future it is planed to realize the appropriate injection moulds that make possible the presentation of probable structural errors of polymer parts. Moulds like this could have big educational meaning. Practical implications: Results received during studies are going to be used during didactic studies with students and during trainings for injection moulding machines operators. Originality/value: Results of studies presented in the article permit us to understand the meaning of simulating computer programs application in designing and initiating to production of polymer parts

Investigations of the plastics flow during the injection molding process - selected results

Nabialek J., Kwiatkowski D.

Journal of Achievements in Materials and Manufacturing Engineering

2006

Vol. 17, nr 1-2

225--228

Purpose: The purpose of present paper was presenting chosen results of investigations on polymer flow during mould cavity filling phase of injection process. Deep understanding of the phenomena which occur during filling the injection mould may lead to more effective design of the processing tools and shortening of the time for implementation and production time. Design/methodology/approach: The results of computer simulations of injection process have been compared with the results of video recording for the plastic flow during filling phase. For the simulation investigations a professional computer software Moldflow Plastics Insight ver. 4.1. has been employed. A specialized injection mould which enables observation and registration of the plastic flow during processing has been employed. The mould enables direct monitoring of the course of phenomena inside the mould cavity in two planes. To record the flow, a digital video camera has been employed. As an example the issue of flowing around the rectangular obstacle of the plastic stream and flowing through the throat have been described. Findings: The results of the investigations enabled documenting of specific phenomena which occur during plastics or their composites injection process. The registered video sequences have been compared with the results of numerical calculations and then it was estimated to what degree the computer simulation of injection process may be useful in practice. Research limitations/implications: The camera enabled to register the flows with the rate of 25 fps. This reduced the scope of the investigations, since at higher plastic flow speeds the registered image became less clear. The investigations were performed on a wide scale, however, only chosen results have been presented. Originality/value: The transparent sight-glasses have been used, made of a material called Zerodur® which is characterized by the coefficient of thermal expansion close to zero.