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Research Papers

Study on Air Accumulation and Influence on Flow Balance in Micro-Injection Molding

[+] Author and Article Information
Wei Cao1

APPT NERC, Zhengzhou University, Zhengzhou 450002, Chinawcao@zzu.edu.cn

Shufeng Gan, Qian Li, Changyu Shen

APPT NERC, Zhengzhou University, Zhengzhou 450002, China

Shubing Ye

 Shenzhen Zhaowei Machinery & Electronics Co., Ltd., Shenzhen 518103, China

1

Corresponding author.

J. Manuf. Sci. Eng 133(1), 011004 (Jan 24, 2011) (6 pages) doi:10.1115/1.4003337 History: Received May 11, 2010; Revised December 10, 2010; Published January 24, 2011; Online January 24, 2011

The conventional finite element method was employed to study the relationship between melt filling and air accumulation in micro-cavities. The variational equation for melt flow with slip boundary condition and air resistance was generalized based on Galerkin principle. To investigate the effect of air accumulation, the governing equation for air flow inside runner was established by dimensionless method. An iterative approach was proposed to solve the coupled melt flow problem and air flow problem. Numerical results show that air accumulation can affect the melt filling in micro-cavity, and closely depends on injection speed. Adjusting branch runner distribution can improve the flow balance, which was convinced by a real micro-part manufacturing.

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Copyright © 2011 by American Society of Mechanical Engineers
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Figures

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Figure 1

Schematic of runner system for mircoring washer molding

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Figure 2

Air pressure in micro-cavity is as a function of time. 1 represents the cavity connected by branch runner A and 2 represents one of the other four cavities.

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Figure 3

Simulated melt front with injection speed of 200 mm/s

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Figure 4

Simulated melt front with injection speed of 400 mm/s

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Figure 5

Simulated melt front with injection speed of 800 mm/s

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Figure 6

Simulated melt front with injection speed of 800 mm/s

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Figure 7

Comparison between (a) short shot part and (b) simulated melt front for micro-motor washer molding with direct branch runner at time 0.5 s

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Figure 8

Comparison between (a) short shot part and (b) simulated melt front for micro-motor washer molding with direct branch runner at time 0.6 s

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Figure 9

Comparison between (a) short shot part and (b) simulated melt front for micro-motor washer molding with modified branch runner at time 0.6 s

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