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Research on the CAE Numerical Simulation of Co-injection Molding

Author: ZhuHongJun
Tutor: LiuHong
School: Zhejiang University of Technology
Course: Mechanical and Electronic Engineering
Keywords: co-injection molding breakthrough phenomenon penetration length uniformity warpage
CLC: TQ320.662
Type: Master's thesis
Year: 2009
Downloads: 22
Quote: 0
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Abstract


As a novel molding process in plastic processing industry, the co-injection molding technology is to inject different polymers melt into the mold cavity simultaneously or sequentially to manufacture the polymer product with a sandwich structure. How to avoid the breakthrough phenomenon of core melt and increase the content of core material in the injection molding process, and obtain the product with high penetration length of core melt, uniformity of distribution for core material and small warpage are of great significance for practical production, application research and theoretical research.This paper choose the material of ABS, PA, PC and PP to research the breakthrough phenomenon of core melt, penetration length of core melt, uniformity of distribution for core material and small warpage, by the numerical simulation of flow and warpage in the Co-injection module of Moldflow Plastics Insight (MPI) software of MOLDFLOW company.The result of simulation shows that the influence of the viscosity ratio core/skin to the flow of core material is tremendous. As the viscosity ratio core/skin increased, the breakthrough phenomenon of core melt is reduced, the content of core material is improved, but the penetration length of core melt decreased and the uniformity of distribution for core material debased. The result of increasing skin melt temperature and core melt temperature are contrary. The increasing of core melt temperature will decrease the content of core material and uniformity of distribution for core material. The influence of mold temperature on the content of core melt and uniformity for core material is small. Melt flow rate has prominent impact on the four technology parameters of core melt flow. The change of melt flow rate caused the change of the viscosity ratio core/skin, and it also result in the flow status of melt including the filling direction and vertical filling direction.The research results of simulation show that melt temperature and melt flow have more complicated impact on the factors mentioned above. The influence related to materials. The viscosity of different materials has various influences on the shear rate variation sensibility caused by melt temperature and melt flow. If the viscosity of material is sensitive to melt temperature or shear rate, the impact of melt temperature or melt flow rate on the breakthrough phenomenon of core melt, penetration length of core melt and uniformity of core material would be significant, and vice versa.The influences of melt viscosity ratio core/skin and melt temperature on the co-injection molding are researched, which provide reference basis for the selection of molding material, adjustment of technological parameter, commercialization production and theoretical research.

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CLC: > Industrial Technology > Chemical Industry > Synthetic resins and plastics industry > General issues > Production process and production technology > Forming > Injection molding
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