CFD-based predictive control of melt temperature in plastic injection molding

A unique method of coupling computational fluid dynamics (CFD) to model predictive control (MPC) for controlling melt temperature in plastic injection molding is presented. The methodology is based on using CFD to generate, via open-loop testing, a temperature and input dependent system model for multi-variable control of a three-heater barrel on an injection molding machine. Results clearly show the benefit of temperature and input dependent system models for MPC control, and that CFD can be used to dramatically reduce the time associated with open-loop testing through physical experiments.     

Warpage prediction of optical media

The warpage of injection–compression‐molded optical media, such as compact discs and digital video discs, due to asymmetric cooling during production is predicted. Thermally induced stress is calculated with a nonisothermal compressible flow simulation with a viscoelastic constitutive model. A finite element analysis is formulated with axisymmetric plate elements based on Kirchhoff thin‐plate theory to simulate the warpage of the disc due to the asymmetric thermal stress and gravity after demolding. Simulation results of warpage for compact‐disc‐recordable moldings are compared with experimental observations under different processing conditions, such as the melt temperature, mold temperature, and packing pressure, with an optical grade of polycarbonate. The comparison shows that the simulation well predicts the effects of various processing conditions. Both the simulation and experiment indicate that of the processing conditions, the mold temperature has the greatest effect on warpage. © 2003 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 41: 859–872, 2003     

Monolithic biocompatible and biodegradable scaffolds for tissue engineering

The state of the art in polymeric materials for tissue engineering as well as the needs and concerns for future medical applications are outlined and discussed and brought into relation to recent developments in polymer chemistry. Particularly, the recent developments in micro‐ and nano‐structured polymeric monoliths designed for these purposes will be discussed. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 2219–2227, 2009     

A low‐dimensional spectral approach for transient axisymmetric free‐surface flow inside thin cavities of arbitrary shape

A low‐dimensional spectral method is used to solve the transient axisymmetric free surface flow inside thin cavities of arbitrary shape. The flow field is obtained on the basis of the lubrication equations, which are expanded in terms of orthonormal functions over the cavity gap. The formulation accounts for nonlinearities stemming from inertia and front location. The work is of close relevance to the filling stage during die casting, and injection molding, or the flow inside annular (extrusion) dies. Both flows under an imposed flow rate, and an imposed pressure at the cavity entrance are examined. The influence of inertia, aspect ratio, gravity, and wall geometry on the evolution of the front, flow rate, and pressure is assessed particularly in the early stage of flow, when a temporal behavior of the ‘boundary‐layer’ type develops. The multiple‐scale method is applied to obtain an approximate solution at small Reynolds number, Re. Comparison with the exact (numerical) solution indicates a wide range of validity for the multiple‐scale approach, including the moderately small Re range. Copyright © 2002 John Wiley & Sons, Ltd.     

The Ising spin glass in finite dimensions: A perturbative study of the free energy

Replica field theory is used to study the n  -dependent free energy of the Ising spin glass in a first order perturbative treatment. Large sample-to-sample deviations of the free energy from its quenched average prove to be Gaussian, independently of the special structure of the order parameter. The free energy difference between the replica symmetric and (infinite level) replica symmetry broken phases is studied in details: the line n(T)$n(T)$ where it is zero coincides with the Almeida–Thouless line for d>8$d>8$. The dimensional domain 6<d<8$6<d<8$ is more complicated, and several scenarios are possible.     

Control-oriented modeling of servo-pump driven injection molding machines in the filling and packing phase

Servo-valves or variable displacement pumps are typically used to control conventional hydraulic injection molding machines (IMMs). Recent developments in electrical drive technology allow to utilize servo-motor driven pumps instead, which is beneficial due to their higher energy efficiency. Their dynamic behavior, however, is significantly different compared to the conventional setup. Thus, currently used mathematical models and control concepts cannot be directly applied. This paper presents a computationally efficient and scalable mathematical model of the injection process for these servo-pump driven IMMs. A first-principles model of the injection machine is combined with a phenomenological model describing the injection process, i.e. the compression of the melt and the polymer flow into the mold. The proposed model is tailored to real-time applications and serves as an ideal basis for the design of model-based control strategies. The feasibility of the proposed model is demonstrated by a number of different experiments. They confirm a high model accuracy over the whole operating range for different mold geometries.     

High-Temperature dispersion zones in cross-linked natural rubber

The complex dielectric constant of natural rubber samples cross-linked by sulfur and dicumyl peroxide has been measured over a frequency range from 1.5 to 3.0 × 10⁵ cps by the bridge method and from 3.0 to 1.0 × 10⁴ cps by the relaxation method. Two dispersion peaks were detected which lay in the measured frequency range at temperatures above the main dispersion zone. Temperature and cross-link density-dependent shift of these peaks were studied and compared with the results obtained by Ferry et al. from complex compliance measurements performed on analogous systems.     

Injection Molding Shrinkage and Mechanical Properties of Polypropylene Blends

Polypropylene (PP) blends based on isotactic polypropylene (iPP), propylene-ethylene block copolymer (bPP), and propylene–ethylene random copolymer (rPP) were prepared by melt blending and the effects of content of bPP and rPP on the shrinkage during solidification and storage and mechanical properties of the blends were studied. It was found that the addition of polypropylene copolymer could effectively reduce the processing shrinkage of iPP and the lowest shrinkage of the blends was achieved at a loading of 2 wt% bPP or rPP. The flexural modulus and tensile strength of the blends decreased a little while the impact strength and elongation at break were improved greatly compared with those of iPP.     

Skin Thickness and β-Crystals Development in Injection-Molded iPP Along the Flow Direction

In this study, iPP was injection molded at 180°C, 200°C, and 220°C. According to polarization optical microscopy (POM) results, for a given part, the skin thickness steadily decreases along the flow direction. However, at the same distance from the gate, the skin thickness of the parts molded at lower melt temperature is larger than that molded at higher melt temperature. It is found that flow time (here, the time taken for melt to pass the specific position along the flow direction) and melt temperature are two significant factors leading to this phenomenon, while the gate size is another one.

The DSC and WAXD results show that the relative fraction of β-form crystals, for a specific part, decreases along the flow direction, which is mainly determined by flow time. However, for the parts molded at different molding temperatures, the fraction of the β-form crystals is mainly determined by the molding temperature, though this influence is very complex.