Injection Moulding Simulation and Validation of Thin Wall Components for Precision Applications

Aminul Islam*, Xiaoliu Li, Maja Wirska

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingArticle in proceedingsResearchpeer-review

Abstract

This paper presents the results of the Moldex3D simulations and experimental validations carried on a complex 3D thin wall part, it critically analyzes the capability of Moldex3D and provides the guideline for more accurate simulation with the commercial softwareMoldex3D. The Boundary Layer Meshing (BLM) mode was adopted in this work to simulate the injection molding process of a hearing aid shell made of Polybutylene Terephthalate (PBT) with 30% glass fiber. Injection molding experiment was conducted to validate the prediction from Moldex3D. Injection time, injection pressure; pressure loss and warpage were treated as the main comparison criteria. Different parameters setting in Moldex3D were investigated to research their influence on the accuracy of the simulation. Results showed that the injection molding process prediction from the simulation was relatively precise when the nozzle geometry and the pressure effect on the material viscosity in the simulation model are considered. The determination of a proper heat transfer coefficient (HTC) is also vital for the simulation accuracy. The agreement between the warpage of the experiment molded parts and simulated parts was not good. Warpage was dominated by the fiber orientation. Predicted warpage was found to be extremely dependent on the filling HTC (Heat Transfer Coefficient) and the fiber orientation model used in Moldex3D, both of which had a significant influence on the fiber orientation.
Original languageEnglish
Title of host publicationAdvances in Manufacturing II
EditorsBartosz Gapiński, Marek Szostak , Vitalii Ivanov
Volume4
PublisherSpringer
Publication date2019
Pages96-107
DOIs
Publication statusPublished - 2019
EventSixth International Scientific-Technical Conference Manufacturing - Poznan University of Technology, Poznan, Poland
Duration: 19 May 201922 May 2019

Conference

ConferenceSixth International Scientific-Technical Conference Manufacturing
Location Poznan University of Technology
CountryPoland
CityPoznan
Period19/05/201922/05/2019

Keywords

  • Moldex3D
  • Injection molding
  • Thin wall part
  • Simulations

Cite this

Islam, A., Li, X., & Wirska, M. (2019). Injection Moulding Simulation and Validation of Thin Wall Components for Precision Applications. In B. Gapiński, M. Szostak , & V. Ivanov (Eds.), Advances in Manufacturing II (Vol. 4, pp. 96-107). Springer. https://doi.org/10.1007/978-3-030-16943-5_9
Islam, Aminul ; Li, Xiaoliu ; Wirska, Maja. / Injection Moulding Simulation and Validation of Thin Wall Components for Precision Applications. Advances in Manufacturing II. editor / Bartosz Gapiński ; Marek Szostak ; Vitalii Ivanov . Vol. 4 Springer, 2019. pp. 96-107
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abstract = "This paper presents the results of the Moldex3D simulations and experimental validations carried on a complex 3D thin wall part, it critically analyzes the capability of Moldex3D and provides the guideline for more accurate simulation with the commercial softwareMoldex3D. The Boundary Layer Meshing (BLM) mode was adopted in this work to simulate the injection molding process of a hearing aid shell made of Polybutylene Terephthalate (PBT) with 30{\%} glass fiber. Injection molding experiment was conducted to validate the prediction from Moldex3D. Injection time, injection pressure; pressure loss and warpage were treated as the main comparison criteria. Different parameters setting in Moldex3D were investigated to research their influence on the accuracy of the simulation. Results showed that the injection molding process prediction from the simulation was relatively precise when the nozzle geometry and the pressure effect on the material viscosity in the simulation model are considered. The determination of a proper heat transfer coefficient (HTC) is also vital for the simulation accuracy. The agreement between the warpage of the experiment molded parts and simulated parts was not good. Warpage was dominated by the fiber orientation. Predicted warpage was found to be extremely dependent on the filling HTC (Heat Transfer Coefficient) and the fiber orientation model used in Moldex3D, both of which had a significant influence on the fiber orientation.",
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Islam, A, Li, X & Wirska, M 2019, Injection Moulding Simulation and Validation of Thin Wall Components for Precision Applications. in B Gapiński, M Szostak & V Ivanov (eds), Advances in Manufacturing II. vol. 4, Springer, pp. 96-107, Sixth International Scientific-Technical Conference Manufacturing , Poznan, Poland, 19/05/2019. https://doi.org/10.1007/978-3-030-16943-5_9

Injection Moulding Simulation and Validation of Thin Wall Components for Precision Applications. / Islam, Aminul; Li, Xiaoliu; Wirska, Maja.

Advances in Manufacturing II. ed. / Bartosz Gapiński; Marek Szostak ; Vitalii Ivanov . Vol. 4 Springer, 2019. p. 96-107.

Research output: Chapter in Book/Report/Conference proceedingArticle in proceedingsResearchpeer-review

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N2 - This paper presents the results of the Moldex3D simulations and experimental validations carried on a complex 3D thin wall part, it critically analyzes the capability of Moldex3D and provides the guideline for more accurate simulation with the commercial softwareMoldex3D. The Boundary Layer Meshing (BLM) mode was adopted in this work to simulate the injection molding process of a hearing aid shell made of Polybutylene Terephthalate (PBT) with 30% glass fiber. Injection molding experiment was conducted to validate the prediction from Moldex3D. Injection time, injection pressure; pressure loss and warpage were treated as the main comparison criteria. Different parameters setting in Moldex3D were investigated to research their influence on the accuracy of the simulation. Results showed that the injection molding process prediction from the simulation was relatively precise when the nozzle geometry and the pressure effect on the material viscosity in the simulation model are considered. The determination of a proper heat transfer coefficient (HTC) is also vital for the simulation accuracy. The agreement between the warpage of the experiment molded parts and simulated parts was not good. Warpage was dominated by the fiber orientation. Predicted warpage was found to be extremely dependent on the filling HTC (Heat Transfer Coefficient) and the fiber orientation model used in Moldex3D, both of which had a significant influence on the fiber orientation.

AB - This paper presents the results of the Moldex3D simulations and experimental validations carried on a complex 3D thin wall part, it critically analyzes the capability of Moldex3D and provides the guideline for more accurate simulation with the commercial softwareMoldex3D. The Boundary Layer Meshing (BLM) mode was adopted in this work to simulate the injection molding process of a hearing aid shell made of Polybutylene Terephthalate (PBT) with 30% glass fiber. Injection molding experiment was conducted to validate the prediction from Moldex3D. Injection time, injection pressure; pressure loss and warpage were treated as the main comparison criteria. Different parameters setting in Moldex3D were investigated to research their influence on the accuracy of the simulation. Results showed that the injection molding process prediction from the simulation was relatively precise when the nozzle geometry and the pressure effect on the material viscosity in the simulation model are considered. The determination of a proper heat transfer coefficient (HTC) is also vital for the simulation accuracy. The agreement between the warpage of the experiment molded parts and simulated parts was not good. Warpage was dominated by the fiber orientation. Predicted warpage was found to be extremely dependent on the filling HTC (Heat Transfer Coefficient) and the fiber orientation model used in Moldex3D, both of which had a significant influence on the fiber orientation.

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M3 - Article in proceedings

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SP - 96

EP - 107

BT - Advances in Manufacturing II

A2 - Gapiński, Bartosz

A2 - Szostak , Marek

A2 - Ivanov , Vitalii

PB - Springer

ER -

Islam A, Li X, Wirska M. Injection Moulding Simulation and Validation of Thin Wall Components for Precision Applications. In Gapiński B, Szostak M, Ivanov V, editors, Advances in Manufacturing II. Vol. 4. Springer. 2019. p. 96-107 https://doi.org/10.1007/978-3-030-16943-5_9