Skip to Main Content
 

Global Search Box

 
 
 
 

Files

File List


osu1044377220.pdf (2.26 MB)

ETD Abstract Container

Abstract Header

MATHEMATICAL MODELING OF THE IN-MOLD COATING PROCESS FOR INJECTION MOLDED THERMOPLASTIC PARTS

Chen, Xu
http://rave.ohiolink.edu/etdc/view?acc_num=osu1044377220

Abstract Details

2003, Doctor of Philosophy, Ohio State University, Industrial and Systems Engineering.
In-Mold Coating (IMC) has been successfully used for many years for exterior body panels made from compression molded Sheet Molding Compound (SMC). The coating material is a single component reactive fluid, designed to improve the surface quality of SMC moldings in terms of functional and cosmetic properties. When injected onto a cured SMC part, IMC cures and bonds to provide a pain-like surface. Because of its distinct advantages, IMC is being considered for application to injection molded thermoplastic parts. For a successful in mold coating operation, there are two key issues related to the flow of the coating. First, the injection nozzle should be located such that the thermoplastic substrate is totally covered and the potential for air trapping is minimized. The selected location should be cosmetically acceptable since it most likely will leave a mark on the coated surface. The nozzle location also needs to be accessible for easy of maintenance. Secondly, the hydraulic force generated by the coating injection pressure should not exceed the available clamping tonnage. If the clamping force is exceeded, coating leakage will occur. In this study, mathematical models for IMC flow on the compressible thermoplastic substrate have been developed. Finite Difference Method (FDM) is first used to solve the 1 dimensional (1D) IMC flow problem. In order to investigate the application of Control Volume based Finite Element Method (CV/FEM) to more complicated two dimensional IMC flow, that method is first evaluated by solving the 1D IMC flow problem. An analytical solution, which can be obtained when a linear relationship between the coating thickness and coating injection pressure is assumed, is used to verify the numerical results. The mathematical models for the 2 dimensional (2D) IMC flow are based on the generalized Hele-Shaw approximation. It has been found experimentally that the power law viscosity model adequately predicts the rheological behavior of the coating. The compressibility of the substrate is modeled by the 2-domain Tait PVT equation. CV/FEM is used to solve the discretized governing equations. A computer code has been developed to predict the fill pattern of the coating and the injection pressure. A number of experiments have been conducted to verify the numerical predictions of the computer code. It has been found both numerically and experimentally that the substrate thickness plays a significant role on the IMC fill pattern.
Jose Castro (Advisor)
IMC; COATING; THERMOPLASTIC; IN-MOLD; INJECTION; Control Volume; coating injection

Recommended Citations

Citations

  • Chen, X. (2003). MATHEMATICAL MODELING OF THE IN-MOLD COATING PROCESS FOR INJECTION MOLDED THERMOPLASTIC PARTS [Doctoral dissertation, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1044377220

    APA Style (7th edition)

  • Chen, Xu. MATHEMATICAL MODELING OF THE IN-MOLD COATING PROCESS FOR INJECTION MOLDED THERMOPLASTIC PARTS. 2003. Ohio State University, Doctoral dissertation. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1044377220.

    MLA Style (8th edition)

  • Chen, Xu. "MATHEMATICAL MODELING OF THE IN-MOLD COATING PROCESS FOR INJECTION MOLDED THERMOPLASTIC PARTS." Doctoral dissertation, Ohio State University, 2003. http://rave.ohiolink.edu/etdc/view?acc_num=osu1044377220

    Chicago Manual of Style (17th edition)

osu1044377220
5,037
© 2003, all rights reserved.
This open access ETD is published by The Ohio State University and OhioLINK.