THERMAL SCIENCE

International Scientific Journal

Authors of this Paper

External Links

Mingliang Hao

,

Haimei Li

OPTIMIZATION AND APPLICATION OF TEMPERATURE FIELD IN RAPID HEAT CYCLING MOLDING

ABSTRACT
The rapid thermal cycle molding belongs to the injection mold temperature control system which is helpful to improve moldability and enhance part quality. Despite many available literatures, rapid thermal cycle molding does not represent a well-developed area of practice. The challenge is the uneven distribution of temperature in the cavity after heating, which mostly leads to defects on the surface of the products. In order to obtain uniform cavity surface temperature distribution of rapid thermal cycle molding, the power of heating rods of the electric-heating system in an injection mold was optimized by the response surface method in this work. The proposed optimization result was applied to design a complex rapid thermal cycle molding injection mold with side core-pulling, holes, and different thickness of an automotive part to verify its effectiveness by injection molding. Compared with initial design, the mold temperature uniformity was remarkably improved by 79%. Based on the optimization and injection molding numerical simulation results, the workable molding process to weaken the weld-lines effects on the quality was suggested and the practical injection molded parts were well produced
KEYWORDS
rapid thermal cycle molding(RHCM), optimization design of heating rod, response surface method(RSM), injection molding, numerical simulation
PAPER SUBMITTED: 2021-06-06
PAPER REVISED: 2021-08-19
PAPER ACCEPTED: 2021-08-27
PUBLISHED ONLINE: 2021-10-10
DOI REFERENCE: https://doi.org/10.2298/TSCI210606291H
CITATION EXPORT: view in browser or download as text file
THERMAL SCIENCE YEAR 2022, VOLUME 26, ISSUE Issue 2, PAGES [1985 - 1997]
REFERENCES
  1. Xiao, C.L., Huang H.X., Optimal design of heating system for rapid thermal cycling mold using particle swarm optimization and finite element method, Applied Thermal Engineering, 64 . (2014), 1 - 2, pp. 462 - 470
  2. Yao, D.G., et al., Rapid thermal cycling of injection molds: An overview on technical approaches and applications, Advances in Polymer Technology, 27 . (2008), 4, pp. 233-255
  3. Li, J.Q., et al., An Experimental Study of Skin Layer in Rapid Heat Cycle Molding, Polymer-Plastics Technology and Engineering, 53 . (2014), 5, pp. 488-496
  4. Saito, T., et al., A new concept of active temperature control for an injection molding process using infrared radiation heating, Polymer Engineering and Science, 42 . (2002), pp. 2418-2429
  5. Wang, G.L., et al., Analysis of thermal cycling efficiency and optimal design of heating/cooling systems for rapid heat cycle injection molding process, Materials & Design, 31 . (2010), 7, pp. 3426-3441
  6. Wang, G.L., et a l., Multi-objective optimization design of the heating/cooling channels of the steam-heating rapid thermal response mold using particle swarm optimization, International Journal of Thermal Sciences, 50 . (2011), 5, pp. 790-802
  7. Zhao, G.Q., et al., Research and application of a new rapid heat cycle molding with electric heating and coolant cooling to improve the surface quality of large LCD TV panels, Polymers for Advanced Technologies, 22 . (2011), 5, pp. 476-487
  8. Chen, S.C., et al., Dynamic mold surface temperature control using induction heating and its effects on the surface appearance of weld line, Journal of Applied Polymer Science, 101 . (2006), 2, pp. 1174-1180
  9. Hua, C.H., Wang, K.J., Optimization of a 3-D high-power LED lamp Orthogonal experime nt method and experimental verification, Thermal science, 25 . (2021), 2B, pp. 1495-1500
  10. Chen, S.C., et al., Simulations and Verifications of Induction Heating on a Mold Plate, International Communications in Heat and Mass Transfer, 31 . (2004), 7, pp. 971-980
  11. Cervantes Vallejo, F., et al., Optimization of the heating system by electrical resistances in a rapid thermal response mold based on MSR-PSO-FEM, Revista Internacional de Métodos Numéricos para Cálculo y Diseño en Ingeniería, 35 . (2019), 3, pp. 40
  12. Li, X.P., et al., Optimal design of heating channels for rapid heating cycle injection mold based on response surface and genetic algorithm, Materials & Design, 30 . (2009), 10, pp. 4317-4323
  13. Nian, S.C., et al., Key parameter s and optimal design of a single-layered induction coil for external rapid mold surface heating, International Communications in Heat and Mass Transfer, 57 . (2014), pp. 109-117
  14. Sun, J.L., et al., Numerical and experimental investigation of induction h eating process of heavy cylinder, Applied Thermal Engineering, 134 . (2018), pp. 341-352
  15. Bao, L., et al., Numerical and experimental research on localized induction heating process for hot stamping steel sheets, International Journal of Heat and Mass Transfer, 151 . (2020), pp. 119422
  16. Zink, B., et al., Thermal analysis based method development for novel rapid tooling applications, International Communications in Heat and Mass Transfer, 108 . (2019), pp. 104297
  17. Jiang, S., et al., Heating properties of ERHCM molds based on heating cell units, Emerging Materials Research, 8 . (2019), 2, pp. 247-252
  18. Sánchez, R., et al., Rapid heating injection moulding: An experimental surface temperature study, Polymer Testing, 93 . (2021), pp. 106928
  19. Xu, Y., et al., Numerical simulation and analysis of phase change heat transfer in crude-oil, Thermal Science, 25. (2021), 2A, pp. 1123-1134
  20. Xiao, C.L., Huang H.X., Optimal design of heating system in rapid thermal cycling blow mold by a two-step method based on sequential quadratic programming, International Communications in Heat and Mass Transfer, 96 . (2018), pp. 114-121
  21. Song, M.C., Moon Y.H., Coupled electromagnetic and thermal analysis of induction heating for the forging of marine crankshafts, App lied Thermal Engineering, 98 . (2016), pp. 98-109,
  22. Chen, S.C., et al., Rapid mold temperature variation for assisting the micro injection of high aspect ratio micro-feature parts using induction heating technology, Journal of Micromechanics and Microengineering, 16 . (2006), 9, pp. 1783-1791
  23. Li, H.M., et al., Numerical Simulations and Verifications of Cyclic and Transient Temperature Variations in Injection Molding Process, Polymer-Plastics Technology and Engineering, 48 . (2008), 1, pp. 1-9
  24. Xi ao, C.L., Huang H.X., Multiobjective optimization design of heating system in electric heating rapid thermal cycling mold for yielding high gloss parts, Journal of Applied Polymer Science, 131 . (2014), 6, pp. 39976
  25. Muszynski, P., et al., Numerical Study of Rapid Cooling of Injection Molds, Advances in Manufacturing Engineering and Materials, icmem (2019), pp. 539-547.
  26. Ozcelik, B., Optimization of injection parameters for mechanical properties of specimens with weld line of polypropylene using Tagu chi method, International Communications in Heat and Mass Transfer . (2011), 38, pp. 1067-1072
  27. Fathi, S., Behravesh A.H., Visualization of the flow history contours at the cross-section of a weld-line in an injected molded part, Journal of Applied Poly mer Science, 109 . (2008), 1, pp. 412-417
  28. Liao, T., et al., Predicting the location of weld line in microinjection‐molded polyethylene via molecular orientation distribution, Journal of Polymer Science Part B: Polymer Physics, 57 . (2019), 24, pp. 1705-171
PDF VERSION [DOWNLOAD]
Optimization and application of temperature field in rapid heat cycling molding

© 2024 Society of Thermal Engineers of Serbia. Published by the Vinča Institute of Nuclear Sciences, National Institute of the Republic of Serbia, Belgrade, Serbia. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution-NonCommercial-NoDerivs 4.0 International licence