This book covers a wide range of applications and uses of simulation and modeling techniques in polymer injection molding, filling a noticeable gap in the literature of design, manufacturing, and the use of plastics injection molding. The authors help readers solve problems in the advanced control, simulation, monitoring, and optimization of injection molding processes. The book provides a tool for researchers and engineers to calculate the mold filling, optimization of processing control, and quality estimation before prototype molding.
Given the importance of injection molding as a process as well as the simulation industry that supports it, there was a need for a book that deals solely with the modeling and simulation of injection molding. This book meets that need. The modeling and simulation details of filling, packing, residual stress, shrinkage, and warpage of amorphous, semi-crystalline, and fiber-filled materials are described. This book is essential for simulation software users, as well as for graduate students and researchers who are interested in enhancing simulation. And for the specialist, numerous appendices provide detailed information on the topics discussed in the chapters.
The use of computers to numerically analyse polymer processing was first reported as for back as the 1950's, and the first commercial software became available around 20 years ago. Much research has been carried out since that time, and this report aims to summarise contemporary trends in both commercial and academic research and development. An additional indexed section containing several hundred abstracts from the Rapra Polymer Library database provides useful references for further reading.
This third edition has been written to thoroughly update the coverage of injection molding in the World of Plastics. There have been changes, including extensive additions, to over 50% of the content of the second edition. Many examples are provided of processing different plastics and relating the results to critiCal factors, which range from product design to meeting performance requirements to reducing costs to zero-defect targets. Changes have not been made that concern what is basic to injection molding. However, more basic information has been added concerning present and future developments, resulting in the book being more useful for a long time to come. Detailed explanations and interpretation of individual subjects (more than 1500) are provided, using a total of 914 figures and 209 tables. Throughout the book there is extensive information on problems and solutions as well as extensive cross referencing on its many different subjects. This book represents the ENCYCLOPEDIA on IM, as is evident from its extensive and detailed text that follows from its lengthy Table of CONTENTS and INDEX with over 5200 entries. The worldwide industry encompasses many hundreds of useful plastic-related computer programs. This book lists these programs (ranging from operational training to product design to molding to marketing) and explains them briefly, but no program or series of programs can provide the details obtained and the extent of information contained in this single sourcebook.
This book covers the most recent and important developments in advanced injection molding technologies, such as intelligent process control; technology innovations and computer simulation for emerging special injection molding processes like microinjection molding, microcellular injection molding, water-assisted foaming, water-assisted injection molding, and variable mold temperature technologies; conductive polymer foams and composites; injection molding of optical products; and an automated mold design navigation system with integrated knowledge management capability. It is intended to be used as a textbook for both introductory and advanced injection molding courses, as a must-have reference for professional engineers and engineering managers who want to keep abreast of the latest technological developments and applications, and in libraries to serve interested readers from both academic and industrial communities as well as the general public. With chapters written by an international team of experts, this book provides a broad and insightful coverage, complementary to other books on injection molding.
This book describes an effective framework for setting the right process parameters and new mold design to reduce the current plastic defects in injection molding. It presents a new approach for the optimization of injection molding process via (i) a new mold runner design which leads to 20 percent reduction in scrap rate, 2.5 percent reduction in manufacturing time, and easier ejection of injected part, (ii) a new mold gate design which leads to less plastic defects; and (iii) the introduction of a number of promising alternatives with high moldability indices. Besides presenting important developments of relevance academic research, the book also includes useful information for people working in the injection molding industry, especially in the green manufacturing field.
Injection Molding Process Modelling presents the application of CAE, statistics and AI in defect identification, control, and optimization of injection molding process for quality production. It showcases CAE in determining the optimal placement of injection points, designing cooling channels, and ensuring that the mold will produce parts with the desired specifications. The book illustrates the capability of the CAE tools to simulate molten plastic flow within a mold during the injection molding process. Explaining how the use of CAE, statistical tools and AI enhances efficiency, accuracy, and collaboration, the book explores the contributions to injection molding in product design and visualization; prototyping and testing; mold design; and analysis and simulation. It emphasizes the integration of statistical tools for optimized efficiency and waste reduction, including statistical process control (SPC), Design of Experiments (DOE), Regression Analysis, Capability Indices, Interaction effects, and many more. The book also illustrates the predictive modelling of typical injection molded product defects using intelligent algorithms. The book will interest industry professionals and engineers working in manufacturing, production, automation, and quality control.
Exploring the chemistry of synthesis, mechanisms of polymerization, reaction engineering of step-growth and chain-growth polymerization, polymer characterization, thermodynamics and structural, mechanical, thermal and transport behavior of polymers as melts, solutions and solids, Fundamentals of Polymer Engineering, Third Edition covers essential concepts and breakthroughs in reactor design and polymer production and processing. It contains modern theories and real-world examples for a clear understanding of polymer function and development. This fully updated edition addresses new materials, applications, processing techniques, and interpretations of data in the field of polymer science. It discusses the conversion of biomass and coal to plastics and fuels, the use of porous polymers and membranes for water purification, and the use of polymeric membranes in fuel cells. Recent developments are brought to light in detail, and there are new sections on the improvement of barrier properties of polymers, constitutive equations for polymer melts, additive manufacturing and polymer recycling. This textbook is aimed at senior undergraduate students and first year graduate students in polymer engineering and science courses, as well as professional engineers, scientists, and chemists. Examples and problems are included at the end of each chapter for concept reinforcement.
Filling a gap in the literature and all set to become the standard in this field, this monograph begins with a look at computational viscoelastic fluid mechanics and studies of turbulent flows of dilute polymer solutions. It then goes on discuss simulations of nanocomposites, polymerization kinetics, computational approaches for polymers and modeling polyelectrolytes. Further sections deal with tire optimization, irreversible phenomena in polymers, the hydrodynamics of artificial and bacterial flagella as well as modeling and simulation in liquid crystals. The result is invaluable reading for polymer and theoretical chemists, chemists in industry, materials scientists and plastics technologists.
