注塑成型充填过程中注射速率的优化设计

给出一种塑料注射成型工艺的优化方法 .将充填过程数值模拟和优化算法相结合 ,以获得均匀熔体前沿速度从而减少塑件翘曲变形为目标 ,对充填过程中的注射速率进行优化 .算例表明 ,本文所提出的工艺优化模型及求解算法是有效的     

气体辅助注塑成型技术—一项向传统注塑工艺挑战的未来技术

气辅注塑成型技术是为克服传统注塑成型和发泡成型的局限性面发展起来，近几年来才开始进入实用阶段的一种新工艺。它利用高压气体在注塑件内部产生中空截面，实现气体积压，消除制品缩痕，完成充填过程。     

聚双环戊二烯反应注射成型

本文介绍了国外有关聚双环戊二烯反应注射成型的研究进展，讨论了国内进行聚双环戊二烯反应注射成型开发研究的现实意义，并对这一领域的发展进行了展望     

气体辅助注射成型表层熔体形成机理的分析

基于等温条件下下幂律流体的流动分析,对圆管气体辅助注射成型过程中影响表层熔体形成的因素进行了分析,指出在等温条件下牛顿流体所形成的表层熔体厚度比值约为0．3,接近试验值0．34－0．37,非牛顿流体的值（＜0．3）小于实际气辅成型值（约0．38）。文中对产生这一偏差的非等温条件下的影响因素进行作了进一步的分析,认为除了熔体温度、模具温度以及气体延迟时间对聚合物表层熔体的形成有重要影响,熔体／气体前沿之间的压力梯度值以及熔体／气体界面之间的剪切应力都对气体穿透过程中表层熔体的形成有重要影响。     

聚合物气体辅助注射成型制品的形态结构

作为一种由常规注射成型发展起来的聚合物加工技术,气体辅助注射成型具有节约原材料、缩短成型周期以及提高制品性能等优点,已得到广泛的应用.由于气辅成型过程是一个在刚、柔双重约束界面条件下进行的多相复杂体系的多次流动过程,因而其形态结构的形成、发展和演化要远比常规注塑成型复杂.然而在气辅成型的形态结构方面,国内外的研究一直以来开展得较少.近年来,作者在聚合物及其共混物、复合材料气辅成型制品的形态结构方面已开展了广泛的研究工作,本文对这些工作和一些重要结果作了总结,并简要分析了成型过程中剪切场对形态演化的影响,最后对该研究方向的发展趋势作了展望.     

半结晶聚合物注射成型中结晶动力学的数值模拟

对半结晶聚合物注射成型过程及其结晶过程进行偶合模拟,分析了二者的相互影响.具体是在注射成型数值模拟中考虑结晶动力学效应,分别在本构方程、能量方程及材料物性参数方程中引入反映结晶效应的参数;同时在结晶动力学计算中考虑流动诱导效应,从能量的角度提出并使用修正的动力学模型,用材料流动过程的耗散能表征流动对结晶的影响.通过对等规聚丙烯(iPP)和聚对苯二甲酸乙二醇酯(PET)两种半结晶聚合物注射过程模拟结果的分析比较,证实成型过程具有加速结晶的作用.同时,材料的结晶也对注射成型加工过程,尤其是保压与冷却过程的温度场分布有较大的影响.     

塑料成型工艺实习CAI课件的开发

针对当前学生实习面临的困难，以Authorware为开发工具，编制了塑料成型工艺实习CAI课件，整个软件图文并茂，图像，动画，解说，音乐相结合，形象地介绍了塑料各种成型工艺的主要原理，生产设备，工艺流程和相关产品，应用本软件学生可以进行模拟实习，该软件激发了学生学习的兴趣，提高了实习质量。     

德英美三国气体辅助注塑技术的发展现状

德英美三国气体辅助注塑技术的发展现状梁瑞凤（中国科学院化学研究所工程塑料国家工程研究中心北京１０００８０）气体辅助注塑成型是利用高压气体在注塑件内部产生中空截面、全面充填过程、实现气体保压、消除制品缩痕的一项９０年代才开始进入实用阶段的塑料成型新技术...     

城市煤气耐硫甲烷化反应器优化分析(英文)

建立了耐硫甲烷化列管式反应器的拟均相二维数学模型，运用隐式差分法求解，对日产五万立方煤气反应器的设备参数及操作参数的灵敏度进行了模拟分析。结果表明，管径对温度分布影响很大，气体入口温度及熔盐流量的影响不显著；气体入口压力及熔盐进口温度是反应器操作的灵敏因素。     

聚合物反应注射成型

本文简要地介绍了反应注射成型(RIM)的发展,RIM的化学体系,RIM过程和制品的成型,RIM过程的主要特点及RIM聚氨酯的主要组分。     

Fabrication of optical waveguide devices using gas‐assisted UV micro/nanoimprinting with soft mold

Wavelength limitation and diffraction of light are the bottlenecks encountered in the production of structures by conventional lithography. Nano‐imprinting has been a potential process for mass production of nanometer structures at low cost. This paper reports an innovative process to replicate the ridge‐shaped microstructures on the silicon mold onto the photoresist using gas‐assisted pressing mechanism and soft mold. The microstructures on the silicon mold are replicated unto PC films. The soft mold is obtained by casting the PDMS with the PC film as templates, PDMS mold and UV‐curable photoresist are brought into contact, and are pressurized by gas and cured by UV‐light at the same time. After curing, structures for optical wave guilding can be obtained, In this process, through the control of gas pressure, the residual layer of the ridge‐shaped component for light guilding can eliminated. Etching is no longer needed to get rid of the residual layer. This process is effective for mass production for replication of microstructures at low cost. Copyright © 2007 John Wiley & Sons, Ltd.     

Simulation of Fibrillation of PC/LCP/Kevlar Blends and Its Characterizations

Kevlar fiber was fluorinated and oxy-fluorinated directly in presence of undiluted fluorine and fluorine gas mixture and processed with Polycarbonate and LCP at 320 °C under 20 rpm in a twin-screw extruder. The composites were then injection molded into dumbbell shaped specimens under different conditions like various mold temperatures, injection temperatures, injection speeds and mold filling rates. Various physico-chemical characterizations have been performed under definite processing parameter. Orientation of fibers under different injection parameters was evaluated using mold flow simulation technique. Most injection molded or extruded structures however, exhibit non-uniform fiber orientation across the final parts, with a diverging variety of different local fiber orientation states. Distinct skin and core regions were observed in the injection molded parts and it has also been found out that fiber orientation is different in skin and core region for both unmodified and modified derivative, which affects the flow behavior. Processing parameters significantly affect the fiber orientation pattern in the skin and core region for all blended materials. It is worth mentioning that the maximum fiber orientation occurred during the extrusion process at the wall but different extent of fiber orientation is observed during the injection molding depending on the shape of the dumbbell specimen. This fibrillation has been corroborated by the SEM study in both the skin and core region.     

Fabrication of buried waveguide microstructure using gas‐assisted micro/nanoimprinting with soft mold

Due to the limitations on the choice of wavelengths available for light source, nanograde structures are facing technological bottlenecks and their method of preparation using current lithography and imaging technology is extremely costly. The idea is thus born to develop a nanopressuring and manufacturing technology, in order to further develop a low‐cost and more reliable technology to manufacture nanodevices in full scale. This study combines the characteristics of soft lithography, photo‐resist, and gas‐assisted pressuring, as well as studies the use of gas‐assisted pressuring and soft mold to emboss photo‐resist to manufacture optical waveguide devices, such that the nanopressuring technology may be more mature. Study results show that polydimethylsiloxane (PDMS) is able to accurately emboss and replicate nanograde buried waveguide structures, by using even pressure gas to achieve full contact with the surface of the substrate thus greatly increasing the effective pressuring area. Also, PDMS soft molds are easier to make with short embossing time to effectively reduce cost. Another advantage of combining gas‐assisted pressuring with PDMS soft molds in the manufacturing process is that PDMS soft molds possess low free energy on the surface and are difficult for resist to adhere. Copyright © 2007 John Wiley & Sons, Ltd.     

Morphological development in water assisted injection molded polyethylene/polyamide‐6 blends

Water assisted injection molding (WAIM) has gradually become one of the most important polymer processing methods for making hollowed parts. This study examined the morphological development in water assisted injection molded high density polyethylene (HDPE)/polyamide‐6 (PA‐6) blends. Samples for microscopic observation were prepared by an 80‐ton injection‐molding machine equipped with a tube cavity and with a water injection unit. A distinct skin layer, core region, and channel layer were observed across the thickness. The shape and size of the dispersed phase depended on the position both across the part thickness and along the flow direction. Small and large particles coexisted in the skin and channel layers, indicating that both coalescence and disintegration of the dispersed phase occurred in these layers. High water pressures were found to mold parts with smaller polyamide particle distributions. Additionally, the morphology of water assisted injection molded parts was compared to that of gas assisted injection molded products. It was found that water molded parts exhibit a smaller polyamide particle distribution than their gas counterparts. Copyright © 2010 John Wiley & Sons, Ltd.     

Construction of Pre-Deformed Shapes for Rapid Tooling in Injection Molding

The major issues in the development of injection molding technology include the progress in CAE and the developments in tool design methodology such as rapid tooling. The applicability of rapid tooling in injection molding was examined using unbalanced cooling to analyze the warpage and shrinkage. Moldflow Plastics Insight simulation software was used for the deformation calculations with different mold thermal conductivities. It can be concluded that the decreasing mold thermal conductivity will dramatically increase the volumetric shrinkage and the warpage as well. Because of these effects, it is of fundamental importance to compensate for the shrinkage and warpage, so in the paper a new design methodology is suggested for rapid tooling, which is based on the pre-deformed model.     

A study of rubber flow in a mold during the tire shaping process using experiment and computer simulation

Automobile tires consist of more than ten layers, including tread, belt, carcass, sidewall, etc. The outermost layer, known as the tread, plays an important role during driving as it comes in direct contact with the road. This tread has grooves with complicated shapes, which are formed by a mold during the shaping process. When the tread rubber does not fill the mold properly, tire quality deteriorates crucially. As such, it is important to observe the flow of the tread rubber during the shaping process. To determine the flow of tread rubber in the mold, we conducted an experiment and computer simulation with white rubber strips inserted into specific areas of the tread. The white rubber strips showed detailed flow behavior of the tread rubber visually in the mold during the shaping process. No significant flows were observed for rubber in the central area of each block of the mold, but more changes were found near the edges of each block. The strips of rubber below the grooves exhibited more significant changes as they were pressed down by the protruding area of the mold. Moreover, there was no flow of rubber between blocks in the mold. This implies the profile design of the extruded tread should match the mold profile and the volume of each block. The experiment and simulation had similar results, and the observations of rubber flow in the mold using simulation proved to be highly useful.     

The mechanism of ultrasonic improvement of weld line strength of injection molded polystyrene and polystyrene/polyethylene blend parts

The effect of ultrasonic oscillations and ultrasonic oscillation‐induced modes on weld line strength of polystyrene(PS) and polystyrene/polyethylene(PS/HDPE) blend was investigated. And the mechanism of ultrasonic improvement of weld line strength of PS and PS/HDPE blend was also studied. The presence of ultrasonic oscillations can enhance the weld line strength of PS and PS/HDPE blend. Compared with mode I(ultrasonic oscillations were induced into mold at the whole process of injection molding), the induced ultrasonic oscillations as mode II(ultrasonic oscillations were induced into mold after injection mold filling) is more effective to increase weld line strength of PS and PS/HDPE blend. The mechanism for ultrasonic improvement of weld line strength of PS and PS/HDPE blend is that the ultrasonic oscillations can improve the molecular diffusion across weld line of the melt at the core, and make against the fusion of melt at the skin. © 2006 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 1520–1530, 2006     

Study on residual stresses of thin-walled injection molding

The residual stresses of the thin-walled injection molding are investigated in this study. It was realized that the behavior of residual stresses in injection molding parts was affected by different process conditions such as melt temperature, mold temperature, packing pressure and filling time. The layer removal method was used to measure the residual stresses at a thin-walled test sample by a milling machine. This simple method was demonstrated to be adequate for a thin-walled part. Moldings under different conditions were investigated to study the effects of the process conditions on the residual stresses of a thin-walled product using the elastic and viscoelastic models. The mold temperature was found to affect the size of the core region and residual stress on the surface layer of a thin-walled part in our studied range. The packing pressure was insensitive to the residual stresses in the studied high-pressure range. The residual stresses predicted by the viscoelastic model are about the same level and trend as compared to the experimental measurement.     

Design of experiment for optimization of plasma-polymerized octafluorocyclobutane coating on very high aspect ratio silicon molds

As-fabricated deep reactive ion etched (DRIE) silicon mold with very high aspect ratio (>10) feature patterns is unsuitable for poly(dimethylsiloxane) (PDMS) replication because of the strong interaction between the Si surface and the replica and the corrugated mold sidewalls. The silicon mold can be conveniently passivated via plasma polymerization of octafluorocyclobutane (C4F8), which is also employed in the DRIE process itself, to enable the mold to be used repeatedly. To optimize the passivation conditions, we have undertaken a Box-Behnken experimental design on the basis of three passivation process parameters (plasma power, C4F8 flow rate, and deposition time). The measured responses were fluorinated film thickness, demolding status/success, demolding force, and fluorine/carbon ratio on the fifth replica surface. The optimal passivation process conditions were predicted to be an input power of 195 W, a C4F8 flow rate of 57 sccm, and a deposition time of 364 s; these were verified experimentally to have high accuracy. Demolding success requires medium-deposited film thickness (66-91 nm), and the thickness of the deposited films correlated strongly with deposition time. At moderate to high ranges, increased plasma power or gas flow rate promoted polymerization over reactive etching of the film. It was also found that small quantities of the fluorinated surface were transferred from the Si mold to the PDMS at each replication, entailing progressive wear of the fluorinated layer.