Analysis of the main factors affecting mass production in the plastic molding process by using the finite element method

Authors

DOI:

https://doi.org/10.15587/1729-4061.2021.248375

Keywords:

mass production, injection, pressure, temperature, finite element, quality

Abstract

Plastic injection molding is widely used in many industrial applications. Plastic products are mostly used as disposable parts or as portable parts for fast replacements in many devices and machines. However, mass production is always adopted as an ideal method to cover the huge demands and customers’ needs. The problems of warpage due to thermal stresses, non-uniform pressure distribution around cavities, shrinkage, sticking and overall products quality are some of the important challenges. The main objective of this work is to analyze the stress distribution around the cavities during the molding and demolding to avoid their effects on the product quality. Moreover, diagnosing the critical pressure points around and overall the cavity projection area, which is subjected to high pressure will help to determine the optimum pressure distribution and ensure filling all cavities at the same time, which is another significant objective. Computer-aided design (CAD) and CATIA V5R20 are adopted for design and modeling procedures. The computer-aided engineering (CAE) commercial software ABAQUS 6141 has been dedicated as finite element simulation packages for the analysis of this process. Simulation results show that stress distribution over the cavities depends on both pressure and temperature gradient over the contact surfaces and can be considered as the main affecting factor. The acceptable ranges of the cavity stresses were determined according to the following values: the cavity and core region temperature of 55–65 °C, filling time of 10–20 s, ejection pressure 0.85 % of injection pressure, and holding time of 10–15 s. Also, theoretical results reveal that the uniform pressure and temperature distribution can be controlled by adjusting the cavities layout, runner, and gate size. Moreover, the simulation process shows that it is possible to facilitate and identify many difficulties during the process and modify the prototype to evaluate the overall manufacturability before further investing in tooling. Furthermore, it is also concluded that tooling iterations will be minimized according to the design of the selected process

Author Biographies

Hani Mizhir Magid, Al-Furat Al-Awsat Technical University

PhD

Department Coordinator

Department of Power Mechanics

Technical College Al-Musaib – Babylon

Badr Kamoon Dabis, Al-Furat Al-Awsat Technical University

Master of Science

Department of Mechanical Engineering

Technical College Al-Musaib – Babylon

Mohammad abed alabas Siba, Middle Technical University

Assistant Professor

Department of Mechanical Techniques

Institute of Technology – Baghdad

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Published

2021-12-29

How to Cite

Magid, H. M., Dabis, B. K., & abed alabas Siba, M. (2021). Analysis of the main factors affecting mass production in the plastic molding process by using the finite element method. Eastern-European Journal of Enterprise Technologies, 6(1 (114), 65–71. https://doi.org/10.15587/1729-4061.2021.248375

Issue

Vol. 6 No. 1 (114) (2021): Engineering technological systems

Section

Engineering technological systems

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Copyright (c) 2021 Hani Mizhir Magid, Badr Kamoon Dabis, Mohammad abed alabas Siba

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