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Sustainable injection moulding: The impact of materials selection and gate location on part warpage and injection pressure

Marton Huszar, Fawzi Belblidia Orcid Logo, Helen Davies Orcid Logo, Cris Arnold, David Bould, Johann Sienz Orcid Logo

Sustainable Materials and Technologies, Volume: 5, Pages: 1 - 8

Swansea University Authors: Fawzi Belblidia Orcid Logo, Helen Davies Orcid Logo, Johann Sienz Orcid Logo

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DOI (Published version): 10.1016/j.susmat.2015.07.001

Abstract

This paper presents an approach of how warpage (i.e. part deflection) and injection pressure of an intricate geometry could be minimised by selecting an optimal thermoplastic material and injection gate location (through which the molten plastic flows into the cavity). The numerical analyses for mou...

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Published in: Sustainable Materials and Technologies
ISSN: 2214-9937
Published: 2015
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URI: https://cronfa.swan.ac.uk/Record/cronfa22736
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The numerical analyses for mould filling considered four gate locations along with a PP (polypropylene), PS (polystyrene) and a fibre-filled PP material (each had different shrinkage characteristics, mechanical property and viscosity). Results of the cavity filling simulations indicated that (on average) the largest and smallest warpage was predicted with the PP and PS respectively. The warpage of the fibre-filled PP showed the most gate location dependent behaviour. In addition, the lowest injection pressure was associated with the fibre-filled PP. For reduced pressure, the best and second best solutions for gate location were the top and middle ones. In addition, specific attention was paid to differential fibre orientation, as one of the most important factors responsible for part warpage. In an attempt to maximise the part stiffness, the fibre-filled PP was selected. It became clear that the gate location affected the melt flow evolution and therefore the fibre orientation. Simulation results showed that bidirectional flow and asymmetrical fibre distribution was achieved with the gate positioned at the mid-section of the part. Unidirectional flow and therefore symmetrical fibre distribution could be achieved by placing the gate at the top section of the part. The injection moulding experimental utilised the fibre-filled PP along with the two aforementioned gate locations. It was discovered that warpage was present when the middle gate was applied, but it was successfully eliminated using the top gate location. It can be stated that differential fibre orientation did not cause warpage, but the asymmetrical distribution of fibre orientation did. The information discussed in the paper may be particularly useful in the early mould/part design stages when any modification can still be easily and cost-effectively implemented. 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spelling 2017-06-30T10:15:51.3910612 v2 22736 2015-07-30 Sustainable injection moulding: The impact of materials selection and gate location on part warpage and injection pressure 7e0feb96ca2d685180b495e8983f3940 0000-0002-8170-0468 Fawzi Belblidia Fawzi Belblidia true false a5277aa17f0f10a481da9e9751ccaeef 0000-0003-4838-9572 Helen Davies Helen Davies true false 17bf1dd287bff2cb01b53d98ceb28a31 0000-0003-3136-5718 Johann Sienz Johann Sienz true false 2015-07-30 AERO This paper presents an approach of how warpage (i.e. part deflection) and injection pressure of an intricate geometry could be minimised by selecting an optimal thermoplastic material and injection gate location (through which the molten plastic flows into the cavity). The numerical analyses for mould filling considered four gate locations along with a PP (polypropylene), PS (polystyrene) and a fibre-filled PP material (each had different shrinkage characteristics, mechanical property and viscosity). Results of the cavity filling simulations indicated that (on average) the largest and smallest warpage was predicted with the PP and PS respectively. The warpage of the fibre-filled PP showed the most gate location dependent behaviour. In addition, the lowest injection pressure was associated with the fibre-filled PP. For reduced pressure, the best and second best solutions for gate location were the top and middle ones. In addition, specific attention was paid to differential fibre orientation, as one of the most important factors responsible for part warpage. In an attempt to maximise the part stiffness, the fibre-filled PP was selected. It became clear that the gate location affected the melt flow evolution and therefore the fibre orientation. Simulation results showed that bidirectional flow and asymmetrical fibre distribution was achieved with the gate positioned at the mid-section of the part. Unidirectional flow and therefore symmetrical fibre distribution could be achieved by placing the gate at the top section of the part. The injection moulding experimental utilised the fibre-filled PP along with the two aforementioned gate locations. It was discovered that warpage was present when the middle gate was applied, but it was successfully eliminated using the top gate location. It can be stated that differential fibre orientation did not cause warpage, but the asymmetrical distribution of fibre orientation did. The information discussed in the paper may be particularly useful in the early mould/part design stages when any modification can still be easily and cost-effectively implemented. An important finding is that the final gate location should only be chosen after the thermoplastic material properties and melt flow direction have been taken into account. The successful reduction of warpage and injection pressure may help to reduce the amount of production waste and energy consumption, ensuring defect-free sustainable manufacturing. Journal Article Sustainable Materials and Technologies 5 1 8 2214-9937 30 9 2015 2015-09-30 10.1016/j.susmat.2015.07.001 © 2015 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license(http://creativecommons.org/licenses/by-nc-nd/4.0/) COLLEGE NANME Aerospace Engineering COLLEGE CODE AERO Swansea University 2017-06-30T10:15:51.3910612 2015-07-30T16:34:28.1647056 Faculty of Science and Engineering School of Engineering and Applied Sciences - Uncategorised Marton Huszar 1 Fawzi Belblidia 0000-0002-8170-0468 2 Helen Davies 0000-0003-4838-9572 3 Cris Arnold 4 David Bould 5 Johann Sienz 0000-0003-3136-5718 6 0022736-15072016142112.pdf Huszar2015.pdf 2016-07-15T14:21:12.0530000 Output 1544072 application/pdf Version of Record true 2016-07-15T00:00:00.0000000 false
title Sustainable injection moulding: The impact of materials selection and gate location on part warpage and injection pressure
spellingShingle Sustainable injection moulding: The impact of materials selection and gate location on part warpage and injection pressure
Fawzi Belblidia
Helen Davies
Johann Sienz
title_short Sustainable injection moulding: The impact of materials selection and gate location on part warpage and injection pressure
title_full Sustainable injection moulding: The impact of materials selection and gate location on part warpage and injection pressure
title_fullStr Sustainable injection moulding: The impact of materials selection and gate location on part warpage and injection pressure
title_full_unstemmed Sustainable injection moulding: The impact of materials selection and gate location on part warpage and injection pressure
title_sort Sustainable injection moulding: The impact of materials selection and gate location on part warpage and injection pressure
author_id_str_mv 7e0feb96ca2d685180b495e8983f3940
a5277aa17f0f10a481da9e9751ccaeef
17bf1dd287bff2cb01b53d98ceb28a31
author_id_fullname_str_mv 7e0feb96ca2d685180b495e8983f3940_***_Fawzi Belblidia
a5277aa17f0f10a481da9e9751ccaeef_***_Helen Davies
17bf1dd287bff2cb01b53d98ceb28a31_***_Johann Sienz
author Fawzi Belblidia
Helen Davies
Johann Sienz
author2 Marton Huszar
Fawzi Belblidia
Helen Davies
Cris Arnold
David Bould
Johann Sienz
format Journal article
container_title Sustainable Materials and Technologies
container_volume 5
container_start_page 1
publishDate 2015
institution Swansea University
issn 2214-9937
doi_str_mv 10.1016/j.susmat.2015.07.001
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Uncategorised{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Uncategorised
document_store_str 1
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description This paper presents an approach of how warpage (i.e. part deflection) and injection pressure of an intricate geometry could be minimised by selecting an optimal thermoplastic material and injection gate location (through which the molten plastic flows into the cavity). The numerical analyses for mould filling considered four gate locations along with a PP (polypropylene), PS (polystyrene) and a fibre-filled PP material (each had different shrinkage characteristics, mechanical property and viscosity). Results of the cavity filling simulations indicated that (on average) the largest and smallest warpage was predicted with the PP and PS respectively. The warpage of the fibre-filled PP showed the most gate location dependent behaviour. In addition, the lowest injection pressure was associated with the fibre-filled PP. For reduced pressure, the best and second best solutions for gate location were the top and middle ones. In addition, specific attention was paid to differential fibre orientation, as one of the most important factors responsible for part warpage. In an attempt to maximise the part stiffness, the fibre-filled PP was selected. It became clear that the gate location affected the melt flow evolution and therefore the fibre orientation. Simulation results showed that bidirectional flow and asymmetrical fibre distribution was achieved with the gate positioned at the mid-section of the part. Unidirectional flow and therefore symmetrical fibre distribution could be achieved by placing the gate at the top section of the part. The injection moulding experimental utilised the fibre-filled PP along with the two aforementioned gate locations. It was discovered that warpage was present when the middle gate was applied, but it was successfully eliminated using the top gate location. It can be stated that differential fibre orientation did not cause warpage, but the asymmetrical distribution of fibre orientation did. The information discussed in the paper may be particularly useful in the early mould/part design stages when any modification can still be easily and cost-effectively implemented. An important finding is that the final gate location should only be chosen after the thermoplastic material properties and melt flow direction have been taken into account. The successful reduction of warpage and injection pressure may help to reduce the amount of production waste and energy consumption, ensuring defect-free sustainable manufacturing.
published_date 2015-09-30T03:26:56Z
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score 10.997933

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