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Experimental and numerical analysis of injection molding with microfeatures

Yu, Liyong
http://rave.ohiolink.edu/etdc/view?acc_num=osu1080318678

Abstract Details

2004, Doctor of Philosophy, Ohio State University, Chemical Engineering.
Injection molding has great potential for mass production of polymer products with microfeatures. In this study, injection molding with micro-features is investigated experimentally and numerically. Different methods were used to fabricate tool steel, photoresist and nickel mold inserts for injection molding with micro-features. Experiments have been conducted and analyzed for the radial flow case and the unidirectional flow case. Simulations based on 2.5D software packages for are preformed. Both numerical simulation and experimental results showed that the injection speed, feature width and mold temperature are important for mold filling. However, conventional midplane simulation is found to be inappropriate for multi-scale structures, typically found in micro-injection molded parts. For the unidirectional flow, an x-z planar simulation based on the general momentum equation is able to achieve better efficiency than 3D simulations. A hybrid numerical technique is developed, which can significantly reduce the computation cost, and yet provide good flow simulation around the microfeatures. The mold-melt heat transfer coefficient and injection speed are shown to be very important factors in determining the filling depth in microstructures. Different choices of the value of the constant heat transfer coefficient give very different results. Therefore, a local heat iii transfer model is collaborated in our code. It produces good prediction in our simulation. However, it may not include all effects. Wall-slip may also contributes to the filling length in microchannels. A decrease of the heat transfer coefficient and the occurrence of wall-slip are likely to occur in micro channels. Further investigations are needed.
Kurt Koelling (Advisor)
218 p.
Engineering, Chemical
mold; microchannels; filling length; MOLDING; mold inserts; filling

Recommended Citations

Citations

  • Yu, L. (2004). Experimental and numerical analysis of injection molding with microfeatures [Doctoral dissertation, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1080318678

    APA Style (7th edition)

  • Yu, Liyong. Experimental and numerical analysis of injection molding with microfeatures. 2004. Ohio State University, Doctoral dissertation. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1080318678.

    MLA Style (8th edition)

  • Yu, Liyong. "Experimental and numerical analysis of injection molding with microfeatures." Doctoral dissertation, Ohio State University, 2004. http://rave.ohiolink.edu/etdc/view?acc_num=osu1080318678

    Chicago Manual of Style (17th edition)

osu1080318678
8,481
© 2004, all rights reserved.
This open access ETD is published by The Ohio State University and OhioLINK.