Simulation of Particle Migration of Powder-Resin System in Injection Molding

[+] Author and Article Information
Y. C. Lam, X. Chen, K. C. Tam

Singapore-MIT Alliance Program, Nanyang Technological University, Singapore 639798, Singapore

S. C. M. Yu

School of Mechanical & Production Engineering, Nanyang Technological University, Singapore 639798, Singapore

J. Manuf. Sci. Eng 125(3), 538-547 (Jul 23, 2003) (10 pages) doi:10.1115/1.1580850 History: Received March 01, 2001; Revised October 01, 2002; Online July 23, 2003
Copyright © 2003 by ASME
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Schematic of illustrating the location of the melt inside the cavity
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Schematic of control volume and finite difference grid used for pressure, temperature, and particle concentration computations respectively
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Mesh of the rectangular plate cavity
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(a) Predicted bulk powder concentration (%) distribution with Dc/Dη=0.66 and Φs=45% (b) Predicted bulk powder concentration (%) distribution with Dc/Dη=0.90 and Φs=45%
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Predicted melt front during the filling stage
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Predicted bulk temperature distribution at the end of filling (t=5 s)
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Predicted bulk powder concentration (%) distribution with Dc/Dη=0.66 and Φs=45% with one gate
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Predicted bulk powder concentration (%) distribution with Dc/Dη=0.66 and Φs=45% with two gates
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(a) Bulk temperature distribution without particle migration at the end of filling (t=2 s) (b) Bulk temperature distribution with particle migration at the end of filling (t=2 s)
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(a) Temperature profile at node 148 as the cavity was filled —▪— Without migration, a=50 μm; —▴— Dc/Dη=0.66,a=50 μm (b) Pressure profile at the gate G as the cavity was filled —▪— Dc/Dη=0.66,a=50 μm; —▴— Without migration, a=50 μm
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(a) Contour plots of particle concentration (%) at (a) Section A-A, (b) Section B-B, (c) Section C-C; The value of the contour of particle volume concentration (%) are: (1) 52.0; (2) 50.2; (3) 48.4; (4) 46.7; (5) 44.9 (6) 43.1; (7) 41.3; (8) 39.5; (9) 37.8; (10) 36.0
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Through thickness velocity profiles at end of filling (t=2 s) at node 148 in Fig. 3 —♦— ϕ̄=0.45; —▪— ϕ̄=0.35; —▴— ϕ̄=0.25; —×— ϕ̄=0.0
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Gate pressure evolution for different mesh sizes —♦— 146 meshes; —▪— 384 meshes; —▴— 680 meshes



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