注塑件熔接痕位置预测技术的研究进展

介绍了注塑件充填过程熔接痕形成的数学模型,综述了数值模拟技术、数值模拟技术结合数学规划理论、阀式浇注塑大型注塑成型制品多浇口进料顺序控制技术等3种注塑件熔接痕位置预测、优化和控制方法,介绍了该技术的分析流程、预测方法及国内外的研究进展和应用实例,熔接痕控制技术,尤其是熔接痕消除技术的完善是今后熔接痕研究的一个重要方向。     

注塑件熔接痕的研究进展

介绍了注塑件熔接痕的形成机理,分析了影响熔接痕强度的各种因素,从注塑工艺参数设定、模具结构设计等方面给出了消除熔接痕或提高熔接痕强度的措施。     

提高注射成型塑料制品熔接痕强度的研究进展

论述了熔接痕的形成原因,分析了熔接痕的微观结构,介绍了通过改善加工方法增强熔接痕强度的措施,指出了增强熔接痕强度研究的开发方向、技术动态和发展趋势。     

注塑件熔接痕强度预测及提高新技术

介绍了注塑件熔接痕强度预测及提高的几种新技术。综述了基于扩散理论和Flory—Huggins晶格理论的预测模型及基于BP神经网络的预测模型。给出了模型的适用范围。简述了热流道多浇口进料顺序控制、注射成型和模具设计等几种提高熔接痕强度、减少或避免熔接痕出现的新技术的作用机理及应用实例,指出进一步完善熔接痕强度预测模型和强度提高技术是今后熔接痕研究的一个重要方向。     

材料流变性能对注塑制品熔接痕的影响

介绍注塑制品熔接痕的分类及其形成,分析材料的流变性能对注塑制品熔接痕外观及性能的影响,着重阐述通过调整注塑工艺参数以改变材料的流变性能,从而改善熔接痕对注塑制品外观及性能的影响,并综合提出减小熔接痕损害的措施与方法。     

热流道顺序浇注成型移除熔接痕研究

为了有效移除注塑制品中的熔接痕,深入分析了熔接痕的形成过程和采用热流道顺序浇注成型移除熔接痕的机理,并使用模流分析软件Moldflow对顺序浇注成型移除熔接痕的过程进行了有限元模拟。模拟分析结果表明,随着阀浇口不同的开闭时机,顺序浇注成型可以有效地控制熔接痕的位置及长度,改善熔接区域的外观和性能,有效避免熔接痕的产生。实验表明,采用顺序浇注成型时制品的熔接痕已基本消除.     

基于CAE技术的注塑成型熔接痕优化设计

介绍了影响熔接痕的各种因素,借助Moldflow模拟分析软件对插座上盖注塑成型进行了模拟,根据结果分析了熔接痕并,优化了模具的浇口位置最,终使熔接痕数量减少且处于不重要的部位。     

材料性质对注塑件熔接痕外观及性能的影响

概述注塑件熔接痕的分类、特点及形成,分析了材料性质如结晶度、松弛时间、特征温度、取向、粘度及所用添加剂对熔接痕处外观和性能的影响及其造成影响的原因,具体分析了影响粘度的因素和添加剂的种类、形态、用量对熔接痕的影响,并从材料性质方面提出了减小熔接痕损害的方法。     

工艺参数对注塑件熔接痕性能的影响

概述了注塑件熔接痕的分类及特点；分析了工艺参数主要包括熔体温度、模具温度、充模速度、注射时间、注射压力、保压压力、后处理等对熔接痕的外观及性能的影响。着重阐述了各工艺参数对熔接痕性能影响的研究进展；综述了优化工艺参数和研究工艺参数对熔接痕影响程度的研究以及数值模拟技术，并从工艺方面提出了减小熔接痕损害的方法。     

汽车车灯聚光片熔接痕的消除

简要介绍了注射成型中熔接痕的影响因素和控制方法,从熔接痕控制方法和聚光片的结构入手,利用Moldnow软件对塑料件进行成型模拟,分析在试模过程中塑料件表面出现熔接痕的原因,通过改变浇口的位置和结构,并进行相应模拟分析,成功解决了聚光片熔接痕缺陷问题,达到了设计要求.     

基于数值模拟的汽车外饰件熔接痕分析及其优化设计

采用Moldflow软件对汽车外饰件的熔接痕进行分析,并基于该软件的二次开发原理对熔接痕结果进行量化输出,以量化后的结果作为评价指标,结合正交设计获得了1组最优工艺参数及各工艺参数对熔接痕的影响规律;最后,应用Moldflow软件对最优工艺参数进行验证。     

大型注塑制品熔接痕分析及解决对策

在研究大型注塑制品熔接痕形成条件的基础上,从塑料制品材料及其产品结构,模具设计与成型工艺等各环节,分析了影响制品熔接痕的因素,建立熔接痕的数学模型；分析了熔接痕CAE的特点及误差,并针对不同影响因素,给出了相应控制对策。     

The V-notch at weld lines in polystyrene injection moldings

A major factor that weakens the weld line in injection moldings is the V-notch structure. Though the existence of a V-notch is well known, its depth variation with molding conditions has not been detailed. The aim of this paper is to clarify the V-notch structure and its effect on the strength of general purpose polystyrene injection moldings. A dog bone type tensile specimen with a weld line was molded under several molding conditions. The surface of the weld line was partially eliminated by cutting with a milling machine to seven levels of cut depth (D_c). As a result, the weld strength increased with D_c to about 50%. The relationship between the weld strength and D_c made it possible to determine the V-notch depth, which vas defined as the “depth of the weld line.” From these results, a hypothesis is proposed that the V-notch has a structure with a fine groove on the surface and a poorly bonded inner layer. This study considered the relationships among the weld strength, the depth of the weld line, and molding conditions.     

基于Kriging和NSGA-Ⅱ的辅以困气改善的熔接痕优化策略

从熔接痕的成型机理出发,考虑了困气状况和熔合温度对熔接痕熔合质量的影响,提出一种以困气改善辅助提升熔接痕熔合质量的方法,建立了以“气穴面积”和“熔接痕处流动前沿温度”为熔接痕熔合质量指标的多目标评价体系,并构建了一种基于Kriging模型和非支配排序遗传算法（NSGA-Ⅱ）的多目标寻优策略,以实现工艺参数的择优选择。以多孔板熔接痕优化为例,选用拉丁超立方抽样（LHS）设计实验,建立并检验反映工艺参数和优化目标之间影响规律的Kriging模型,采用NSGA-Ⅱ确定多目标优化问题的Pareto前沿及其最优解。仿真及生产实验结果表明所建立的多目标优化策略能有效实现熔接痕的多目标优化,同时以困气改善辅助提升熔接痕熔合质量的方法效果显著。     

A numerical and experimental study on weld lines formation and strength in extrusion

In this work, we present a study on numerical and experimental approaches aiming to improve our understanding about the relation between the flow conditions and the strength of weld lines in extruded profiles. For this purpose, a prototype extrusion die that comprises a movable spider leg is used to produce tapes under different flow conditions, by varying the location of the spider leg and the flow rate. The same case studies are numerically studied, considering a viscoelastic Giesekus constitutive model. The numerical results are then investigated to identify potential relationships between the flow conditions, in which the weld lines are formed, with the strength of the weld line experimentally characterized. The results obtained allow identifying a clear correlation between the flow conditions and the weld‐line strength. POLYM. ENG. SCI., 58:249–260, 2018. © 2017 Society of Plastics Engineers     

A study on weld line morphology and mechanical strength of injection molded polystyrene/poly(methyl methacrylate) blends

In this work, the mechanical strength and weld line morphology of injection molded polystyrene/poly(methyl methacrylate) (PS/PMMA) blends were investigated by scanning electron microscopy (SEM) and mechanical property test. The experimental results show that the tensile strength of PS/PMMA blends get greatly decreased due to the presence of the weld line. Although the tensile strength without the weld line of PS/PMMA (70/30) is much higher than that of the PS/PMMA (30/70) blend, their tensile strength with weld line shows reversed change. The viscosity ratio of dispersed phase over matrix is a very important parameter for control of weld‐line morphology of the immiscible polymer blend. In PS/PMMA (70/30) blend, the PMMA dispersed domains at the core of the weld line are spherically shaped, which is the same as bulk. While in the PS/PMMA (30/70) blend, the viscosity of the dispersed PS phase is lower than that of the PMMA matrix, the PS phase is absent at the weld line, and PS particles are highly oriented parallel to the weld line, which is a stress concentrator. This is why weld line strength of PS/PMMA (30/70) is lower than that of PS/PMMA (70/30) blend. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 1856–1865, 2002; DOI 10.1002/app.10450     

Evaluation of healing models to predict the weld line strength of the amorphous thermoplastic polystyrene by injection molding simulation

In many injection molded parts weld lines are often unavoidable. These cause optical defects and a reduction of the mechanical properties of the part. Therefore, the predictability of the weld line strength at an early stage of development would provide a significant advantage by avoiding costly iterations of the mold and increases the understanding of the correlation between process history of the melt and weld line strength. For this purpose, a calculation routine has been developed to predict the weld line strength based on injection molding simulation. Different models to calculate the healing of a weld line are compared and analyzed. By adding a factor to consider the shear rate in addition to the temperature and the pressure and after calibration to one design of experiment setting of the experimental data, the prediction of the weld line strength shows good agreement for all examined process setpoints of the experimental data for polystyrene.     

The unique flow of polypropylene at the weld line behind an obstacle in injection molding

In this article, a weld line placed behind an obstacle in an injection‐molded plaque made of metallic mold‐in‐color polypropylene (PP) was investigated. A broad uneven glossy section was visually observed along the weld line after the v‐notch weld disappeared. Although disk‐shaped metallic pigments were oriented parallel to the wall according to laminar flow, the pigment particles at the weld behind the obstacle were ordered vertically at the center of the depth direction. In PP molded without pigment, a black line was observed at the same position in the metallic weld. Based on a measurement of the crystal structure, the black line was caused by the rapid cooling of molten PP. Elongational flow occurred along the weld line after the diminishing v‐notch weld. The unique flow ordered the pigments obliquely at the advancing flow front and disturbed the subsequent flow of hot PP which transferred heat to the crystallizing mass. POLYM. ENG. SCI., 2011. © 2010 Society of Plastics Engineers     

Effect of process parameters on crack characteristics in laser welding of Al2O3 ceramic

The crack of ceramic weld is a worldwide problem for brittle material, high energy laser beam is expected to solve this problem. In this paper, the crack of fiber laser welding of Al₂O₃ ceramics was studied. The weld crack rate was used to characterize the crack condition of weld, and the influences of laser power, welding speed and defocusing distance on crack characteristics were carried out. The results showed that Al₂O₃ ceramics weld has obvious crack tendency, and the cracks mainly appeared on the weld center line. When the crack appeared on the weld center line, there was crack-free on the base metal. When the defocusing distance increased from +3 mm to +20 mm, the number of cracks gradually decreased. When the defocusing distance was greater than +17 mm, cracks-free appeared on the weld and base metal. Abaqus software was used to simulate the relationship between crack and stress based on thermal elastoplastic theory. The high crack areas, few crack areas and free crack areas were divided according to the maximum principal stress value. No matter what welding conditions, as long as the maximum principal stress was less than 1576 MPa, there was crack-free on the weld and base metal.