Science.gov

Sample records for injection molding

  1. INJECTION-MOLDING APPARATUS

    DOEpatents

    Lobell, G.M.

    1958-02-11

    This patent is drawn to an injection molding apparatus for producing a tube closed at one end wherein the normally unsupported end of the core located in the cavity during the injection of the molten material to fill the space between the core and cavity wall, which supporting means is automatically removed from operation during the forming of the closed end of the tube. This support means is a plug extending through the end of the core into a recess in the bottom of the cavity where the closed end of the tube is to be formed. The plug is spring pressed into said recess and is forced out of the recess by a slidable bushing at the top of the cavity which is moved against the force of the spring by the molten material when it fills the uppormost open end portion of the cavity, thereby permitting the closed end of the tube to be formed.

  2. Low-pressure injection molding

    SciTech Connect

    Mangels, J.A. )

    1994-05-01

    Ceramic injection molding experienced a revival in the 1970s and 1980s with the application of ceramics for gas turbine components. Concurrently, techniques were being developed for the injection molding of powdered metal compositions into complex shaped articles. The impetus for the development of injection molding as a ceramic fabrication process lay in the potential to produce complex-shaped components to near-net shape. In the ceramic injection molding process, ceramic powders are processed to obtain the desired particle size, distribution and morphology and blended to obtain a homogeneous distribution. These powders are then mixed with the organic binders, generally in a heated, highshear mixer at temperatures above the melting point of the organic binders. The injection molding mix is pelletized, cooled and fed into an injection molding machine. The molding mix is reheated to a fluid state and injected under high pressure (7--70 MPa) into a die cavity. The molded part is removed from the tooling after the molding mix has solidified in the die. The organic binders are then removed from the component at temperatures up to 400 C, generally by some combination of wicking and thermal decomposition. Finally, the component is sintered to obtain its final ceramic properties, using conventional ceramic processes.

  3. Ceramic injection molding material analysis, modeling and injection molding simulation

    NASA Astrophysics Data System (ADS)

    Drummer, D.; Messingschlager, S.

    2014-05-01

    In comparison to unfilled polymers, a ceramic feedstocks has a very high viscosity, a very high heat conductivity and a different pvT-behavior. So far standard simulation tools for plastic injection molding are capable of simulating unfilled or fiber filled compounds with their typical low viscosity and heat conductivity etc. but not for very high ceramic powder filled polymers. This article shows an approach of preparing and adding ceramic feedstocks to standard injection molding tools. Two different feedstocks are used.

  4. Injection Molding of Plastics from Agricultural Materials

    SciTech Connect

    Bhattacharya, M.; Ruan, R.

    2001-02-22

    The objective of this research was to conduct a systematic study to relate injection molding parameters to properties of blends of starch and synthetic polymer. From this study, we wished to develop a thorough understanding of the injection molding process and gain significant insight into designing molds and aiding in developing products cheaply and efficiently.

  5. Injection molding ceramics to high green densities

    NASA Technical Reports Server (NTRS)

    Mangels, J. A.; Williams, R. M.

    1983-01-01

    The injection molding behavior of a concentrated suspension of Si powder in wax was studied. It was found that the injection molding behavior was a function of the processing techniques used to generate the powder. Dry ball-milled powders had the best molding behavior, while air classified and impact-milled powders demonstrated poorer injection moldability. The relative viscosity of these molding batches was studied as a function of powder properties: distribution shape, surface area, packing density, and particle morphology. The experimental behavior, in all cases, followed existing theories. The relative viscosity of an injection molding composition composed of dry ball-milled powders could be expressed using Farris' relation.

  6. Porous media heat transfer for injection molding

    DOEpatents

    Beer, Neil Reginald

    2016-05-31

    The cooling of injection molded plastic is targeted. Coolant flows into a porous medium disposed within an injection molding component via a porous medium inlet. The porous medium is thermally coupled to a mold cavity configured to receive injected liquid plastic. The porous medium beneficially allows for an increased rate of heat transfer from the injected liquid plastic to the coolant and provides additional structural support over a hollow cooling well. When the temperature of the injected liquid plastic falls below a solidifying temperature threshold, the molded component is ejected and collected.

  7. Planning an Injection Mold Design Training Program.

    ERIC Educational Resources Information Center

    Allyn, Edward P.

    With the increased use of plastics worldwide the shortage of trained personnel in moldmaking and design for plastic injection molds is becoming critical. Local schools and community colleges should provide courses in mold design and mold making, since most workers presently learn while working under experienced designers on the job. Following this…

  8. Particle Image Velocimetry During Injection Molding

    NASA Astrophysics Data System (ADS)

    Bress, Thomas; Dowling, David

    2012-11-01

    Injection molding involves the unsteady non-isothermal flow of a non-Newtonian polymer melt. An optical-access mold has been used to perform particle image velocimetry (PIV) on molten polystyrene during injection molding. Velocimetry data of the mold-filling flow will be presented. Statistical assessments of the velocimetry data and scaled residuals of the continuity equation suggest that PIV can be conducted in molten plastics with an uncertainty of +/-2 percent. Simulations are often used to model polymer flow during injection molding to design molds and select processing parameters but it is difficult to determine the accuracy of these simulations due to a lack of in-mold velocimetry and melt-front progression data. Moldflow was used to simulate the filling of the optical-access mold, and these simulated results are compared to the appropriately-averaged time-varying velocity field measurements. Simulated results for melt-front progression are also compared with the experimentally observed flow fronts. The ratio of the experimentally measured average velocity magnitudes to the simulation magnitudes was found on average to be 0.99 with a standard deviation of 0.25, and the difference in velocity orientations was found to be 0.9 degree with a standard deviation of 3.2 degrees. formerly at the University of Michigan.

  9. Rapid control of mold temperature during injection molding process

    NASA Astrophysics Data System (ADS)

    Liparoti, Sara; Hunag, Tsang Min; Sorrentino, Andrea; Titomanlio, Giuseppe; Cakmak, Mukerrem

    2015-05-01

    The control of mold surface temperature is an important factor that determines surface morphology and its dimension in thickness direction. It can also affect the frozen molecular orientation and the mold surface replicability in injection molded products. In this work, thin thermally active films were used to quickly control the mold surface temperature. In particular, an active high electrical conductivity carbon black loaded polyimide composites sandwiched between two insulating thin polymeric layers was used to condition the mold surface. By controlling the heating time, it was possible to control precisely the temporal variation of the mold temperature surface during the entire cycle. The surface heating rate was about 40°C/s and upon contact with the polymer the surface temperature decreased back to 40°C within about 5 s; the overall cycle time increased only slightly. The effect on cross section sample morphology of samples of iPP were analyzed and discussed on the basis of the recorded temperature evolution.

  10. Rapid control of mold temperature during injection molding process

    SciTech Connect

    Liparoti, Sara; Titomanlio, Giuseppe; Hunag, Tsang Min; Cakmak, Mukerrem; Sorrentino, Andrea

    2015-05-22

    The control of mold surface temperature is an important factor that determines surface morphology and its dimension in thickness direction. It can also affect the frozen molecular orientation and the mold surface replicability in injection molded products. In this work, thin thermally active films were used to quickly control the mold surface temperature. In particular, an active high electrical conductivity carbon black loaded polyimide composites sandwiched between two insulating thin polymeric layers was used to condition the mold surface. By controlling the heating time, it was possible to control precisely the temporal variation of the mold temperature surface during the entire cycle. The surface heating rate was about 40°C/s and upon contact with the polymer the surface temperature decreased back to 40°C within about 5 s; the overall cycle time increased only slightly. The effect on cross section sample morphology of samples of iPP were analyzed and discussed on the basis of the recorded temperature evolution.

  11. Powder Injection Molding of Titanium Components

    SciTech Connect

    Simmons, Kevin L.; Nyberg, Eric A.; Weil, K. Scott; Miller, Megan R.

    2005-01-01

    Powder injection molding (PIM) is a well-established, cost-effective method of fabricating small-to-moderate size metal components. Derived from plastic injection molding and employing a mixture of metal powder and plastic binder, the process has been used with great success in manufacturing a wide variety of metal products, including those made from stainless steel, nickel-based superalloys, and copper alloys. Less progress has been achieved with titanium and other refractory metal alloys because of problems with alloy impurities that are directly attributable to the injection molding process. Specifically, carbon, oxygen, and nitrogen are left behind during binder removal and become incorporated into the chemistry and microstructure of the material during densification. Even at low concentration, these impurities can cause severe degradation in the mechanical properties of titanium and its alloys. We have developed a unique blend of PIM constituents where only a small volume fraction of binder (~5 – 10 vol%) is required for injection molding; the remainder of the mixture consists of the metal powder and binder solvent. Because of the nature of decomposition in the binder system and the relatively small amount used, the binder is eliminated almost completely from the pre-sintered component during the initial stage of a two-step heat treatment process. Results will be presented on the first phase of this research, in which the binder, injection molding, de-binding and sintering schedule were developed. Additional data on the mechanical and physical properties of the material produced will be discussed.

  12. Dynamic Feed Control For Injection Molding

    DOEpatents

    Kazmer, David O.

    1996-09-17

    The invention provides methods and apparatus in which mold material flows through a gate into a mold cavity that defines the shape of a desired part. An adjustable valve is provided that is operable to change dynamically the effective size of the gate to control the flow of mold material through the gate. The valve is adjustable while the mold material is flowing through the gate into the mold cavity. A sensor is provided for sensing a process condition while the part is being molded. During molding, the valve is adjusted based at least in part on information from the sensor. In the preferred embodiment, the adjustable valve is controlled by a digital computer, which includes circuitry for acquiring data from the sensor, processing circuitry for computing a desired position of the valve based on the data from the sensor and a control data file containing target process conditions, and control circuitry for generating signals to control a valve driver to adjust the position of the valve. More complex embodiments include a plurality of gates, sensors, and controllable valves. Each valve is individually controllable so that process conditions corresponding to each gate can be adjusted independently. This allows for great flexibility in the control of injection molding to produce complex, high-quality parts.

  13. The research of UV curing injection molding

    NASA Astrophysics Data System (ADS)

    Xie, Pengcheng; Chang, Le; Song, Le; Cai, Tianze; Ding, Yumei; Yang, Weimin

    2015-05-01

    The micro-injection molding technology and the UV (ultraviolet) curing technique are combined to bring about a new plastic forming method, UV curing injection molding. The mean weight of micro-product is an important process characteristic for UV curing injection molding as well as the surface quality of micro-features is another important process characteristic for this new plastic forming method. This research investigates three effects of processing factors on the mass-change rate of micro-product and the surface quality of micro-features. In every particular, the following two factors are considered: UV material system temperature and the packing pressure. The study revealed that as usual, the micro-products gain weight with the imported increasing UV material system temperature and the improved packing pressure. Meanwhile, the increasing packing pressure also improves the surface quality, yet, warming the UV system temperature up has no effect on the quality of the product.

  14. Nanostructuring steel for injection molding tools

    NASA Astrophysics Data System (ADS)

    Al-Azawi, A.; Smistrup, K.; Kristensen, A.

    2014-05-01

    The production of nanostructured plastic items by injection molding with ridges down to 400 nm in width, which is the smallest line width replicated from nanostructured steel shims, is presented. Here we detail a micro-fabrication method where electron beam lithography, nano-imprint lithography and ion beam etching are combined to nanostructure the planar surface of a steel wafer. Injection molded plastic parts with enhanced surface properties, like anti-reflective, superhydrophobic and structural colors can be achieved by micro- and nanostructuring the surface of the steel molds. We investigate the minimum line width that can be realized by our fabrication method and the influence of etching angle on the structure profile during the ion beam etching process. Trenches down to 400 nm in width have been successfully fabricated into a 316 type electro-polished steel wafer. Afterward a plastic replica has been produced by injection molding with good structure transfer fidelity. Thus we have demonstrated that by utilizing well-established fabrication techniques, nanostructured steel shims that are used in injection molding, a technique that allows low cost mass fabrication of plastic items, are produced.

  15. Injection molding and debinding of micro gears fabricated by micro powder injection molding

    NASA Astrophysics Data System (ADS)

    Ni, Xin-lei; Yin, Hai-qing; Liu, Lin; Yi, Shan-jie; Qu, Xuan-hui

    2013-01-01

    Micro powder injection molding (μPIM) was investigated for possible mass production of micro-components at relatively low cost. However, scaling down to such a level produces challenges in injection molding and debinding. Micro gears were fabricated by μPIM from in-house feedstock. The effect of injection speed and injection pressure on the replication of the micro gear cavity was investigated. Solvent debinding and thermal debinding processes were discussed. The results show that micro gears can be successfully fabricated under the injection pressure of 70 MPa and the 60% injection speed. Either too low or too high injection speed can cause incomplete filling of micro gears. The same is the case with too low injection pressure. Too high injection pressure can bring cracks. Solvent debinding of micro gears was performed in a mixture of petroleum ether and ethanol. Subsequently, micro gears were successfully debound by a multistep heating schedule.

  16. Thermal monitoring of the thermoplastic injection molding process with FBGs

    NASA Astrophysics Data System (ADS)

    Alberto, Nélia J.; Nogueira, Rogério N.; Neto, Victor F.

    2014-08-01

    Injection molding is an important polymer processing method for manufacturing plastic components. In this work, the thermal monitoring of the thermoplastic injection molding is presented, since temperature is a critical parameter that influences the process features. A set of fiber Bragg gratings were multiplexed, aiming a two dimensional monitoring of the mold. The results allowed to identify the different stages of the thermoplastic molding cycle. Additionally, the data provide information about the heat transfer phenomena, an important issue for the thermoplastic injection sector, and thus for an endless number of applications that employ this type of materials.

  17. Comparison of injection molding and injection/compression molding for the replication of microstructure

    NASA Astrophysics Data System (ADS)

    Hong, Seokkwan; Hwang, Jeongho; Kang, Jeongjin; Yoon, Kyunghwan

    2015-11-01

    Because of increasing interest in the functional surfaces including micro- or nano-patterns, the mass production of such surfaces has been actively researched. Both conventional injection molding (CIM) and injection/compression molding (ICM) of micro-patterns were investigated in the present study. The molding subject is a multi-scale structure that consists of a macro-scale thin plate and micro-scale patterns formed regularly on its surface. The transcription ratios of micro pattern made by CIM and ICM for different flow length were experimentally measured, and the origin of the obtained results was identified through numerical analysis. It was found that the cavity pressure and polymer temperature are the most important factors for micro-pattern filling; in particular, the polymer temperature is the key factor determining the transcription ratio. It was also found that the difference in CIM and ICM micro-pattern transcription ratios originates from the differences in the cavity pressure history if other molding conditions are the same.

  18. Optomechanical details in injection-molded assemblies

    NASA Astrophysics Data System (ADS)

    Hebert, Raymond T.

    1995-12-01

    With the advent of low-cost electro-optic components such as LEDs, laser diodes and CCD imaging devices, the cost and performance demands now fall upon the optical subsystems in order to achieve realistic marketing targets for many emerging commercial and consumer products. One of the many benefits of injection-molded plastic optics is the diversity of features that are available to the design team. Once designed and incorporated into the tooling, many features are virtually free in high-volume production. These features can include mechanical details as well as optical functions. Registration features can be included for precisely positioning optical elements to one another or to other assemblies such as printed circuit boards or housings. Snaps, compression features, spring-loading elements, standoffs, self-tapping screws or ultrasonically weldable features can greatly facilitate ease of assembly.

  19. Hydrogen silsesquioxane mold coatings for improved replication of nanopatterns by injection molding

    NASA Astrophysics Data System (ADS)

    Hobæk, Thor Christian; Matschuk, Maria; Kafka, Jan; Pranov, Henrik J.; Larsen, Niels B.

    2015-03-01

    We demonstrate the replication of nanosized pillars in polymer (cyclic olefin copolymer) by injection molding using nanostructured thermally cured hydrogen silsesquioxane (HSQ) ceramic coatings on stainless steel mold inserts with mold nanostructures produced by a simple embossing process. At isothermal mold conditions, the average pillar height increases by up to 100% and a more uniform height distribution is observed compared to a traditional metal mold insert. Thermal heat transfer simulations predict that the HSQ film retards the cooling of the polymer melt during the initial stages of replication, thus allowing more time to fill the nanoscale cavities compared to standard metal molds. A monolayer of a fluorinated silane (heptadecafluorotrichlorosilane) deposited on the mold surface reduces the mold/polymer interfacial energy to support demolding of the polymer replica. The mechanical stability of thermally cured HSQ makes it a promising material for nanopattern replication on an industrial scale without the need for slow and energy intensive variotherm processes.

  20. Injection molding of ceramics using a polyacetal based binder system

    SciTech Connect

    Ebenhoech, J.S.

    1996-06-01

    Among the production routes to small complex ceramic parts, powder injection molding is the most attractive alternative. It combines near net shape capability with good surface finish and is easy to automate. With the development of the catalytic debinding process for polyacetal binders, the main impediments for the acceptance of ceramic injection molding as a mass production method can be overcome. The use of this system ensures short molding cycle times, high green strength and fast debinding without deformation. Ready to mold compounds are commercially available for various oxide and non-oxide ceramic materials as well as the equipment needed for this process.

  1. Study on heat flux from resin to mold in injection molding process

    SciTech Connect

    Nishiwaki, Nobuhiko; Hori, Sankei

    1999-07-01

    Recently, an injection molding of thermoplastic is widely used in many industries, because this manufacturing method is very suitable for mass production. For injection molding processes, a number of software packages for simulating an injection molding process have been developed. It is assumed in these software packages that the heat transfer coefficient between the resin and the mold surface is constant at the filling or cooling stages. In general, when melted resin flows into the mold, heat is generated in the flowing resin because of the high viscosity at the filling stage. Moreover at the cooling stage, a separation of the molded part from the mold surface generally occurs because of shrinkage of the molded material. Therefore, the heat transfer coefficient has not been accurately obtained yet at these stages. In this paper, the temperature near the surface of the mold cavity has been experimentally measured, so the heat flux that flows from the resin to the mold has been able to be analytically estimated by an inverse conduction method. On the other hand, the separating behavior of the resin from the mold surface has been measured using an ultrasonic transducer attached to the outer surface of the stationary mold. The heat flux that flows from the resin to the mold has been analytically estimated. The apparent heat transfer coefficient can be obtained from the heat flux and the representative temperature difference, which is measured by an ultrasonic technique. It was discovered that the heat flux and the apparent heat transfer coefficient are hardly influenced by the separation.

  2. Effects of mold geometry on fiber orientation of powder injection molded metal matrix composites

    SciTech Connect

    Ahmad, Faiz Aslam, Muhammad Altaf, Khurram Shirazi, Irfan

    2015-07-22

    Fiber orientations in metal matrix composites have significant effect on improving tensile properties. Control of fiber orientations in metal injection molded metal composites is a difficult task. In this study, two mold cavities of dimensions 6x6x90 mm and 10x20x180 mm were used for comparison of fiber orientation in injection molded metal composites test parts. In both mold cavities, convergent and divergent flows were developed by modifying the sprue dimensions. Scanning electron microscope (SEM) was used to examine the fiber orientations within the test samples. The results showed highly aligned fiber in injection molded test bars developed from the convergent melt flow. Random orientation of fibers was noted in the composites test bars produced from divergent melt flow.

  3. Fabrication of sinterable silicon nitride by injection molding

    NASA Technical Reports Server (NTRS)

    Quackenbush, C. L.; French, K.; Neil, J. T.

    1982-01-01

    Transformation of structural ceramics from the laboratory to production requires development of near net shape fabrication techniques which minimize finish grinding. One potential technique for producing large quantities of complex-shaped parts at a low cost, and microstructure of sintered silicon nitride fabricated by injection molding is discussed and compared to data generated from isostatically dry-pressed material. Binder selection methodology, compounding of ceramic and binder components, injection molding techniques, and problems in binder removal are discussed. Strength, oxidation resistance, and microstructure of sintered silicon nitride fabricated by injection molding is discussed and compared to data generated from isostatically dry-pressed material.

  4. Injection molding simulation with variothermal mold temperature control of highly filled polyphenylene sulfide

    NASA Astrophysics Data System (ADS)

    Birkholz, A.; Tschiersky, M.; Wortberg, J.

    2015-05-01

    For the installation of a fuel cell stack to convert chemical energy into electricity it is common to apply bipolar plates to separate and distribute reaction gases and cooling agents. For reducing manufacturing costs of bipolar plates a fully automated injection molding process is examined. The high performance thermoplastic matrix material, polyphenylene sulfide (PPS), defies against the chemical setting and the operation temperature up to 200 °C. To adjust also high electrical and thermal conductivity, PPS is highly filled with various carbon fillers up to an amount of 65 percentage by volume. In the first step two different structural plates (one-sided) with three different gate heights and molds are designed according to the characteristics of a bipolar plate. To cope with the approach that this plate should be producible on standard injection molding machines with variothermal mold temperature control, injection molding simulation is used. Additionally, the simulation should allow to formulate a quality prediction model, which is transferrable to bipolar plates. Obviously, the basis for a precise simulation output is an accurate description of the material properties and behavior of the highly filled compound. This, the design of the structural plate and mold and the optimization via simulation is presented, as well. The influence of the injection molding process parameters, e.g. injection time, cycle times, packing pressure, mold temperature, and melt temperature on the form filling have been simulated to determine optimal process conditions. With the aid of the simulation and the variothermal mold temperature control it was possible to reduce the required melt temperature below the decomposition temperature of PPS. Thereby, hazardous decomposition products as hydrogen sulfide are obviated. Thus, the health of the processor, the longevity of the injection molding machine as well as the material and product properties can be protected.

  5. Smart plastic functionalization by nanoimprint and injection molding

    NASA Astrophysics Data System (ADS)

    Zalkovskij, Maksim; Thamdrup, Lasse H.; Smistrup, Kristian; Andén, Thomas; Johansson, Alicia C.; Mikkelsen, Niels Jørgen; Madsen, Morten Hannibal; Garnæs, Jørgen; Kristiansen, Tommy Tungelund; Diemer, Mads; Døssing, Michael; Minzari, Daniel; Tang, Peter Torben; Kristensen, Anders; Taboryski, Rafael; Essendrop, Søren; Nielsen, Theodor; Bilenberg, Brian

    2015-03-01

    In this paper, we present a route for making smart functionalized plastic parts by injection molding with sub-micrometer surface structures. The method is based on combining planar processes well known and established within silicon micro and sub-micro fabrication with proven high resolution and high fidelity with truly freeform injection molding inserts. The link between the planar processes and the freeform shaped injection molding inserts is enabled by the use of nanoimprint with flexible molds for the pattern definition combined with unidirectional sputter etching for transferring the pattern. With this approach, we demonstrate the transfer of down to 140 nm wide holes on large areas with good structure fidelity on an injection molding steel insert. The durability of the sub-micrometer structures on the inserts have been investigated by running two production series of 102,000 and 73,000 injection molded parts, respectively, on two different inserts and inspecting the inserts before and after the production series and the molded parts during the production series.

  6. Research on machine vision system of monitoring injection molding processing

    NASA Astrophysics Data System (ADS)

    Bai, Fan; Zheng, Huifeng; Wang, Yuebing; Wang, Cheng; Liao, Si'an

    2016-01-01

    With the wide development of injection molding process, the embedded monitoring system based on machine vision has been developed to automatically monitoring abnormality of injection molding processing. First, the construction of hardware system and embedded software system were designed. Then camera calibration was carried on to establish the accurate model of the camera to correct distortion. Next the segmentation algorithm was applied to extract the monitored objects of the injection molding process system. The realization procedure of system included the initialization, process monitoring and product detail detection. Finally the experiment results were analyzed including the detection rate of kinds of the abnormality. The system could realize the multi-zone monitoring and product detail detection of injection molding process with high accuracy and good stability.

  7. Mathematical modeling of the process of filling a mold during injection molding of ceramic products

    NASA Astrophysics Data System (ADS)

    Kulkov, S. N.; Korobenkov, M. V.; Bragin, N. A.

    2015-10-01

    Using the software package Fluent it have been predicted of the filling of a mold in injection molding of ceramic products is of great importance, because the strength of the final product is directly related to the presence of voids in the molding, making possible early prediction of inaccuracies in the mold prior to manufacturing. The calculations were performed in the formulation of mathematical modeling of hydrodynamic turbulent process of filling a predetermined volume of a viscous liquid. The model used to determine the filling forms evaluated the influence of density and viscosity of the feedstock, and the injection pressure on the mold filling process to predict the formation of voids in the area caused by the shape defect geometry.

  8. Residual stresses in injection molded products

    NASA Astrophysics Data System (ADS)

    Jansen, K. M. B.

    2015-12-01

    During the molding process residual stresses are formed due to thermal contraction during cooling as well as the local pressure history during solidification. In this paper a simple analytical model is reviewed which relates residual stresses, product shrinkage as well as warpage to the temperature and pressure histories during molding. Precise excimer laser layer removal measurements were performed to verify the predicted residual stress distributions. In addition, detailed shrinkage and warpage measurements on a large series of polymers and for different molding conditions were performed and are shown to compare well with the model predictions.

  9. Residual orientation in micro-injection molded parts

    SciTech Connect

    Healy, John; Edward, Graham H.; Knott, Robert B.

    2008-06-30

    The residual orientation following micro-injection molding of small rectangular plates with linear polyethylene has been examined using small-angle neutron scattering, and small- and wide-angle X-ray scattering. The effect of changing the molding conditions has been examined, and the residual chain orientation has been compared to the residual orientation of the crystallites as a function of position in the sample. This study has found that, for micromoldings, the orientation of the crystallites decreases with increasing injection speed and increasing mold thickness. The combined data suggest that the majority of the orientation present comes from oriented crystal growth rather than residual chain orientation.

  10. Measurement of Melt Pressure Distribution on Injection Mold Cavity Surface

    NASA Astrophysics Data System (ADS)

    Murata, Yasuhiko; Nukariya, Akihiro; Matsui, Hiroshi; Yoshinaga, Kazuhiro; Yokoi, Hidetoshi

    In order to clarify undesirable molding phenomena in injection molding, it is important to measure melt pressure distribution on the injection mold cavity in detail. In a previous paper, we reported a new method for measuring melt pressure distribution on the injection mold cavity surface using a mold with a pressure transmission pin array and tactile sensor. In this study, we attempted to measure the variation of melt pressure distribution when the injection rate and the holding pressure are changed. The results indicate phenomenon in which pressure remains near the gate in the cavity until the instant the mold is opened. This phenomenon is considered to be due to the extreme increase in melt density from the filling process through the pressure holding process and cooling process, which causes the melt to cool and solidify before it can shrink adequately. Furthermore, it was also found that there exists a close relation between the thickness distribution, residual pressure distribution and birefringence pattern of molded products.

  11. Rapid control of mold temperature during injection molding process: Effect of packing pressure

    NASA Astrophysics Data System (ADS)

    Liparoti, Sara; Sorrentino, Andrea; Titomanlio, Giuseppe

    2015-12-01

    A thorough analysis of the effect of operative conditions of injection molding process on the morphology distribution inside the obtained molded is performed, with particular reference to semi- crystalline polymers. In particular, fully characterized injection molding tests are presented using an isotactic polypropylene, previously carefully characterized as far as most of properties of interest. The effects of mold temperature and packing conditions are analyzed. The mold temperature was controlled by a thin heating device, composed by polyimide as insulating layer and polyimide loaded carbon black as electrical conductive layer, that is able to increase temperature on mold surface in few seconds (70°C/s) by joule effect and cool down soon after. The shear layer thickness in the molded is reduced in the samples produced at high mold temperatures, that means high electrical power and long heating time, and this reduction is more significant at lower packing pressures, indeed, at 360bar as packing pressure and 20s as heating time the shear layer disappear. The resulting morphology was analyzed by optical microscope.

  12. Residual stresses in injection molded shape memory polymer parts

    NASA Astrophysics Data System (ADS)

    Katmer, Sukran; Esen, Huseyin; Karatas, Cetin

    2016-03-01

    Shape memory polymers (SMPs) are materials which have shape memory effect (SME). SME is a property which has the ability to change shape when induced by a stimulator such as temperature, moisture, pH, electric current, magnetic field, light, etc. A process, known as programming, is applied to SMP parts in order to alter them from their permanent shape to their temporary shape. In this study we investigated effects of injection molding and programming processes on residual stresses in molded thermoplastic polyurethane shape memory polymer, experimentally. The residual stresses were measured by layer removal method. The study shows that injection molding and programming process conditions have significantly influence on residual stresses in molded shape memory polyurethane parts.

  13. Two-component co-injection and transfer molding and gas-assisted injection molding of polymers: Simulation and experiment

    NASA Astrophysics Data System (ADS)

    Li, Chengtao

    Two-component molding is a novel process for manufacturing polymer products with a sandwich structure or a hollow structure. Typically, two different materials are injected or transferred into a mold sequentially or simultaneously. The skin is generally a prime polymer with required surface and bulk properties for intended use. The core can be solid, foam or gas. Obtaining a uniform encapsulated structure is difficult and there are no science-based rules for optimization of process setup. Thus, a physical model and process simulations have been developed based on the kinematics and dynamics of a moving interface, and Hele-Shaw approximation. The model has incorporated temperature and shear rate dependences of viscosity of both skin and core component into the transient interface evolution. Based on the developed model, simulations have been carried out to study flow rate controlled simultaneous co-injection molding of thermoplastics, pressure-controlled sequential transfer molding of rubber compounds, and gas-assisted injection molding (GAIM). The simulation results were compared with the experimental data, and in general, good agreement was found between the predicted and experimentally measured interface distribution in moldings. For simultaneous co-injection molding, it is found that material pairs with a broad range of viscosities may be utilized. Breakthrough phenomena are mainly determined by the volume of melt of initial single phase injection and rheological properties of material combinations. When the core has a lower viscosity than the skin, or the volume of initial injection of skin melt is smaller, breakthrough is very likely. However, the breakthrough can be eliminated by controlling injection rate of the skin and core melts. For sequential transfer molding, it is found that the rubber distribution in moldings are dominated by the rheological properties of components and the volume fraction transferred, but independent of the gate pressure. When the

  14. Autosterilization of biodegradable implants by injection molding process.

    PubMed

    König, C; Ruffieux, K; Wintermantel, E; Blaser, J

    1997-01-01

    Sterilization of degradable implants by standard procedures may damage the parts due to the labile chemical nature of the polymers. This study examined whether the injection molding process used for the production of polymeric parts may itself sterilize the implant due to high temperature, pressure, and shear forces applied. Poly-D,L-lactic acid (PDLLA) and poly-L-lactic acid (PLLA) granules were contaminated with thermoresistant spores of Bacillus stearothermophilus (>10(5) spores/g). Sterile and contaminated granules of both polymers were injection molded and tested for sterility. All 27 samples produced with sterile PDLLA and processed at 120 degrees C and all 18 samples produced with sterile PLLA at 200 degrees C remained sterile after injection molding and handling. However, in five out of 28 PDLLA samples and in one out of 26 PLLA samples produced with contaminated material, spores had survived the process. In conclusion, the injection molding process could not reliably sterilize parts produced with polylactic acid granules that were heavily contaminated with thermoresistant organisms. However, the number of viable spores was significantly reduced by more than 99.99%. Thus, the injection molding process might allow the autosterilization of parts produced with raw material that is not heavily contaminated. PMID:9178738

  15. Injection molded polymer optics in the 21st Century

    NASA Astrophysics Data System (ADS)

    Beich, William S.

    2005-08-01

    Precision polymer optics, manufactured by injection molding techniques, has been a key enabling technology for several decades now. The technology, which can be thought of as a subset of the wider field of precision optics manufacturing, was pioneered in the United States by companies such as Eastman Kodak, US Precision Lens, and Polaroid. In addition to suppliers in the U.S. there are several companies worldwide that design and manufacture precision polymer optics, for example Philips High Tech Plastics in Europe and Fujinon in Japan. Designers who are considering using polymer optics need a fundamental understanding of exactly how the optics are created. This paper will survey the technology and processes that are employed in the successful implementation of a polymer optic solution from a manufacturer's perspective. Special emphasis will be paid to the unique relationship between the molds and the optics that they produce. We will discuss the key elements of production: molding resins, molds and molding equipment, and metrology. Finally we will offer a case study to illustrate just how the optics designer carries a design concept through to production. The underlying theme throughout the discussion of polymer optics is the need for the design team to work closely with an experienced polymer optics manufacturer with a solid track record of success in molded optics. As will be seen shortly, the complex interaction between thermoplastics, molds, and molding machines dictates the need for working closely with a supplier who has the critical knowledge needed to manage all aspects of the program.

  16. An investigation into the injection molding of PMR-15 polyimide

    NASA Technical Reports Server (NTRS)

    Colaluca, M. A.

    1984-01-01

    The chemorheological behavior of the PRM-15 molding compounds were characterized, the range of suitable processing parameters for injection molding in a reciprocating screw injection molding machine was determined, and the effects of the injection molding processing parameters on the mechanical properties of molded PMR-15 parts were studied. The apparatus and procedures for measuring viscosity and for determining the physical response of the material during heating are described. Results show that capillary rheometry can be effectively used with thermosets if the equipment is designed to overcome some of the inherent problems of these materials. A uniform temperature was provided in the barrel by using a circulating hot oil system. Standard capillary rheometry methods can provide the dependence of thermoset apparent viscosity on shear rate, temperature, and time. Process conditions resulting in complete imidization should be carefully defined. Specification of controlled oven temperature is inadequate and can result in incomplete imidization. For completely imidized PMR-15 heat at 15 C/min melt flow without gas evolution occurs in the temperature range of 325 C to 400 C.

  17. Injection molding of optics for high volume consumer products

    NASA Astrophysics Data System (ADS)

    de Schipper, Rien

    2012-03-01

    For high volume consumer products using optical technology, plastics injection molding is a very suitable technology. In optical component fabrication, astonishing results are be booked. However, to achieve success, excellent performance is needed in mastering different technologies such as polymer processing, evaporated coatings, tool making, ultra-precision turning of metals and optical metrology.

  18. PHYSICAL PROPERTIES OF EXTRUDED AND INJECTION MOLDED CORN GLUTEN MEAL

    Technology Transfer Automated Retrieval System (TEKTRAN)

    This study was performed to investigate the compounding of corn gluten meal (CGM) and decanoic acid and to evaluate their mechanical properties. The mixture of CGM and 30% decanoic acid was compounded in a twin screw extruder, followed by injection molding. Scanning electron microscopy (SEM), tens...

  19. FPGA-Based Multiprocessor System for Injection Molding Control

    PubMed Central

    Muñoz-Barron, Benigno; Morales-Velazquez, Luis; Romero-Troncoso, Rene J.; Rodriguez-Donate, Carlos; Trejo-Hernandez, Miguel; Benitez-Rangel, Juan P.; Osornio-Rios, Roque A.

    2012-01-01

    The plastic industry is a very important manufacturing sector and injection molding is a widely used forming method in that industry. The contribution of this work is the development of a strategy to retrofit control of an injection molding machine based on an embedded system microprocessors sensor network on a field programmable gate array (FPGA) device. Six types of embedded processors are included in the system: a smart-sensor processor, a micro fuzzy logic controller, a programmable logic controller, a system manager, an IO processor and a communication processor. Temperature, pressure and position are controlled by the proposed system and experimentation results show its feasibility and robustness. As validation of the present work, a particular sample was successfully injected. PMID:23202036

  20. FPGA-based multiprocessor system for injection molding control.

    PubMed

    Muñoz-Barron, Benigno; Morales-Velazquez, Luis; Romero-Troncoso, Rene J; Rodriguez-Donate, Carlos; Trejo-Hernandez, Miguel; Benitez-Rangel, Juan P; Osornio-Rios, Roque A

    2012-01-01

    The plastic industry is a very important manufacturing sector and injection molding is a widely used forming method in that industry. The contribution of this work is the development of a strategy to retrofit control of an injection molding machine based on an embedded system microprocessors sensor network on a field programmable gate array (FPGA) device. Six types of embedded processors are included in the system: a smart-sensor processor, a micro fuzzy logic controller, a programmable logic controller, a system manager, an IO processor and a communication processor. Temperature, pressure and position are controlled by the proposed system and experimentation results show its feasibility and robustness. As validation of the present work, a particular sample was successfully injected. PMID:23202036

  1. Microinjection molding of thermoplastic polymers: morphological comparison with conventional injection molding

    NASA Astrophysics Data System (ADS)

    Giboz, Julien; Copponnex, Thierry; Mélé, Patrice

    2009-02-01

    The skin-core crystalline morphology of injection-molded semi-crystalline polymers is well documented in the scientific literature. The thermomechanical environment provokes temperature and shear gradients throughout the entire thickness of the part during molding, thus influencing the polymer crystallization. Crystalline morphologies of a high-density polyethylene (HDPE) micromolded part (μpart) and a classical part (macropart) are compared with optical, thermal and x-ray diffraction analyses. Results show that the crystalline morphologies with regard to thickness vary between the two parts. While a 'skin-core' morphology is present for the macropart, the μpart exhibits a specific 'core-free' morphology, i.e. no spherulite is present at the center of the thickness. This result seems to be generated under the specific conditions used in microinjection molding that lead to the formation of smaller and more oriented crystalline entities.

  2. Injection molding of thermoplastic elastomers for microstructured substrates

    NASA Astrophysics Data System (ADS)

    Birkar, Smita

    Amorphous and semi-crystalline thermoplastic polymers have been widely investigated for injection molding of parts with microstructured surfaces. Microstructured surfaces injection molded from thermoplastic elastomers have emerging applications as superhydrobic surfaces and patterned adhesives, but there is a limited understanding of the factors affecting replication with these materials. This research was a continued investigation of block copolymer thermoplastic elastomers as well as the first in-depth examination of thermoplastic vulcanizates for injection molding microfeatures. The first focus of this research was the interactions between tooling aspect ratio and feature orientation (negative and positive tooling) and thermoplastic elastomer hard segment content on microfeature replication. Electroformed nickel tooling having positive and negative features with different geometries and aspect ratios of 0.02:1 to 2:1 were molded from three copolyester thermoplastic elastomers with similar chemistry and different hardness values. The tooling and part features were characterized for feature depth and height as well as feature definition using scanning electron microscopy and optical profilometry. Results were correlated with elastomer properties. In the second parts of this research, the effects of microfeature spacing on the replication of thermoplastic elastomer features was investigated using micropillars with two diameters (10 and 20 mum) and three spacing ratios (0.5:1, 1:1, and 2:1). The tooling and part features were characterized for feature depth and height as well as feature definition using scanning electron microscopy and optical profilometry. Feature spacing significantly affected the replication of micropillars using a thermoplastic elastomer. This replication was competition between cooling and pressurization of the melt. Wider spacing between smaller features allowed cooling in the tooling lands to dominate the feature filling. Higher pressures did

  3. Direct processing of continuous fibers onto injection molding machines

    NASA Astrophysics Data System (ADS)

    Truckenmueller, F. M.

    1993-06-01

    A new injection molding process 'DIF' (Direct Incorporation of Continuous Fibers) is proposed whereby roving strands are directly incorporated into the polymer melt by using a reciprocating-screw-plasticating unit. The DIF-technology offers the possibility to substitute the relatively expensive pultrusion process which is used to produce long fiber pellets. Furthermore it can be used as a fast and flexible R&D tool. In order to improve fiber dispersion with minimum fiber breakage a new mixing non-return-valve 'LFMR' (Long Fiber Mixing Ring) was developed based on the 'Twente Mixing Ring'; Its mixing capacity and influence on processing characteristics, fiber breakage and property profile of the injection molded parts is examined and compared to a general purpose non-return-valve of the ring type. The results of fundamental mechanical and physical property investigations are presented including dispersion of fiber clusters and bundles, fiber length distribution and fiber orientation.

  4. Injection molding of iPP samples in controlled conditions and resulting morphology

    NASA Astrophysics Data System (ADS)

    Sessa, Nino; De Santis, Felice; Pantani, Roberto

    2015-12-01

    Injection molded parts are driven down in size and weight especially for electronic applications. In this work, an investigation was carried out on the process of injection molding of thin iPP samples and on the morphology of these parts. Melt flow in the mold cavity was analyzed and described with a mathematical model. Influence of mold temperature and injection pressure was analyzed. Samples orientation was studied using optical microscopy.

  5. Injection molding of iPP samples in controlled conditions and resulting morphology

    SciTech Connect

    Sessa, Nino De Santis, Felice Pantani, Roberto

    2015-12-17

    Injection molded parts are driven down in size and weight especially for electronic applications. In this work, an investigation was carried out on the process of injection molding of thin iPP samples and on the morphology of these parts. Melt flow in the mold cavity was analyzed and described with a mathematical model. Influence of mold temperature and injection pressure was analyzed. Samples orientation was studied using optical microscopy.

  6. Effects of polymer melt compressibility on mold filling in micro-injection molding

    NASA Astrophysics Data System (ADS)

    Nguyen, Q. M. P.; Chen, X.; Lam, Y. C.; Yue, C. Y.

    2011-09-01

    In conventional injection molding, the molten polymer in the filling stage is generally assumed to be incompressible. However, this assumption may not be valid in micro-injection molding, since high injection pressure is normally required to avoid short shots. This paper presents both numerical and experimental investigations on the effects of polymer melt compressibility on mold filling into a micro-thickness impression. The study was conducted on six different part thicknesses ranging from 920 to 370 µm. A high-flow COC TOPAS 5013L-10 polymer was chosen as the TOPAS family has recently attracted significant interest for its use in microfluidic applications. A combined finite element/finite difference/control volume approach was adopted to simulate the compressible flow. The shear viscosity of a polymer melt was characterized by the Cross-WLF model, while the melt compressibility was modeled with a double-domain Tait equation. The results obtained indicated that the compressibility of the polymer melt has significant effects on impression pressure and density distribution in the fully filled part with thickness smaller than 620 µm and that the effects become more pronounced with a decrease in part thickness.

  7. A Novel Method of Injection Molding Titanium Components

    SciTech Connect

    Nyberg, Eric A.; Simmons, Kevin L.; Weil, K. Scott

    2005-05-01

    We have developed a unique blend of powder injection molding feedstock materials in which only a small volume fraction of binder (< 8%) is required; the remainder of the mixture consists of the metal powder and a solid aromatic solvent. Because of the nature of the decomposition in the binder system and the relatively small amount used, the binder is eliminated almost completely from the pre-sintered component during the initial stage of a two-step heat treatment process.

  8. Applications of thin carbon coatings and films in injection molding

    NASA Astrophysics Data System (ADS)

    Cabrera, Eusebio Duarte

    In this research, the technical feasibility of two novel applications of thin carbon coatings is demonstrated. The first application consists of using thin carbon coatings on molds for molding ultra-thin plastic parts (<0.5 mm thickness) with lower pressures by promoting wall slip. The second application consists of a new approach to provide electromagnetic interference (EMI) shielding for plastic parts using in mold coated nanoparticle thin films or nanopapers to create a conductive top layer. During this research, the technical feasibility of a new approach was proven which provides injection molding of ultra-thin parts at lower pressures, without the need of fast heating/fast cooling or other expensive mold modification. An in-house developed procedure by other members of our group, was employed for coating the mold surface using chemical vapor deposition (CVD) resulting in a graphene coating with carbide bonding to the mold surface. The coating resulted in a significant decrease of surface friction and consequently easiness of flow when compared to their uncoated counterparts. Thermoplastic polymers and their composites are a very attractive alternative but are hindered by the non-conductive nature of polymers. There are two general approaches used to date to achieve EMI shielding for plastic products. One is to spray a conductive metal coating onto the plastic surface forming a layer that must maintain its shielding effectiveness (SE), and its adhesion to the plastic throughout the expected life of the product. However, metal coatings add undesirable weight and tend to corrode over time. Furthermore, scratching the coating may create shielding failure; therefore, a protective topcoat may be required. The other approach is to use polymer composites filled with conductive fillers such as carbon black (CB), carbon nanofiber (CNF), and carbon nanotube (CNT). While conductive fillers may increase the electrical conductivity of polymer composites, the loading of

  9. Integral optical system design of injection molded optics

    NASA Astrophysics Data System (ADS)

    Baumer, Stefan M.; Shulepova, Lena; Willemse, Jan; Renkema, Kor

    2003-11-01

    Injection molded optics are frequently applied in many high volume applications. Bar code scanners, CD / DVD systems, CMOS cameras are a few examples. In all of these applications cost effective and fast design cycles are essential. At Philips High Tech Plastics we developed a design system that touches on all different aspects of the system design. Starting with traditional lens design (sequential ray tracing) and tolernacing we transport the initial design into mechanical solid modeling. During mechanical modeling, tolerances, injection molding design rules and integration of mechanical features, reference marks, etc. are incorporated as well. Here the full advantage of injection molding can be utilized. After the opto - mechanical modeling the system is ported back to non - sequential ray tracing for ghost - and stray light analysis. Finally extended tolerancing is performed in order to come to a robust high volume product. If necessary all or several steps in this design process are repeated in order to arrive at the final design. As an additional requirement the metrology possibilities for the design are checked in at an early stage. This integral system approach to optical design, including optical modeling (sequential and non-sequential) combined with mechanical solid modeling is presented using some recent examples.

  10. Investigation of interfacial fracture behavior on injection molded parts

    NASA Astrophysics Data System (ADS)

    Fischer, Matthieu; Ausias, Gilles; Kuehnert, Ines

    2016-03-01

    In this study the interfacial morphology of different polymers joined by various assembly injection molding (AIM) technologies were discussed. Melt streams were injected successively using tools with core-back or rotation techniques. To compare bulk specimen strength and weld line strength, the fracture behavior of different specimen scales and thin sections were investigated. An in-situ SEM tensile test and a new thin section testing device which is used in polarized (transmitted) light microscopy were used to observe specimen failure. The effects of processing on spherulitic structures were linked to bonding strength and mechanical properties.

  11. Investigations on injection molded, glass-fiber reinforced polyamide 6 integral foams using breathing mold technology

    NASA Astrophysics Data System (ADS)

    Roch, A.; Kehret, L.; Huber, T.; Henning, F.; Elsner, P.

    2015-05-01

    Investigations on PA6-GF50 integral foams have been carried out using different material systems: longfiber- and shortfiber-reinforced PA6 as well as unreinforced PA6 as a reference material. Both chemical and physical blowing agents were applied. Breathing mold technology (decompression of the mold) was selected for the foaming process. The integral foam design, which can be conceived as a sandwich structure, helps to save material in the neutral axis area and maintains a distance between load-bearing, unfoamed skin layers. For all test series an initial mold gap of 2.5 mm was chosen and the same amount of material was injected. In order to realize different density reductions, the mold opening stroke was varied. The experiments showed that, at a constant mass per unit area, integral polyamide 6 foams have a significantly higher bending stiffness than compact components, due to their higher area moment of inertia after foaming. At a constant surface weight the bending stiffness in these experiments could be increased by up to 600 %. Both shortfiber- and longfiber-reinforced polyamide 6 showed an increase in energy absorption during foaming.

  12. Injection molded 1{endash}3 piezocomposite velocity sensors

    SciTech Connect

    Gentilman, R.L.; Bowen, L.J.; Fiore, D.F.; Pham, H.T.; Serwatka, W.J.

    1996-04-01

    A cost-effective technology has been developed for producing 1{endash}3 piezoelectric ceramic/polymer composites and transducers for underwater actuators, pressure sensors, and velocity sensors. Applications include active and passive sonar, underwater imaging, and active surface control. The key technology in the manufacturing process in the PZT ceramic injection molding process, in which an entire array of piezoelectric elements is molded to final net shape in one operation. Several designs of low-profile, area-averaging 1{endash}3 piezocomposite accelerometers have been fabricated. The initial breadboard accelerometers were made using a prepoled 50{times}50 mm injection molded 1{endash}3 PZT-5H preforms, containing 361 identical rods on a common baseplate. Additional mass was attached to the baseplate, which was metallized to serve as an electrode, and the free ends of the PZT rods were bonded to a fixed surface, which also functions as the other electrode. Subsequently, a manufacturing process was developed to create accelerometer {open_quote}{open_quote}islands{close_quote}{close_quote} within a 1{endash}3 piezocomposite transducer. The accelerometers can be made in arbitrary areas, shapes, and arrangements within the transducer panel, with the remaining area used either as a hydrophone or an actuator. This integral accelerometer technology is being optimized as part of an ARPA-funded active surface control program. This paper reviews the current state-of-the-art of injection molded piezocomposite transducers and describes some of the velocity sensor configurations made using this technology. {copyright} {ital 1996 American Institute of Physics.}

  13. Modeling injection molding of net-shape active ceramic components.

    SciTech Connect

    Baer, Tomas; Cote, Raymond O.; Grillet, Anne Mary; Yang, Pin; Hopkins, Matthew Morgan; Noble, David R.; Notz, Patrick K.; Rao, Rekha Ranjana; Halbleib, Laura L.; Castaneda, Jaime N.; Burns, George Robert; Mondy, Lisa Ann; Brooks, Carlton, F.

    2006-11-01

    To reduce costs and hazardous wastes associated with the production of lead-based active ceramic components, an injection molding process is being investigated to replace the current machining process. Here, lead zirconate titanate (PZT) ceramic particles are suspended in a thermoplastic resin and are injected into a mold and allowed to cool. The part is then bisque fired and sintered to complete the densification process. To help design this new process we use a finite element model to describe the injection molding of the ceramic paste. Flow solutions are obtained using a coupled, finite-element based, Newton-Raphson numerical method based on the GOMA/ARIA suite of Sandia flow solvers. The evolution of the free surface is solved with an advanced level set algorithm. This approach incorporates novel methods for representing surface tension and wetting forces that affect the evolution of the free surface. Thermal, rheological, and wetting properties of the PZT paste are measured for use as input to the model. The viscosity of the PZT is highly dependent both on temperature and shear rate. One challenge in modeling the injection process is coming up with appropriate constitutive equations that capture relevant phenomenology without being too computationally complex. For this reason we model the material as a Carreau fluid and a WLF temperature dependence. Two-dimensional (2D) modeling is performed to explore the effects of the shear in isothermal conditions. Results indicate that very low viscosity regions exist near walls and that these results look similar in terms of meniscus shape and fill times to a simple Newtonian constitutive equation at the shear-thinned viscosity for the paste. These results allow us to pick a representative viscosity to use in fully three-dimensional (3D) simulation, which because of numerical complexities are restricted to using a Newtonian constitutive equation. Further 2D modeling at nonisothermal conditions shows that the choice of

  14. Investigation of micro-injection molding based on longitudinal ultrasonic vibration core.

    PubMed

    Qiu, Zhongjun; Yang, Xue; Zheng, Hui; Gao, Shan; Fang, Fengzhou

    2015-10-01

    An ultrasound-assisted micro-injection molding method is proposed to improve the rheological behavior of the polymer melt radically, and a micro-injection molding system based on a longitudinal ultrasonic vibration core is developed and employed in the micro-injection molding process of Fresnel lenses. The verification experiments show that the filling mold area of the polymer melt is increased by 6.08% to 19.12%, and the symmetric deviation of the Fresnel lens is improved 15.62% on average. This method improved the filling performance and replication quality of the polymer melt in the injection molding process effectively. PMID:26479615

  15. Rapid and low-cost prototyping of medical devices using 3D printed molds for liquid injection molding.

    PubMed

    Chung, Philip; Heller, J Alex; Etemadi, Mozziyar; Ottoson, Paige E; Liu, Jonathan A; Rand, Larry; Roy, Shuvo

    2014-01-01

    Biologically inert elastomers such as silicone are favorable materials for medical device fabrication, but forming and curing these elastomers using traditional liquid injection molding processes can be an expensive process due to tooling and equipment costs. As a result, it has traditionally been impractical to use liquid injection molding for low-cost, rapid prototyping applications. We have devised a method for rapid and low-cost production of liquid elastomer injection molded devices that utilizes fused deposition modeling 3D printers for mold design and a modified desiccator as an injection system. Low costs and rapid turnaround time in this technique lower the barrier to iteratively designing and prototyping complex elastomer devices. Furthermore, CAD models developed in this process can be later adapted for metal mold tooling design, enabling an easy transition to a traditional injection molding process. We have used this technique to manufacture intravaginal probes involving complex geometries, as well as overmolding over metal parts, using tools commonly available within an academic research laboratory. However, this technique can be easily adapted to create liquid injection molded devices for many other applications. PMID:24998993

  16. Rapid and Low-cost Prototyping of Medical Devices Using 3D Printed Molds for Liquid Injection Molding

    PubMed Central

    Chung, Philip; Heller, J. Alex; Etemadi, Mozziyar; Ottoson, Paige E.; Liu, Jonathan A.; Rand, Larry; Roy, Shuvo

    2014-01-01

    Biologically inert elastomers such as silicone are favorable materials for medical device fabrication, but forming and curing these elastomers using traditional liquid injection molding processes can be an expensive process due to tooling and equipment costs. As a result, it has traditionally been impractical to use liquid injection molding for low-cost, rapid prototyping applications. We have devised a method for rapid and low-cost production of liquid elastomer injection molded devices that utilizes fused deposition modeling 3D printers for mold design and a modified desiccator as an injection system. Low costs and rapid turnaround time in this technique lower the barrier to iteratively designing and prototyping complex elastomer devices. Furthermore, CAD models developed in this process can be later adapted for metal mold tooling design, enabling an easy transition to a traditional injection molding process. We have used this technique to manufacture intravaginal probes involving complex geometries, as well as overmolding over metal parts, using tools commonly available within an academic research laboratory. However, this technique can be easily adapted to create liquid injection molded devices for many other applications. PMID:24998993

  17. Foam injection molding of elastomers with iron microparticles

    NASA Astrophysics Data System (ADS)

    Volpe, Valentina; D'Auria, Marco; Sorrentino, Luigi; Davino, Daniele; Pantani, Roberto

    2015-12-01

    In this work, a preliminary study of foam injection molding of a thermoplastic elastomer, Engage 8445, and its microcomposite loaded with iron particles was carried out, in order to evaluate the effect of the iron microparticles on the foaming process. In particular, reinforced samples have been prepared by using nanoparticles at 2% by volume. Nitrogen has been used as physical blowing agent. Foamed specimens consisting of neat and filled elastomer were characterized by density measurements and morphological analysis. While neat Engage has shown a well developed cellular morphology far from the injection point, the addition of iron microparticles considerably increased the homogeneity of the cellular morphology. Engage/iron foamed samples exhibited a reduction in density greater than 32%, with a good and homogeneous cellular morphology, both in the transition and in the core zones, starting from small distances from the injection point.

  18. Ion channel recordings on an injection-molded polymer chip.

    PubMed

    Tanzi, Simone; Matteucci, Marco; Christiansen, Thomas Lehrmann; Friis, Søren; Christensen, Mette Thylstrup; Garnaes, Joergen; Wilson, Sandra; Kutchinsky, Jonatan; Taboryski, Rafael

    2013-12-21

    In this paper, we demonstrate recordings of the ion channel activity across the cell membrane in a biological cell by employing the so-called patch clamping technique on an injection-molded polymer microfluidic device. The findings will allow direct recordings of ion channel activity to be made using the cheapest materials and production platform to date and with the potential for very high throughput. The employment of cornered apertures for cell capture allowed the fabrication of devices without through holes and via a scheme comprising master origination by dry etching in a silicon substrate, electroplating in nickel and injection molding of the final part. The most critical device parameters were identified as the length of the patching capillary and the very low surface roughness on the inside of the capillary. The cross-sectional shape of the orifice was found to be less critical, as both rectangular and semicircular profiles seemed to have almost the same ability to form tight seals with cells with negligible leak currents. The devices were functionally tested using human embryonic kidney cells expressing voltage-gated sodium channels (Nav1.7) and benchmarked against a commercial state-of-the-art system for automated ion channel recordings. These experiments considered current-voltage (IV) relationships for activation and inactivation of the Nav1.7 channels and their sensitivity to a local anesthetic, lidocaine. Both IVs and lidocaine dose-response curves obtained from the injection-molded polymer device were in good agreement with data obtained from the commercial system. PMID:24154831

  19. Atmosphere control during debinding of powder injection molded parts

    NASA Astrophysics Data System (ADS)

    Moore, J. A.; Jarding, B. P.; Lograsso, B. K.; Anderson, I. E.

    1995-06-01

    Atmosphere control during debinding of powder injection molded (PIM) parts is an important parameter to consider. Experimental results have shown that a stagnant atmosphere containing volatiles evolved during debinding can cause slumping of the green samples. Removal of volatiles from the sample zone aids debinding and can reduce cycle times and improve sample quality. Residual carbon and oxygen can be controlled during debinding by adjusting the atmosphere composition. This paper presents the results of PIM 70 vol% spherical copper powder and 30 vol% binder. Debinding atmospheres were altered to determine the effect of debinding on the green body and the sintered sample.

  20. Capabilities Of Micro Powder Injection Molding For Microparts Manufacturing

    NASA Astrophysics Data System (ADS)

    Kong, X.; Barriere, T.; Gelin, J. C.

    2011-01-01

    The Micro-PIM processing technology satisfies the increasing demand in terms of smaller parts and miniaturization. Research works in this area have been carried out at FEMTO-ST Institute by performing the injection molding with 316L stainless steel fine powders and polymer binders. Several formulations with different proportion of powders and binders as well various polymers have been tested, and then a well adapted one has been selected. The process to select the well adapted formulation and the rheological characteristics of the feedstock realized according with the selected formulation are also detailed. Several test specimens have been successfully manufactured.

  1. The technology and commercial status of powder-injection molding

    NASA Astrophysics Data System (ADS)

    Bose, Animesh

    1995-08-01

    The process of powder-injection molding (PIM) is a viable and competitive commercial technique that is being used to process complex-shaped parts of various materials in moderate to high volumes. The hey advantage of the process is its unique ability to combine materials selection flexibility with the complex shape-forming ability of plastics. Although the PIM process has been discussed in the open literature for more than quarter of a century, it has become a commercial reality only during the last decade or so. Currently, there is a tremendous interest in this unique technology throughout the world. As a result, the PIM industry is poised for significant growth.

  2. Molds

    MedlinePlus

    ... touching mold or mold spores may cause allergic reactions or asthma attacks in sensitive people. Molds can cause fungal infections. In addition, mold exposure may irritate your eyes, skin, nose, ...

  3. A micro powder injection molding apparatus for high aspect ratio metal micro-structure production

    NASA Astrophysics Data System (ADS)

    Fu, Gang; Tor, Shubeng; Loh, Ngiaphiang; Tay, Beeyen; Hardt, David E.

    2007-09-01

    A new variotherm molding apparatus is presented in this paper for the fabrication of high aspect ratio 316L stainless steel micro-structures using micro powder injection molding (μPIM) technology. The molding apparatus prototype includes an injection mold in which a silicon insert with an array of 24 × 24 (576) microcavities is mounted, a set of rapid tempering systems for the mold and a set of vacuum systems. The key advantage of this molding apparatus lies in the real-time monitoring and rapid adjustment of the mold cavity temperature during injection molding and part ejection, which makes molding and demolding of high aspect ratio green micro-structures possible. For example, incomplete filling occurs while injection molding micro-structures of 60 µm × height 191 µm with an aspect ratio of 3.2 using a conventional mold. In comparison, smaller micro-structures with higher aspect ratio are produced successfully in the case of the new molding apparatus, e.g. micro-structures of 40 µm × height 174 µm with an aspect ratio of 4.35 and 20 µm × height 160 µm with an aspect ratio of 8 were molded successfully.

  4. Fabrication of Composite Material Using Gettou Fiber by Injection Molding

    NASA Astrophysics Data System (ADS)

    Setsuda, Roy; Fukumoto, Isao; Kanda, Yasuyuki

    This study investigated the mechanical properties of composite using gettou (shell ginger) fiber as reinforcement fabricated from injection molding. Gettou fiber is a natural fiber made from gettou, a subtropical plant that is largely abundant in Okinawa, Japan. We used the stem part of gettou plant and made the gettou fiber by crushing the stem. The composite using gettou fiber contributed to low shrinkage ratio, high bending strength and high flexural modulus. The mechanical strength of composite using long gettou fiber showed higher value than composite using short gettou fiber. Next, because gettou is particularly known for its anti-mold characteristic, we investigated the characteristic in gettou plastic composite. The composite was tested against two molds: aspergillius niger and penicillium funiculosum. The 60% gettou fiber plastic composite was found to satisfy the JISZ2801 criterion. Finally, in order to predict the flexural modulus of composite using gettou fiber by Halpin-Tsai equation, the tensile elastic modulus of single gettou fiber was measured. The tendency of the experimental results of composite using gettou fiber was in good agreement with Halpin-Tsai equation.

  5. A Study on the Optimization for Metal Injection Molding Process

    NASA Astrophysics Data System (ADS)

    Jung, M. K.; Jang, K. C.; Lee, D. G.; Kim, M. H.

    2011-01-01

    The objective of this paper is study the optimization for metal injection molding process by using the design of experiments (DOE) and numerical analysis. In order to determine optimal process parameters, experiment and computerized analysis have been performed for various process conditions. Proper coded and uncoded regression equations and optimization for responses (flow front temperature, part weight, filling time, cycle time, and volumetric shrinkage) achieved from studying and verifying interrelation of the factors. About 70% of whole binder extracted within about 10 minutes and temperature of solvent is higher, the debinding rate is fast. 50° C was the most suitable condition for solvent extraction because of crack occurrence on green body at 55° C. It took about 14.5 hours to perform secondary thermal debinding, which was only about 35% of the entire time taken compared with single thermal debinding process, even if it considers solvent extraction time required. Therefore, the applied method greatly reduces the debinding time. The excellent process capability showed that the PPM total and Z.Bench were 9,946.8 and 2.33 showing good quality rate of around 99.01% and sigma level of 3.83. As a result, the process and optimization have been improved, and the proposed approach could be successfully reflected on the metal injection molding.

  6. Injection molded high precision freeform optics for high volume applications

    NASA Astrophysics Data System (ADS)

    Dick, Lars; Risse, Stefan; Tünnermann, Andreas

    2012-03-01

    Injection molding offers a cost-efficient method for manufacturing high precision plastic optics for high-volume applications. Optical surfaces such as flats, spheres and also aspheres are meanwhile state-of-the-art in the field of plastic optics. The demand for surfaces without symmetric properties, commonly referred to as freeform surfaces, continues to rise. Currently, new mathematical approaches are under consideration which allow for new complex optical designs. Such novel optical designs strongly encourage development of new manufacturing methods. Specifically, new surface descriptions without an axis of symmetry, new ultra precision machining methods and non-symmetrical shrinkage compensation strategies have to be developed to produce freeform optical surfaces with high precision for high-volume applications. This paper will illustrate a deterministic and efficient way for the manufacturing of ultra precision injection molding tool inserts with submicron precision and show the manufacturing of replicated freeform surfaces with micrometer range shape accuracy at diameters up to 40 mm with a surface roughness of approximately 2 nm.

  7. CREEP MODELING FOR INJECTION-MOLDED LONG-FIBER THERMOPLASTICS

    SciTech Connect

    Nguyen, Ba Nghiep; Kunc, Vlastimil; Bapanapalli, Satish K.

    2008-06-30

    This paper proposes a model to predict the creep response of injection-molded long-fiber thermoplastics (LFTs). The model accounts for elastic fibers embedded in a thermoplastic resin that exhibits the nonlinear viscoelastic behavior described by the Schapery’s model. It also accounts for fiber length and orientation distributions in the composite formed by the injection-molding process. Fiber length and orientation distributions were measured and used in the analysis that applies the Eshelby’s equivalent inclusion method, the Mori-Tanaka assumption (termed as the Eshelby-Mori-Tanaka approach) and the fiber orientation averaging technique to compute the overall strain increment resulting from an overall constant applied stress during a given time increment. The creep model for LFTs has been implemented in the ABAQUS finite element code via user-subroutines and has been validated against the experimental creep data obtained for long-glass-fiber/polypropylene specimens. The effects of fiber orientation and length distributions on the composite creep response are determined and discussed.

  8. Interrelationship between structure-property-processings in injection molded polymeric products

    SciTech Connect

    Kim, Hyun Seog; Lee, Jae Wook

    1996-12-31

    Injection molding process is one of the major polymer processings for the polymeric products. This process is extensively used in the net-shaped production of plastic parts due to its capability to meet requirements of stringent dimensional accuracy and short cycle time. Specially the injection molding process consists of large, fast deformation and phase changes, which has much of processing parameters. Therefore it is important to optimize the injection molding conditions from the point of view of both productivity and product quality. In this study, we have investigated in the injection molding process for polymeric systems focusing on the understanding of structure-property-processing interrelationship and its utilization in the processing.

  9. The use of variable speed drives to retrofit hydraulic injection molding machines

    SciTech Connect

    Ambs, L.; Frerker, M.M.

    1998-06-01

    Injection molding is a common method of plastic processing in which thermoplastic materials can be molded into arbitrary complex shapes. Most injection molding machines use complicated hydraulic systems to perform the necessary work of the process. Hydraulic system flow and pressure requirements vary throughout the cycle and in many cases, excess fluid that is not required by the process is throttled back to the reservoir, wasting motor energy and producing additional thermal load on the cooling system. Variable speed drives can be used to allow injection molding machine hydraulic systems to vary the amount of fluid being pumped and thus reduce the amount of fluid that is throttled reducing the amount of wasted energy. This article discusses injection molding machine processes and develops a protocol for assessing the efficacy of variable speed drive retrofits for hydraulic injection molding machines.

  10. Curing rate and flowing properties of silicone rubber at injection molding

    SciTech Connect

    Yoshino, M.; Nakamura, T. )

    1992-04-01

    Generally, silicone rubbers are mold-cured after mixing the rubber and peroxide curing agent with a two-roll mill or a kneader. Typically this is done at pressures of 5 MPa to 10 MPa and at temperatures between 120 to 200 C. Compression molding, transfer molding and injection molding are common molding ways for silicone rubbers. Recently, injection molding techniques are developing rapidly that have the advantages of molding automatically with high cycle mechanisms. To reduce the molding time and to make a precision part, both the flowing and curing properties of a particular rubber compound will be important. In this article, correlations between the curing and the flowing properties of silicone rubber are investigated by using the Rheovulkameter device.

  11. Investigation of the adhesion interface obtained through two-component injection molding

    NASA Astrophysics Data System (ADS)

    Fetecau, Catalin; Stan, Felicia; Dobrea, Daniel

    2011-01-01

    In this paper we study the interface strength obtained through two-component (2C) injection molding of LDPE-HDPE polymers. First, numerical simulation of the over-molding process is carried out using Moldflow technology. Second, butt-joint specimens were produced by over-molding under different process condition, and tested. Two injection sequences were considered, injection of LDPE on HDPE polymer, and HDLE on LDPE, respectively. To investigate the effects of the mold surface roughness on the polymers adhesion at interface, different inserts with different roughness are employed.

  12. 3D Fiber Orientation Simulation for Plastic Injection Molding

    NASA Astrophysics Data System (ADS)

    Lin, Baojiu; Jin, Xiaoshi; Zheng, Rong; Costa, Franco S.; Fan, Zhiliang

    2004-06-01

    Glass fiber reinforced polymer is widely used in the products made using injection molding processing. The distribution of fiber orientation inside plastic parts has direct effects on quality of molded parts. Using computer simulation to predict fiber orientation distribution is one of most efficient ways to assist engineers to do warpage analysis and to find a good design solution to produce high quality plastic parts. Fiber orientation simulation software based on 2-1/2D (midplane /Dual domain mesh) techniques has been used in industry for a decade. However, the 2-1/2D technique is based on the planar Hele-Shaw approximation and it is not suitable when the geometry has complex three-dimensional features which cannot be well approximated by 2D shells. Recently, a full 3D simulation software for fiber orientation has been developed and integrated into Moldflow Plastics Insight 3D simulation software. The theory for this new 3D fiber orientation calculation module is described in this paper. Several examples are also presented to show the benefit in using 3D fiber orientation simulation.

  13. Injection molded polymeric micropatterns for bone regeneration study.

    PubMed

    Zanchetta, Erika; Guidi, Enrica; Della Giustina, Gioia; Sorgato, Marco; Krampera, Mauro; Bassi, Giulio; Di Liddo, Rosa; Lucchetta, Giovanni; Conconi, Maria Teresa; Brusatin, Giovanna

    2015-04-01

    An industrially feasible process for the fast mass-production of molded polymeric micro-patterned substrates is here presented. Microstructured polystyrene (PS) surfaces were obtained through micro injection molding (μIM) technique on directly patterned stamps realized with a new zirconia-based hybrid spin-on system able to withstand 300 cycles at 90 °C. The use of directly patterned stamps entails a great advantage on the overall manufacturing process as it allows a fast, flexible, and simple one-step process with respect to the use of milling, laser machining, electroforming techniques, or conventional lithographic processes for stamp fabrication. Among the different obtainable geometries, we focused our attention on PS replicas reporting 2, 3, and 4 μm diameter pillars with 8, 9, 10 μm center-to-center distance, respectively. This enabled us to study the effect of the substrate topography on human mesenchymal stem cells behavior without any osteogenic growth factors. Our data show that microtopography affected cell behavior. In particular, calcium deposition and osteocalcin expression enhanced as diameter and interpillar distance size increases, and the 4-10 surface was the most effective to induce osteogenic differentiation. PMID:25756304

  14. Molds

    MedlinePlus

    Molds are fungi that can be found both outdoors and indoors. They grow best in warm, damp and humid conditions. If ... spots in your house, you will probably get mold. Molds can cause health problems. Inhaling or touching ...

  15. Fabrication of injection molded sintered alpha SiC turbine components

    NASA Technical Reports Server (NTRS)

    Storm, R. S.; Ohnsorg, R. W.; Frechette, F. J.

    1981-01-01

    Fabrication of a sintered alpha silicon carbide turbine blade by injection molding is described. An extensive process variation matrix was carried out to define the optimum fabrication conditions. Variation of molding parameters had a significant impact on yield. Turbine blades were produced in a reasonable yield which met a rigid quality and dimensional specification. Application of injection molding technology to more complex components such as integral rotors is also described.

  16. A senior manufacturing laboratory for determining injection molding process capability

    NASA Technical Reports Server (NTRS)

    Wickman, Jerry L.; Plocinski, David

    1992-01-01

    The following is a laboratory experiment designed to further understanding of materials science. This subject material is directed at an upper level undergraduate/graduate student in an Engineering or Engineering Technology program. It is assumed that the student has a thorough understanding of the process and quality control. The format of this laboratory does not follow that which is normally recommended because of the nature of process capability and that of the injection molding equipment and tooling. This laboratory is instead developed to be used as a point of departure for determining process capability for any process in either a quality control laboratory or a manufacturing environment where control charts, process capability, and experimental or product design are considered important topics.

  17. Microcellular foam injection molding with cellulose nanofibers (CNFs)

    NASA Astrophysics Data System (ADS)

    Ohshima, Masahiro; Kubota, Masaya; Ishihara, Shota; Hikima, Yuta; Sato, Akihiro; Sekiguchi, Takafumi

    2016-03-01

    Cellulose nanofibers (CNFs) nanocomposites polypropylene foams are prepared by microcellular foam injection molding with core-back operation. The modified CNFs were blended with isotactic-polypropylene (i-PP) at different CNFs weight percentages and foamed to investigate the effect of CNFs on cell morphology. CNFs in i-PP increased the elastic modulus and induced a strain hardening behavior. CNFs also shifted the crystallization temperature of i-PP to higher temperature and enhanced crystallization. With these changes in rheological and thermal properties, CNFs could reduce the cell size and increase the cell density of the foams. By adjusting the core-back timing i.e., foaming temperature, the closed cell and the nano-fibrillated open cellular structure could be produced. The flexural modulus and bending strength of foams were measured by three point flexural tester. The flexural modulus and bending strength were increased as the CNFs content in i-PP was increased at any foam expansion ratio.

  18. Imprinted and injection-molded nano-structured optical surfaces

    NASA Astrophysics Data System (ADS)

    Christiansen, Alexander B.; Højlund-Nielsen, Emil; Clausen, Jeppe; Caringal, Gideon P.; Mortensen, N. Asger; Kristensen, Anders

    2013-09-01

    Inspired by nature, nano-textured surfaces have attracted much attention as a method to realize optical surface functionality. The moth-eye antireflective structure and the structural colors of Morpho butterflies are well- known examples used for inspiration for such biomimetic research. In this paper, nanostructured polymer surfaces suitable for up-scalable polymer replication methods, such as imprinting/embossing and injection-molding, are discussed. The limiting case of injection-moulding compatible designs is investigated. Anti-reflective polymer surfaces are realized by replication of Black Silicon (BSi) random nanostructure surfaces. The optical transmission at normal incidence is measured for wavelengths from 400 nm to 900 nm. For samples with optimized nanostructures, the reflectance is reduced by 50 % compared to samples with planar surfaces. The specular and diffusive reflection of light from polymer surfaces and their implication for creating structural colors is discussed. In the case of injection-moulding compatible designs, the maximum reflection of nano-scale textured surfaces cannot exceed the Fresnel reflection of a corresponding flat polymer surface, which is approx. 4 % for normal incidence. Diffraction gratings provide strong color reflection defined by the diffraction orders. However, the apperance varies strongly with viewing angles. Three different methods to address the strong angular-dependence of diffraction grating based structural color are discussed.

  19. Effect of cross sectional geometry on PDMS micro peristaltic pump performance: comparison of SU-8 replica molding vs. micro injection molding.

    PubMed

    Graf, Neil J; Bowser, Michael T

    2013-10-01

    Two different fabrication methods were employed to fabricate micropumps with different cross-sectional channel geometries. The first was to fabricate rectangular cross-sectional microchannel geometries using the well known fabrication method of replica molding (REM). The second, and far less utilized fabrication technique, was to create microchannel molds using an in-house fabricated handheld micro injection molding apparatus. The injection mold apparatus was designed for use with elastomeric room temperature vulcanization (RTV) polymers, as opposed to most other injection molding machines, which are designed for use with thermoplastic polymers. The injection mold's bottom plate was used as a microchannel molding template. The molding template was created by threading a small-diameter wire (150 μm or less) through the injection mold's bottom plate, with subsequent adhesion and smoothing of a thin piece of aluminum foil over the wire-raised injection mold template. When molded against, the template produced a rounded/Gaussian-shaped PDMS microchannel. The design of the injection mold will be presented, along with a direct comparison for micropump performance metrics such as flow rate, valving characteristics, and maximum backpressures attainable for each of the respective micropump channel geometries. PMID:23917263

  20. Modeling and flow analysis of pure nylon polymer for injection molding process

    NASA Astrophysics Data System (ADS)

    Nuruzzaman, D. M.; Kusaseh, N.; Basri, S.; Oumer, A. N.; Hamedon, Z.

    2016-02-01

    In the production of complex plastic parts, injection molding is one of the most popular industrial processes. This paper addresses the modeling and analysis of the flow process of the nylon (polyamide) polymer for injection molding process. To determine the best molding conditions, a series of simulations are carried out using Autodesk Moldflow Insight software and the processing parameters are adjusted. This mold filling commercial software simulates the cavity filling pattern along with temperature and pressure distributions in the mold cavity. In the modeling, during the plastics flow inside the mold cavity, different flow parameters such as fill time, pressure, temperature, shear rate and warp at different locations in the cavity are analyzed. Overall, this Moldflow is able to perform a relatively sophisticated analysis of the flow process of pure nylon. Thus the prediction of the filling of a mold cavity is very important and it becomes useful before a nylon plastic part to be manufactured.

  1. Effects of process parameters in plastic, metal, and ceramic injection molding processes

    NASA Astrophysics Data System (ADS)

    Lee, Shi W.; Ahn, Seokyoung; Whang, Chul Jin; Park, Seong Jin; Atre, Sundar V.; Kim, Jookwon; German, Randall M.

    2011-09-01

    Plastic injection molding has been widely used in the past and is a dominant forming approach today. As the customer demands require materials with better engineering properties that were not feasible with polymers, powder injection molding with metal and ceramic powders has received considerable attention in recent decades. To better understand the differences in the plastic injection molding, metal injection molding, and ceramic injection molding, the effects of the core process parameters on the process performances has been studied using the state-of-the-art computer-aided engineering (CAE) design tool, PIMSolver® The design of experiments has been conducted using the Taguchi method to obtain the relative contributions of various process parameters onto the successful operations.

  2. Low Cost Injection Mold Creation via Hybrid Additive and Conventional Manufacturing

    SciTech Connect

    Dehoff, Ryan R.; Watkins, Thomas R.; List, III, Frederick Alyious; Carver, Keith; England, Roger

    2015-12-01

    The purpose of the proposed project between Cummins and ORNL is to significantly reduce the cost of the tooling (machining and materials) required to create injection molds to make plastic components. Presently, the high cost of this tooling forces the design decision to make cast aluminum parts because Cummins typical production volumes are too low to allow injection molded plastic parts to be cost effective with the amortized cost of the injection molding tooling. In addition to reducing the weight of components, polymer injection molding allows the opportunity for the alternative cooling methods, via nitrogen gas. Nitrogen gas cooling offers an environmentally and economically attractive cooling option, if the mold can be manufactured economically. In this project, a current injection molding design was optimized for cooling using nitrogen gas. The various components of the injection mold tooling were fabricated using the Renishaw powder bed laser additive manufacturing technology. Subsequent machining was performed on the as deposited components to form a working assembly. The injection mold is scheduled to be tested in a projection setting at a commercial vendor selected by Cummins.

  3. Flexural Properties of Injection-Molded Bamboo/pbs Composites

    NASA Astrophysics Data System (ADS)

    Ohkita, Kazuya; Takagi, Hitoshi

    In recent years, from an environmental perspective, there has been increasing interest in the change to a sustainable society. The use of natural-fiber-reinforced biodegradable composites has been proposed as one solution. Bamboo is an often used renewable bio-resource; it has an inherent advantage of rapid growth. Polybutylene succinate (PBS), used as matrix resin, has biodegradable characteristics. This paper describes flexural properties of bamboo/PBS composites prepared by injection molding. The following results were obtained. The flexural modulus was improved with increasing bamboo powder contents when the cylinder temperature of the injection molder was 140°C. However, the flexural strength showed the opposite tendency to be decreased with increasing bamboo powder contents. An SEM photomicrograph of the fracture surface for bamboo/PBS composites showed typical fracture behavior of pull-out fibers without fiber fracture. Furthermore, there was no adhesion of PBS resin on the bamboo fiber surface. Processing conditions affected mechanical properties of bamboo/PBS composites, imparting higher flexural strength and flexural modulus at high cylinder temperatures such as 180°C and 200°C.

  4. Research in manufacturing of micro-structured injection molded polymer parts

    NASA Astrophysics Data System (ADS)

    Lucyshyn, Thomas; Struklec, Tobias; Burgsteiner, Martin; Graninger, Georg; Holzer, Clemens

    2015-12-01

    An overview of current research results is given for the topic of injection molding of micro-structured polymer parts regarding filling behavior and demolding process of micro-structures as well as the production of micro-structures on curved surfaces. In order to better understand how micro-structures are formed during the filling stage of injection molding, a study was performed on a test part with micro-channels placed parallely and perpendicularly to flow direction. Short shots with a highly fluent Polypropylene grade were injection molded with the melt front stopping in the structure fields. The melt and mold temperature, the injection rate as well as the use of a variotherm heating system were varied in a systematic Design of Experiments. The shape of the flow front was investigated with the optical measurement system Alicona InfiniteFocus. The data gained was analyzed with Matlab scripts and provided the needed distance to completely fill the structures as a reference value. The next topic covers the demolding step, which is a crucial process step in injection molding of micro-structured parts as the successfully replicated structures often get destroyed in the following demolding step. In order to evaluate the influence of the four aspects polymer, mold surface (coatings), structure (geometry and placement) and process settings on the demolding behavior, an injection mold with integrated measurement system was built, which makes it possible to measure the demolding force respectively a demolding energy under process conditions. These values can be used to quantitatively compare the impact of the above mentioned influencing factors on demolding. Finally, a concept to produce micro-structures on curved surfaces with injection molding is shown: A flat metal premaster structure is used to produce an elastomeric polymer (dimethylsiloxane) master in a casting process. This master is fixed in a conventional injection mold and a thermoplastic polymer is replicated

  5. Analyzing melt homogeneity in a single screw plasticizing unit of an injection molding machine

    NASA Astrophysics Data System (ADS)

    Straka, K.; Praher, B.; Steinbichler, G.

    2013-10-01

    In injection molding investigations on mixing efficiency and thermal homogeneity of the melt in the screw chamber are of great interest as the directly effect the quality of the molded parts. For most injection molding applications mixing is performed in the single screw plasticizing unit of the injection molding machine. In this work, a CFD approach with two coupled fluid domains is used in order to describe the plasticizing process in an injection molding machine. One domain rotates and translates in axial direction (screw), the other one increases its length (chamber). On basis of the calculated pressure, velocity and temperature field of the polymer melt the thermal melt homogeneity is investigated. To analyze the optical-mechanical homogeneity of the melt a Euler-Lagrangian method is used to calculate the distribution of tracer particles within the screw chamber.

  6. FIBER LENGTH DISTRIBUTION MEASUREMENT FOR LONG GLASS AND CARBON FIBER REINFORCED INJECTION MOLDED THERMOPLASTICS

    SciTech Connect

    Kunc, Vlastimil; Frame, Barbara J; Nguyen, Ba N.; TuckerIII, Charles L.; Velez-Garcia, Gregorio

    2007-01-01

    Procedures for fiber length distribution (FLD) measurement of long fiber reinforced injection molded thermoplastics were refined for glass and carbon fibers. Techniques for sample selection, fiber separation, digitization and length measurement for both fiber types are described in detail. Quantitative FLD results are provided for glass and carbon reinforced polypropylene samples molded with a nominal original fiber length of 12.7 mm (1/2 in.) using equipment optimized for molding short fiber reinforced thermoplastics.

  7. Effect of Cross Sectional Geometry on PDMS Micro Peristaltic Pump Performance: Comparison of SU-8 Replica Molding vs. Micro Injection Molding

    PubMed Central

    Graf, Neil J.

    2013-01-01

    Two different fabrication methods were employed to fabricate micropumps with different cross-sectional channel geometries. The first was to fabricate rectangular cross-sectional microchannel geometries using the well known fabrication method of replica molding (REM).1 The second, and far less utilized fabrication technique, was to create microchannel molds using an in-house fabricated handheld micro injection molding apparatus. The injection mold apparatus was designed for use with elastomeric room temperature vulcanization (RTV) polymers, as opposed to most other injection molding machines, which are designed for use with thermoplastic polymers. The injection mold’s bottom plate was used as a microchannel molding template. The molding template was created by threading a small-diameter wire (150 μm or less) through the injection mold’s bottom plate, with subsequent adhesion and smoothing of a thin piece of aluminum foil over the wire-raised injection mold template. When molded against, the template produced a rounded/Gaussian-shaped PDMS microchannel. The design of the injection mold will be presented, along with a direct comparison for micropump performance metrics such as flow rate, valving characteristics, and maximum backpressures attainable for each of the respective micropump channel geometries. PMID:23917263

  8. Processing study of injection molding of silicon nitride for engine applications

    NASA Technical Reports Server (NTRS)

    Rorabaugh, M. E.; Yeh, H. C.

    1985-01-01

    The high hardness of silicon nitride, which is currently under consideration as a structural material for such hot engine components as turbine blades, renders machining of the material prohibitively costly; the near net shape forming technique of injection molding is accordingly favored as a means for component fabrication. Attention is presently given to the relationships between injection molding processing parameters and the resulting microstructural and mechanical properties of the resulting engine parts. An experimental program has been conducted under NASA sponsorship which tests the quality of injection molded bars of silicon nitride at various stages of processing.

  9. Improved silicon carbide for advanced heat engines. I - Process development for injection molding

    NASA Technical Reports Server (NTRS)

    Whalen, Thomas J.; Trela, Walter

    1989-01-01

    Alternate processing methods have been investigated as a means of improving the mechanical properties of injection-molded SiC. Various mixing processes (dry, high-sheer, and fluid) were evaluated along with the morphology and particle size of the starting beta-SiC powder. Statistically-designed experiments were used to determine significant effects and interactions of variables in the mixing, injection molding, and binder removal process steps. Improvements in mechanical strength can be correlated with the reduction in flaw size observed in the injection molded green bodies obtained with improved processing methods.

  10. Analysis of cavity pressure and warpage of polyoxymethylene thin walled injection molded parts: Experiments and simulations

    NASA Astrophysics Data System (ADS)

    Guerrier, P.; Tosello, G.; Hattel, J. H.

    2015-05-01

    Process analysis and simulations on molding experiments of 3D thin shell parts have been conducted. Moldings were carried out with polyoxymethylene (POM). The moldings were performed with cavity pressure sensors in order to compare experimental process results with simulations. The warpage was characterized by measuring distances using a tactile coordinate measuring machine (CMM). Molding simulations have been executed taking into account actual processing conditions. Various aspects have been considered in the simulation: machine barrel geometry, injection speed profiles, cavity injection pressure, melt and mold temperatures, material rheological and pvT characterization. Factors investigated for comparisons were: injection pressure profile, short shots length, flow pattern, and warpage. A reliable molding experimental database was obtained, accurate simulations were conducted and a number of conclusions concerning improvements to simulation accuracy are presented regarding: pvT data, mesh, short shots, cavity pressure for process control validation as well as molding machine geometry modelling. Eventually, a methodology for improved molding simulations of cavity injection pressure, filling pattern and warpage was established.

  11. Properties of high density polyethylene – Paulownia wood flour composites via injection molding

    Technology Transfer Automated Retrieval System (TEKTRAN)

    Paulownia wood (PW) flour is evaluated as a bio-based fiber reinforcement. Composites of high density polyethylene (HDPE), 25% by weight of PW, and either 0% or 5% by weight of maleated polyethylene (MAPE) were produced by twin screw compounding followed by injection molding. Molded test composite...

  12. Optimization of injection molding parameters for poly(styrene-isobutylene-styrene) block copolymer

    NASA Astrophysics Data System (ADS)

    Fittipaldi, Mauro; Garcia, Carla; Rodriguez, Luis A.; Grace, Landon R.

    2016-03-01

    Poly(styrene-isobutylene-styrene) (SIBS) is a widely used thermoplastic elastomer in bioimplantable devices due to its inherent stability in vivo. However, the properties of the material are highly dependent on the fabrication conditions, molecular weight, and styrene content. An optimization method for injection molding is herein proposed which can be applied to varying SIBS formulations in order to maximize ultimate tensile strength, which is critical to certain load-bearing implantable applications. The number of injection molded samples required to ascertain the optimum conditions for maximum ultimate tensile strength is limited in order to minimize experimental time and effort. Injection molding parameters including nozzle temperature (three levels: 218, 246, and 274 °C), mold temperature (three levels: 50, 85, and 120 °C), injection speed (three levels: slow, medium and fast) and holding pressure time (three levels: 2, 6, and 10 seconds) were varied to fabricate dumbbell specimens for tensile testing. A three-level L9 Taguchi method utilizing orthogonal arrays was used in order to rank the importance of the different injection molding parameters and to find an optimal parameter setting to maximize the ultimate tensile strength of the thermoplastic elastomer. Based on the Taguchi design results, a Response Surface Methodology (RSM) was applied in order to build a model to predict the tensile strength of the material at different injection parameters. Finally, the model was optimized to find the injection molding parameters providing maximum ultimate tensile strength. Subsequently, the theoretically-optimum injection molding parameters were used to fabricate additional dumbbell specimens. The experimentally-determined ultimate tensile strength of these samples was found to be in close agreement (1.2%) with the theoretical results, successfully demonstrating the suitability of the Taguchi Method and RSM for optimizing injection molding parameters of SIBS.

  13. Numerical prediction of flow induced fibers orientation in injection molded polymer composites

    NASA Astrophysics Data System (ADS)

    Oumer, A. N.; Hamidi, N. M.; Mat Sahat, I.

    2015-12-01

    Since the filling stage of injection molding process has important effect on the determination of the orientation state of the fibers, accurate analysis of the flow field for the mold filling stage becomes a necessity. The aim of the paper is to characterize the flow induced orientation state of short fibers in injection molding cavities. A dog-bone shaped model is considered for the simulation and experiment. The numerical model for determination of the fibers orientation during mold-filling stage of injection molding process was solved using Computational Fluid Dynamics (CFD) software called MoldFlow. Both the simulation and experimental results showed that two different regions (or three layers of orientation structures) across the thickness of the specimen could be found: a shell region which is near to the mold cavity wall, and a core region at the middle of the cross section. The simulation results support the experimental observations that for thin plates the probability of fiber alignment to the flow direction near the mold cavity walls is high but low at the core region. It is apparent that the results of this study could assist in decisions regarding short fiber reinforced polymer composites.

  14. Injection-Molded Soft Magnets Prepared from Fe-Based Metallic Glass: Mechanical and Magnetic Properties

    NASA Astrophysics Data System (ADS)

    Zhong, Tian; Huang, Ran; Huang, Jia; Ouyang, Wei

    2015-10-01

    The injection-molded metallic glass soft magnet is prepared from the powder of melt-spun ribbon of Fe36Co36B20Si4Nb4 glassy alloy and Nylon 6,6 of wt.% from 5 to 20 via the polymer injection molding technology. The product is characterized by the SEM, mechanical, and magnetic test. The results indicate that this type of materials has comparable mechanical properties and morphological feature with the conventional injection-molded NdFeB magnet and exhibits excellent soft magnetic behaviors. The magnetic properties of the injected magnets are compared with the raw metallic glass, solvent-casted resin bonding magnets, and thermal-treated magnets to confirm that the processing temperature of Nylon injection does not affect the magnetism. The injection technology is a practical processing method to be applied on the metallic glass for potential usage.

  15. Molecular orientation distributions during injection molding of liquid crystalline polymers: Ex situ investigation of partially filled moldings

    SciTech Connect

    Fang, Jun; Burghardt, Wesley R.; Bubeck, Robert A.

    2013-01-10

    The development of molecular orientation in thermotropic liquid crystalline polymers (TLCPs) during injection molding has been investigated using two-dimensional wide-angle X-ray scattering coordinated with numerical computations employing the Larson-Doi polydomain model. Orientation distributions were measured in 'short shot' moldings to characterize structural evolution prior to completion of mold filling, in both thin and thick rectangular plaques. Distinct orientation patterns are observed near the filling front. In particular, strong extension at the melt front results in nearly transverse molecular alignment. Far away from the flow front shear competes with extension to produce complex spatial distributions of orientation. The relative influence of shear is stronger in the thin plaque, producing orientation along the filling direction. Exploiting an analogy between the Larson-Doi model and a fiber orientation model, we test the ability of process simulation tools to predict TLCP orientation distributions during molding. Substantial discrepancies between model predictions and experimental measurements are found near the flow front in partially filled short shots, attributed to the limits of the Hele-Shaw approximation used in the computations. Much of the flow front effect is however 'washed out' by subsequent shear flow as mold filling progresses, leading to improved agreement between experiment and corresponding numerical predictions.

  16. Design and fabrication of optical homogenizer with micro structure by injection molding process

    NASA Astrophysics Data System (ADS)

    Chen, C.-C. A.; Chang, S.-W.; Weng, C.-J.

    2008-08-01

    This paper is to design and fabricate an optical homogenizer with hybrid design of collimator, toroidal lens array, and projection lens for beam shaping of Gaussian beam into uniform cylindrical beam. TracePro software was used to design the geometry of homogenizer and simulation of injection molding was preceded by Moldflow MPI to evaluate the mold design for injection molding process. The optical homogenizer is a cylindrical part with thickness 8.03 mm and diameter 5 mm. The micro structure of toroidal array has groove height designed from 12 μm to 99 μm. An electrical injection molding machine and PMMA (n= 1.4747) were selected to perform the experiment. Experimental results show that the optics homogenizer has achieved the transfer ratio of grooves (TRG) as 88.98% and also the optical uniformity as 68% with optical efficiency as 91.88%. Future study focuses on development of an optical homogenizer for LED light source.

  17. Influence of the polypropylene structure on the replication of nanostructures by injection molding

    NASA Astrophysics Data System (ADS)

    Vera, Julie; Brulez, Anne-Catherine; Contraires, Elise; Larochette, Mathieu; Valette, Stéphane; Benayoun, Stéphane

    2015-11-01

    In this paper, an experimental study of replication by injection molding of sub-micrometer features is presented. Two polypropylenes with different melt flow rates (MFR) were used throughout this study. The used removable mold insert was textured with a femtosecond laser. Replication of these periodic structures, called ripples, is thus investigated. Despite different MFR, we show that the viscosities of the two polymers at the investigated temperatures and injection shear rates are similar. The reproducibility of the injected molded samples and the texture of the mold were analyzed. We propose a specific methodology to quantify the reproducibility quality replicas. The latter introduces morphological parameters such as anisotropy rate, power density, etc. A difference between the two replicas was noticeable. Based on rheological analysis, the viscosity was ruled out as the origin of this difference. Other properties were identified as the source such as the chain length and the stress relaxation time. Their impact on the replication quality was investigated and found interesting.

  18. Experimental and numerical analysis of the temperature distribution of injection molded products using protruding microprobes

    NASA Astrophysics Data System (ADS)

    Liu, Shih-Jung; Ho, Chia-Wei

    2011-05-01

    Injection molding has been one of the most important polymer processing methods for manufacturing plastic parts. In the process, the temperature is an important parameter that influences process features such as cycle times, crystallization rates, degree of crystallinity, melt flow properties, and molded product qualities. This study aims to, experimentally and numerically, examine the three-dimensional temperature distribution along the melt flow path of injection molded parts. A special experimental set-up, which includes an injection mold equipped with protruding microprobes for guiding embedded thermocouples, was designed and built to measure the temperature field along the flow path, i.e., inside the runner and the cavity, of injection molded products. The experimental results suggested that the disturbance induced by the probes remained negligible and precise temperature profiles could be measured at various positions inside the cavity. A significant increase of melt temperature was found to result from the viscous dissipation of the polymeric materials in the runner. Additionally, a commercially available code was employed to simulate and predict the temperature variation in injection molded parts. It was shown that the numerical simulation predicted better the temperature distributions inside the cavity than those along the runner.

  19. Mechanical and Electrical Properties of Vapor Grown Carbon Fiber/Polypropylene Composites Made by Injection Molding

    NASA Astrophysics Data System (ADS)

    Takahashi, Yoshihiko; Yamagiwa, Yoshitoshi; Kiyono, Ryoutaro; Fujii, Tsuneo

    We made pellets by adding 0-20 wt% vapor grown carbon fiber (VGCF) to polypropylene and made an injection molding test piece with the pellets so as to test the rheological, as well as the mechanical, electrical, and injection molding properties. In the test piece made by injection molding, the quantity of VGCF in the surface layer is extremely small as compared to the quantity of addition. The value of resistance at the end of flow of the injection-molded product is smaller than that measured at other locations, which is considered to be the influence of the fountain flow at the end of flow. In addition, it is known that the above phenomenon is attributable to the fact that the orientation is in the direction of thickness in the same way as the orientation of glass fiber and carbon fiber. Even if the additive rate of VGCF is the same, the value of resistance changes substantially depending on the thickness of injection-molded products. One of the causes is considered to be the orientation of VGCF, and the orientation of VGCF in the test piece is considered to be strong in the direction of flow. There exists a proportionality relation between the shear rate and the value of resistance calculated on the basis of the rate of flow, which is one of the molding conditions.

  20. Reduction of birefringence in a skin-layer of injection molded polymer strips using CO{sub 2} laser irradiation

    SciTech Connect

    Kurosaki, Yasuo; Satoh, Isao; Saito, Takushi

    1995-12-31

    Injection molding of polymers is currently utilized for numerous industrial applications. Because of high productivity and stable quality of molded products, the injection-molding process makes the production costs lower, and therefore, is expected to spread more widely in the future. This paper deals with a technique for improving the optical quality of injection molded polymer products using radiative heating. The birefringence frozen in a skin-layer of the molded part was reduced by CO{sub 2} laser heating, and the efficiency of this technique was investigated experimentally. Namely, a simple numerical calculation was performed to estimate the heating efficiency of CO{sub 2} laser in the polymer, effects of radiation heating on the skin-layer of the molded polymer were observed by using a mold with transparent windows, and the residual birefringence frozen in the final molded specimen was measured. The results clearly showed that the birefringence in the skin-layer of injection molded polymer strips was reduced with CO{sub 2} laser heating. The authors believe that the proposed method for reducing the birefringence frozen in injection-molded polymer products is suitable for practical molding, because process time required for the injection-molding is only slightly increased with this method.

  1. Microcellular injection molding and particulate leaching of thermoplastic polyurethane (TPU) scaffolds

    NASA Astrophysics Data System (ADS)

    Mi, Hao-Yang; Jing, Xin; Turng, Lih-Sheng; Peng, Xiang-Fang

    2014-05-01

    Microcellular injection moldingand particulate leaching methods were combined to fabricate porousand interconnectedthermoplastic polyurethane (TPU) tissue engineering scaffolds. Water soluble polyvinyl alcohol (PVOH) and sodium chloride (NaCl) were used as porogens to improve the porosity and interconnectivity, as well as the hydrophilicity, of the scaffolds. The effect of each factor-namely, PVOH, NaCl, and microcellular injection molding-on scaffold morphology was investigated. It was found that the microcellular injection molding processwas effectiveatproducing high pore density and porosity. The addition of PVOH decreasedthe pore diameter and increasedthe pore density. Furthermore, scaffolds with NaCl and PVOH porogens hadbetter interconnectivity. The residual PVOH improved the hydrophilicity of the scaffold.

  2. Study of process parameters on optical qualities for injection-molded plastic lenses.

    PubMed

    Lai, Huai En; Wang, Pei Jen

    2008-04-20

    Numerical simulations for mold-flow analysis and experimental measurements of injection-molded plastic lenses have been conducted for investigation of optical qualities, residual birefringence, and form accuracy resulting from various pertinent process conditions. First, residual birefringence distributions on the lens have been predicted and verified experimentally. Furthermore, full-scale factorial design of experiments was conducted to comprehend the influences of qualities, such as shear stresses, form accuracy, and volumetric deviation, on the measured primary or Seidel aberrations. In conclusion, residual birefringence induced by stresses represented by photoelasticity measurements agrees well with the numerical predictions and the experimental results indicate that the residual birefringence is mainly generated during the mold-filling stage. In addition, spherical aberration of the injection-molded plastic lenses is more sensitive to the pertinent qualities as compared to coma and astigmatism. PMID:18425174

  3. A Model for Fiber Length Attrition in Injection-Molded Long-Fiber Composites

    SciTech Connect

    TuckerIII, Charles L.; Phelps, Jay H; El-Rahman, Ahmed Abd; Kunc, Vlastimil

    2013-01-01

    Long-fiber thermoplastic (LFT) composites consist of an engineering thermoplastic matrix with glass or carbon reinforcing fibers that are initially 10 to 13 mm long. When an LFT is injection molded, flow during mold filling orients the fibers and degrades the fiber length. Fiber orientation models for injection molding are well developed, and special orientation models for LFTs have been developed. Here we present a detailed quantitative model for fiber length attrition in a flowing fiber suspension. The model tracks a discrete fiber length distribution (FLD) at each spatial node. Key equations are a conservation equation for total fiber length, and a breakage rate equation. The breakage rate is based on buckling of fibers due to hydrodynamic forces, when the fibers are in unfavorable orientations. The FLD model is combined with a mold filling simulation to predict spatial and temporal variations in fiber length distribution in a mold cavity during filling. The predictions compare well to experiments on a glassfiber/ PP LFT molding. Fiber length distributions predicted by the model are easily incorporated into micromechanics models to predict the stress-strain behavior of molded LFT materials. Author to whom correspondence should be addressed; electronic mail: ctucker@illinois.edu 1

  4. Electrical and dielectric properties of foam injection-molded polypropylene/multiwalled carbon nanotube composites

    SciTech Connect

    Ameli, A.; Nofar, M.; Saniei, M.; Hossieny, N.; Park, C. B.; Pötschke, P.

    2015-05-22

    A combination of high dielectric permittivity (ε′) and low dielectric loss (tan δ) is required for charge storage applications. In percolative systems such as conductive polymer composites, however, obtaining high ε′ and low tan δ is very challenging due to the sharp insulation-conduction transition near the threshold region. Due to the particular arrangement of conductive fillers induced by both foaming and injection molding processes, they may address this issue. Therefore, this work evaluates the application of foam injection molding process in fabricating polymer nanocomposites for energy storage. Polypropylene-multiwalled carbon nanotubes (PP-MWCNT) composites were prepared by melt mixing and foamed in an injection molding process. Electrical conductivity (σ), ε′ and tan δ were then characterized. Also, scanning and transmission electron microscopy (SEM and TEM) was used to investigate the carbon nanotube’s arrangement as well as cellular morphology. The results showed that foam injection-molded composites exhibited highly superior dielectric properties to those of solid counterparts. For instance, foamed samples had ε′=68.3 and tan δ =0.05 (at 1.25 vol.% MWCNT), as opposed to ε′=17.8 and tan δ=0.04 in solid samples (at 2.56 vol.% MWCNT). The results of this work reveal that high performance dielectric nanocomposites can be developed using foam injection molding technologies for charge storage applications.

  5. Electrical and dielectric properties of foam injection-molded polypropylene/multiwalled carbon nanotube composites

    NASA Astrophysics Data System (ADS)

    Ameli, A.; Nofar, M.; Saniei, M.; Hossieny, N.; Park, C. B.; Pötschke, P.

    2015-05-01

    A combination of high dielectric permittivity (ɛ') and low dielectric loss (tan δ) is required for charge storage applications. In percolative systems such as conductive polymer composites, however, obtaining high ɛ' and low tan δ is very challenging due to the sharp insulation-conduction transition near the threshold region. Due to the particular arrangement of conductive fillers induced by both foaming and injection molding processes, they may address this issue. Therefore, this work evaluates the application of foam injection molding process in fabricating polymer nanocomposites for energy storage. Polypropylene-multiwalled carbon nanotubes (PP-MWCNT) composites were prepared by melt mixing and foamed in an injection molding process. Electrical conductivity (σ), ɛ' and tan δ were then characterized. Also, scanning and transmission electron microscopy (SEM and TEM) was used to investigate the carbon nanotube's arrangement as well as cellular morphology. The results showed that foam injection-molded composites exhibited highly superior dielectric properties to those of solid counterparts. For instance, foamed samples had ɛ'=68.3 and tan δ =0.05 (at 1.25 vol.% MWCNT), as opposed to ɛ'=17.8 and tan δ=0.04 in solid samples (at 2.56 vol.% MWCNT). The results of this work reveal that high performance dielectric nanocomposites can be developed using foam injection molding technologies for charge storage applications.

  6. Dimensional Changes of Acrylic Resin Denture Bases: Conventional Versus Injection-Molding Technique

    PubMed Central

    Gharechahi, Jafar; Asadzadeh, Nafiseh; Shahabian, Foad; Gharechahi, Maryam

    2014-01-01

    Objective: Acrylic resin denture bases undergo dimensional changes during polymerization. Injection molding techniques are reported to reduce these changes and thereby improve physical properties of denture bases. The aim of this study was to compare dimensional changes of specimens processed by conventional and injection-molding techniques. Materials and Methods: SR-Ivocap Triplex Hot resin was used for conventional pressure-packed and SR-Ivocap High Impact was used for injection-molding techniques. After processing, all the specimens were stored in distilled water at room temperature until measured. For dimensional accuracy evaluation, measurements were recorded at 24-hour, 48-hour and 12-day intervals using a digital caliper with an accuracy of 0.01 mm. Statistical analysis was carried out by SPSS (SPSS Inc., Chicago, IL, USA) using t-test and repeated-measures ANOVA. Statistical significance was defined at P<0.05. Results: After each water storage period, the acrylic specimens produced by injection exhibited less dimensional changes compared to those produced by the conventional technique. Curing shrinkage was compensated by water sorption with an increase in water storage time decreasing dimensional changes. Conclusion: Within the limitations of this study, dimensional changes of acrylic resin specimens were influenced by the molding technique used and SR-Ivocap injection procedure exhibited higher dimensional accuracy compared to conventional molding. PMID:25584050

  7. The reflectivity, wettability and scratch durability of microsurface features molded in the injection molding process using a dynamic tool tempering system

    NASA Astrophysics Data System (ADS)

    Kuhn, Sascha; Burr, August; Kübler, Michael; Deckert, Matthias; Bleesen, Christoph

    2011-02-01

    In this paper the replication qualities of periodically and randomly arranged micro-features molded in the injection molding process and their effects on surface properties are studied. The features are molded in PC, PMMA and PP at different mold wall temperatures in order to point out the necessity and profitability of a variotherm mold wall temperature control system. A one-dimensional heat conduction model is proposed to predict the cycle times of the variotherm injection molding processes. With regard to these processes, the molding results are compared to the molded surface feature heights using an atomic force microscope. In addition, the effects of the molded surface features on macroscopic surfaces are characterized in terms of light reflection using a spectrometer and in terms of water wettability by measuring the static contact angle. Furthermore, due to the sensitivity of the surface features on the molded parts, their durability is compared in a scratch test with a diamond tip. This leads to successful implementation in applications in which the optical appearance, in terms of gloss and reflection, and the water repellence, in terms of drag flow and adhesion, are of importance.

  8. Bio-inspired piezoelectric artificial hair cell sensor fabricated by powder injection molding

    NASA Astrophysics Data System (ADS)

    Han, Jun Sae; Oh, Keun Ha; Moon, Won Kyu; Kim, Kyungseop; Joh, Cheeyoung; Seo, Hee Seon; Bollina, Ravi; Park, Seong Jin

    2015-12-01

    A piezoelectric artificial hair cell sensor was fabricated by the powder injection molding process in order to make an acoustic vector hydrophone. The entire process of powder injection molding was developed and optimized for PMN-PZT ceramic powder. The artificial hair cell sensor, which consists of high aspect ratio hair cell and three rectangular mechanoreceptors, was precisely fabricated through the developed powder injection molding process. The density and the dielectric property of the fabricated sensor shows 98% of the theoretical density and 85% of reference dielectric property of PMN-PZT ceramic powder. With regard to homogeneity, three rectangular mechanoreceptors have the same dimensions, with 3 μm of tolerance with 8% of deviation of dielectric property. Packaged vector hydrophones measure the underwater acoustic signals from 500 to 800 Hz with -212 dB of sensitivity. Directivity of vector hydrophone was acquired at 600 Hz as analyzing phase differences of electric signals.

  9. Cooling effects study by considering a turbulence model in injection molding

    NASA Astrophysics Data System (ADS)

    Hsu, Fu-Hung; Wu, Bo-Han; Huang, Chao-Tsai; Chang, Rong-Yeu

    2014-05-01

    Cooling stage is critical in injection molding process. A well designed cooling system can effectively shorten cycle time and improve product quality. Three-dimensional cooling analysis has been embedded in injection molding simulation which provides a useful tool for cooling system design validation. However, the current simulation tool is not perfect yet since it does not consider turbulent flow and pipe surface roughness effect. In the current study, a latest simulation tool was applied which can predict the turbulent flow effect on cooling. Two cooling systems (conventional and conformal) were simulated and compared to each other. Turbulence model and surface roughness effects were also studied. The simulation results show a good agreement with experimental data which is helpful at the design stage of an injection molding cooling system.

  10. The shrinkage behavior and surface topographical investigation for micro metal injection molding

    NASA Astrophysics Data System (ADS)

    Islam, A.; Giannekas, N.; Marhöfer, D. M.; Tosello, G.; Hansen, H. N.

    2015-05-01

    Metal injection molding (MIM) is a near net shape manufacturing technology that can produce highly complex and dimensionally stable parts for high end engineering applications. Despite the recent growth and industrial interest, micro metal molding is yet to be the field of extensive research especially when it is compared with micro molding of thermoplastics. The current paper presents a thorough investigation on the process of metal injection molding where it systematically characterizes the effects of important process conditions on the shrinkage and surface quality of molded parts with micro features. Effects of geometrical factors like feature dimensions and distance from the gate on the replication quality are studied. The influence of process conditions on the achievable roughness for the final metal parts is discussed based on the experimental findings. The test geometry is characterized by 2½D surface structures containing thin ribs of different aspect ratios and thicknesses in the sub-mm dimensional range. The test parts were molded from Catamold 316L with a conventional injection molding machine. Afterwards, the parts were de-binded and sintered to produce the final test samples. Among the different process parameters studied, the melt temperature was the most influential parameters for better replication and dimensional stability of the final part. The results presented in the paper clearly show that the shrinkage in metal part is not uniform in the micro scale. It depends on the feature dimensions and also on the process conditions. A thin section of the part exhibits higher relative shrinkage compared with a thicker section. Based on these findings, it can be concluded that a micro part molded by MIM process will have higher relative shrinkage compared to a macro part made with the same process.

  11. Influence of Mold Surface Treatments on Flow of Polymer in Injection Moulding. Application to Weldlines

    NASA Astrophysics Data System (ADS)

    Chailly, M.; Charmeau, J.-Y.; Bereaux, Y.; Monasse, B.

    2007-04-01

    Due to increasing expectations from the market, the aspect of molded parts has to be improved constantly. Some of the defects observed on these parts such as weldlines are related to the filling stage. To limit this, we investigated the influence on weldlines using various surface deposits on the mold surface, mainly PVD and PACVD deposits : Chromium nitride (CrN), Titanium nitride (TiN), Diamond like Carbon (DLC), Chromium and polished steel (PG) on an instrumented plate mold. Injection campaign was led on three polymers which differ in terms of nature (amorphous, semi-crystalline, copolymers). We studied the evolution of the dimensions of weldlines appearing on the plate using the same injection parameters for a given polymer, but with various deposits and thicknesses. Another aspect that had been investigated is the morphology of the weldline through the thickness of the part, depending on polymer nature. Adhesion of polymer at the flow front with the mold surface proved to change. The modification of the initial contact in the filling stage and thus the thermal resistance at the mold implied a change in the process, increasing or reducing the pressure loss in the flow and differential shrinkage in the final part. The induced impact on dimensions of the weldlines allowed to distinguish which surface treatments were able to reduce the defect. A complementary study was led on both polymers in molten state and deposits in terms of wetting using a sessile drop method to confirm the adhesion at the polymer/mold interface. This study proved the influence of the use of surface treatments has clearly an impact on the filling stage of the injection molding process, and it is necessary to get a better knowledge of the interactions between physical adhesion, tribology of polymer/mold contact, and thermal properties of the coatings and their impact on solidification of the polymer.

  12. Long-Fiber Thermoplastic Injection Molded Composites: from Process Modeling to Property Prediction

    SciTech Connect

    Nguyen, Ba Nghiep; Holbery, Jim D.; Johnson, Kenneth I.; Smith, Mark T.

    2005-09-01

    Recently, long-fiber filled thermoplastics have become a great interest to the automotive industry since these materials offer much better property performance (e.g. elastic moduli, strength, durability…) than their short-fiber analogues, and they can be processed through injection molding with some specific tool design. However, in order that long-fiber thermoplastic injection molded composites can be used efficiently for automotive applications, there is a tremendous need to develop process and constitutive models as well as computational tools to predict the microstructure of the as-formed composite, and its resulting properties and macroscopic responses from processing to the final product. The microstructure and properties of such a composite are governed by i) flow-induced fiber orientation, ii) fiber breakage during injection molding, and iii) processing conditions (e,g. pressure, mold and melt temperatures, mold geometries, injection speed, etc.). This paper highlights our efforts to address these challenging issues. The work is an integrated part of a research program supported by the US Department of Energy, which includes • The development of process models for long-fiber filled thermoplastics, • The construction of an interface between process modeling and property prediction as well as the development of new constitutive models to perform linear and nonlinear structural analyses, • Experimental characterization of model parameters and verification of the model predictions.

  13. An apparatus for in situ x-ray scattering measurements during polymer injection molding

    NASA Astrophysics Data System (ADS)

    Rendon, Stanley; Fang, Jun; Burghardt, Wesley R.; Bubeck, Robert A.

    2009-04-01

    We report a novel instrument for synchrotron-based in situ x-ray scattering measurements during injection molding processing. It allows direct, real-time monitoring of molecular-scale structural evolution in polymer materials undergoing a complex processing operation. The instrument is based on a laboratory-scale injection molding machine, and employs customized mold tools designed to allow x-ray access during mold filling and subsequent solidification, while providing sufficient robustness to withstand high injection pressures. The use of high energy, high flux synchrotron radiation, and a fast detector allows sufficiently rapid data acquisition to resolve time-dependent orientation dynamics in this transient process. Simultaneous monitoring of temperature and pressure signals allows transient scattering data to be referenced to various stages of the injection molding cycle. Representative data on a commercial liquid crystalline polymer, Vectra® B950, are presented to demonstrate the features of this apparatus; however, it may find application in a wide range of polymeric materials such as nanocomposites, semicrystalline polymers and fiber-reinforced thermoplastics.

  14. Flow-induced birefringence: the hidden PSF killer in high performance injection-molded plastic optics

    NASA Astrophysics Data System (ADS)

    Chidley, Matthew D.; Tkaczyk, Tomasz; Kester, Robert; Descour, Michael R.

    2006-02-01

    A 7-mm OD, NA = 1 water immersion injection-molded plastic endoscope objective has been fabricated for a laser scanning fiber confocal reflectance microscope (FCRM) system specifically designed for in vivo detection of cervical and oral pre-cancers. Injection-molded optics was selected for the ability to incorporate aspheric surfaces into the optical design and its high volume capabilities. Our goal is high performance disposable endoscope probes. This objective has been built and tested as a stand-alone optical system, a Strehl ratio greater than 0.6 has been obtained. One of the limiting factors of optical performance is believed to be flow-induced birefringence. We have investigated different configurations for birefringence visualization and believe the circular polariscope is most useful for inspection of injection-molded plastic optics. In an effort to decrease birefringence effects, two experiments were conducted. They included: (1) annealing of the optics after fabrication and (2) modifying the injection molding prameters (packing pressures, injection rates, and hold time). While the second technique showed improvement, the annealing process could not improve quality without physically warping the lenses. Therefore, to effectively reduce flow-induced birefringence, molding conditions have to be carefully selected. These parameters are strongly connected to the physical part geometry. Both optical design and fabrication technology have to be considered together to deliver low birefringence while maintaining the required manufacturing tolerances. In this paper we present some of our current results that illustrate how flow-induced birefringence can degrade high performance injection-molded plastic optical systems.

  15. An easy-to-decompose binder for Ti metal injection molding: Preparation and characterization of feedstock

    NASA Astrophysics Data System (ADS)

    Hayat, Muhammad Dilawer; Wen, Guian; Cao, Peng

    2015-03-01

    Impurity control is crucial to Ti metal powder injection molding (Ti-MIM) since titanium is a universal solvent to interstitial elements such as oxygen, carbon and nitrogen. In this study, a low decomposition temperature binder system was developed; the rheological and solvent debinding assessments of the feedstock formulated from this binder were performed. Solvent mixing was employed to prepare homogeneous feedstocks. Effects of powder shape and solid loading on rheological properties were evaluated. After injection molding, a debinding profile was constructed. The debound parts were then characterized by microstructural observation.

  16. A new binder for powder injection molding titanium and other reactive metals

    SciTech Connect

    Weil, K. Scott; Nyberg, Eric A.; Simmons, Kevin L.

    2006-06-26

    We have developed a new aromatic-based binder for powder injection molding (PIM) reactive metals, such as titanium, zirconium, niobium, tungsten, and molybdenum. Because of careful selection of the binder constituents, thermal removal is readily accomplished at low temperatures and short-times via vacuum sublimation. In this way the binder can be cleanly extracted from the green part prior to sintering to minimize the amount of residual carbon left in the final component. Rheological measurements indicate that powder loadings in the PIM feedstock as high as 67 vol% could be achieved using the new binder system, while still maintaining low mixing torques and injection molding pressures.

  17. Surface topographic characterization for polyamide composite injection molds made of aluminum and copper alloys.

    PubMed

    Pereira, A; Hernández, P; Martinez, J; Pérez, J A; Mathia, T G

    2014-01-01

    In order to ensure flexibility and rapid new product development, the mold industry made use of soft materials for cavity inserts in injection molds. However, materials of this kind are prone to wear. This article analyzes the topographic characterization of the surface and wear processes in injection molds cavities. Two materials have been used to produce the cavities: aluminum alloy EN AW‐6082 T4 and copper alloy Cu Zn39 Pb3. The surface topography was measured with the use of optical interferometry profiling technology; roughness and surface parameters were determined according to ISO 4287, ISO 25178, and EUR 15178N. In order to complete this research, an experimental part with different thicknesses and shapes was designed, and cavity inserts of aluminum and copper were made. Polyamide PA6, with 30% fiberglass reinforcement, was employed in the experimental procedure. Measurements of cavity mold surfaces were performed after 9,200 cycles on each mold and at different locations on the mold. The surface measurement was made with a white light vertical scanning interferometry, also known as coherence scanning interferometry (ISO DIS 25178‐604). The results are analyzed and differences between the two types of cavity inserts materials are discussed. PMID:23447356

  18. Three-Dimensional Simulation And Design Sensitivity Analysis Of The Injection Molding Process

    NASA Astrophysics Data System (ADS)

    Ilinca, Florin; Hétu, Jean-François

    2004-06-01

    Getting the proper combination of different process parameters such as injection speed, melt temperature and mold temperature is important in getting a part that minimizes warpage and has the desired mechanical properties. Very often a successful design in injection molding comes at the end of a long trial and error process. Design Sensitivity Analysis (DSA) can help molders improve the design and can produce substantial investment savings in both time and money. This paper investigates the ability of the sensitivity analysis to drive an optimization tool in order to improve the quality of the injected part. The paper presents the solution of the filling stage of the injection molding process by a 3D finite element solution algorithm. The sensitivity of the solution with respect to different process parameters is computed using the continuous sensitivity equation method. Solutions are shown for the non-isothermal filling of a rectangular plate with a polymer melt behaving as a non-Newtonian fluid. The paper presents the equations for the sensitivity of the velocity, pressure and temperature and their solution by finite elements. Sensitivities of the solution with respect to the injection speed, the melt and mold temperatures are shown.

  19. Measurement and computation of thermal stresses in injection molding of amorphous and crystalline polymers

    NASA Astrophysics Data System (ADS)

    Farhoudi, Yalda

    1998-12-01

    An integrated experimental and theoretical study of the residual thermal stresses has been carried out. The final stress profiles along the thickness were measured in an amorphous and a semi-crystalline injection molded polymer using the layer removal technique. The two materials exhibited drastically distinct residual profiles. Furthermore, processing parameters such as melt and coolant temperatures, pressure history, and mold thickness were found to modify the profiles. In order to elucidate the findings, two models were derived. The two-dimensional free mold shrinkage model was developed to provide a rapid estimation of thermal stresses and the main features of their profile. A more complex model was developed by integrating the stress analysis with the simulation of the complete injection molding cycle by McKam. This model accounts for the fountain flow effect, the crystallization, and the PVT behavior of the material. With the help of the model predictions, explanations were provided for the occurrence of various regions in the residual stress profiles. Transitions or reversal of the regions under variable conditions or material properties were observed to be mainly determined by the ratio of the thermal to the pressure effects. Using these concepts, practical conclusions were drawn for controlling the residual stresses. As an alternative for optimization of injection molding with respect to residual stresses, inverse methods were developed to calculate the pressure history or the initial temperature distribution required to produce a prescribed residual stress distribution. These methods were tested using direct solutions with added errors and experimental stress data.

  20. Foam injection molding of poly(lactic acid) with physical blowing agents

    NASA Astrophysics Data System (ADS)

    Pantani, R.; Sorrentino, A.; Volpe, V.; Titomanlio, G.

    2014-05-01

    Foam injection molding uses environmental friendly blowing agents under high pressure and temperature to produce parts having a cellular core and a compact solid skin (the so-called "structural foam"). The addition of a supercritical gas reduces the part weight and at the same time improves some physical properties of the material through the promotion of a faster crystallization; it also leads to the reduction of both the viscosity and the glass transition temperature of the polymer melt, which therefore can be injection molded adopting lower temperatures and pressures. These aspects are of extreme interest for biodegradable polymers, which often present a very narrow processing window, with the suitable processing temperatures close to the degradation conditions. In this work, foam injection molding was carried out by an instrumented molding machine, able to measure the pressure evolution in different positions along the flow-path. The material adopted was a biodegradable polymer, namely the Poly(lactic acid), PLA. The effect of a physical blowing agent (PBA) on the viscosity was measured. The density reduction and the morphology of parts obtained by different molding conditions was assessed.

  1. Adhesion strength between thermoplastics and its polyurethane coating made by using the technology combination of injection molding and reaction injection molding

    NASA Astrophysics Data System (ADS)

    Bloß, P.; Böhme, A.; Müller, J.; Krajewsky, P.; Michaelis, J.

    2014-05-01

    A complete equipment for injection molding (IM) of a thermoplastic (TP) carrier and reaction injection molding (RIM) of polyurethane (PUR) coatings including IM and RIM machines, a color module for PUR, and a robot was built up. A modularly composed sliding split mold was constructed and manufactured allowing different parts including thicker (2 mm thickness) soft touch and thin (0.4 mm) lacquer PUR coatings. As TP PC/ABS and PA6 GF15 compounds were used, and aromatic and aliphatic PUR systems as well. From the parts made by IM+RIM, test specimens for peel force measurements were cut. These investigations were performed prior and after ageing under climatic conditions @ 50 % RH and temperature changes between -30 °C and 90 °C. By varying IM processing parameters, we have found that mold and TP temperatures are particularly important for the adhesion strength between TP and PUR. The waiting time between the end of TP cooling and PUR injection has a minor influence on its mean value. However, to short waiting times may result in inhomogeneous adhesion. It was surprising that surface defects of the TP carrier leads also to inhomogeneous adhesion. We have observed that ageing may cause an increase and decrease of adhesions strength depending on the TP+PUR system used. We have found that the results are valid only for the actual TP and PUR combination. A generalization seems to be inappropriate, hence, the actual combination should be investigated to prevent unwanted surprises when the coated TP part is in its application.

  2. Powder Injection Molding of Ceria-Stabilized, Zirconia-Toughened Mullite Parts for UAV Engine Components

    NASA Astrophysics Data System (ADS)

    Martin, Renee; Vick, Michael; Enneti, Ravi K.; Atre, Sundar V.

    2013-11-01

    Powder injection molding (PIM) of ceria-stabilized, zirconia-toughened mullite composites were investigated in the present article with the goal of obtaining performance enhancement in complex geometries for energy and transportation applications. A powder-polymer mixture (feedstock) was developed and characterized to determine its suitability for fabricating complex components using the PIM process. Test specimens were injection molded and subsequently debound and sintered. The sintered properties indicated suitable properties for engine component applications used in unmanned aerial vehicles (UAVs). The measured feedstock properties were used in computer simulations to assess the mold-filling behavior for a miniature turbine stator. The results from the measurements of rheological and thermal properties of the feedstock combined with the sintered properties of the ceria-stabilized, zirconia-toughened mullite strongly indicate the potential for enhancing the performance of complex geometries used in demanding operating conditions in UAV engines.

  3. Validation of New Process Models for Large Injection-Molded Long-Fiber Thermoplastic Composite Structures

    SciTech Connect

    Nguyen, Ba Nghiep; Jin, Xiaoshi; Wang, Jin; Kunc, Vlastimil; Tucker III, Charles L.

    2012-02-23

    This report describes the work conducted under the CRADA Nr. PNNL/304 between Battelle PNNL and Autodesk whose objective is to validate the new process models developed under the previous CRADA for large injection-molded LFT composite structures. To this end, the ARD-RSC and fiber length attrition models implemented in the 2013 research version of Moldflow was used to simulate the injection molding of 600-mm x 600-mm x 3-mm plaques from 40% glass/polypropylene (Dow Chemical DLGF9411.00) and 40% glass/polyamide 6,6 (DuPont Zytel 75LG40HSL BK031) materials. The injection molding was performed by Injection Technologies, Inc. at Windsor, Ontario (under a subcontract by Oak Ridge National Laboratory, ORNL) using the mold offered by the Automotive Composite Consortium (ACC). Two fill speeds under the same back pressure were used to produce plaques under slow-fill and fast-fill conditions. Also, two gating options were used to achieve the following desired flow patterns: flows in edge-gated plaques and in center-gated plaques. After molding, ORNL performed measurements of fiber orientation and length distributions for process model validations. The structure of this report is as follows. After the Introduction (Section 1), Section 2 provides a summary of the ARD-RSC and fiber length attrition models. A summary of model implementations in the latest research version of Moldflow is given in Section 3. Section 4 provides the key processing conditions and parameters for molding of the ACC plaques. The validations of the ARD-RSC and fiber length attrition models are presented and discussed in Section 5. The conclusions will be drawn in Section 6.

  4. Thermal properties of extruded/injection-molded poly(lactic acid) and biobased composites

    Technology Transfer Automated Retrieval System (TEKTRAN)

    In order to determine the degree of compatibility between PLA and different biomaterials (fibers), PLA was compounded with sugar beet pulp and apple fibers. Fibers were added at 85:15 and 70:30 PLA:Fiber. The composites were blended by extrusion followed by injection molding. Differential Scannin...

  5. DAMAGE MODELING OF INJECTION-MOLDED SHORT- AND LONG-FIBER THERMOPLASTICS

    SciTech Connect

    Nguyen, Ba Nghiep; Kunc, Vlastimil; Bapanapalli, Satish K.; Phelps, Jay; Tucker III, Charles L.

    2009-10-30

    This article applies the recent anisotropic rotary diffusion – reduced strain closure (ARD-RSC) model for predicting fiber orientation and a new damage model for injection-molded long-fiber thermoplastics (LFTs) to analyze progressive damage leading to total failure of injection-molded long-glass-fiber/polypropylene (PP) specimens. The ARD-RSC model was implemented in a research version of the Autodesk Moldflow Plastics Insight (MPI) processing code, and it has been used to simulate injection-molding of a long-glass-fiber/PP plaque. The damage model combines micromechanical modeling with a continuum damage mechanics description to predict the nonlinear behavior due to plasticity coupled with damage in LFTs. This model has been implemented in the ABAQUS finite element code via user-subroutines and has been used in the damage analyses of tensile specimens removed from the injection-molded long-glass-fiber/PP plaques. Experimental characterization and mechanical testing were performed to provide input data to support and validate both process modeling and damage analyses. The predictions are in agreement with the experimental results.

  6. CO-INJECTION RESIN TRANSFER MOLDING FOR OPTIMIZATION OF INTEGRAL ARMOR

    EPA Science Inventory

    To address the cost and performance barriers which hinder the introduction of composite materials for combat ground vehicle applications, Co-Injection Resin Transfer Molding (CIRTM) and Diffusion Enhanced Adhesion (DEA) have been recently invented and developed at the Army Resear...

  7. A Study of Micro Injection Molding for High-Aspect-Ratio Optical Fiber Ferrules

    NASA Astrophysics Data System (ADS)

    Lin, Zheng-Guan.; Tseng, Shi-Chang; Wang, James; Su, Yi-Chung

    2004-06-01

    This study focused on manufacture of high-aspect-ratio optical fiber ferrules by micro thermoplastic injection molding technique. In the past, the optical fiber connectors were produced by ceramic powder injection molding and subsequent precision grinding process. In this work, plastic micro injection molding technique was attempted to manufacture net-shaped products at once. Each ferrule has a micro through hole in the center. The hole's diameter is 125±1μm, and its length is 9mm. During micro molding, how to keep the micro core pin at the center becomes a critical issue. In this work, a guiding slide system is introduced to hold the micro pin continuously. And the slide movement was controlled by a spring behind it. Such a guiding system can help reduce mis-alignment of the micro core pin and increase its life time. Taguchi's design of experiment was used to evaluate the effects of processing parameters on final properties. Experimental results reveal that the higher the spring force, the larger the product weight and the lower the shrinkage. In order to obtain better uniformity of diameters at different locations, diameters at three locations were measured. Measured data showed the shrinkage of diameter in the middle is greater than those at two ends. It is because the two ends cooled faster than the center region. This can be improved by applying higher mold temperature or appropriate holding pressure or holding time. The new design concept can be applied in molding micro tubes, especially for the high aspect ratio cases.

  8. In-situ Formation of Ti Alloys via Powder Injection Molding

    SciTech Connect

    Simmons, Kevin L.; Nyberg, Eric A.; Weil, K. Scott; Miller, Megan R.

    2005-01-01

    We have developed a unique blend of powder injection molding (PIM) feedstock materials in which only a small volume fraction of binder (< 8%) is required; the remainder of the mixture consists of the metal powder and a solid aromatic solvent. Because of the nature of the decomposition in the binder system and the relatively small amount used, the binder can be completely removed from the molded component during heat treatment. Here, we present results from an initial study on in-situ titanium alloy formation in near-net shape components manufactured by this novel PIM technique.

  9. Determination of injection molding process windows for optical lenses using response surface methodology.

    PubMed

    Tsai, Kuo-Ming; Wang, He-Yi

    2014-08-20

    This study focuses on injection molding process window determination for obtaining optimal imaging optical properties, astigmatism, coma, and spherical aberration using plastic lenses. The Taguchi experimental method was first used to identify the optimized combination of parameters and significant factors affecting the imaging optical properties of the lens. Full factorial experiments were then implemented based on the significant factors to build the response surface models. The injection molding process windows for lenses with optimized optical properties were determined based on the surface models, and confirmation experiments were performed to verify their validity. The results indicated that the significant factors affecting the optical properties of lenses are mold temperature, melt temperature, and cooling time. According to experimental data for the significant factors, the oblique ovals for different optical properties on the injection molding process windows based on melt temperature and cooling time can be obtained using the curve fitting approach. The confirmation experiments revealed that the average errors for astigmatism, coma, and spherical aberration are 3.44%, 5.62%, and 5.69%, respectively. The results indicated that the process windows proposed are highly reliable. PMID:25321095

  10. Surface Orientation in Injection-Molded Thermotropic Liquid Crystalline Copolyester (TLCP) Plaques

    NASA Astrophysics Data System (ADS)

    Bubeck, Robert; Fang, Jun; Burghardt, Wesley; Burgard, Susan; Robertson, Katherine; Fischer, Daniel

    2008-03-01

    Attenuated total reflection Fourier transform infra-red (ATR-FTIR), C K edge near edge X-ray adsorption fine structure (NEXAFS) spectroscopies, and 2-D WAXS in transmission were used to characterize surface orientation in thermotropic liquid crystalline copolyester (TLCP) injection-molded plaques to varying depths into the samples. Injection-molded TLCPs have bimodal orientation states due to contributions from ``skin'' and ``core'' regions resulting from extensional and shear flow, respectively, in the mold. The NEXAFS is sensitive to the orientation of the molecular pi orbital of backbone phenyl groups of the top 2 nm of a surface. ATR-FTIR obtained using a Herrick Seagull variable angle reflectance accessory is sensitive for dichroic ratios to a depth of 5 microns. Orientation parameters derived from the 1502/cm absorption band for equivalent positions are often typically about 5 to 10 percent less by ATR-FTIR than by NEXAFS. The orientational states are being correlated with physical properties of injection-molded TLCP samples.

  11. Evaluation of Mechanical Properties of Injection Molding Composites Reinforced by Bagasse Fiber

    NASA Astrophysics Data System (ADS)

    Cao, Yong; Fukumoto, Isao

    BMC (Bulk Molding Compound) is composed of UP (Unsaturated Polyester) resin, glass fibers, and bagasse fibers which have been obtained after squeezing sugar cane. Our purpose is to use the bagasse fibers as reinforcement and filler in BMC to fabricate composites by injection molding and injection compression molding. The mechanical properties of injection molding composites were improved after adding the bagasse fibers. Observing the fracture surface of the tensile test specimen through SEM, we could notice the glass fibers were penetrated into the bagasse fibers longitudinally. Along with UP resin solidifying, the glass fibers were firmly fixed in the bagasse fibers and finally united with them. This phenomenon could bring on the same effect as the glass fibers length was prolonged, so that the adhesion interface between fiber and matrix resin became larger, which leads to the increase in the mechanical properties. Otherwise, it was observed that UP resin sufficiently permeated the bagasse fibers and solidified. This also contributes to enhancing the mechanical properties drastically.

  12. A review of contamination related hydraulic pump problems in Japanese injection molding, extrusion and rubber molding industries

    SciTech Connect

    Sasaki, Akira

    1997-12-31

    It is known that contamination of hydraulic oil is one of the major factors causing hydraulic pump problems. Many test reports on contaminant sensibility of hydraulic pumps have been published with new oil and standard dusts but the results of these tests could not guarantee to predict in-service performance. This report describes three cases investigated. The first investigation was done on hydraulic pumps used for injection molding machines application. The causes of pump problems were examined by analysis of maintenance records. The second investigation was performed to determine overhaul frequency of hydraulic pumps used for aluminum extruders. By introducing a new method of hydraulic oil management which reduces oil oxidation products, pump life was extended from 3,000 to 15,000 hours. The third investigation was done to determine the relationship between pump problems and contamination levels of hydraulic oils of 411 rubber molding machines for 20 months. The results showed that pump problems appeared at half the recommended oil lifetimes for these fluids. These studies showed that the cause of pump problems was clogging of suction strainers leading to pump cavitation. The clogged strainers were washed with several different solvents to identify the causes of suction strainer clogging. Clogging of suction strainers was attributable to sticky oxidation products of hydraulic oils. Electrostatic oil cleaners removed not only micron range solid particles bu also submicron size particles. Hydraulic pump problems have been substantially reduced by introducing this new method of contamination control.

  13. Dynamic penetration behavior of core-material in multi-cavity co-injection molding

    NASA Astrophysics Data System (ADS)

    Huang, Chao-Tsai CT; Yang, Jackie; Chang, Rong-Yeu

    2015-12-01

    Co-Injection Molding and multi-cavity molding are very common processes for plastic manufacturing. These two systems are sometimes combined and applied to some structure products. The core penetration and flow balance control problems are very difficult to manage. The inside mechanism of co-injection multi-cavity system is not fully figured out yet. In this study, we have focused on the penetration phenomena of core-material in a co-injection multi-cavity molding. The dynamic penetration behavior of core is very sensitive to injection flow rate and skin/core ratio. The longest core penetration has been shown to change dramatically from one runner to the other. In addition, the core penetration behavior will display imbalance at the end of filling. The more core ratio it is, the longer core penetration flows through runner to cavity. However, due to the multi-cavity geometrical structure, the balance of the core penetration for multi-cavity is still challenging. Finally, the simulation is validated with some literature. The results showed that both simulation and experiment are in a good agreement in trend

  14. Local mechanical properties of LFT injection molded parts: Numerical simulations versus experiments

    NASA Astrophysics Data System (ADS)

    Desplentere, F.; Soete, K.; Bonte, H.; Debrabandere, E.

    2014-05-01

    In predictive engineering for polymer processes, the proper prediction of material microstructure from known processing conditions and constituent material properties is a critical step forward properly predicting bulk properties in the finished composite. Operating within the context of long-fiber thermoplastics (LFT, length < 15mm) this investigation concentrates on the prediction of the local mechanical properties of an injection molded part. To realize this, the Autodesk Simulation Moldflow Insight 2014 software has been used. In this software, a fiber breakage algorithm for the polymer flow inside the mold is available. Using well known micro mechanic formulas allow to combine the local fiber length with the local orientation into local mechanical properties. Different experiments were performed using a commercially available glass fiber filled compound to compare the measured data with the numerical simulation results. In this investigation, tensile tests and 3 point bending tests are considered. To characterize the fiber length distribution of the polymer melt entering the mold (necessary for the numerical simulations), air shots were performed. For those air shots, similar homogenization conditions were used as during the injection molding tests. The fiber length distribution is characterized using automated optical method on samples for which the matrix material is burned away. Using the appropriate settings for the different experiments, good predictions of the local mechanical properties are obtained.

  15. Foam injection molding of thermoplastic elastomers: Blowing agents, foaming process and characterization of structural foams

    NASA Astrophysics Data System (ADS)

    Ries, S.; Spoerrer, A.; Altstaedt, V.

    2014-05-01

    Polymer foams play an important role caused by the steadily increasing demand to light weight design. In case of soft polymers, like thermoplastic elastomers (TPE), the haptic feeling of the surface is affected by the inner foam structure. Foam injection molding of TPEs leads to so called structural foam, consisting of two compact skin layers and a cellular core. The properties of soft structural foams like soft-touch, elastic and plastic behavior are affected by the resulting foam structure, e.g. thickness of the compact skins and the foam core or density. This inner structure can considerably be influenced by different processing parameters and the chosen blowing agent. This paper is focused on the selection and characterization of suitable blowing agents for foam injection molding of a TPE-blend. The aim was a high density reduction and a decent inner structure. Therefore DSC and TGA measurements were performed on different blowing agents to find out which one is appropriate for the used TPE. Moreover a new analyzing method for the description of processing characteristics by temperature dependent expansion measurements was developed. After choosing suitable blowing agents structural foams were molded with different types of blowing agents and combinations and with the breathing mold technology in order to get lower densities. The foam structure was analyzed to show the influence of the different blowing agents and combinations. Finally compression tests were performed to estimate the influence of the used blowing agent and the density reduction on the compression modulus.

  16. Simulation-based process windows simultaneously considering two and three conflicting criteria in injection molding

    PubMed Central

    Rodríguez-Yáñez, Alicia Berenice; Méndez-Vázquez, Yaileen

    2014-01-01

    Process windows in injection molding are habitually built with only one performance measure in mind. In reality, a more realistic picture can be obtained when considering multiple performance measures at a time, especially in the presence of conflict. In this work, the construction of process windows for injection molding (IM) is undertaken considering two and three performance measures in conflict simultaneously. The best compromises between the criteria involved are identified through the direct application of the concept of Pareto-dominance in multiple criteria optimization. The aim is to provide a formal and realistic strategy to set processing conditions in IM operations. The resulting optimization approach is easily implementable in MS Excel. The solutions are presented graphically to facilitate their use in manufacturing plants. PMID:25530927

  17. Monitoring of binder removal from injection molded ceramics using air-coupled ultrasound at high temperature.

    PubMed

    Wright, W D; Hutchins, D A

    1999-01-01

    A pair of capacitance-type air-coupled ultrasonic transducers have been constructed that were capable of operating in air at temperatures of 500 to 600 degrees C. These devices were then used to monitor the pyrolytic removal of organic binder from injection molded silicon nitride ceramic components using air-coupled ultrasound inside a furnace at elevated temperatures. Through-thickness waveforms were obtained in the ceramic and compared with simultaneous measurements of the mass of the sample. Both the ultrasonic velocity and signal amplitudes could be used to monitor the change in mass of the injection molded ceramic, and other phenomena (such as softening and redistribution of the binder) were observed. PMID:18238465

  18. Anisotropic injection molding of strontium ferrite powder using a PP/PEG binder system

    NASA Astrophysics Data System (ADS)

    Lee, S. H.; Jeung, W. Y.

    2001-05-01

    In this study, new binder system for anisotropic injection molding of Sr-ferrite was developed and a process for injection molding of Sr-ferrite was optimized. The developed binder system is composed of 30 vol% PP, 60 vol% PEG-20 000 and 10 vol% PEG-4000. The extraction by water was applied to remove the major binder components PEGs and the minor binder component, PP, was subsequently burned out in air. Behaviors of extraction and thermal debinding with time and debinding atmosphere and variations of the magnetic properties with sintering temperature were studied. The sintered magnets made by PIM process showed residual carbon content of 230 ppm and a maximum energy product of 4.2 MGOe.

  19. From Process Modeling to Elastic Property Prediction for Long-Fiber Injection-Molded Thermoplastics

    SciTech Connect

    Nguyen, Ba Nghiep; Kunc, Vlastimil; Frame, Barbara J.; Phelps, Jay; Tucker III, Charles L.; Bapanapalli, Satish K.; Holbery, James D.; Smith, Mark T.

    2007-09-13

    This paper presents an experimental-modeling approach to predict the elastic properties of long-fiber injection-molded thermoplastics (LFTs). The approach accounts for fiber length and orientation distributions in LFTs. LFT samples were injection-molded for the study, and fiber length and orientation distributions were measured at different locations for use in the computation of the composite properties. The current fiber orientation model was assessed to determine its capability to predict fiber orientation in LFTs. Predicted fiber orientations for the studied LFT samples were also used in the calculation of the elastic properties of these samples, and the predicted overall moduli were then compared with the experimental results. The elastic property prediction was based on the Eshelby-Mori-Tanaka method combined with the orientation averaging technique. The predictions reasonably agree with the experimental LFT data

  20. Two component tungsten powder injection molding - An effective mass production process

    NASA Astrophysics Data System (ADS)

    Antusch, Steffen; Commin, Lorelei; Mueller, Marcus; Piotter, Volker; Weingaertner, Tobias

    2014-04-01

    Tungsten and tungsten-alloys are presently considered to be the most promising materials for plasma facing components for future fusion power plants. The Karlsruhe Institute of Technology (KIT) divertor design concept for the future DEMO power plant is based on modular He-cooled finger units and the development of suitable mass production methods for such parts was needed. A time and cost effective near-net-shape forming process with the advantage of shape complexity, material utilization and high final density is Powder Injection Molding (PIM). This process allows also the joining of two different materials e.g. tungsten with a doped tungsten alloy, without brazing. The complete technological process of 2-Component powder injection molding for tungsten materials and its application on producing real DEMO divertor parts, characterization results of the finished parts e.g. microstructure, hardness, density and joining zone quality are discussed in this contribution.

  1. Optimization and evaluation of metal injection molding by using X-ray tomography

    SciTech Connect

    Yang, Shidi; Zhang, Ruijie; Qu, Xuanhui

    2015-06-15

    6061 aluminum alloy and 316L stainless steel green bodies were obtained by using different injection parameters (injection pressure, speed and temperature). After injection process, the green bodies were scanned by X-ray tomography. The projection and reconstruction images show the different kinds of defects obtained by the improper injection parameters. Then, 3D rendering of the Al alloy green bodies was used to demonstrate the spatial morphology characteristics of the serious defects. Based on the scanned and calculated results, it is convenient to obtain the proper injection parameters for the Al alloy. Then, reasons of the defect formation were discussed. During mold filling, the serious defects mainly formed in the case of low injection temperature and high injection speed. According to the gray value distribution of projection image, a threshold gray value was obtained to evaluate whether the quality of green body can meet the desired standard. The proper injection parameters of 316L stainless steel can be obtained efficiently by using the method of analyzing the Al alloy injection. - Highlights: • Different types of defects in green bodies were scanned by using X-ray tomography. • Reasons of the defect formation were discussed. • Optimization of the injection parameters can be simplified greatly by the way of X-ray tomography. • Evaluation standard of the injection process can be obtained by using the gray value distribution of projection image.

  2. Correlation between Rheotens measurements and reinforcement of polymer nanocomposites in the injection molding compounder

    NASA Astrophysics Data System (ADS)

    Battisti, Markus G.; Friesenbichler, Walter; Duretek, Ivica; Guttmann, Peter

    2015-04-01

    The evaluation of the effectiveness of reinforcement of polymers and polymer nanocomposites(PNCs), in particular the improvement of Young's modulus, is made by performing standardized tensile tests. Structural and morphological characterizations typically are investigated using expensive techniques like transmission electron microscopy (TEM), X- ray scattering and sometimes also rheological analyses (rotational rheometry). The objective of this study is to generate faster and economically advantageous data to verify the quality of the produced PNC-compound in an on-line measurement system. Subsequently injection molded parts are processed by using the Injection Molding Compounder (PNC-IMC) “by only one plasticizing process”. In comparison to the conventional compounding process, where the compound has to be pelletized and fed into the injection molding machine for the second plasticizing process, injection molding compounding combines these two processing steps. This paper shows first results and problems with the implementation of the Rheotens equipment into the concept of the IMC. Different processing techniques and various processing conditions were compared and the occurring effects were detected both with tensile testing and extensional melt rheology. Both, the increase of the Young's modulus by using layered silicates as nanofillersis compared to the virgin polypropylene and the correlation of the level of melt strength with Rheotens measurements is shown. These results give a good overview on both the possibilities and the limitations of the material pre-tests by the use of extensional rheology in the concept of the IMC for producing PNCs. Further studies to enable a fast and efficient way of estimating the level of reinforcement in PNCs by means of Rheotens measurements will be carried out towards industrial usability. Furthermore the verification of exfoliation and intercalation of the layered silicates in the polymer matrix using small angle X- ray

  3. Particle morphology influence on mechanical and biocompatibility properties of injection molded Ti alloy powder.

    PubMed

    Gülsoy, H Özkan; Gülsoy, Nagihan; Calışıcı, Rahmi

    2014-01-01

    Titanium and Titanium alloys exhibits properties that are excellent for various bio-applications. Metal injection molding is a processing route that offers reduction in costs, with the added advantage of near net-shape components. Different physical properties of Titanium alloy powders, shaped and processed via injection molding can achieve high complexity of part geometry with mechanical and bioactivity properties, similar or superior to wrought material. This study describes that the effect of particle morphology on the microstructural, mechanical and biocompatibility properties of injection molded Ti-6Al-4V (Ti64) alloy powder for biomaterials applications. Ti64 powders irregular and spherical in shape were injection molded with wax based binder. Binder debinding was performed in solvent and thermal method. After debinding the samples were sintered under high vacuum. Metallographic studies were determined to densification and the corresponding microstructural changes. Sintered samples were immersed in a simulated body fluid (SBF) with elemental concentrations that were comparable to those of human blood plasma for a total period of 15 days. Both materials were implanted in fibroblast culture for biocompatibility evaluations were carried out. The results show that spherical and irregular powder could be sintered to a maximum theoretical density. Maximum tensile strength was obtained for spherical shape powder sintered. The tensile strength of the irregular shape powder sintered at the same temperature was lower due to higher porosity. Finally, mechanical tests show that the irregular shape powder has lower mechanical properties than spherical shape powder. The sintered irregular Ti64 powder exhibited better biocompatibility than sintered spherical Ti64 powder. Results of study showed that sintered spherical and irregular Ti64 powders exhibited high mechanical properties and good biocompatibility properties. PMID:25201399

  4. Injection molding of silicon carbide capable of being sintered without pressure

    NASA Technical Reports Server (NTRS)

    Muller-Zell, A.; Schwarzmeier, R.

    1984-01-01

    The most suitable SiC mass for injection molding of SiC articles (for subsequent pressureless sintering) consisted of beta SiC 84, a wax mixture 8, and polyethylene or polystyrene 8 parts. The most effective method for adding the binders was by dissolving them in a solvent and subsequent evaporation. The sequence of component addition was significant, and all parameters were optimized together rather than individually.

  5. Study of tile/fiber systems manufactured from Kharkov injection molded and Kuraray SCSN-81 scintillators

    NASA Astrophysics Data System (ADS)

    Nemashkalo, A.; Popov, V.; Rubashkin, A.; Sorokin, P.; Zatserklianiy, A.; Borisenko, A.; Senchishin, V.; Skrebtsov, O.; Bolotov, V.

    1998-12-01

    We present the measurements of light output, light yield uniformity, and recovery after radiation damage of the tile/fiber systems made from the Kharkov injection molded and Kuraray SCSN-81 scintillators. The tiles were trapezoidal in shape, 131×90×122 mm3, with a Kuraray Y11 multiclad WLS read-out. The results are compared with those obtained using the tile/fiber systems manufactured from the Kuraray SCSN-81 scintillator and tested under the same conditions.

  6. Prediction of fiber orientation in injection-molded parts using three-dimensional simulations

    NASA Astrophysics Data System (ADS)

    Wang, Jin; Cook, Peter; Bakharev, Alex; Costa, Franco; Astbury, David

    2016-03-01

    The Folgar-Tucker (F-T) model is widely used in most commercial software packages and research programs to predict the fiber orientation distribution in injection-molded fiber-reinforced composites. However, experimental measurements reveal that the F-T model normally results in much higher fiber alignment than observed because it tends to over-predict the orientation kinetics. The Reduced Strain Closure (RSC) model was developed, based on the F-T model, to capture the slow orientation kinetics in an objective fashion. Previous studies demonstrate that t he RSC model yields good agreement of fiber orientation with experimental measurements in shell element simulations using the Hele-Shaw flow approximation. This paper focuses on the RSC model in three-dimensional finite element simulations. The fiber orientation predictions were compared to the orientation measurements in a number of injection-molded parts of various shapes and dimensions and molded with various injection speeds. The RSC model is able to capture the orientation distribution through the part thickness and the average orientation trends along the flow length without the need to tailor the inlet orientation condition to pre-existing data.

  7. An Elastic-Plastic and Strength Prediction Model for Injection-Molded Long-Fiber Thermoplastics

    SciTech Connect

    Nguyen, Ba Nghiep; Kunc, Vlastimil; Phelps, Jay; Tucker III, Charles L.; Bapanapalli, Satish K.

    2008-09-01

    This paper applies a recently developed model to predict the elastic-plastic stress/strain response and strength of injection-molded long-fiber thermoplastics (LFTs). The model combines a micro-macro constitutive modeling approach with experimental characterization and modeling of the composite microstructure to determine the composite stress/strain response and strength. Specifically, it accounts for elastic fibers embedded in a thermoplastic resin that exhibits the elastic-plastic behavior obeying the Ramberg-Osgood relation and J-2 deformation theory of plasticity. It also accounts for fiber length, orientation and volume fraction distributions in the composite formed by the injection-molding process. Injection-molded-long-glass-fiber/polypropylene (PP) specimens were prepared for mechanical characterization and testing. Fiber length, orientation, and volume fraction distributions were then measured at some selected locations for use in the computation. Fiber orientations in these specimens were also predicted using an anisotropic rotary diffusion model developed for LFTs. The stress-strain response of the as-formed composite was computed by an incremental procedure that uses the Eshelby’s equivalent inclusion method, the Mori-Tanaka assumption and a fiber orientation averaging technique. The model has been validated against the experimental stress-strain results obtained for these long-glass-fiber/PP specimens.

  8. Color measurement of plastics - From compounding via pelletizing, up to injection molding and extrusion

    NASA Astrophysics Data System (ADS)

    Botos, J.; Murail, N.; Heidemeyer, P.; Kretschmer, K.; Ulmer, B.; Zentgraf, T.; Bastian, M.; Hochrein, T.

    2014-05-01

    The typical offline color measurement on injection molded or pressed specimens is a very expensive and time-consuming process. In order to optimize the productivity and quality, it is desirable to measure the color already during the production. Therefore several systems have been developed to monitor the color e.g. on melts, strands, pellets, the extrudate or injection molded part already during the process. Different kinds of inline, online and atline methods with their respective advantages and disadvantages will be compared. The criteria are e.g. the testing time, which ranges from real-time to some minutes, the required calibration procedure, the spectral resolution and the final measuring precision. The latter ranges between 0.05 to 0.5 in the CIE L*a*b* system depending on the particular measurement system. Due to the high temperatures in typical plastics processes thermochromism of polymers and dyes has to be taken into account. This effect can influence the color value in the magnitude of some 10% and is barely understood so far. Different suitable methods to compensate thermochromic effects during compounding or injection molding by using calibration curves or artificial neural networks are presented. Furthermore it is even possible to control the color during extrusion and compounding almost in real-time. The goal is a specific developed software for adjusting the color recipe automatically with the final objective of a closed-loop control.

  9. Quality Control of Injection Molded Eyewear by Non-Contact Deflectometry

    NASA Astrophysics Data System (ADS)

    Speck, A.; Zelzer, B.; Langenbucher, A.; Eppig, T.

    2014-07-01

    Occupational eye wear such as safety spectacles are manufactured by injection molding techniques. Testing of the assembled safety spectacle lenses in transmission is state of the art, but there is a lack of surface measurement systems for occupational safety lenses. The purpose of this work was to validate a deflectometric setup for topography measurement, detection of defects and visualization of the polishing quality, e.g. casting indentations or impressions, for the production process of safety spectacles. The setup is based on a customized stereo phase measuring deflectometer (PMD), equipped with 3 cameras with f'1,2 = 16 mm and f'3 = 8.5 mm and a specified measurement uncertainty of ± 3 μm. Sixteen plastic lenses and 8 corresponding injection molds from 4 parallel cavities were used for validation of the deflectometer. For comparison an interferometric method and a reference standard (< λ/10 super polished) was used. The accuracy and bias with a spherical safety spectacle sample was below 1 μm, according to DIN ISO 5725-2.2002-12. The repeatability was 2.1 μm and 35.7 μm for a blind radius fit. In conclusion, the PMD technique is an appropriate tool for characterizing occupational safety spectacle and injections mold surfaces. With the presented setup we were able to quantify the surface quality. This can be useful and may optimize the quality of the end product, in addition to standardized measuring systems in transmission.

  10. Recycling plastic scrap: Injection molding. (Latest citations from the Rubber and Plastics Research Association database). Published Search

    SciTech Connect

    1995-01-01

    The bibliography contains citations concerning the recycling of scrap plastic produced in the injection molding process. Plastic pellets made from scrap, that are used in the injection molding process, are also discussed. Recycling equipment and automated recycling systems are described. The reuse of plastic scrap culled from junk automobiles and packaging materials is discussed, and waste byproducts from polyurethane production are described. (Contains a minimum of 88 citations and includes a subject term index and title list.)

  11. Recycling plastic scrap: Injection molding. (Latest citations from the Rubber and Plastics Research Association database). Published Search

    SciTech Connect

    1996-04-01

    The bibliography contains citations concerning the recycling of scrap plastic produced in the injection molding process. Plastic pellets made from scrap, that are used in the injection molding process, are also discussed. Recycling equipment and automated recycling systems are described. The reuse of plastic scrap culled from junk automobiles and packaging materials is discussed, and waste byproducts from polyurethane production are described. (Contains 50-250 citations and includes a subject term index and title list.) (Copyright NERAC, Inc. 1995)

  12. Wall-slip of highly filled powder injection molding compounds: Effect of flow channel geometry and roughness

    SciTech Connect

    Hausnerova, Berenika; Sanetrnik, Daniel; Paravanova, Gordana

    2014-05-15

    The paper deals with the rheological behavior of highly filled compounds proceeded via powder injection molding (PIM) and applied in many sectors of industry (automotive, medicine, electronic or military). Online rheometer equipped with slit dies varying in surface roughness and dimensions was applied to investigate the wall-slip as a rheological phenomenon, which can be considered as a parameter indicating the separation of compound components (polymer binder and metallic powder) during high shear rates when injection molded.

  13. Recycling plastic scrap: Injection molding. (Latest citations from the Rubber and Plastics Research Association database). Published Search

    SciTech Connect

    Not Available

    1994-05-01

    The bibliography contains citations concerning the recycling of scrap plastic produced in the injection molding process. Plastic pellets made from scrap, that are used in the injection molding process, are also discussed. Recycling equipment and automated recycling systems are described. The reuse of plastic scrap culled from junk automobiles and packaging materials is discussed, and waste byproducts from polyurethane production are described. (Contains a minimum of 80 citations and includes a subject term index and title list.)

  14. Recycling plastic scrap: Injection molding. (Latest citations from the Rubber and Plastics Research Association database). Published Search

    SciTech Connect

    1997-02-01

    The bibliography contains citations concerning the recycling of scrap plastic produced in the injection molding process. Plastic pellets made from scrap, that are used in the injection molding process, are also discussed. Recycling equipment and automated recycling systems are described. The reuse of plastic scrap culled from junk automobiles and packaging materials is discussed, and waste byproducts from polyurethane production are described. (Contains 50-250 citations and includes a subject term index and title list.) (Copyright NERAC, Inc. 1995)

  15. Wall-slip of highly filled powder injection molding compounds: Effect of flow channel geometry and roughness

    NASA Astrophysics Data System (ADS)

    Hausnerova, Berenika; Sanetrnik, Daniel; Paravanova, Gordana

    2014-05-01

    The paper deals with the rheological behavior of highly filled compounds proceeded via powder injection molding (PIM) and applied in many sectors of industry (automotive, medicine, electronic or military). Online rheometer equipped with slit dies varying in surface roughness and dimensions was applied to investigate the wall-slip as a rheological phenomenon, which can be considered as a parameter indicating the separation of compound components (polymer binder and metallic powder) during high shear rates when injection molded.

  16. Structural scheme optimization design for the stationary platen of a precision plastic injection molding machine

    NASA Astrophysics Data System (ADS)

    Ren, Bin; Zhang, Shuyou; Tan, Jianrong

    2014-07-01

    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.

  17. An application of CO{sub 2} laser interference heating for polymer injection molding process

    SciTech Connect

    Saito, Takushi; Satoh, Isao; Kurosaki, Yasuo

    1999-07-01

    In this paper, the authors studied the small scale (less than 1 mm) local heat transfer control of injection molded polymer products by using CO{sub 2} laser interferometry. This technique could provide precise local temperature control of the product surface during the process. Residual birefringence of the irradiated surface was successfully distributed according to the interference pattern. This scale of heat transfer control has not been realized through common conductive heat transfer methods. To establish the laser interference heating, a CO{sub 2} laser, a set of optical equipment, and a transparent window of Zinc-selenide were used. To control the heat transfer on the molded polymer surface, the interfered laser beam was introduced through the window. Polystyrene resin was used to investigate the feasibility of this method. In the experiment, the control ability of the property distribution on a molded polymer surface was studied under various conditions. To confirm the viability of this technique, optical strain frozen in the molded polymer surface was measured with a polarizing microscope as birefringence. As the result, it was clearly shown that the residual birefringence had an equal spaced distribution. Also, the contrast between the irradiated and un-irradiated portions was obvious regardless of the polymer melt velocity and radiation intensity. This method may be applied to the production of diffraction gratings which have geometrically smooth surfaces.

  18. Numerical approach of the injection molding process of fiber-reinforced composite with considering fiber orientation

    NASA Astrophysics Data System (ADS)

    Nguyen Thi, T. B.; Yokoyama, A.; Ota, K.; Kodama, K.; Yamashita, K.; Isogai, Y.; Furuichi, K.; Nonomura, C.

    2014-05-01

    One of the most important challenges in the injection molding process of the short-glass fiber/thermoplastic composite parts is being able to predict the fiber orientation, since it controls the mechanical and the physical properties of the final parts. Folgar and Tucker included into the Jeffery equation a diffusive type of term, which introduces a phenomenological coefficient for modeling the randomizing effect of the mechanical interactions between the fibers, to predict the fiber orientation in concentrated suspensions. Their experiments indicated that this coefficient depends on the fiber volume fraction and aspect ratio. However, a definition of the fiber interaction coefficient, which is very necessary in the fiber orientation simulations, hasn't still been proven yet. Consequently, this study proposed a developed fiber interaction model that has been introduced a fiber dynamics simulation in order to obtain a global fiber interaction coefficient. This supposed that the coefficient is a sum function of the fiber concentration, aspect ratio, and angular velocity. The proposed model was incorporated into a computer aided engineering simulation package C-Mold. Short-glass fiber/polyamide-6 composites were produced in the injection molding with the fiber weight concentration of 30 wt.%, 50 wt.%, and 70 wt.%. The physical properties of these composites were examined, and their fiber orientation distributions were measured by micro-computed-tomography equipment μ-CT. The simulation results showed a good agreement with experiment results.

  19. Numerical approach of the injection molding process of fiber-reinforced composite with considering fiber orientation

    SciTech Connect

    Nguyen Thi, T. B. E-mail: yokoyama@kit.ac.jp; Yokoyama, A. E-mail: yokoyama@kit.ac.jp; Ota, K. E-mail: katsuhiro-kodama@toyobo.jp E-mail: yumiko-isogai@toyobo.jp E-mail: chisato-nonomura@toyobo.jp; Kodama, K. E-mail: katsuhiro-kodama@toyobo.jp E-mail: yumiko-isogai@toyobo.jp E-mail: chisato-nonomura@toyobo.jp; Yamashita, K. E-mail: katsuhiro-kodama@toyobo.jp E-mail: yumiko-isogai@toyobo.jp E-mail: chisato-nonomura@toyobo.jp; Isogai, Y. E-mail: katsuhiro-kodama@toyobo.jp E-mail: yumiko-isogai@toyobo.jp E-mail: chisato-nonomura@toyobo.jp; Furuichi, K. E-mail: katsuhiro-kodama@toyobo.jp E-mail: yumiko-isogai@toyobo.jp E-mail: chisato-nonomura@toyobo.jp; Nonomura, C. E-mail: katsuhiro-kodama@toyobo.jp E-mail: yumiko-isogai@toyobo.jp E-mail: chisato-nonomura@toyobo.jp

    2014-05-15

    One of the most important challenges in the injection molding process of the short-glass fiber/thermoplastic composite parts is being able to predict the fiber orientation, since it controls the mechanical and the physical properties of the final parts. Folgar and Tucker included into the Jeffery equation a diffusive type of term, which introduces a phenomenological coefficient for modeling the randomizing effect of the mechanical interactions between the fibers, to predict the fiber orientation in concentrated suspensions. Their experiments indicated that this coefficient depends on the fiber volume fraction and aspect ratio. However, a definition of the fiber interaction coefficient, which is very necessary in the fiber orientation simulations, hasn't still been proven yet. Consequently, this study proposed a developed fiber interaction model that has been introduced a fiber dynamics simulation in order to obtain a global fiber interaction coefficient. This supposed that the coefficient is a sum function of the fiber concentration, aspect ratio, and angular velocity. The proposed model was incorporated into a computer aided engineering simulation package C-Mold. Short-glass fiber/polyamide-6 composites were produced in the injection molding with the fiber weight concentration of 30 wt.%, 50 wt.%, and 70 wt.%. The physical properties of these composites were examined, and their fiber orientation distributions were measured by micro-computed-tomography equipment μ-CT. The simulation results showed a good agreement with experiment results.

  20. Optimization of Micro Metal Injection Molding By Using Grey Relational Grade

    SciTech Connect

    Ibrahim, M. H. I.; Muhamad, N.; Sulong, A. B.; Nor, N. H. M.; Harun, M. R.; Murtadhahadi; Jamaludin, K. R.

    2011-01-17

    Micro metal injection molding ({mu}MIM) which is a variant of MIM process is a promising method towards near net-shape of metallic micro components of complex geometry. In this paper, {mu}MIM is applied to produce 316L stainless steel micro components. Due to highly stringent characteristic of {mu}MIM properties, the study has been emphasized on optimization of process parameter where Taguchi method associated with Grey Relational Analysis (GRA) will be implemented as it represents novel approach towards investigation of multiple performance characteristics. Basic idea of GRA is to find a grey relational grade (GRG) which can be used for the optimization conversion from multi objectives case which are density and strength to a single objective case. After considering the form 'the larger the better', results show that the injection time(D) is the most significant followed by injection pressure(A), holding time(E), mold temperature(C) and injection temperature(B). Analysis of variance (ANOVA) is also employed to strengthen the significant of each parameter involved in this study.

  1. The demolding of powder injection molded micro-structures: analysis, simulation and experiment

    NASA Astrophysics Data System (ADS)

    Fu, G.; Tor, S. B.; Loh, N. H.; Tay, B. Y.; Hardt, D. E.

    2008-07-01

    This paper studies the demolding of an array of powder injection molded micro-structures based on a variotherm mold. The demolding of the micro-structures array was analyzed both theoretically and experimentally. Finite element method (FEM) software ABAQUS was used to analyze and simulate the demolding of an array of 24 × 24 (total of 576) micro-structures. It was found that there exists a 'critical temperature' at which the demolding force for the micro-structures array is a minimum. The stress distribution of the micro-structures and demolding force for the micro-structures during the course of demolding were analyzed for both demolding temperatures higher and lower than the critical temperature. Packing pressure and demolding temperature have an apparent impact on the demolding force. A series of demolding force measuring experiments at different packing pressures and demolding temperatures were conducted to verify the theoretical results.

  2. Injection-Molded Long-Fiber Thermoplastic Composites: From Process Modeling to Prediction of Mechanical Properties

    SciTech Connect

    Nguyen, Ba Nghiep; Kunc, Vlastimil; Jin, Xiaoshi; Tucker III, Charles L.; Costa, Franco

    2013-12-18

    This article illustrates the predictive capabilities for long-fiber thermoplastic (LFT) composites that first simulate the injection molding of LFT structures by Autodesk® Simulation Moldflow® Insight (ASMI) to accurately predict fiber orientation and length distributions in these structures. After validating fiber orientation and length predictions against the experimental data, the predicted results are used by ASMI to compute distributions of elastic properties in the molded structures. In addition, local stress-strain responses and damage accumulation under tensile loading are predicted by an elastic-plastic damage model of EMTA-NLA, a nonlinear analysis tool implemented in ABAQUS® via user-subroutines using an incremental Eshelby-Mori-Tanaka approach. Predicted stress-strain responses up to failure and damage accumulations are compared to the experimental results to validate the model.

  3. Determination of physical properties in injection molded composites using the design of experiments method

    SciTech Connect

    Hawks, V.; Saunders, D.; Strong, A.B.; Cole, D. )

    1992-07-01

    The benefits of using Design of Experiments (DOE) for determining effects of critical factors are significantly greater than using one-at-a-time experimental techniques. The volume and validity of the information gained from DOE, especially for manufacturing processes, is very high due to the strong statistical basis of the method and highly organized nature of the results. The use of DOE is described in the case of injection molding of composites to improve and better understand the effects of critical factors on the physical properties of the finished parts. The factors, fiber length, fiber concentration, part temperature, and mold thickness, were tested using a full factorial experiment. The results demonstrated the significance of the factors and their interactions on tensile strength, modulus of elasticity, and elongation.

  4. Simulation and experiment research on the proportional pressure control of water-assisted injection molding

    NASA Astrophysics Data System (ADS)

    Zhou, Hua; Chen, Yinglong; Zhang, Zengmeng; Yang, Huayong

    2012-05-01

    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.

  5. Results on powder injection molding of Ni{sub 3}Al and application to other intermetallic compositions

    SciTech Connect

    Cooper, R.M.

    1992-12-31

    Net forming processes are under development to allow affordable production of intermetallic components. Powder injection molding (PIM) mav be employed for the production of complex-shaped intermetallic geometries. Proper choice of powder parameters and processing conditions can lead to the formation of fullv dense structures through pressure-less sintering. In this study, Ni{sub 3}Al with 0.04 wt.-% boron has been successfully injection molded and sintered to full density. A yield strength of 340 MPa, ultimate tensile strength (UTS) of 591 MPa, and 8% elongation were attained for injection molded and sintered tensile bars. Powder characteristics and sintering behavior are given for the nickel aluminide employed in this study to highlight the powder attributes needed for injection molding. Molding parameters, debinding and sintering schedules, along, with mechanical properties are presented to indicate the viability of PIM for intermetallics. This approach based on the understanding of key powder characteristics and use of the reactive synthesis powder process mav be extended to the successful injection molding of other intermetallic systems.

  6. Results on powder injection molding of Ni[sub 3]Al and application to other intermetallic compositions

    SciTech Connect

    Cooper, R.M.

    1992-01-01

    Net forming processes are under development to allow affordable production of intermetallic components. Powder injection molding (PIM) mav be employed for the production of complex-shaped intermetallic geometries. Proper choice of powder parameters and processing conditions can lead to the formation of fullv dense structures through pressure-less sintering. In this study, Ni[sub 3]Al with 0.04 wt.-% boron has been successfully injection molded and sintered to full density. A yield strength of 340 MPa, ultimate tensile strength (UTS) of 591 MPa, and 8% elongation were attained for injection molded and sintered tensile bars. Powder characteristics and sintering behavior are given for the nickel aluminide employed in this study to highlight the powder attributes needed for injection molding. Molding parameters, debinding and sintering schedules, along, with mechanical properties are presented to indicate the viability of PIM for intermetallics. This approach based on the understanding of key powder characteristics and use of the reactive synthesis powder process mav be extended to the successful injection molding of other intermetallic systems.

  7. Using Direct Metal Deposition to Fabricate Mold Plates for an Injection Mold Machine Allowing for the Evaluation of Cost Effective Near-Sourcing Opportunities in Larger, High Volume Consumer Products

    SciTech Connect

    Duty, Chad E; Groh, Bill

    2014-10-31

    ORNL collaborated with Radio Systems Corporation to investigate additive manufacturing (AM) of mold plates for plastic injection molding by direct metal deposition. The team s modelling effort identified a 100% improvement in heat transfer through use of conformal cooling lines that could be built into the mold using a revolutionary design enabled by additive manufacturing. Using the newly installed laser deposition system at the ORNL Manufacturing Demonstration Facility (MDF) a stainless steel mold core was printed.

  8. Numerical Simulation of the Flow Behavior and Breakthrough Phenomenon in Co-Injection Molding

    NASA Astrophysics Data System (ADS)

    Ilinca, Florin; Hétu, Jean-François

    2007-05-01

    A study of the flow behavior during sequential co-injection molding is shown using a three-dimensional finite element flow analysis code. Solutions of the non-Newtonian, non-isothermal melt flow are obtained by solving the momentum, continuity and energy equations. Two additional transport equations are solved for tracking polymer/air and skin/core polymers interfaces. The co-injection model is integrated into the NRC's 3D injection molding software. Solutions are shown for the filling of a spiral-flow mould for which experimental measurements are available. The numerical approach predicts the core advance stage during which the core flow front catches up on the skin flow front and the core expansion phase when the flow fronts of core and skin materials advance together without breakthrough. The breakthrough phenomenon is also predicted. The predicted flow front behavior is compared to the experimental observations for various skin/core melt temperature and skin/core viscosity ratio. Simulation results are in good agreement with experimental data and indicate correctly the trends in solution change when processing parameters are changing.

  9. Effect of pressure on viscosity at high shear rates by using an injection molding machine

    NASA Astrophysics Data System (ADS)

    Volpe, Valentina; Pantani, Roberto

    2015-12-01

    The difficulties in performing accurate measurements of the effect of pressure on the viscosity of the polymeric materials results in a shortage of relevant experimental data in the literature. In this work, an atactic polystyrene has been characterized to determine the effect of pressure on viscosity during the injection molding process. In particular, the nozzle of the injection molding machine has been modified to host a slit rheometer that allows obtaining in-line rheological measurements by means of two pressure transducers. Slits with two different geometries have been adopted, in order to obtain a wide range of shear rates (102-105 s-1). Experiments have been conducted at increasing injection flow rates, corresponding to different shear rates. By analyzing the measured pressures it has been possible to determine the coefficient β, which describes the effect of pressure on viscosity. Results show that the effect of pressure on viscosity decreases on increasing the shear rate until a plateau is reached at very high shear rates.

  10. CE chips fabricated by injection molding and polyethylene/thermoplastic elastomer film packaging methods.

    PubMed

    Huang, Fu-Chun; Chen, Yih-Far; Lee, Gwo-Bin

    2007-04-01

    This study presents a new packaging method using a polyethylene/thermoplastic elastomer (PE/TPE) film to seal an injection-molded CE chip made of either poly(methyl methacrylate) (PMMA) or polycarbonate (PC) materials. The packaging is performed at atmospheric pressure and at room temperature, which is a fast, easy, and reliable bonding method to form a sealed CE chip for chemical analysis and biomedical applications. The fabrication of PMMA and PC microfluidic channels is accomplished by using an injection-molding process, which could be mass-produced for commercial applications. In addition to microfluidic CE channels, 3-D reservoirs for storing biosamples, and CE buffers are also formed during this injection-molding process. With this approach, a commercial CE chip can be of low cost and disposable. Finally, the functionality of the mass-produced CE chip is demonstrated through its successful separation of phiX174 DNA/HaeIII markers. Experimental data show that the S/N for the CE chips using the PE/TPE film has a value of 5.34, when utilizing DNA markers with a concentration of 2 ng/microL and a CE buffer of 2% hydroxypropyl-methylcellulose (HPMC) in Tris-borate-EDTA (TBE) with 1% YO-PRO-1 fluorescent dye. Thus, the detection limit of the developed chips is improved. Lastly, the developed CE chips are used for the separation and detection of PCR products. A mixture of an amplified antibiotic gene for Streptococcus pneumoniae and phiX174 DNA/HaeIII markers was successfully separated and detected by using the proposed CE chips. Experimental data show that these DNA samples were separated within 2 min. The study proposed a promising method for the development of mass-produced CE chips. PMID:17311242

  11. Fabrication of Micro Gears by Micro-Powder Injection-Compression Molding

    NASA Astrophysics Data System (ADS)

    Jang, Jin Man; Lee, Wonsik; Son, Seong-Ho; Ko, Se-Hyun; Kim, Il-Ho

    Micro-spur gears were fabricated by powder injection-compression molding and micro-two-step gears were produced through stacking and sintering of the green parts. Shrinkage of micro-gears by sintering was larger in teeth and with increase of compression pressure, shrinkage was decreased due to increase of density in green parts. Surface roughness of sintered body was reduced to a few hundreds of nanometers by ultrasonic micro-polishing. The joining of green bodies by stacking and sintering was achieved using the pressurized sintering and insert of feedstock powders between both green bodies.

  12. Compact surface plasmon resonance biosensor utilizing an injection-molded prism

    NASA Astrophysics Data System (ADS)

    Chen, How-Foo; Chen, Chih-Han; Chang, Yun-Hsiang; Chuang, Hsin-Yuan

    2016-05-01

    Targeting at a low cost and accessible diagnostic device in clinical practice, a compact surface plasmon resonance (SPR) biosensor with a large dynamic range in high sensitivity is designed to satisfy commercial needs in food safety, environmental bio-pollution monitoring, and fast clinical diagnosis. The core component integrates an optical coupler, a sample-loading plate, and angle-tuning reflectors is injection-molded as a free-from prism made of plastic optics. This design makes a matching-oil-free operation during operation. The disposability of this low-cost component ensures testing or diagnosis without cross contamination in bio-samples.

  13. Microstructure and Mechanical Properties of Titanium Components Fabricated by a New Powder Injection Molding Technique

    SciTech Connect

    Nyberg, Eric A.; Miller, Megan R.; Simmons, Kevin L.; Weil, K. Scott

    2005-05-01

    We have developed a powder injection molding (PIM) binder system for titanium that employs naphthalene as the primary constituent to facilitate easy binder removal and mitigate problems with carbon contamination. In the study presented here, we examined densification behavior, microstructure, and mechanical properties in specimens formed by this process. In general, we found that we could achieve tensile strengths comparable to wrought titanium in the PIM-formed specimens, but that maximum elongation was less than expected. Chemical and microstructural analyses suggest that use of higher purity powder and further process optimization will lead to significant improvements in ductility.

  14. Mechanical Properties of Injection Molded B 4C-C Ceramics

    NASA Astrophysics Data System (ADS)

    Schwetz, Karl A.; Sigl, Lorenz S.; Pfau, Lothar

    1997-10-01

    Various mechanical properties of carbon-doped boron carbide ceramics, prepared by the fabrication route, injection molding/pressureless sintering/post-hot isostatic pressing (HIP) were investigated as a function of the sintering temperature and the carbon additive level used. An optimum combination of mechanical properties (flexural stregth, fracture toughness, Young's modulus, Knoop's hardness) is thus obtained with 100% dense and very fine grained materials (mean grain size 1-4 μm) which were sintered at temperatures from 2150 to 2175°C and post-HIPed at 2050°/200 MPa Ar, having an approximate final composition of 96 B4C-4C (wt%).

  15. Effect of rheological parameters on curing rate during NBR injection molding

    NASA Astrophysics Data System (ADS)

    Kyas, Kamil; Stanek, Michal; Manas, David; Skrobak, Adam

    2013-04-01

    In this work, non-isothermal injection molding process for NBR rubber mixture considering Isayev-Deng curing kinetic model, generalized Newtonian model with Carreau-WLF viscosity was modeled by using finite element method in order to understand the effect of volume flow rate, index of non-Newtonian behavior and relaxation time on the temperature profile and curing rate. It was found that for specific geometry and processing conditions, increase in relaxation time or in the index of non-Newtonian behavior increases the curing rate due to viscous dissipation taking place at the flow domain walls.

  16. Reaction injection molding and direct covalent bonding of OSTE+ polymer microfluidic devices

    NASA Astrophysics Data System (ADS)

    Sandström, N.; Shafagh, R. Z.; Vastesson, A.; Carlborg, C. F.; van der Wijngaart, W.; Haraldsson, T.

    2015-07-01

    In this article, we present OSTE+RIM, a novel reaction injection molding (RIM) process that combines the merits of off-stoichiometric thiol-ene epoxy (OSTE+) thermosetting polymers with the fabrication of high quality microstructured parts. The process relies on the dual polymerization reactions of OSTE+ polymers, where the first curing step is used in OSTE+RIM for molding intermediately polymerized parts with well-defined shapes and reactive surface chemistries. In the facile back-end processing, the replicated parts are directly and covalently bonded and become fully polymerized using the second curing step, generating complete microfluidic devices. To achieve unprecedented rapid processing, high replication fidelity and low residual stress, OSTE+RIM uniquely incorporates temperature stabilization and shrinkage compensation of the OSTE+ polymerization during molding. Two different OSTE+ formulations were characterized and used for the OSTE+RIM fabrication of optically transparent, warp-free and natively hydrophilic microscopy glass slide format microfluidic demonstrator devices, featuring a storage modulus of 2.3 GPa and tolerating pressures of at least 4 bars.

  17. Visualization analysis of injection molding phenomena in hot-runner system

    NASA Astrophysics Data System (ADS)

    Yokoi, Hidetoshi; Kanetoh, Yoshinori; Takamatsu, Ryohei; Endo, Takumi; Chang, Hao; Chayamichi, Toru

    2016-03-01

    Various unsolved defects are known to occur in hot-runner molds, such as stagnation of resins in the manifold channel, asymmetrical cavity filling behavior, flow marks, gate marks, etc. We have been clarifying the causes of various molding defects specifically using visualization technologies inside mold cavity and manifold. This report introduces and discusses the following topics, particularly focusing on clarifying the behavior of resins; (1) Comparison of the imbalanced cavity filling phenomena in between side-fed and center-fed types of valve-gate hot-runner systems, (2) Visualization analysis of the melt flow behaviors and stagnation phenomena inside hot-runner manifolds, (3) Behavior of each stagnant melt around the valve-pin and inner hot-nozzle surfaces, (4) Void generation phenomena remaining on the surface of the valve-pin tip, (5) Melt temperature distribution on the cavity surface during the filling process, (6) Melt temperature profile inside the flowing melt injected from the valve gate, etc.

  18. Enteric-coating of pulsatile-release HPC capsules prepared by injection molding.

    PubMed

    Macchi, E; Zema, L; Maroni, A; Gazzaniga, A; Felton, L A

    2015-04-01

    Capsular devices based on hydroxypropyl cellulose (Klucel® LF) intended for pulsatile release were prepared by injection molding (IM). In the present work, the possibility of exploiting such capsules for the development of colonic delivery systems based on a time-dependent approach was evaluated. For this purpose, it was necessary to demonstrate the ability of molded cores to undergo a coating process and that coated systems yield the desired performance (gastric resistance). Although no information was available on the coating of IM substrates, some issues relevant to that of commercially-available capsules are known. Thus, preliminary studies were conducted on molded disks for screening purposes prior to the spray-coating of HPC capsular cores with Eudragit® L 30 D 55. The ability of the polymeric suspension to wet the substrate, spread, start penetrating and initiate hydration/swelling, as well as to provide a gastroresistant barrier was demonstrated. The coating of prototype HPC capsules was carried out successfully, leading to coated systems with good technological properties and able to withstand the acidic medium with no need for sealing at the cap/body joint. Such systems maintained the original pulsatile release performance after dissolution of the enteric film in pH 6.8 fluid. Therefore, they appeared potentially suitable for the development of a colon delivery platform based on a time-dependent approach. PMID:25585355

  19. Development of a statistically proven injection molding method for reaction bonded silicon nitride, sintering reaction bonded silicon nitride, and sintered silicon nitride

    NASA Astrophysics Data System (ADS)

    Steiner, Matthias

    A statistically proven, series injection molding technique for ceramic components was developed for the construction of engines and gas turbines. The flow behavior of silicon injection-molding materials was characterized and improved. Hot-isostatic-pressing reaction bonded silicon nitride (HIPRBSN) was developed. A nondestructive component evaluation method was developed. An injection molding line for HIPRBSN engine components precombustion chamber, flame spreader, and valve guide was developed. This line allows the production of small series for engine tests.

  20. Time-Dependent Properties of Multimodal Polyoxymethylene Based Binder for Powder Injection Molding

    NASA Astrophysics Data System (ADS)

    Gonzalez-Gutierrez, Joamin; Stringari, Gustavo Beulke; Zupancic, Barbara; Kubyshkina, Galina; Bernstorff, Bernd Von; Emri, Igor

    Powder injection molding (PIM) is one of the most versatile methods for the manufacturing of small complex shaped components from metal, ceramic or cemented carbide powders for the use in many applications. PIM consists of mixing the powder and a polymeric binder, injecting this mixture in a mold, debinding and then sintering. Catalytic debinding of polyoxymethylene (POM) is attractive since it shows high debinding rates and low risk of cracking. This work examines the possibility of using POM with bimodal molecular mass distribution as the main component of the binding agent by studying its time-dependent properties and comparing them to monomodal POM. Furthermore, possible optimization of the binder formulation was investigated by the addition of shorter polymeric chains (wax) to bimodal POM, as to create a multimodal material. It was observed that the magnitude of the complex viscosity for the commercial bimodal material was more than 2 times lower than for the chemically identical monomodal POM within the investigated frequency range and temperature. Viscosity values were observed to drop as the content of wax was increased, without compromising the binders mechanical properties in solid state. A new formulation of bimodal POM plus 8 wt.% of added wax provided the most appropriate results from investigated combinations. This work has shown how the addition of short polymeric chains in POM influences its time-dependent properties in solid and molten state, which can be an important tool for the optimization of binders designed to be used in PIM technology.

  1. Rheological and thermal performance of newly developed binder systems for ceramic injection molding

    NASA Astrophysics Data System (ADS)

    Hausnerova, Berenika; Kasparkova, Vera; Hnatkova, Eva

    2016-05-01

    In a novel binder system, carnauba wax was considered to replace the synthetic backbone polymers (polyolefins) enhancing the environmental sustainability of Ceramic Injection Molding (CIM) technology. The paper presents comparison of the rheological performance and thermal behavior of the aluminum oxide CIM feedstocks based on a binder containing carnauba wax with those consisting of a commercial binder. Further, acrawax (N, N'-Ethylene Bis-stearamide) has been considered as another possible substitute of polyolefins. For both proposed substitutes there is a significant reduction in viscosity, and in case of carnauba wax based feedstock also in processing temperature, which is essential for injection molding of reactive powders. Thermal characterization comprised analyses of single neat binders, their mixtures and mixtures with aluminum oxide. The presence of powder lowered melting temperatures of all tested binders except of polyolefin. Further depression in melting point of poly(ethylene glycol) is observed in combination with polyolefin in the presence of powder, and it is related to changes in size of the crystalline domains.

  2. Effect of Fe3P addition on magnetic properties and microstructure of injection molded iron

    NASA Astrophysics Data System (ADS)

    Ma, Jidong; Qin, Mingli; Tian, Lusha; Zhang, Lin; Khan, Dil Faraz; Ding, Xiangying; Qu, Xuanhui; Zhang, Houan

    2016-01-01

    Phosphorus powder was used to improve the performance of iron based alloy products fabricated by metal injection molding. Seven kinds of Fe-xP soft magnetic alloys were formed using carbonyl iron powder and Phosphorus powder as raw materials where x=0-1.2 wt% with 0.2 wt% increment. Samples were sintered in hydrogen atmosphere at the temperature range of 1100-1450 °C for varied times. The effects of sintering temperature and time on the density, microstructure and magnetic properties like magnetic induction, maximum permeability and coercive force of the alloys were examined. The results demonstrated that better magnetic performances of the injection molded Fe-xP alloy is due to increased density of the sintered compacts because of formation of liquid phase at low temperature. For Fe-0.8%P alloy, optimum density 7.84 g/cm3 (relative density 99%) and magnetic induction (B6000) 1.77 T, maximum permeability 17,100 were obtained at sintering temperature 1420 °C while the coercive force was 21 A/m respectively.

  3. Magnesium Powder Injection Molding (MIM) of Orthopedic Implants for Biomedical Applications

    NASA Astrophysics Data System (ADS)

    Wolff, M.; Schaper, J. G.; Suckert, M. R.; Dahms, M.; Ebel, T.; Willumeit-Römer, R.; Klassen, T.

    2016-04-01

    Metal injection molding (MIM) has a high potential for the economic near-net-shape mass production of small-sized and complex-shaped parts. The motivation for launching Mg into the MIM processing chain for manufacturing biodegradable medical implants is related to its compatibility with human bone and its degradation in a non-toxic matter. It has been recognized that the load-bearing capacity of MIM Mg parts is superior to that of biodegradable polymeric components. However, the choice of appropriate polymeric binder components and alloying elements enabling defect-free injection molding and sintering is a major challenge for the use of MIM Mg parts. This study considered the full processing chain for MIM of Mg-Ca alloys to achieve ultimate tensile strength of up to 141 MPa with tensile yield strength of 73 MPa, elongation at fracture Af of 7% and a Young's modulus of 38 GPa. To achieve these mechanical properties, a thermal debinding study was performed to determine optimal furnace and atmosphere conditions, sintering temperature, heating rates, sintering time and pressure.

  4. The effects of process parameters on injection-molded PZT ceramics part fabrication- compounding process rheology.

    SciTech Connect

    Halbleib, Laura L.; Yang, Pin; Mondy, Lisa Ann; Burns, George Robert

    2005-05-01

    Solid solutions of lead-based perovskites are the backbone materials of the piezoelectric components for transducer, actuator, and resonator applications. These components, typically small in size, are fabricated from large sintered ceramic slugs using grinding and lapping processes. These operations increase manufacturing costs and produce a large hazardous waste stream, especially when component size decreases. To reduce costs and hazardous wastes associated with the production of these components, an injection molding technique is being investigated to replace the machining processes. The first step in the new technique is to compound an organic carrier with a ceramic powder. The organic carrier is a thermoplastic based system composed of a main carrier, a binder, and a surfactant. Understanding the rheology of the compounded material is necessary to minimize the creation of defects such as voids or cavities during the injection-molding process. An experiment was performed to model the effects of changes in the composition and processing of the material on the rheological behavior. Factors studied included: the surfactant of the organic carrier system, the solid loading of the compounded material, and compounding time. The effects of these factors on the viscosity of the material were investigated.

  5. Bulk and Surface Molecular Orientation Distribution in Injection-molded Liquid Crystalline Polymers: Experiment and Simulation

    SciTech Connect

    Fang, J.; Burghardt, W; Bubeck, R; Burgard, S; Fischer, D

    2010-01-01

    Bulk and surface distributions of molecular orientation in injection-molded plaques of thermotropic liquid crystalline polymers (TLCPs) have been studied using a combination of techniques, coordinated with process simulations using the Larson-Doi 'polydomain' model. Wide-angle X-ray scattering was used to map out the bulk orientation distribution. Fourier Transform Infrared Attenuated Total Reflectance (FTIR-ATR) and Near-Edge X-ray Absorption Fine Structure (NEXAFS) were utilized to probe the molecular orientation states to within about {approx}5 {micro}m and {approx}2 nm, respectively, of the sample surface. These noninvasive, surface-sensitive techniques yield reasonable self-consistency, providing complementary validation of the robustness of these methods. An analogy between Larson-Doi and fiber orientation models has allowed the first simulations of TLCP injection molding. The simulations capture many fine details in the bulk orientation distribution across the sample plaque. Direct simulation of surface orientation at the level probed by FTIR-ATR and NEXAFS was not possible due to the limited spatial resolution of the simulations. However, simulation results extracted from the shear-dominant skin region are found to provide a qualitatively accurate indicator of surface orientation. Finally, simulations capture the relation between bulk and surface orientation states across the different regions of the sample plaque.

  6. High numerical aperture injection-molded miniature objective for fiber-optic confocal reflectance microscopy

    NASA Astrophysics Data System (ADS)

    Chidley, Matthew Douglas

    This dissertation presents the design of a miniature injection-molded objective lens for a fiber-optic confocal reflectance microscope. This is part of an effort to demonstrate the ability to fabricate low cost, high performance biomedical optics for high resolution in vivo imaging. Disposable endoscopic microscope objectives could help in vivo confocal microscopy technology mature to enable large-scale clinical screening and detection of early cancers and pre-cancerous lesions. This five lens plastic objective has been tested as a stand-alone optical system and has been coupled to a confocal microscope for in vivo imaging of cells and tissue. Changing the spacing and rotation of the individual optical elements can compensate for fabrication inaccuracies and improve performance. An optical-bench testing system was constructed to allow interactive alignment during testing. The modulation transfer function (MTF) of the miniature objective lens is determined using the slanted-edge method. A custom MATLAB program, edgeMTF, was written to collect, analyze, and record test data. An estimated Strehl ratio of 0.64 and an MTF value of 0.70, at the fiber-optic bundle Nyquist frequency, have been obtained. The main performance limitations of the miniature objective are mechanical alignment and flow-induced birefringence. Annealing and experimental injection molding runs were conducted in effort to reduce birefringence.

  7. Modification of the logic and control system for the 80-ounce injection molding machine

    SciTech Connect

    Domer, G.A.

    1990-01-01

    The modification of the hydraulic logic and control system for the 80-ounce injection molding machine in the Molding and Machining, Plastics, department was required to allow production of near net size thick-walled parts and machining stock from high-shrinkage materials while retaining the original logic for standard product. The control system that was developed allows the new capability of open clamp injection. This capability will replace the present method of purchasing machining stock from an outside source. The control system was implemented with a Giddings Lewis Programmable Industrial Computer 409 (G L PiC 409). Hydraulic modifications included adding Vickers servo valves, an Inductosyn position transducer, and MOOG pressure transducers to perform force and position control. The control system provides two capabilities, NORMAL and SERVO. The NORMAL mode is defined as operating the machine according to original design specifications. The SERVO mode is defined as operating the machine according to a recipe in open loop position control then in closed loop force control. The G L PiC 409 controls the tasks of both modes. A selector switch determines the mode of operation (NORMAL or SERVO). The NORMAL mode uses the original hydraulic circuits, and the SERVO mode diverts fluid into the modified hydraulic circuits. 11 figs.

  8. (The control of microstructures during consolidation and injection molding of colloidal dispersions)

    SciTech Connect

    Not Available

    1991-01-01

    The existing three-year grant pertaining to The control of micro-structures during consolidation and injection molding of colloidal dispersions'' began July 1, 1988 as a continuation of a previous grant. The overall effort seeks to answer fundamental questions relevant to the colloidal processing of submicron particles leading to ceramic materials for strutural, electronic, or optical applications. At the outset two distinct projects were envisioned, an exploration of the ultrasonic enhancement of disorder-order transitions and a detailed study of injection molding of very dense dispersion, with each weighted toward experiments but with theoretical components. As the effort evolved the focus shifted in response to the interests of the students attracted to the project, the identification of interesting related problems through technical meetings, and different insights gained during participation in a DOE sponsored workshop. The scope that has emerged encompasses: completion of research begun during the first grant period on disorder-order transitions occurring during sedimentation, the consolidation of flocculated dispersions via filtration and the assembly of nanometer-sized particle into dense packings.

  9. Simulation of gas-assisted injection mold-cooling process using line source model approach for gas channel

    SciTech Connect

    Chang, Y.P.; Hu, S.Y.; Chen, S.C.

    1998-10-01

    Gas-assisted injection molding (GAIM) process, being an innovative injection molding process, can substantially reduce production expenses through reduction in material cost, reduction in clamp tonnage and reduction in cycle time. Whether it is feasible to perform an integrated simulation for process simulation based on a unified CAE model for gas-assisted injection molding (GAIM) is a great concern. In the present study, numerical algorithms based on the same CAE model used for process simulation regarding filling and packaging stages were developed to simulate the cooling phase of GAIM using a cycle-averaged three-dimensional modified boundary element technique similar to that used for conventional injection molding. However, to use the current CAE model for analysis, gas channel was modeled by two-node elements using line source approach. It was found that this new modeling not only affects the mold wall temperature calculation very slightly but also reduces the computer time by 95% as compared with a full gas channel modeling required a lot of triangular elements on gas channel surface. This investigation indicates that it is feasible to achieve an integrated process simulation for GAIM under one CAE model resulting in great computational efficiency for industrial application.

  10. Numerical prediction of fiber orientation in injection-molded short-fiber/thermoplastic composite parts with experimental validation

    NASA Astrophysics Data System (ADS)

    Thi, Thanh Binh Nguyen; Morioka, Mizuki; Yokoyama, Atsushi; Hamanaka, Senji; Yamashita, Katsuhisa; Nonomura, Chisato

    2015-05-01

    Numerical prediction of the fiber orientation in the short-glass fiber (GF) reinforced polyamide 6 (PA6) composites with the fiber weight concentration of 30%, 50%, and 70% manufactured by the injection molding process is presented. And the fiber orientation was also directly observed and measured through X-ray computed tomography. During the injection molding process of the short-fiber/thermoplastic composite, the fiber orientation is produced by the flow states and the fiber-fiber interaction. Folgar and Tucker equation is the well known for modeling the fiber orientation in a concentrated suspension. They included into Jeffrey's equation a diffusive type of term by introducing a phenomenological coefficient to account for the fiber-fiber interaction. Our developed model for the fiber-fiber interaction was proposed by modifying the rotary diffusion term of the Folgar-Tucker equation. This model was presented in a conference paper of the 29th International Conference of the Polymer Processing Society published by AIP conference proceeding. For modeling fiber interaction, the fiber dynamic simulation was introduced in order to obtain a global fiber interaction coefficient, which is sum function of the fiber concentration, aspect ratio, and angular velocity. The fiber orientation is predicted by using the proposed fiber interaction model incorporated into a computer aided engineering simulation package C-Mold. An experimental program has been carried out in which the fiber orientation distribution has been measured in 100 x 100 x 2 mm injection-molded plate and 100 x 80 x 2 mm injection-molded weld by analyzed with a high resolution 3D X-ray computed tomography system XVA-160α, and calculated by X-ray computed tomography imaging. The numerical prediction shows a good agreement with experimental validation. And the complex fiber orientation in the injection-molded weld was investigated.

  11. Numerical prediction of fiber orientation in injection-molded short-fiber/thermoplastic composite parts with experimental validation

    SciTech Connect

    Thi, Thanh Binh Nguyen; Morioka, Mizuki; Yokoyama, Atsushi; Hamanaka, Senji; Yamashita, Katsuhisa; Nonomura, Chisato

    2015-05-22

    Numerical prediction of the fiber orientation in the short-glass fiber (GF) reinforced polyamide 6 (PA6) composites with the fiber weight concentration of 30%, 50%, and 70% manufactured by the injection molding process is presented. And the fiber orientation was also directly observed and measured through X-ray computed tomography. During the injection molding process of the short-fiber/thermoplastic composite, the fiber orientation is produced by the flow states and the fiber-fiber interaction. Folgar and Tucker equation is the well known for modeling the fiber orientation in a concentrated suspension. They included into Jeffrey’s equation a diffusive type of term by introducing a phenomenological coefficient to account for the fiber-fiber interaction. Our developed model for the fiber-fiber interaction was proposed by modifying the rotary diffusion term of the Folgar-Tucker equation. This model was presented in a conference paper of the 29{sup th} International Conference of the Polymer Processing Society published by AIP conference proceeding. For modeling fiber interaction, the fiber dynamic simulation was introduced in order to obtain a global fiber interaction coefficient, which is sum function of the fiber concentration, aspect ratio, and angular velocity. The fiber orientation is predicted by using the proposed fiber interaction model incorporated into a computer aided engineering simulation package C-Mold. An experimental program has been carried out in which the fiber orientation distribution has been measured in 100 x 100 x 2 mm injection-molded plate and 100 x 80 x 2 mm injection-molded weld by analyzed with a high resolution 3D X-ray computed tomography system XVA-160α, and calculated by X-ray computed tomography imaging. The numerical prediction shows a good agreement with experimental validation. And the complex fiber orientation in the injection-molded weld was investigated.

  12. Monitoring of residual stresses in injection-molded plastics with holographic interferometry

    NASA Astrophysics Data System (ADS)

    Sanchez, Lilia A.; Hornberger, Lee E.

    2002-01-01

    Residual stresses are often trapped in injection-molded plastic parts due to the rapid cooling of the material in this manufacturing process. These stresses are a common source of failure in plastic components in automobiles, appliances and computers and are difficult to measure with conventional residual-stress experimental methods. Real-time holographic interferometry appears to be a viable technique to identify and monitor these stresses in plastic parts. In this investigation, holographic interferometry was used to monitor the relaxation of residual stresses in the plastic-molded actuator arm of a computer hard drive. In the first phase of this study, the relaxation of these residual stresses as a function of temperature was observed. In the second phase, the time to completely relax the residual stresses in the plastic part at an elevated temperature, the annealing temperature, was determined. In the third phase of this investigation, the rate of relaxation of these residual stresses as a function of time at various operating temperatures, was studied. Based on the results of this study, holographic interferometry appears to be a powerful research tool in the study of residual stresses in plastic parts. It also has the potential to be a practical tool for the inspection of manufactured plastic parts for the presence of residual stress.

  13. Visualization analysis of tiger-striped flow mark generation phenomena in injection molding

    NASA Astrophysics Data System (ADS)

    Owada, Shigeru; Yokoi, Hidetoshi

    2016-03-01

    The generation mechanism of tiger-striped flow marks of polypropylene (PP)/rubber/talc blends in injection molding was investigated by dynamic visualization analysis in a glass-inserted mold. The analysis revealed that the behavior of the melt flow front correlates with the flow mark generation. The cloudy part in the tiger-striped flow marks corresponded to the low transcription rate area of the melt diverging near the cavity wall, while the glossy part corresponded to the high transcription rate area of the melt converging toward the cavity wall side. The melt temperature at the high transcription rate area was slightly lower than that at the low transcription rate area. These phenomena resulted due to the difference in the temperature of the melt front that was caused by the asymmetric fountain flow. These results suggest the followings; At the moment when the melt is broken near the one side of cavity wall due to piling the extensional strains up to a certain level, the melt spurts out near the broken side. It results in generating asymmetric fountain flow temporarily to relax the extensional front surface, which moves toward the opposite side to form the high transcription area.

  14. Evaluation of the rigidity of dentures made of injection-molded materials.

    PubMed

    Wadachi, Juro; Sato, Masayuki; Igarashi, Yoshimasa

    2013-01-01

    Dentures made of 2 different types of injection-molded thermoplastic resins (polyamide resin and polyester resin) and a denture made of conventional heat-polymerized resin were used to create an experimental model of a mandibular molar region with a two-tooth gap. In the experimental model, a force of 100 N was applied onto the mesial fossa of the first molars of the dentures, and comparisons were performed by measuring the pressure applied under the denture base and the subsidence rate of the denture. The polyamide resin denture showed the highest subsidence, exerted the highest pressure on the underlying mucosa, and showed significant differences with the other types of dentures. The findings showed that polyamide resins have the lowest degree of elasticity, and that when resins with such low elasticities are used in the denture base, they should preferably be reinforced with metals. PMID:23719015

  15. Biodegradability of injection molded bioplastic pots containing polylactic acid and poultry feather fiber.

    PubMed

    Ahn, H K; Huda, M S; Smith, M C; Mulbry, W; Schmidt, W F; Reeves, J B

    2011-04-01

    The biodegradability of three types of bioplastic pots was evaluated by measuring carbon dioxide produced from lab-scale compost reactors containing mixtures of pot fragments and compost inoculum held at 58 °C for 60 days. Biodegradability of pot type A (composed of 100% polylactic acid (PLA)) was very low (13 ± 3%) compared to literature values for other PLA materials. Near infrared spectroscopy (NIRS) results suggest that the PLA undergoes chemical structural changes during polymer extrusion and injection molding. These changes may be the basis of the low biodegradability value. Biodegradability of pot types B (containing 5% poultry feather, 80% PLA, 15% starch), and C (containing 50% poultry feather, 25% urea, 25% glycerol), were 53 ± 2% and 39 ± 3%, respectively. More than 85% of the total biodegradation of these bioplastics occurred within 38 days. NIRS results revealed that poultry feather was not degraded during composting. PMID:21320772

  16. Injection Molding of Polystyrene Matrix Composites Filled with Vapor Grown Carbon Fiber

    NASA Astrophysics Data System (ADS)

    Enomoto, Kazuki; Yasuhara, Toshiyuki; Ohtake, Naoto; Kato, Kazunori

    Vapor grown carbon fiber (VGCF) is a kind of carbon nanotube (CNT), which has outstanding properties such as high mechanical strength and high electrical conductivity. In this study, injection molding properties of polystyrene (PS) filled with VGCF and evaluation of mechanical and electrical properties are discussed in comparison with composites in which conventional carbon fillers were filled. As a result, volume resistivity of VGCF/PS composites dropped significantly between VGCF concentration of 3 and 4vol.%. Resistivity of the composites filled with VGCF was 1.2×102Ω·cm when VGCF concentration was 11.6vol.%. The resistivity was significantly lower than that of composites which were filled with conventional carbon fillers. The elastic modulus slightly increases with increasing VGCF concentration, whereas the tensile strength slightly decreases in the VGCF concentration in the range from 0 to 12vol.%.

  17. Research on properties of carbon black/polypropylene composites by dynamic injection molding

    NASA Astrophysics Data System (ADS)

    Wu, Ming-Chun; He, Guang-Jian; Huang, Zhao-Xia; Zhou, Li-Ying; He, He-Zhi

    2016-03-01

    Polymer composites filled with conductive carbon black (CB) are gaining popularity for electromagnetic shielding applications. Dynamic injection molding method was adopted to study the influences of vibration force field on electrical properties of polypropylene/CB composites. The results showed that the percolation phenomenon of conductivity of composites occurred at 15wt% and the calculated SE was positive correlated with the variation trend of conductivity. The calculated SE of composite was more than 30dB at a CB concentration of 30wt%, which could obtain good shielding effects. The result could offer optimum vibration parameters for producing electromagnetic shielding composites by respectively changing the amplitudes and frequencies of the vibration force field.

  18. End Uses Mechanical Properties Settled By The Modified Sintering Conditions Of The Metal Injection Molding Process

    SciTech Connect

    Marray, Tarek; Jaccquet, Philippe; Moinard-Checot, Delphine; Fabre, Agnes; Barrallier, Laurent

    2011-01-17

    Most common mechanical applications require parts with specific properties as hard faced features. It is well known that treating parts under suitable atmospheres may improve hardness and strength yield of steels. Heat treatment process and more particularly thermo-chemical diffusion processes (such as carburizing or its variation: carbonitriding) can be performed to reach the industrial hardness profile requirements. In this work, a low-alloyed steel feedstock based on water soluble binder system is submitted to the MIM process steps (including injection molding, debinding and sintering). As-sintered parts are then treated under a low pressure carbonitriding treatment. This contribution focuses on preliminary results such as microstructural analyses and mechanical properties which are established at each stage of the process to determine and monitor changes.

  19. Mechanical properties of injection molded B{sub 4}C-C ceramics

    SciTech Connect

    Schwetz, K.A.; Sigl, L.S.; Pfau, L.

    1997-10-01

    Various mechanical properties of carbon-doped boron carbide ceramics, prepared by the fabrication route, injection molding/pressureless sintering/post-hot isostatic pressing (HIP) were investigated as a function of the sintering temperature and the carbon additive level used. An optimum combination of mechanical properties (flexural strength, fracture toughness, Young`s modulus, Knoop`s hardness) is thus obtained with 100% dense and very fine grained materials (mean grain size 1-4 {mu}m) which were sintered at temperatures from 2150 to 2175{degrees}C and post HIPed at 2050{degrees}/200 MPa Ar, having an approximate final composition of 96 B{sub 4}C-4C (wt%).

  20. A wide variety of injection molding technologies is now applicable to small series and mass production

    NASA Astrophysics Data System (ADS)

    Bloß, P.; Jüttner, G.; Jacob, S.; Löser, C.; Michaelis, J.; Krajewsky, P.

    2014-05-01

    Micro plastic parts open new fields for application, e. g., to electronics, sensor technologies, optics, and medical engineering. Before micro parts can go to mass production, there is a strong need of having the possibility for testing different designs and materials including material combinations. Hence, flexible individual technical and technological solutions for processing are necessary. To manufacture high quality micro parts, a micro injection moulding machine named formicaPlast based on a two-step plunger injection technology was developed. Resulting from its design, the residence time and the accuracy problems for managing small shot volumes with reproducible high accuracy are uncompromisingly solved. Due to their simple geometry possessing smooth transitions and non adherent inner surfaces, the plunger units allow to process "all" thermoplastics from polyolefines to high performance polymers, optical clear polymers, thermally sensitive bioresorbables, highly filled systems (the so-called powder injection molding PIM), and liquid silicon rubber (LSR, here with a special kit). The applied platform strategy in the 1K and 2K version allows integrating automation for assembling, handling and packaging. A perpendicular arrangement allows encapsulation of inserts, also partially, and integration of this machine into process chains. Considering a wide variety of different parts consisting of different materials, the high potential of the technology is demonstrated. Based on challenging industrial parts from electronic applications (2K micro MID and bump mat, where both are highly structured parts), the technological solutions are presented in more detail.

  1. A wide variety of injection molding technologies is now applicable to small series and mass production

    SciTech Connect

    Bloß, P. E-mail: juettner@kuz-leipzig.de E-mail: loeser@kuz-leipzig.de E-mail: krajewsky@kuz-leipzig.de; Jüttner, G. E-mail: juettner@kuz-leipzig.de E-mail: loeser@kuz-leipzig.de E-mail: krajewsky@kuz-leipzig.de; Jacob, S. E-mail: juettner@kuz-leipzig.de E-mail: loeser@kuz-leipzig.de E-mail: krajewsky@kuz-leipzig.de; Löser, C. E-mail: juettner@kuz-leipzig.de E-mail: loeser@kuz-leipzig.de E-mail: krajewsky@kuz-leipzig.de; Michaelis, J. E-mail: juettner@kuz-leipzig.de E-mail: loeser@kuz-leipzig.de E-mail: krajewsky@kuz-leipzig.de; Krajewsky, P. E-mail: juettner@kuz-leipzig.de E-mail: loeser@kuz-leipzig.de E-mail: krajewsky@kuz-leipzig.de

    2014-05-15

    Micro plastic parts open new fields for application, e. g., to electronics, sensor technologies, optics, and medical engineering. Before micro parts can go to mass production, there is a strong need of having the possibility for testing different designs and materials including material combinations. Hence, flexible individual technical and technological solutions for processing are necessary. To manufacture high quality micro parts, a micro injection moulding machine named formicaPlast based on a two-step plunger injection technology was developed. Resulting from its design, the residence time and the accuracy problems for managing small shot volumes with reproducible high accuracy are uncompromisingly solved. Due to their simple geometry possessing smooth transitions and non adherent inner surfaces, the plunger units allow to process 'all' thermoplastics from polyolefines to high performance polymers, optical clear polymers, thermally sensitive bioresorbables, highly filled systems (the so-called powder injection molding PIM), and liquid silicon rubber (LSR, here with a special kit). The applied platform strategy in the 1K and 2K version allows integrating automation for assembling, handling and packaging. A perpendicular arrangement allows encapsulation of inserts, also partially, and integration of this machine into process chains. Considering a wide variety of different parts consisting of different materials, the high potential of the technology is demonstrated. Based on challenging industrial parts from electronic applications (2K micro MID and bump mat, where both are highly structured parts), the technological solutions are presented in more detail.

  2. Microstructure and mechanical behavior of metal injection molded Ti-Nb binary alloys as biomedical material.

    PubMed

    Zhao, Dapeng; Chang, Keke; Ebel, Thomas; Qian, Ma; Willumeit, Regine; Yan, Ming; Pyczak, Florian

    2013-12-01

    The application of titanium (Ti) based biomedical materials which are widely used at present, such as commercially pure titanium (CP-Ti) and Ti-6Al-4V, are limited by the mismatch of Young's modulus between the implant and the bones, the high costs of products, and the difficulty of producing complex shapes of materials by conventional methods. Niobium (Nb) is a non-toxic element with strong β stabilizing effect in Ti alloys, which makes Ti-Nb based alloys attractive for implant application. Metal injection molding (MIM) is a cost-efficient near-net shape process. Thus, it attracts growing interest for the processing of Ti and Ti alloys as biomaterial. In this investigation, metal injection molding was applied to the fabrication of a series of Ti-Nb binary alloys with niobium content ranging from 10wt% to 22wt%, and CP-Ti for comparison. Specimens were characterized by melt extraction, optical microscopy, X-ray diffraction (XRD), scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and transmission electron microscopy (TEM). Titanium carbide formation was observed in all the as-sintered Ti-Nb binary alloys but not in the as-sintered CP-Ti. Selected area electron diffraction (SAED) patterns revealed that the carbides are Ti2C. It was found that with increasing niobium content from 0% to 22%, the porosity increased from about 1.6% to 5.8%, and the carbide area fraction increased from 0% to about 1.8% in the as-sintered samples. The effects of niobium content, porosity and titanium carbides on mechanical properties have been discussed. The as-sintered Ti-Nb specimens exhibited an excellent combination of high tensile strength and low Young's modulus, but relatively low ductility. PMID:23994942

  3. Thermal Properties of Extruded Injection-Molded Polycaprolactone/Gluten Bioblends Characterized by TGA, DSC, SEM and Infrared Photoacoustic Spectroscopy

    Technology Transfer Automated Retrieval System (TEKTRAN)

    In order to determine the degree of compatibility between Polycaprolactone resin (PCL) and vital wheat gluten (VG), PCL was compounded with VG at 90:10, 80:20, 70:30, 60:40, 50:50, and 30:70. The composites were blended by extrusion followed by injection molding. Thermal, morphological, and struct...

  4. Study on the gas-liquid interface and polymer melt front in gas-assisted injection molding

    SciTech Connect

    Shen, Y.K.

    1997-03-01

    The algorithms are developed to predict the gas-liquid interface in gas-assisted injection molding. The simulation of two-dimensional, transient, non-isothermal and high viscous flow between two parallel plates with the generalized Newtonian fluid is presented in detail. The model takes into account the effects of the gas-liquid interface and polymer melt front.

  5. CONVERSION OF WIND POWER TO HYDROGEN FUEL: DESIGN OF AN ALTERNATIVE ENERGY SYSTEM FOR AN INJECTION MOLDING FACILITY

    EPA Science Inventory

    Injection molding plants are large consumers of electricity. At its current level of operations, Harbec Plastics (Ontario, NY) uses about 2,000,000 kilowatt-hours of electricity per year. Based on the US average fuel mix, approximately 1.5 pounds of CO2

  6. Development of an injection molded ethylene-vinyl acetate copolymer (EVA) intravaginal insert for the delivery of progesterone to cattle.

    PubMed

    Cappadoro, A J; Luna, J A

    2015-07-01

    The purpose of this study was to develop a new injection-molded intravaginal insert manufactured from ethylene-vinyl acetate containing progesterone for a 7-day insertion period in cattle. The manufacturing process resulted in a reduction in the residual drug compared to the silicone insert available while still maintaining biological performance. PMID:26022232

  7. The effects of boundary conditions on the dimensional changes and residual stresses in injection-molded parts

    SciTech Connect

    Bushko, W.C.; Stokes, V.K.

    1995-12-31

    The solidification of a molten layer of amorphous thermoplastic between cooled parallel plates is used to model the mechanics of part shrinkage and the buildup of residual stresses in the injection-molding process. Flow effects are neglected, and a thermorheologically simple thermoviscoelastic material model is assumed. The model allows material to be added to fill the space created by the pressure applied during solidification, so that this model can be used to assess packing-pressure effects in injection molding. The interactions between the mold surfaces and the solidifying material are accounted for by modeling different types of constraints through different model boundary conditions. For several different sets of boundary conditions, parametric results are presented on the effects of the packing pressure-the pressure applied during solidification to counteract the effects of volumetric shrinkage of the thermoplastic--on the in-plane and through-thickness shrinkages, and on residual stresses in plaque-like geometries. Plaques that can shrink in the in-plane direction while in the mold are shown to shrink more and to have higher residual stresses than plaques that are fully constrained while in the mold. Although the results are presented in terms of normalized variables based on the properties of bisphenol-A polycarbonate, they can be interpreted for other amorphous thermoplastics such as modified polyphenylene oxide, polyetherimide, and acrylonitrile-butadiene-styrene.

  8. Short-term and long-term behavior of PP-polymer nanocomposites produced by injection molding compounding

    NASA Astrophysics Data System (ADS)

    Battisti, M. G.; Guttmann, P.; Chitu, L.; Friesenbichler, W.

    2015-05-01

    There are only few investigations considering the impact of nanoscale fillers on the mechanical und thermo-mechanical properties of polymers. Particularly there is a lack of results regarding long term creep behavior of Polypropylene-based polymer nanocomposites (PNCs). Therefore, the objective of this study is to determine the influence of nanofiller content on the mechanical and thermo-mechanical behavior of Polypropylene-based PNCs. Processing of the test specimens was carried out using the Polymer NanoComposite Injection Molding Compounder (PNC-IMC). In comparison to the conventional compounding process, in which the compound must be pelletized and fed into the injection molding machine for the second plasticizing process, injection molding compounding combines these two processing steps. Material compounding and subsequent injection molding are done directly with only one plasticizing process, using a heated melt pipe and a melt accumulator for melt transfer from the compounder to the injection molding machine. The PNCs were produced in the 3-in-1 process at the PNC-IMC, where all components (polymer, compatibilizer, nanofiller) were added simultaneously into the compounder. Furthermore, the polymer melt was treated using elongational flow generating devices for better intercalation and exfoliation of the nanofillers. Tensile tests were made to characterize the short-term-mechanical properties. Tensile creep tests show the influence of nanofillers on the long-term-creep-performance and dynamic mechanical tests (DMA) were performed to investigate the thermo-mechanical behavior. Both, the improvements in the mechanical and thermo-mechanical properties in comparison to the pure polypropylene are shown and give an excellent overview of possibilities and limitations of the PNCs. Further research will focus on the detailed understanding of the different mechanisms of property improvement of layered silicates in polymer. By using small angle X-ray scattering

  9. Multiple-Step Injection Molding for Fibrin-Based Tissue-Engineered Heart Valves

    PubMed Central

    Weber, Miriam; Gonzalez de Torre, Israel; Moreira, Ricardo; Frese, Julia; Oedekoven, Caroline; Alonso, Matilde; Rodriguez Cabello, Carlos J.

    2015-01-01

    Heart valves are elaborate and highly heterogeneous structures of the circulatory system. Despite the well accepted relationship between the structural and mechanical anisotropy and the optimal function of the valves, most approaches to create tissue-engineered heart valves (TEHVs) do not try to mimic this complexity and rely on one homogenous combination of cells and materials for the whole construct. The aim of this study was to establish an easy and versatile method to introduce spatial diversity into a heart valve fibrin scaffold. We developed a multiple-step injection molding process that enables the fabrication of TEHVs with heterogeneous composition (cell/scaffold material) of wall and leaflets without the need of gluing or suturing components together, with the leaflets firmly connected to the wall. The integrity of the valves and their functionality was proved by either opening/closing cycles in a bioreactor (proof of principle without cells) or with continuous stimulation over 2 weeks. We demonstrated the potential of the method by the two-step molding of the wall and the leaflets containing different cell lines. Immunohistology after stimulation confirmed tissue formation and demonstrated the localization of the different cell types. Furthermore, we showed the proof of principle fabrication of valves using different materials for wall (fibrin) and leaflets (hybrid gel of fibrin/elastin-like recombinamer) and with layered leaflets. The method is easy to implement, does not require special facilities, and can be reproduced in any tissue-engineering lab. While it has been demonstrated here with fibrin, it can easily be extended to other hydrogels. PMID:25654448

  10. Multiple-Step Injection Molding for Fibrin-Based Tissue-Engineered Heart Valves.

    PubMed

    Weber, Miriam; Gonzalez de Torre, Israel; Moreira, Ricardo; Frese, Julia; Oedekoven, Caroline; Alonso, Matilde; Rodriguez Cabello, Carlos J; Jockenhoevel, Stefan; Mela, Petra

    2015-08-01

    Heart valves are elaborate and highly heterogeneous structures of the circulatory system. Despite the well accepted relationship between the structural and mechanical anisotropy and the optimal function of the valves, most approaches to create tissue-engineered heart valves (TEHVs) do not try to mimic this complexity and rely on one homogenous combination of cells and materials for the whole construct. The aim of this study was to establish an easy and versatile method to introduce spatial diversity into a heart valve fibrin scaffold. We developed a multiple-step injection molding process that enables the fabrication of TEHVs with heterogeneous composition (cell/scaffold material) of wall and leaflets without the need of gluing or suturing components together, with the leaflets firmly connected to the wall. The integrity of the valves and their functionality was proved by either opening/closing cycles in a bioreactor (proof of principle without cells) or with continuous stimulation over 2 weeks. We demonstrated the potential of the method by the two-step molding of the wall and the leaflets containing different cell lines. Immunohistology after stimulation confirmed tissue formation and demonstrated the localization of the different cell types. Furthermore, we showed the proof of principle fabrication of valves using different materials for wall (fibrin) and leaflets (hybrid gel of fibrin/elastin-like recombinamer) and with layered leaflets. The method is easy to implement, does not require special facilities, and can be reproduced in any tissue-engineering lab. While it has been demonstrated here with fibrin, it can easily be extended to other hydrogels. PMID:25654448

  11. The evaluation of vacuum venting and variotherm process for improving the replication by injection molding of high aspect ratio micro features for biomedical application

    NASA Astrophysics Data System (ADS)

    Sorgato, Marco; Lucchetta, Giovanni

    2015-05-01

    The aspect ratio achievable in replicating micro features is one of the most important process characteristics and it is a major manufacturing constraint in applying injection molding in a range of micro engineering applications. Vacuum venting has been reported to be an effective technique in replicating micro features by microinjection molding. High surface-to-volume ratio and reduced dimensions of micro parts promote the instantaneous drop of melt temperature and consequently lead to incomplete filling. This study aims to investigate the effects of variotherm process, cavity evacuation and their interaction on the production of a micro fluidic filter for biomedical applications. A low-viscosity polystyrene and a cyclic olefin copolymer were molded applying a combination of mold evacuation and a rapid mold temperature variation that keeps the cavity temperature above the glass transition temperature during the injection phase. The research revealed the importance of these molding technologies in enhancing part filling and the replication quality for high aspect ratio micro features.

  12. Modeling and Analysis of Process Parameters for Evaluating Shrinkage Problems During Plastic Injection Molding of a DVD-ROM Cover

    NASA Astrophysics Data System (ADS)

    Öktem, H.

    2012-01-01

    Plastic injection molding plays a key role in the production of high-quality plastic parts. Shrinkage is one of the most significant problems of a plastic part in terms of quality in the plastic injection molding. This article focuses on the study of the modeling and analysis of the effects of process parameters on the shrinkage by evaluating the quality of the plastic part of a DVD-ROM cover made with Acrylonitrile Butadiene Styrene (ABS) polymer material. An effective regression model was developed to determine the mathematical relationship between the process parameters (mold temperature, melt temperature, injection pressure, injection time, and cooling time) and the volumetric shrinkage by utilizing the analysis data. Finite element (FE) analyses designed by Taguchi (L27) orthogonal arrays were run in the Moldflow simulation program. Analysis of variance (ANOVA) was then performed to check the adequacy of the regression model and to determine the effect of the process parameters on the shrinkage. Experiments were conducted to control the accuracy of the regression model with the FE analyses obtained from Moldflow. The results show that the regression model agrees very well with the FE analyses and the experiments. From this, it can be concluded that this study succeeded in modeling the shrinkage problem in our application.

  13. Influence of the power law index on the fiber breakage during injection molding by numerical simulations

    NASA Astrophysics Data System (ADS)

    Desplentere, Frederik; Six, Wim; Bonte, Hilde; Debrabandere, Eric

    2013-04-01

    In predictive engineering for polymer processes, the proper prediction of material microstructure from known processing conditions and constituent material properties is a critical step forward properly predicting bulk properties in the finished composite. Operating within the context of long-fiber thermoplastics (LFT, length > 15mm) this investigation concentrates on the influence of the power law index on the final fiber length distribution within the injection molded part. To realize this, the Autodesk Simulation Moldflow Insight Scandium 2013 software has been used. In this software, a fiber breakage algorithm is available from this release on. Using virtual material data with realistic viscosity levels allows to separate the influence of the power law index on the fiber breakage from the other material and process parameters. Applying standard settings for the fiber breakage parameters results in an obvious influence on the fiber length distribution through the thickness of the part and also as function of position in the part. Finally, the influence of the shear rate constant within the fiber breakage model has been investigated illustrating the possibility to fit the virtual fiber length distribution to the possible experimentally available data.

  14. Orientation distribution and process modeling of thermotropic liquid crystalline copolyester (TLCP) injection-moldings

    NASA Astrophysics Data System (ADS)

    Bubeck, Robert; Fang, Jun; Burghardt, Wesley; Burgard, Susan; Fischer, Daniel

    2009-03-01

    The influence of melt processing conditions upon mechanical properties and degrees of compound molecular orientation have been thoroughly studied for a series of well-defined injection molded samples fabricated from VECTRA (TM) A950 and 4,4'-dihydroxy-a-methylstilbene TLCPs. Fracture and tensile data were correlated with processing conditions, orientation, and molecular weight. Mechanical properties for both TLCPs were found to follow a ``universal'' Anisotropy Factor (AF) associated with the bimodal orientation states in the plaques determined from 2-D WAXS. Surface orientations were globally surveyed using Attenuated Total Reflectance -- Fourier Transform Infrared (ATR-FTIR) spectroscopy and C K edge Near-Edge X-ray Absorption Fine Structure (NEXAFS). The results derived from the two spectroscopy techniques confirmed each other well. These results along with those from 2-D WAXS in transmission were compared with the results of process modeling using a commercial program, MOLDFLOW(TM). The agreement between model predictions and the measured orientation states was gratifyingly good.

  15. Comparative study of pore structure evolution during solvent and thermal debinding of powder injection molded parts

    SciTech Connect

    Hwang, K.S.; Hsieh, Y.M.

    1996-02-01

    The solvent debinding process has been widely accepted in the powder injection molding (PIM) industry due to its short debinding cycle. In the current study, specimens were immersed in a heptane bath for different lengths of time, and the pore structure evolvement in the compact was analyzed. Mercury porosimetry analyses and scanning electron micrographs showed that the binder extraction started from the surface and progressed toward the center of the compacts. As the debinding continued, the pores grew and were widely distributed in size. This pore structure evolvement was different from that of straight thermal debinding in which the pore size distribution was quite narrow and the mean pore diameter shifted toward smaller sizes as debinding time increased. After the soluble binders were extracted, parts were subjected to a subsequent thermal debinding during which these pores served as conduits for decomposed gas to escape. Concurrently, the remaining binder became fluidlike and was redistributed within the compact due to capillarity. This pore structure, as observed from the mercury intrusion curves, showed a sharp increase in the pore volume at the 0.8-{micro}m size, followed by a series of fine pores, which is different from the pore structure of straight thermal debinding. The difference in the pore structure evolvement between solvent and thermal debinding and its effect on the debinding rate are discussed.

  16. Thermal shock behavior of tungsten based alloys manufactured via powder injection molding

    NASA Astrophysics Data System (ADS)

    Pintsuk, G.; Blagoeva, D.; Opschoor, J.

    2013-11-01

    The focus of this work is to address mechanical strength and recrystallization resistance through thermal shock investigation of newly developed fine grained tungsten base materials (i.e., pure tungsten and two doped tungsten-grades incorporating either 1 or 5 vol%Y2O3 produced via powder injection molding (PIM)). Therefore, repetitive ELM (edge localized mode)-like loads (n = 100) were applied by means of an electron beam at various temperatures between RT and 400 °C (673 K) with a pulse duration of 1 ms and an absorbed power density of up to 1.13 GW/m2. The microstructural properties, e.g. grain size, and Y2O3-particle distribution, were correlated with crack formation at a certain temperature, the crack propagation direction towards the bulk material and the amount of plastic deformation/surface roughening at higher temperatures. Thereby, it was shown that W-1 vol%Y2O3 outperformed all other investigated grades and reference materials from literature.

  17. Ceramic micro-injection molded nozzles for serial femtosecond crystallography sample delivery

    SciTech Connect

    Beyerlein, K. R.; Adriano, L.; Heymann, M.; Kirian, R.; Knoska, J.; Wilde, F.; Chapman, H. N.; Bajt, S.

    2015-12-08

    Serial femtosecond crystallography (SFX) using X-ray Free-Electron Lasers (XFELs) allows for room temperature protein structure determination without evidence of conventional radiation damage. In this method, a liquid suspension of protein microcrystals can be delivered to the X-ray beam in vacuum as a micro-jet, which replenishes the crystals at a rate that exceeds the current XFEL pulse repetition rate. Gas dynamic virtual nozzles produce the required micrometer-sized streams by the focusing action of a coaxial sheath gas and have been shown to be effective for SFX experiments. Here, we describe the design and characterization of such nozzles assembled from ceramic micro-injection molded outer gas-focusing capillaries. Trends of the emitted jet diameter and jet length as a function of supplied liquid and gas flow rates are measured by a fast imaging system. The observed trends are explained by derived relationships considering choked gas flow and liquidflow conservation. In conclusion, the performance of these nozzles in a SFX experiment is presented, including an analysis of the observed background.

  18. Comparative study of pore structure evolution during solvent and thermal debinding of powder injection molded parts

    NASA Astrophysics Data System (ADS)

    Hwang, K. S.; Hsieh, Y. M.

    1996-02-01

    The solvent debinding process has been widely accepted in the powder injection molding (PIM) industry due to its short debinding cycle. In the current study, specimens were immersed in a heptane bath for different lengths of time, and the pore structure evolvement in the compact was analyzed. Mercury porosimetry analyses and scanning electron micrographs showed that the binder extraction started from the surface and progressed toward the center of the compacts. As the debinding contin-ued, the pores grew and were widely distributed in size. This pore structure evolvement was different from that of straight thermal debinding in which the pore size distribution was quite narrow and the mean pore diameter shifted toward smaller sizes as debinding time increased. After the soluble binders were extracted, parts were subjected to a subsequent thermal debinding during which these pores served as conduits for decomposed gas to escape. Concurrently, the remaining binder became fluidlike and was redistributed within the compact due to capillarity. This pore structure, as observed from the mercury intrusion curves, showed a sharp increase in the pore volume at the 0.8-µm size, followed by a series of fine pores, which is different from the pore structure of straight thermal debinding. The difference in the pore structure evolvement between solvent and thermal debinding and its effect on the debinding rate are discussed.

  19. Simulation of polymer removal from a powder injection molding compact by thermal debinding

    NASA Astrophysics Data System (ADS)

    Lam, Y. C.; Yu, S. C. M.; Tam, K. C.; Shengjie, Ying

    2000-10-01

    Powder injection molding (PIM) is an important net-shape manufacturing process. Thermal debinding is a common methodology for the final removal of residual polymer from a PIM compact prior to sintering. This process is an intricate combination of evaporation, liquid and gas migration, pyrolysis of polymer, and heat transfer in porous media. A better understanding of thermal debinding could lead to optimization of the process to prevent the formation of defects. Simulation of the process based on an integrated mathematical model for mass and heat transfer in porous media is proposed. The mechanisms of mass transport, i.e., liquid flow, gas flow, vapor diffusion, and convection, as well as the phase transitions of polymer, and their interactions, are included in the model. The macroscopic partial differential equations are formulated by volume averaging of the microscopic conservation laws. The basic equations consist of mass conservation and energy conservation and are solved numerically. Polymer residue, pressure, and temperature distributions are predicted. The importance of the various mass transfer mechanisms is evaluated. The effects of key mass transfer parameters on thermal debinding are discussed. It is revealed from the results that the assumed binder front, which is supposed to recede into the powder compact as removal progresses, does not exist. The mass flux of polymer liquid is of the same order of the mass flux of polymer vapor in the gas phase, and the polymer vapor diffusion in the liquid phase is negligible.

  20. Debinding Process of Fe-6Ni-4Cu Compact Fabricated by Metal Injection Molding

    NASA Astrophysics Data System (ADS)

    Wang, Jenn-Shing; Lin, Shih-Pin; Hon, Min-Hsiung; Wang, Moo-Chin

    2000-02-01

    The debinding process in the case of metal injection molding for fabrication of the Fe-6Ni-4Cu compact and variables such as temperature and time has been studied. The debinding process of multiple organic binders in the Fe-6Ni-4Cu compact was investigated by thermal gravimetric analysis (TGA) weight loss and mercury porosimetry analysis. The weight loss of wax and SA dramatically increases from below 10 wt% to 76.0 wt% and 86.0 wt% after immersion in 35°C and 40°C n-hexane for 6 h, respectively. The interdiffusion coefficients of the binder and solvent are 9.763× 10-7 cm2/s and 1.295× 10-6 cm2/s, respectively. The temperature dependent interdiffusion coefficient for the Fe-6Ni-4Cu compact can be expressed as Dx=4.534× 10\\exp({-}5437.2/T). The distribution of pore size is about 0.1-1.9 μm for the Fe-6Ni-4Cu compact.

  1. Ceramic micro-injection molded nozzles for serial femtosecond crystallography sample delivery

    SciTech Connect

    Beyerlein, K. R.; Heymann, M.; Kirian, R.; Adriano, L.; Bajt, S.; Knoška, J.; Wilde, F.; Chapman, H. N.

    2015-12-15

    Serial femtosecond crystallography (SFX) using X-ray Free-Electron Lasers (XFELs) allows for room temperature protein structure determination without evidence of conventional radiation damage. In this method, a liquid suspension of protein microcrystals can be delivered to the X-ray beam in vacuum as a micro-jet, which replenishes the crystals at a rate that exceeds the current XFEL pulse repetition rate. Gas dynamic virtual nozzles produce the required micrometer-sized streams by the focusing action of a coaxial sheath gas and have been shown to be effective for SFX experiments. Here, we describe the design and characterization of such nozzles assembled from ceramic micro-injection molded outer gas-focusing capillaries. Trends of the emitted jet diameter and jet length as a function of supplied liquid and gas flow rates are measured by a fast imaging system. The observed trends are explained by derived relationships considering choked gas flow and liquid flow conservation. Finally, the performance of these nozzles in a SFX experiment is presented, including an analysis of the observed background.

  2. Foam injection molding of polypropylene/stainless steel fiber composites for efficient EMI shielding

    NASA Astrophysics Data System (ADS)

    Ameli, A.; Nofar, M.; Saniei, M.; Wang, S.; Park, C. B.

    2016-03-01

    Lightweight polypropylene/stainless-steel fiber (PP-SSF) composites with 15-35% density reduction were fabricated using foam injection molding and supercritical carbon dioxide (CO2). The electrical percolation threshold, through-plane electrical conductivity, and electromagnetic interference (EMI) shielding effectiveness (SE) of the PP-SSF composite foams were characterized and compared against the solid samples. The effects of the plasticizing gas and the void fraction on fiber breakage and orientation were also investigated. Microstructure characterization showed that the presence of dissolved CO2 decreased fiber breakage by about 30%, and together with foaming action, contributed to less preferential orientation of fibers. Consequently, the percolation threshold decreased up to four folds from 0.85 to 0.21 vol.% as the void fraction increased from 0 to 35%. The specific EMI SE was also significantly enhanced. A maximum specific EMI SE of 75 dB.g-1cm3 was achieved in PP-1.1 vol.% SSF composite foams, which was highly superior to 38 dB.g-1cm3 of the solid PP-1.0 vol.% SSF composites. The results reveal that light and efficient products with a lower fiber content can be developed by foam for EMI shielding applications.

  3. Ceramic micro-injection molded nozzles for serial femtosecond crystallography sample delivery

    NASA Astrophysics Data System (ADS)

    Beyerlein, K. R.; Adriano, L.; Heymann, M.; Kirian, R.; Knoška, J.; Wilde, F.; Chapman, H. N.; Bajt, S.

    2015-12-01

    Serial femtosecond crystallography (SFX) using X-ray Free-Electron Lasers (XFELs) allows for room temperature protein structure determination without evidence of conventional radiation damage. In this method, a liquid suspension of protein microcrystals can be delivered to the X-ray beam in vacuum as a micro-jet, which replenishes the crystals at a rate that exceeds the current XFEL pulse repetition rate. Gas dynamic virtual nozzles produce the required micrometer-sized streams by the focusing action of a coaxial sheath gas and have been shown to be effective for SFX experiments. Here, we describe the design and characterization of such nozzles assembled from ceramic micro-injection molded outer gas-focusing capillaries. Trends of the emitted jet diameter and jet length as a function of supplied liquid and gas flow rates are measured by a fast imaging system. The observed trends are explained by derived relationships considering choked gas flow and liquid flow conservation. Finally, the performance of these nozzles in a SFX experiment is presented, including an analysis of the observed background.

  4. Powder Injection Molding for mass production of He-cooled divertor parts

    NASA Astrophysics Data System (ADS)

    Antusch, S.; Norajitra, P.; Piotter, V.; Ritzhaupt-Kleissl, H.-J.

    2011-10-01

    A He-cooled divertor for future fusion power plants has been developed at KIT. Tungsten and tungsten alloys are presently considered the most promising materials for functional and structural divertor components. The advantages of tungsten materials lie, e.g. in the high melting point, and low activation, the disadvantages are high hardness and brittleness. The machinig of tungsten, e.g. milling, is very complex and cost-intensive. Powder Injection Molding (PIM) is a method for cost effective mass production of near-net-shape parts with high precision. The complete W-PIM process route is outlined and, results of product examination discussed. A binary tungsten powder feedstock with a grain size distribution in the range 0.7-1.7 μm FSSS, and a solid load of 50 vol.% was developed. After heat treatment, the successfully finished samples showed promising results, i.e. 97.6% theoretical density, a grain size of approximately 5 μm, and a hardness of 457 HV0.1.

  5. Acoustic Emission Detection of Macro-Cracks on Engraving Tool Steel Inserts during the Injection Molding Cycle Using PZT Sensors

    PubMed Central

    Svečko, Rajko; Kusić, Dragan; Kek, Tomaž; Sarjaš, Andrej; Hančič, Aleš; Grum, Janez

    2013-01-01

    This paper presents an improved monitoring system for the failure detection of engraving tool steel inserts during the injection molding cycle. This system uses acoustic emission PZT sensors mounted through acoustic waveguides on the engraving insert. We were thus able to clearly distinguish the defect through measured AE signals. Two engraving tool steel inserts were tested during the production of standard test specimens, each under the same processing conditions. By closely comparing the captured AE signals on both engraving inserts during the filling and packing stages, we were able to detect the presence of macro-cracks on one engraving insert. Gabor wavelet analysis was used for closer examination of the captured AE signals' peak amplitudes during the filling and packing stages. The obtained results revealed that such a system could be used successfully as an improved tool for monitoring the integrity of an injection molding process. PMID:23673677

  6. Acoustic emission detection of macro-cracks on engraving tool steel inserts during the injection molding cycle using PZT sensors.

    PubMed

    Svečko, Rajko; Kusić, Dragan; Kek, Tomaž; Sarjaš, Andrej; Hančič, Aleš; Grum, Janez

    2013-01-01

    This paper presents an improved monitoring system for the failure detection of engraving tool steel inserts during the injection molding cycle. This system uses acoustic emission PZT sensors mounted through acoustic waveguides on the engraving insert. We were thus able to clearly distinguish the defect through measured AE signals. Two engraving tool steel inserts were tested during the production of standard test specimens, each under the same processing conditions. By closely comparing the captured AE signals on both engraving inserts during the filling and packing stages, we were able to detect the presence of macro-cracks on one engraving insert. Gabor wavelet analysis was used for closer examination of the captured AE signals' peak amplitudes during the filling and packing stages. The obtained results revealed that such a system could be used successfully as an improved tool for monitoring the integrity of an injection molding process. PMID:23673677

  7. Injection molding as a one-step process for the direct production of pharmaceutical dosage forms from primary powders.

    PubMed

    Eggenreich, K; Windhab, S; Schrank, S; Treffer, D; Juster, H; Steinbichler, G; Laske, S; Koscher, G; Roblegg, E; Khinast, J G

    2016-05-30

    The objective of the present study was to develop a one-step process for the production of tablets directly from primary powder by means of injection molding (IM), to create solid-dispersion based tablets. Fenofibrate was used as the model API, a polyvinyl caprolactame-polyvinyl acetate-polyethylene glycol graft co-polymer served as a matrix system. Formulations were injection-molded into tablets using state-of-the-art IM equipment. The resulting tablets were physico-chemically characterized and the drug release kinetics and mechanism were determined. Comparison tablets were produced, either directly from powder or from pre-processed pellets prepared via hot melt extrusion (HME). The content of the model drug in the formulations was 10% (w/w), 20% (w/w) and 30% (w/w), respectively. After 120min, both powder-based and pellet-based injection-molded tablets exhibited a drug release of 60% independent of the processing route. Content uniformity analysis demonstrated that the model drug was homogeneously distributed. Moreover, analysis of single dose uniformity also revealed geometric drug homogeneity between tablets of one shot. PMID:27012981

  8. PP-polymer nanocomposites with improved mechanical properties using elongational flow devices at the injection molding compounder

    NASA Astrophysics Data System (ADS)

    Battisti, M. G.; Friesenbichler, W.

    2014-05-01

    Numerous researches have been done in the field of improving PP by adding nanofillers. Consistently good scientific results and positive industrial feedback were reached; however, the industrial interest is still low due to the high technological and financial risks and too less benefit. Our experiments, using the worldwide unique Polymer NanoComposite Injection Molding Compounder (PNC-IMC) which combines the two processing steps of compounding and injection molding, showed an impressive increase of both mechanical and thermal properties, but more or less in the same range than in other publications. Thus we tried to improve the materials by using elongational flow generating devices for better intercalation and exfoliation of nanofillers in the polymer melt. This paper will give an overview on our first investigations, carried out on both a high pressure capillary rheometer (HPCR) and the injection molding machine (IMM) focusing on the mechanical properties. The PNCs were produced at the PNC-IMC with the 3in1 process. After the treatment in the HPCR the material was crushed, plates were prepared using a hydraulic vacuum press and tensile bars were milled, respectively tensile bars were produced with the IMM. The Young's modulus was successfully slightly improved. Thus future research will focus on both, the mechanism of improvement and the implementation of several of these devices into the PNC-IMC.

  9. Fabrication of Bonding-Type Hollow Microneedle Array by Injection Molding and Evaluation of its Puncture Characteristics

    NASA Astrophysics Data System (ADS)

    Ogai, Noriyuki; Sugimura, Ryo; Tamaru, Takuya; Takiguchi, Yoshihiro

    A microneedle array which consists from small needles compared to a conventional metal injection needle is expected as a low invasive transdermal medical treatment device, and many fabrication approach have been conducted. In this study, we fabricated plastic hollow microneedle array by a fabrication method based on the combination of injection molding, bonding and assembly techniques. To evaluate puncture characteristics of the fabricated needle, we measured a puncture force to silicone rubber by experimental equipment using loadcell and automatic stage. Furthermore, we propose and demonstrate a new method to measure actual punctured depth from punctured trace on the needle surface modified by O2 plasma treatment.

  10. In-line polariscopic checking of plastic molded-injected lenses: preliminary results

    NASA Astrophysics Data System (ADS)

    Arasa, J.; Mayershofer, D.; Romero, J.

    2015-05-01

    Plastic injection molded lenses have improved its performance and, nowadays, are as usual as glass lenses in image forming devices. However, the manufacturing process induces the surface generation and the material transformation in the same stage. Moreover, the process also includes an annealing stage to remove the internal stress with temperature cycles but only works up to a certain level and not beyond, leaving relevant traces for high values. During the manufacturing process of a plastic lens, a liquid-solid phase transformation occurs, and in this transition not all the volume of the lens achieves the same density. This change of density is translated into a local change of refractive index that can be expressed as a retardation phase plane using the Jones Matrix notation. The detection and measurement of the value of the retardation of the phase plane is thus the clue to manufacture good and controlled quality plastic lenses. We have tested an in-line polariscopic arrangement to obtain a 2D map of the tension distribution in the bulk of the lens. This test is performed in the first 30 seconds after the injection molding process for two main reasons: first the stress values are still high because the lenses do not have enough time to relax the internal tensions and obtain the final shape, and second, we can remove the wrong lenses in the first moments and introduce only the good lenses in the annealing stage. The proposed instrument is based in a transmission polariscopic arrangement. A collimated light beam is used to illuminate the sample, once the light crosses the sample, it is collected with an afocal system and the image is recorded in a CMOS sensor. Selecting an afocal system to capture the image is a useful decision because the lateral magnification can be maintained when small changes in the sample position are introduced. However the produced lenses can vary their focal lengths from on series to another. To avoid problems with the change of the

  11. Predictive Engineering Tools for Injection-molded Long-Carbon-Fiber Thermoplastic Composites - FY 2014 Third Quarterly Report

    SciTech Connect

    Nguyen, Ba Nghiep; Sanborn, Scott E.; Mathur, Raj N.; Sharma, Bhisham; Sangid, Michael D.; Wang, Jin; Jin, Xiaoshi; Costa, Franco; Gandhi, Umesh N.; Mori, Steven; Tucker III, Charles L.

    2014-08-15

    This report describes the technical progresses made during the third quarter of FY 2014: 1) Autodesk introduced the options for fiber inlet condition to the 3D solver. These options are already available in the mid-plane/dual domain solver. 2) Autodesk improved the accuracy of 3D fiber orientation calculation around the gate. 3) Autodesk received consultant services from Prof. C.L. Tucker at the University of Illinois on the implementation of the reduced order model for fiber length, and discussed with Prof. Tucker the methods to reduce memory usage. 4) PlastiComp delivered to PNNL center-gated and edge-fan-gated 20-wt% to 30-wt% LCF/PP and LCF/PA66 (7”x7”x1/8”) plaques molded by the in-line direct injection molding (D-LFT) process. 5) PlastiComp molded ASTM tensile, flexural and impact bars under the same D-LFT processing conditions used for plaques for Certification of Assessment and ascertaining the resultant mechanical properties. 6) Purdue developed a new polishing routine, utilizing the automated polishing machine, to reduce fiber damage during surface preparation. 7) Purdue used a marker-based watershed segmentation routine, in conjunction with a hysteresis thresholding technique, for fiber segmentation during fiber orientation measurement. 8) Purdue validated Purdue’s fiber orientation measurement method using the previous fiber orientation data obtained from the Leeds machine and manually measured data by the University of Illinois. 9) PNNL conducted ASMI mid-plane analyses for a 30wt% LCF/PP plaque and compared the predicted fiber orientations with the measured data provided by Purdue University at the selected locations on this plaque. 10) PNNL put together the DOE 2014 Annual Merit Review (AMR) presentation with the team and presented it at the AMR meetings on June 17, 2014. 11) PNNL built ASMI dual domain models for the Toyota complex part and commenced mold filling analyses of the complex part with different wall thicknesses in order to

  12. Evaluation of Micro-drilling Technologies for Metal Injection Molded 420 Stainless Steel

    NASA Astrophysics Data System (ADS)

    Silverman, David Elion

    Metal injection molded (MIM) 420 stainless steel is a commonly used material for high-value products such as fuel injector nozzles. However, the trade-offs involved in using different micro-drilling processes on this material are not well-documented in literature. This thesis presents a micro-drilling study of MIM 420 stainless steel using four candidate processes, viz., micro-electrical discharge drilling (micro-EDD), ultrasonically-assisted micro-EDD, micro-mechanical drilling (micro-MD) and ultrasonically-assisted micro-MD. The micro-EDD results shows that the use of ultrasonic vibrations significantly improves the overall process time, spark erosion efficiency and material removal rate of the process. However, this improvement comes at the expense of increased tool wear and surface roughness, especially while machining under high discharge energy conditions. The micro-MD results show that the use of ultrasonic vibrations is beneficial in lowering the thrust force, drilling torque and tool-wear at chipload values greater than the minimum chip thickness of the material. However, the ultrasonic vibrations do not have a notable effect on the surface roughness or on the size of the exit burrs. The results obtained from this study have been used to develop a Likert-type comparison scale to enable application-specific selection of micro-drilling processes for MIM 420 stainless steel. Finally, the benefits of using the ultrasonically-assisted micro-EDD process seen during the laboratory tests at Rensselaer were observed to carry over to the production environment of our NYSERDA funded industrial sponsor.

  13. Reproducibility Study of NiTi Parts Made by Metal Injection Molding

    NASA Astrophysics Data System (ADS)

    Bram, M.; Bitzer, M.; Buchkremer, H. P.; Stöver, D.

    2012-12-01

    Powder metallurgy (P/M) is an attractive manufacturing process for net-shaped NiTi parts considering the limited machinability of NiTi alloys. Nevertheless, the industrial implementation of P/M processing for NiTi alloys is not trivial. To become competitive to manufacturing of NiTi alloys based on established ingot metallurgy, combination of fully pronounced shape memory behavior with sufficient mechanical properties is required. Successful use of P/M technology is strongly influenced by high affinity of NiTi alloys for uptake of oxygen and carbon, which leads to the formation of oxygen-containing Ti2Ni and TiC phases coupled with increase of Ni content in the matrix. In the case of Ni-rich NiTi alloys, this increase leads to a shift of phase transformation temperatures to lower values. Furthermore, precipitation of Ni4Ti3 during cooling from sintering temperature is difficult to avoid. Even if these precipitates might be used to decrease the Ni:Ti ratio of the matrix balancing oxygen and carbon uptake, significant loss of ductility arises, especially in the case of finely dispersed Ni4Ti3 precipitates. In the present work, each step of P/M manufacturing is discussed regarding its influence on the specific properties of NiTi alloys. The work is based on the application of prealloyed, gas atomized NiTi powders. Metal injection molding was used for net-shaped manufacturing of tensile samples, which enabled detailed study of sintering behavior combined with investigation of shape memory and mechanical properties depending on particle size, oxygen and carbon content as well as precipitation of Ni4Ti3 phase.

  14. Finger-powered microfluidic systems using multilayer soft lithography and injection molding processes.

    PubMed

    Iwai, Kosuke; Shih, Kuan Cheng; Lin, Xiao; Brubaker, Thomas A; Sochol, Ryan D; Lin, Liwei

    2014-10-01

    Point-of-care (POC) and disposable biomedical applications demand low-power microfluidic systems with pumping components that provide controlled pressure sources. Unfortunately, external pumps have hindered the implementation of such microfluidic systems due to limitations associated with portability and power requirements. Here, we propose and demonstrate a 'finger-powered' integrated pumping system as a modular element to provide pressure head for a variety of advanced microfluidic applications, including finger-powered on-chip microdroplet generation. By utilizing a human finger for the actuation force, electrical power sources that are typically needed to generate pressure head were obviated. Passive fluidic diodes were designed and implemented to enable distinct fluids from multiple inlet ports to be pumped using a single actuation source. Both multilayer soft lithography and injection molding processes were investigated for device fabrication and performance. Experimental results revealed that the pressure head generated from a human finger could be tuned based on the geometric characteristics of the pumping system, with a maximum observed pressure of 7.6 ± 0.1 kPa. In addition to the delivery of multiple, distinct fluids into microfluidic channels, we also employed the finger-powered pumping system to achieve the rapid formation of both water-in-oil droplets (106.9 ± 4.3 μm in diameter) and oil-in-water droplets (75.3 ± 12.6 μm in diameter) as well as the encapsulation of endothelial cells in droplets without using any external or electrical controllers. PMID:25102160

  15. Miniature injection-molded optics for fiber-optic, in vivo confocal microscopy

    NASA Astrophysics Data System (ADS)

    Chidley, Matthew D.; Liang, Chen; Descour, Michael R.; Sung, Kung-Bin; Richards-Kortum, Rebecca R.; Gillenwater, Ann

    2002-12-01

    In collaboration with the Department of Biomedical Engineering at the University of Texas at Austin and the UT MD Anderson Cancer Center, a laser scanning fiber confocal reflectance microscope (FCRM) system has been designed and tested for in vivo detection of cervical and oral pre-cancers. This system along with specially developed diagnosis algorithms and techniques can achieve an unprecedented specificity and sensitivity for the diagnosis of pre-cancers in epithelial tissue. The FCRM imaging system consists of an NdYAG laser (1064 nm), scanning mirrors/optics, precision pinhole, detector, and an endoscopic probe (the objective). The objective is connected to the rest of the imaging system via a fiber bundle. The fiber bundle allows the rest of the system to be remotely positioned in a convenient location. Only the objective comes into contact with the patient. It is our intent that inexpensive mass-produced disposable endoscopic probes would be produced for large clinical trials. This paper touches on the general design process of developing a miniature, high numerical aperture, injection-molded (IM) objective. These IM optical designs are evaluated and modified based on manufacturing and application constraints. Based on these driving criteria, one specific optical design was chosen and a detailed tolerance analysis was conducted. The tolerance analysis was custom built to create a realistic statistical analysis for integrated IM lens elements that can be stacked one on top of another using micro-spheres resting in tiny circular grooves. These configurations allow each lens element to be rotated and possibly help compensate for predicted manufacturing errors. This research was supported by a grant from the National Institutes of Health (RO1 CA82880). Special thanks go to Applied Image Group/Optics for the numerous fabrication meetings concerning the miniature IM objective.

  16. Tribological and mechanical performance evaluation of metal prosthesis components manufactured via metal injection molding.

    PubMed

    Melli, Virginia; Juszczyk, Mateusz; Sandrini, Enrico; Bolelli, Giovanni; Bonferroni, Benedetta; Lusvarghi, Luca; Cigada, Alberto; Manfredini, Tiziano; De Nardo, Luigi

    2015-01-01

    The increasing number of total joint replacements, in particular for the knee joint, has a growing impact on the healthcare system costs. New cost-saving manufacturing technologies are being explored nowadays. Metal injection molding (MIM) has already demonstrated its suitability for the production of CoCrMo alloy tibial trays, with a significant reduction in production costs, by holding both corrosion resistance and biocompatibility. In this work, mechanical and tribological properties were evaluated on tibial trays obtained via MIM and conventional investment casting. Surface hardness and wear properties were evaluated through Vickers hardness, scratch and pin on disk tests. The MIM and cast finished tibial trays were then subjected to a fatigue test campaign in order to obtain their fatigue load limit at 5 millions cycles following ISO 14879-1 directions. CoCrMo cast alloy exhibited 514 HV hardness compared to 335 HV of MIM alloy, furthermore it developed narrower scratches with a higher tendency towards microploughing than microcutting, in comparison to MIM CoCrMo. The observed fatigue limits were (1,766 ± 52) N for cast tibial trays and (1,625 ± 44) N for MIM ones. Fracture morphologies pointed out to a more brittle behavior of MIM microstructure. These aspects were attributed to the absence of a fine toughening and surface hardening carbide dispersion in MIM grains. Nevertheless, MIM tibial trays exhibited a fatigue limit far beyond the 900 N of maximum load prescribed by ISO and ASTM standards for the clinical application of these devices. PMID:25577214

  17. Low Speed Technology for Small Turbine Development Reaction Injection Molded 7.5 Meter Wind Turbine Blade

    SciTech Connect

    David M. Wright; DOE Project Officer - Keith Bennett

    2007-07-31

    An optimized small turbine blade (7.5m radius) was designed and a partial section molded with the RIM (reaction-injection molded polymer) process for mass production. The intended market is for generic three-bladed wind turbines, 100 kilowatts or less, for grid-assist end users with rural and semi-rural sites, such as the farm/ranch market, having low to moderate IEC Class 3-4 wind regimes. This blade will have substantial performance improvements over, and be cheaper than, present-day 7.5m blades. This is made possible by the injection-molding process, which yields high repeatability, accurate geometry and weights, and low cost in production quantities. No wind turbine blade in the 7.5m or greater size has used this process. The blade design chosen uses a RIM skin bonded to a braided infused carbon fiber/epoxy spar. This approach is attractive to present users of wind turbine blades in the 5-10m sizes. These include rebladeing California wind farms, refurbishing used turbines for the Midwest farm market, and other manufacturers introducing new turbines in this size range.

  18. Comparison of peri-implant bone formation around injection-molded and machined surface zirconia implants in rabbit tibiae.

    PubMed

    Kim, Hong-Kyun; Woo, Kyung Mi; Shon, Won-Jun; Ahn, Jin-Soo; Cha, Seunghee; Park, Young-Seok

    2015-01-01

    The aim of this study was to compare osseointegration and surface characteristics of zirconia implants made by the powder injection molding (PIM) technique against those made by the conventional milling procedure in rabbit tibiae. Surface characteristics of 2 types of implants were evaluated. Sixteen rabbits received 2 types of external hex implants with similar geometry, either machined zirconia implants or PIM zirconia implants, in the tibiae. Removal torque tests and histomorphometric analyses were performed. The roughness of the PIM zirconia implants was higher than that of machined zirconia implants. The PIM zirconia implants exhibited significantly higher bone-implant contact and removal torque values than the machined zirconia implants (p<0.001). The osseointegration of the PIM zirconia implant is promising, and PIM, using the roughened mold etching technique, can produce substantially rougher surfaces on zirconia implants. PMID:26235717

  19. Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites - Fourth FY 2015 Quarterly Report

    SciTech Connect

    Nguyen, Ba Nghiep; Fifield, Leonard S.; Wollan, Eric J.; Roland, Dale; Gandhi, Umesh N.; Mori, Steven; Lambert, Gregory; Baird, Donald G.; Wang, Jin; Costa, Franco; Tucker III, Charles L.

    2015-11-13

    During the last quarter of FY 2015, the following technical progress has been made toward project milestones: 1) PlastiComp used the PlastiComp direct in-line (D-LFT) Pushtrusion system to injection mold 40 30wt% LCF/PP parts with ribs, 40 30wt% LCF/PP parts without ribs, 10 30wt% LCF/PA66 parts with ribs, and 35 30wt% LCF/PA66 parts without ribs. In addition, purge materials from the injection molding nozzle were obtained for fiber length analysis, and molding parameters were sent to PNNL for process modeling. 2) Magna cut samples at four selected locations (named A, B, C and D) from the non-ribbed Magna-molded parts based on a plan discussed with PNNL and the team and shipped these samples to Virginia Tech for fiber orientation and length measurements. 3) Virginia Tech started fiber orientation and length measurements for the samples taken from the complex parts using Virginia Tech’s established procedure. 4) PNNL and Autodesk built ASMI models for the complex parts with and without ribs, reviewed process datasheets and performed preliminary analyses of these complex parts using the actual molding parameters received from Magna and PlastiComp to compare predicted to experimental mold filling patterns. 5) Autodesk assisted PNNL in developing the workflow to use Moldflow fiber orientation and length results in ABAQUS® simulations. 6) Autodesk advised the team on the practicality and difficulty of material viscosity characterization from the D-LFT process. 7) PNNL developed a procedure to import fiber orientation and length results from a 3D ASMI analysis to a 3D ABAQUS® model for structural analyses of the complex part for later weight reduction study. 8) In discussion with PNNL and Magna, Toyota developed mechanical test setups and built fixtures for three-point bending and torsion tests of the complex parts. 9) Toyota built a finite element model for the complex parts subjected to torsion loading. 10) PNNL built the 3D ABAQUS® model of the complex ribbed

  20. A Fully Coupled Simulation and Optimization Scheme for the Design of 3D Powder Injection Molding Processes

    SciTech Connect

    Ayad, G.; Barriere, T.; Gelin, J. C.; Liu, B.

    2007-05-17

    The paper is concerned with optimization and parametric identification of Powder Injection Molding process that consists first in injection of powder mixture with polymer binder and then to the sintering of the resulting powders parts by solid state diffusion. In the first part, one describes an original methodology to optimize the injection stage based on the combination of Design Of Experiments and an adaptive Response Surface Modeling. Then the second part of the paper describes the identification strategy that one proposes for the sintering stage, using the identification of sintering parameters from dilatometer curves followed by the optimization of the sintering process. The proposed approaches are applied to the optimization for manufacturing of a ceramic femoral implant. One demonstrates that the proposed approach give satisfactory results.

  1. Predictive engineering tools for injection-molded long-carbon-fiber thermoplastic composites - FY 2015 third quarterly report

    SciTech Connect

    Nguyen, Ba Nghiep; Fifield, Leonard S.; Mori, Steven; Gandhi, Umesh N.; Wang, Jin; Costa, Franco; Wollan, Eric J.; Tucker, III, Charles L.

    2015-07-01

    During the third quarter of FY 2015, the following technical progress has been made toward project milestones: 1) Magna oversaw the tool build and prepared the molding plan for the complex part of Phase II. 2) PlastiComp hosted a visit by Magna and Toyota on April 23rd to finalize the molding scope and schedule. The plan for molding trials including selection of molding parameters for both LFT and D-LFT for the U-shape complex part was established. 3) Toyota shipped the U-shape complex part tool to Magna on May 28th, 2015. 4) Plasticomp provided 30wt% LCF/PP and 30wt% LCF/PA66 compounded pellets to Magna for molding the complex part. 5) Magna performed preliminary molding trials on June 2nd, 2015 to validate wall thickness, fill profile, tool temperature and shot size requirements for the complex part. 6) Magna performed the first complex part run on June 16th and 17th, 2015 at Magna’s Composite Centre of Excellence in Concord, ON, Canada. Dale Roland of Plasticomp, and Umesh Gandhi of Toyota also attended the molding. 7) Magna discussed and finalized the plan with PNNL and the team for cutting samples from molded parts at selected locations for fiber orientation and length measurements. 8) Magna provided the computer-aided design (CAD) files of the complex parts with and without ribs to PNNL and Autodesk to build the corresponding ASMI models for injection molding simulations. Magna also provided the actual parameters used. 9) Plasticomp’s provided knowledge and experience of molding LCF materials essential to the successful molding of the parts including optimization of fill speed, tool temperatures, and plasticizing conditions for the 30wt% LCF/PP and 30wt% LCF/PA66 materials in both rib and non-rib versions. 10) Magna molded additional parts for evaluation of mechanical property testing including torsional stiffness on June 29th and 30th, 2015 at Magna’s Composite Center of Excellence. 11) Toyota began preparation for the torsion test of the specimens

  2. Spray-formed tooling for injection molding and die casting applications

    SciTech Connect

    K. M. McHugh; B. R. Wickham

    2000-06-26

    Rapid Solidification Process (RSP) Tooling{trademark} is a spray forming technology tailored for producing molds and dies. The approach combines rapid solidification processing and net-shape materials processing in a single step. The ability of the sprayed deposit to capture features of the tool pattern eliminates costly machining operations in conventional mold making and reduces turnaround time. Moreover, rapid solidification suppresses carbide precipitation and growth, allowing many ferritic tool steels to be artificially aged, an alternative to conventional heat treatment that offers unique benefits. Material properties and microstructure transformation during heat treatment of spray-formed H13 tool steel are described.

  3. Spray-formed Tooling for Injection Molding and Die Casting Applications

    SciTech Connect

    Mc Hugh, Kevin Matthew

    2000-06-01

    Rapid Solidification Process (RSP) ToolingTM is a spray forming technology tailored for producing molds and dies. The approach combines rapid solidification processing and net-shape materials processing in a single step. The ability of the sprayed deposit to capture features of the tool pattern eliminates costly machining operations in conventional mold making and reduces turnaround time. Moreover, rapid solidification suppresses carbide precipitation and growth, allowing many ferritic tool steels to be artificially aged, an alternative to conventional heat treatment that offers unique benefits. Material properties and microstructure transformation during heat treatment of spray-formed H13 tool steel are described.

  4. Portable CE system with contactless conductivity detection in an injection molded polymer chip for on-site food analysis

    NASA Astrophysics Data System (ADS)

    Becker, Holger; Mühlberger, Holger; Hoffmann, Werner; Clemens, Thomas; Klemm, Richard; Gärtner, Claudia

    2008-02-01

    We present a compact portable chip-based capillary electrophoresis system that employs capacitively coupled contactless conductivity detection (C 4D) operating at 4 MHz as an alternative detection method compared to the commonly used optical detection employing laser-induced fluorescence. The disposable chip for this system is fabricated out of PMMA using injection molding; the electrodes are screen-printed or thin-film electrodes. The system allows the measurement of small ions like Li, Na, K typically present in foodstuff like milk and mineral water as well as acids in wine.

  5. Application of Rapid Prototyping and Wire Arc Spray to the Fabrication of Injection Mold Tools (MSFC Center Director's Discretionary Fund)

    NASA Technical Reports Server (NTRS)

    Cooper, K. G.

    2000-01-01

    Rapid prototyping (RP) is a layer-by-layer-based additive manufacturing process for constructing three-dimensional representations of a computer design from a wax, plastic, or similar material. Wire arc spray (WAS) is a metal spray forming technique, which deposits thin layers of metal onto a substrate or pattern. Marshall Space Flight Center currently has both capabilities in-house, and this project proposed merging the two processes into an innovative manufacturing technique, in which intermediate injection molding tool halves were to be fabricated with RP and WAS metal forming.

  6. Improved silicon carbide for advanced heat engines. II - Pressureless sintering and mechanical properties of injection molded silicon carbide

    NASA Technical Reports Server (NTRS)

    Whalen, Thomas J.; Baer, J. R.

    1989-01-01

    The influence on density and strength of pressureless sintering in vacuum and argon environments has been evaluated with injection molded SiC materials. Main effects and two factor interactions of sintering (cycle variables temperature, time, heating rate, and atmosphere) were assessed. An improved understanding of the influence of the processing flaws and sintering conditions has been obtained. Strength and density have improved from a baseline level of 299 MPa (43.3 Ksi) and 94 pct of theoretical density to values greater than 483 MPa (70 Ksi) and 97 pct.

  7. Development of an injection molded poly(epsilon-caprolactone) intravaginal insert for the delivery of progesterone to cattle.

    PubMed

    Rathbone, Michael J; Bunt, Craig R; Ogle, Colin R; Burggraaf, Shane; Macmillan, Keith L; Pickering, Kim

    2002-12-13

    This paper reports experiments conducted to research, develop and clinically evaluate an injection molded intravaginal insert manufactured from the biodegradable polyester poly(epsilon-caprolactone). The study demonstrated that it is possible to engineer poly(epsilon-caprolactone) into a shape that is well retained, and can be used as a platform for the controlled delivery of progesterone via the vagina of cows. Field evaluation showed that the poly(epsilon-caprolactone) intravaginal inserts containing 10% (w/w) progesterone were at least as effective clinically as the commercially available CIDR intravaginal insert. PMID:12480312

  8. Evaluation of hot-melt extrusion and injection molding for continuous manufacturing of immediate-release tablets.

    PubMed

    Melocchi, Alice; Loreti, Giulia; Del Curto, Maria Dorly; Maroni, Alessandra; Gazzaniga, Andrea; Zema, Lucia

    2015-06-01

    The exploitation of hot-melt extrusion and injection molding for the manufacturing of immediate-release (IR) tablets was preliminarily investigated in view of their special suitability for continuous manufacturing, which represents a current goal of pharmaceutical production because of its possible advantages in terms of improved sustainability. Tablet-forming agents were initially screened based on processability by single-screw extruder and micromolding machine as well as disintegration/dissolution behavior of extruded/molded prototypes. Various polymers, such as low-viscosity hydroxypropylcellulose, polyvinyl alcohol, polyvinyl alcohol-polyethylene glycol graft copolymer, various sodium starch glycolate grades (e.g., Explotab(®) CLV) that could be processed with no need for technological aids, except for a plasticizer, were identified. Furthermore, the feasibility of both extruded and molded IR tablets from low-viscosity hydroxypropylcellulose or Explotab(®) CLV was assessed. Explotab(®) CLV, in particular, showed thermoplastic properties and a very good aptitude as a tablet-forming agent, starting from which disintegrating tablets were successfully obtained by either techniques. Prototypes containing a poorly soluble model drug (furosemide), based on both a simple formulation (Explotab(®) CLV and water/glycerol as plasticizers) and formulations including dissolution/disintegration adjuvants (soluble and effervescent excipients) were shown to fulfill the USP 37 dissolution requirements for furosemide tablets. PMID:25761921

  9. NON-POLLUTING COMPOSITES REPAIR AND REMANUFACTURING FOR MILITARY APPLICATIONS: CO-INJECTION RESIN TRANSFER MOLDING

    EPA Science Inventory

    Vacuum-assisted resin transfer molding (VARTM) processes have been proven to be cost-effective manufacturing techniques for large composite structures. However, their use has been limited to single resin systems. A large variety of composite structures requires multiple resins to...

  10. Fabrication of long-focal-length plano-convex microlens array by combining the micro-milling and injection molding processes.

    PubMed

    Chen, Lei; Kirchberg, Stefan; Jiang, Bing-Yan; Xie, Lei; Jia, Yun-Long; Sun, Lei-Lei

    2014-11-01

    A uniform plano-convex spherical microlens array with a long focal length was fabricated by combining the micromilling and injection molding processes in this work. This paper presents a quantitative study of the injection molding process parameters on the uniformity of the height of the microlenses. The variation of the injection process parameters, i.e., barrel temperature, mold temperature, injection speed, and packing pressure, was found to have a significant effect on the uniformity of the height of the microlenses, especially the barrel temperature. The filling-to-packing switchover point is also critical to the uniformity of the height of the microlenses. The optimal uniformity was achieved when the polymer melts completely filled the mold cavity, or even a little excessively filled the cavity, during the filling stage. In addition, due to the filling resistance, the practical filling-to-packing switchover point can vary with the change of the filling processing conditions and lead to a non-negligible effect on the uniformity of the height of the microlenses. Furthermore, the effect of injection speed on the uniformity of the height of the microlenses was analyzed in detail. The results indicated that the effect of injection speed on the uniformity of the height of the microlenses is mainly attributed to the two functions of injection speed: transferring the filling-to-packing switchover point and affecting the distribution of residual flow stress in the polymer melt. PMID:25402902