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Injection Molding

This document summarizes an injection molding study that analyzed the effect of mold temperature on frozen layer fraction. The study varied mold temperature from 0°C to 100°C while keeping other parameters like melt temperature constant. It was found that a mold temperature of 90°C or higher resulted in a frozen layer fraction of 0, indicating this temperature produced the best part quality with minimal geometry changes. A graph shows frozen layer fraction decreasing significantly as mold temperature increases.

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Edward Choh
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223 views22 pages

Injection Molding

This document summarizes an injection molding study that analyzed the effect of mold temperature on frozen layer fraction. The study varied mold temperature from 0°C to 100°C while keeping other parameters like melt temperature constant. It was found that a mold temperature of 90°C or higher resulted in a frozen layer fraction of 0, indicating this temperature produced the best part quality with minimal geometry changes. A graph shows frozen layer fraction decreasing significantly as mold temperature increases.

Uploaded by

Edward Choh
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Injection Molding

Name : Jin Khang Choh


UID : 3897384
Lab : 3
Lab Instructor : Devin Berg
Problem Description
• This study is meant to determine the mechanical effect of
certain parameter in injection process on the parts produced.

• List of parameter that can be controlled on injection molding


machine

- Mold Temperature
- Melt Injection Temperature
- Filling Control
- Injection Time
- Flow Rate
- Ram Speed Profile
• The effect of mold temperature on parts will
be chosen as the subject to study, with mold
temperature, varying from 0°C to 100°C, and
other parameter remain constant.

• The output process variables of interest will


be frozen layer fraction in the end of the filling
process.
Allowable range
• The frozen layer changes the geometry of the
core during the injection process

• The value of frozen layer should be low, to


avoid change of geometry properties on the
part that is produced such as shrinkage.
Constant Parameter
• Melt temperature : 255°C
• Velocity/Pressure Switch over
- by volume filled : 97 %
• Runner diameter : 3mm
• Injection time = 1 second
• Material used : Terluran GP-35
Ram Speed Profile
% filling pressure vs time
Dimension of parts
Simulations : At mold temp = 0°C

Frozen Layer Fraction: 0.2276


At mold temp = 10°C

Frozen Layer Fraction: 0.2064


At mold temp : 20°C

Frozen Layer Fraction: 0.1837


At mold temp : 30°C

Frozen Layer Fraction: 0.1594


At mold temp : 40°C

Frozen Layer Fraction: 0.1332


At mold temp : 50°C

Frozen Layer Fraction: 0.1058


At mold temp : 60°C

Frozen Layer Fraction: 0.0765


At mold temp : 70°C

Frozen Layer Fraction: 0.0445


At mold temp : 80°C

Frozen Layer Fraction: 0.0096


At mold temp : 90°C

Frozen Layer Fraction: 0.000


At mold temp : 100°C

Frozen Layer Fraction: 0.000


Graph of Frozen layer fraction versus
mold temperature
Frozen Layer Fraction Vs Mold temperature
0.25

0.2

0.15
Frozen Layer Fraction

0.1

0.05

0
0 20 40 60 80 100 120

-0.05
Mold Temperature
Result
• At Mold temperature = 90°C , the frozen layer
fraction = 0.000

• Therefore, it is the best simulation if frozen


layer fraction is the sole criteria of the part.

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