Numerical simulation and experimental analysis for evaluating warpage of a 3D thin-walled polymeric part using the injection compression molding process

SÖNMEZ D., AKDOĞAN EKER A.

INTERNATIONAL POLYMER PROCESSING, cilt.37, sa.2, ss.164-175, 2022 (SCI-Expanded) identifier identifier

  • Yayın Türü: Makale / Tam Makale
  • Cilt numarası: 37 Sayı: 2
  • Basım Tarihi: 2022
  • Doi Numarası: 10.1515/ipp-2021-4197
  • Dergi Adı: INTERNATIONAL POLYMER PROCESSING
  • Derginin Tarandığı İndeksler: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Chemical Abstracts Core, Compendex
  • Sayfa Sayıları: ss.164-175
  • Anahtar Kelimeler: analysis of variance (ANOVA), injection compression molding (ICM), Taguchi design, thin-walled polymeric parts, warpage, OPTIMIZATION, STRESS, FLOW
  • Yıldız Teknik Üniversitesi Adresli: Evet

Özet

Injection compression molding (ICM) is a nontraditional hybrid injection molding (IM) process that has been utilized to mold a wide range of the latest and difficult-to-manufacture precision parts that require high dimensional accuracy and no residual stresses. This paper introduces the accurate calculation of warpage for ICM by numerical simulation via Moldflow software, and a comparison of results with products produced experimentally by ICM. To begin with, the process parameters of ICM were discussed based on the numerical simulations. The effects of process parameters, namely melt temperature, mold temperature, compression pressure, and compression distance, on warpage behavior of a molded 3D BJ356MO polypropylene (PP) (100MFI) part were investigated using Taguchi analysis. The obtained warpage results with optimum process parameters were compared with experimental measurements to test the validity of the simulation model of ICM. It was found that the numerical simulations of the ICM show good agreement with experimental measurements.