注射压缩成型与常规注射成型的模腔压力对比分析

在自主开发的注射压缩模具上安装模腔压力传感器,从工艺角度出发,对常规注射成型和注射压缩成型的模腔压力进行了工艺相关性的对比与分析。结果表明,注射压缩可有效降低注射压力和模腔压力,使模腔压力场更加均匀。常规注射成型中模腔压力受模具温度的影响最大,其次为熔体温度、保压时间和保压压力,而注射压缩成型中压缩速率对模腔压力的影响最大,其次为熔体温度和模具温度,压缩行程最弱。低残余应力与低翘曲变形进一步验证了注射压缩的技术优势和压力场特征,表明了模腔压力具有重要的工艺性能指导作用。     

Dependence Map-Based Flow Control to Reduce Void Content in Liquid Composite Molding

Prohibitive costs are preventing liquid composite molding processes, such as resin transfer molding, from gaining greater popularity. The high costs are mainly due to lack of automation and repeatability. Variations inherent in the preform cutting and placement process lead to unpredictable resin infusion patterns that sometimes form regions devoid of resin. This compromises the structural integrity of the composite and the part is rejected as scrap. Control during the filling stage of liquid composite molding processes have been shown to redirect the flow towards regions difficult to impregnate, providing a greater percentage of acceptable manufactured composite parts. However, many of the current techniques have various limitations. Many off-line control approaches depend on anticipation of problems, and on-line approaches are geometrically limited and can be computationally intensive if executed during manufacturing. The present work combines off-line and on-line approaches to infuse and fill the mold containing fabrics in an attempt to eliminate their shortcomings and reduce the limitations. First, off-line computationally intensive control algorithms based on the specific part geometry and locations for the sensors and injection gates are created. Next, on-line control is initiated with the off-line parameter guidelines. The approach will be presented and illustrated with several case studies to demonstrate geometrical independence in a simulation environment. Comparison will be made between part success rate using no control, other control techniques, and the proposed control approach. Validation in a laboratory environment is also conducted.     

Forming characteristics during the high-pressure resin transfer molding process for CFRP

The high-pressure resin transfer molding (HP-RTM) process has potential applicability to the mass production of lightweight vehicles made of carbon fiber-reinforced plastic in the automotive industry. In recent years, the development of robust equipment, new processes, and fast cure matrix systems have significantly reduced the cycle time to less than 5 min. In this study, the cavity pressure of the HP-RTM process was monitored to analyze the molding characteristics. The mold was equipped with two cavity pressure sensors and three temperature sensors. The cavity pressure characteristics during the HP-RTM injection, pressurization, and curing processes were studied. Selected process parameters such as the mold cap size, maximum pressing force, and injection volume were analyzed. The results demonstrated correlations between the selected process parameters and final forming characteristics.     

Effects of Injection Molding Parameters on the Production of Microstructures by Micropowder Injection Molding

Micropowder injection molding (μPIM) is a potential low-cost process for the mass production of metal or ceramic microstructures. In order to obtain good molded microstructures and to avoid molding defects, it is important to select suitable injection molding parameters. In this paper, the selection of injection molding conditions for the production of 316L stainless steel microstructures by μPIM is presented. Silicon mold inserts with 24 × 24 microcavities were injection molded on a conventional injection molding machine. The dimensions of each microcavity were Φ 100 μ m × depth 200 μm, giving an aspect ratio of 2. The distance between each microcavity was 200 μm. Five sets of experiments were conducted by varying one injection molding parameter at a time. The parameters included injection pressure, holding pressure, holding time, mold temperature, and melt temperature. Higher injection pressure and holding pressure were required during the injection molding process due to the small dimensions of the microcavities and the large number of microcavities (576 microcavities). High mold temperature was required for complete filling of the microcavities. Molded microstructures without visual defects were obtained using appropriate injection molding parameters. Catalytic debinding and sintering of the 316L stainless steel microstructures were successfully conducted.     

Replication of metal microstructures by micro powder injection molding

In this paper, a study on the production of 316L stainless steel microstructures by μPIM (powder injection molding) is presented. Two types of mold inserts were used and the molding was conducted on a conventional injection molding machine. Based on the characteristics of the mold inserts and the feedstock, suitable processing parameters were selected. Some requirements for the production of the microstructures are discussed. For example, a relatively high mold temperature, high injection pressure and holding pressure were required. The study showed that 316L stainless steel microstructures of φ100 × 200 μm can be injection molded, but there were incomplete filling and demolding problem in the case of smaller microstructures of φ60 × 191 μm. The molded parts were successfully debound and sintered.     

Acoustic emission monitoring of split formation during Charpy impact testing of high strength steel

Abstract

Acoustic emission (AE) monitoring has been used to detect split formation during room temperature low blow Charpy impact testing of high strength thick strip steels. The AE signal analysis identified separate signals originating from hammer impact, plastic deformation (verified using Charpy impact testing on mild steel with no splits) and split initiation/growth. The presence of splits was confirmed by sectioning and fractography, and the splits were brittle in nature. A possible correlation between the AE signal features and fracture mode is presented.     

Constraints on monitoring resin flow in the resin transfer molding (RTM) process by using thermocouple sensors

In this study, a thermocouple sensor system was used to monitor the resin transfer molding (RTM) process. These sensors are low-cost and durable; and they do not disturb the resin flow. They can be used if the inlet resin is either hotter or colder than the mold walls. In experiments of this study, much of the hot resin’s internal energy was transferred to cold mold walls by conduction, when the mold parts were made of a material with high thermal conductivity, such as aluminum. A mathematical model based on 1D flow and 2D unsteady energy conservation was developed to investigate the heat transfer between resin and mold walls. The numerical solution of this model is in qualitative agreement with the results of our experiments. The thermocouple sensor system developed is more useful with the following process parameters: low thermal conductivity of mold material, high resin flow rate, high temperature difference between inlet resin and initial mold walls, and high specific heat of resin. However, for the typical use of RTM materials and typical injection parameters, thermocouples should not be preferred over other sensor types and should be used with caution due to the shortcomings investigated in this study.     

Monitoring of resin flow in the resin transfer molding (RTM) process using point-voltage sensors

Multiple point-voltage sensors were used to monitor the mold filling stage of the resin transfer molding (RTM) process. Both lineal- and point-voltage sensors are electrical circuits in which the two poles of the sensor are closed when liquid thermoset resin arrives at the sensor location in the mold cavity. The electrical conductance of the liquid resin causes an increase in the output voltage, V_sens of the circuit. Although the gradually varying in situ data of a lineal sensor is more informative than a point-voltage sensor, lineal-voltage sensors might mislead the user if the resin covers the wires at multiple sections, or if the resin covers the wires starting from an unexpected section. Two kinds of sensors were developed: a set of similar, wrapped and compact lineal-voltage sensors acting as point-voltage sensors; and a point-voltage sensor with voltage amplification. Without this amplification, the increase in V_sens might be difficult to detect if the resin system has a low electrical conductivity and there is noise in the DAQ system. The accuracy and reliability of the new sensor system was verified by comparing the in situ sensor data with the visually recorded resin flow.     

注射成型流道温度分布的测量分析方法

树脂温度的分布对注射成型过程的充填平衡具有重要影响。由于型腔中传感器的安装空间有限,至今为止还没有合适的方法来测量注射成型过程中流道和小尺寸型腔中树脂温度场的分布。为了解决这一问题,文中设计了一套新式的移动式温度测量系统,该系统采用常规尺寸红外线传感器和红外线纤维传感器来测量注射模具流道内树脂温度场分布。测量结果显示,...     

v/p转压方式对注塑制品质量重复精度的影响

对注射成型中四种不同的v/p(射速/压力)转压方式的工艺性能进行了研究,以制品质量作为验证参数,同时考虑了模具温度的变化.研究发现,注塑制品质量重复精度的提高除了受到转压方式的影响还同相应转压方式下的工艺参数设定有关;制品质量的变化受模具温度的影响,常规转压方式下,制品质量随模具温度升高而降低,而模腔熔体温度转压方式下...     

Application of calcium carbonate in resin transfer molding process: An experimental investigation

The resin transfer molding (RTM) process is used to manufacture advanced composite materials made of continuous glass or carbon fibers embedded in a thermoset polymer matrix. In this process, a fabric preform is prepared, and is then placed into a mold cavity. After the preform is compacted between the mold parts, thermoset polymer is transferred from an injection machine to the mold cavity through injection gate(s). Resin flows through the porous fabric, and eventually flows out through the ventilation port(s). After the resin cure process (cross‐linking of the polymer), the mold is opened and the part is removed. The objective of this study is to verify the application of calcium carbonate mixed in resin in the RTM process. Several rectilinear infiltration experiments were conducted using glass fiber mat molded in a RTM system with cavity dimensions of 320 × 150 × 3.6 mm, room temperature, maximum injection pressure 0.202 bar and different content of CaCO₃ (10 and 40%) and particle size (mesh opening 38 and 75 µm). The results show that the use of filled resin with CaCO₃ influences the preform impregnation during the RTM molding, changing the filling time and flow front position, however it is possible to make composite with a good quality and low cost.     

蒸气辅助快速热循环注塑技术及模温响应模拟

快速热循环注塑采用动态模温控制新策略,可以彻底解决常规注塑工艺存在的短射、喷射痕、缩痕、流动痕、熔接痕、浮纤等缺陷。文中通过对快速热循环注塑工艺与常规注塑工艺的比较,深入研究了蒸气辅助快速热循环注塑工艺的原理,制定了相应的工艺流程,提出了一套新的利用蒸气加热和冷凝水冷却的动态模温控制方案。利用ANSYS模拟了快速热循环注塑工艺和常规注塑工艺的模温响应过程,分别获得了两种注塑工艺的模具加热速率和冷却速率,讨论了快速热循环注塑对塑件成型周期的影响规律。     

注塑成型计算机模拟

塑料制品的几何形状各异，模腔内的流动复杂，导致价格昂贵的模具开发费用。通过流变学方法对充模过程进行定量模拟，可以为模具统计与注塑工艺优化提供定量依据。对注塑成型有关的数学模型作了讨论，给出了充模，保压和冷却３个阶段的数学模型，讨论了流道流动和三维薄壁模腔流动，还对反应注射成型计算机模拟作了讨论。     

微注射成型研究进展

微注射成型是一种低成本大规模复制聚合物微制件的有效方法。文中从微结构特征复制性能、工艺参数的分析和优化、模具表面光洁度对聚合物流动行为的影响、过程建模与仿真、微注射成型的熔接痕缺陷以及微塑件的组织形态与力学性能等方面阐述微注射成型的最新研究进展。最后指出开发特殊微注射成型技术、新型微模具加工技术,以及将微注射成型与其他微纳加工技术集成,制作多种材料复杂功能微系统将成为今后的研究方向和发展趋势。     

Stability of the vertical bearing structures of the Syracuse Cathedral: experimental and numerical evaluation

In the present paper the results from a recent monitoring campaign and numerical analysis performed on the ancient Cathedral of Syracuse in Sicily are presented. The acoustic emission (AE) technique is adopted to assess the damage pattern evolution. The localization of the propagating cracks is obtained using six synchronized AE sensors. A clear correlation between the regional seismic activity and the AE acquisition data is shown. In fact the AE count rate presents peaks corresponding to the main seismic events. In addition, a numerical analysis of the vertical bearing structures of the Cathedral is presented. The nonlinear Finite Element model is particularly refined to account for the cracking in the most damaged pillar. Some recent seismic events in the area acted as crack propagators. The crack occurrence obtained from the numerical analysis agrees quite well with the crack localization provided by the AE monitoring.     

Oriented morphology and enhanced mechanical properties of poly(l-lactic acid) from shear controlled orientation in injection molding

This study investigates the effect of operative parameters of shear controlled orientation in injection molding (SCORIM) on poly(l-lactic acid), PLLA, and compared with conventional injection molded (CIM) PLLA. The in situ structure development was carried out with systematic variations of mold temperature and shearing time. The energy at break and maximum stress of all the SCORIM processed PLLA are higher than the CIM processed PLLA without sacrificing the modulus. The overall increments in maximum stress and energy at break were 134% and 641%, respectively. Significant enhancements in ductility for the SCORIM processed PLLA are shown to be a consequence of preferential molecular orientation of large fraction of core. The orientation of core is more pronounced at low mold temperature conditions and was increased with increasing shearing time at both the low and high mold temperatures. The processing–morphology and morphology–mechanical property relationships were then established.     

Energy extraction for a self-energized pressure sensor

With the prolific use of sensors for manufacturing process monitoring, proper power supply and installation scheme has assumed an increasingly central role. Cable-based sensor powering, while commonly used on the factory floor, faces various real-world constraints. It is desirable that the power required by the sensors be "extracted" from the process being monitored itself to enable "self-energized" sensing. Such a novel design for a wireless pressure sensor for injection molding process monitoring is presented in this paper. The focus is on the energy extraction mechanism from the pressure transients exerted by the polymer melt during the injection molding process to power a piezoelectric signal transmitter, which digitally reconstructs the polymer melt pressure profile. An analytical model examining the energy conversion mechanism due to interactions between the mechanical strain and the electric field developed within the energy extraction device is first established. Using a coupled-field analysis, a numerical model is then developed to evaluate the electromechanical properties dependent upon the geometric effects of the energy extraction device. The two models are then compared with experimental results obtained from a functional prototype to evaluate the relevance of the assumptions made and the modeling accuracy. Preliminary experimental results describing the integration of the energy extraction device with the ultrasonic transmitter and the subsequent transmission of pressure information acoustically through a block of steel are also presented. The presented design introduces a new generation of self-energized sensors that can be employed for the condition monitoring of a wide range of high-energy manufacturing processes.     

微流控芯片基片与盖片一体化注塑成型研究

针对微流控芯片基片与盖片的结构特点,提出了定模先行抽芯机构,设计制造了微流控芯片基片与盖片一体化注塑成型模具,并进行注塑成型试验研究.结果表明:定模先行抽芯机构可以有效解决盖片上圆孔状储液池成型与脱模的技术难题,如何使微通道复制完全是微流控芯片基片注塑成型的主要技术难点;模具温度对提高微通道复制度起决定性作用,注射速度和熔体温度是次要因素,而注射压力相对其他因素影响力较差,但必须保持在一个较高的水平,依此形成塑料微流控芯片的注塑成型工艺规范.     

Fracture behavior of wasted activated carbon powder composites

At the Waterworks Bureau (Tokyo Metropolitan Government), activated carbon has been used for filtering water. After being used for the filtering process, it is normally disposed or burned for thermal recycling. However, CO₂ emissions occur during the thermal recycling. This work focuses on the identification of mechanical behavior of recycled wasted activated carbon (WAC) in order to elaborate smart materials having mechanical–electrical functions. Acoustic emission technique (AE) was used intensively as characterization support in which sensors were attached to detect microdamage during bending tests. At first, the resonant frequencies of the specimens were measured using the through-transmission test. The resonant frequencies of the specimens containing low weight fractions of WAC powder were less in comparison to the frequencies of the specimens with higher volume fraction. The frequency analysis was carried out with the projected wavelet transform on the signals detected during bending tests. Obtained data showed that, typically, the first major peaks showed the resonant frequency of the sensors, while the second major peaks exhibited signals indicative of resin cracking. The surfaces of the fractured specimens were analyzed by optical microscopy in order to visualize the crack formation and propagation on the activated carbon composite under flexural stresses. Consequently, fractographic and AE analyses provide better understanding of the failure mechanisms involved.