NDLI: Cavity Specific Control of Melt Flow During Injection Molding Processes

Content Provider	The American Society of Mechanical Engineers (ASME) Digital Collection
Author	John, P. Coulter
Copyright Year	2003
Abstract	The competitive global marketplace of the new century requires that industrial organizations develop capabilities to rapidly produce increasingly complex products with improved quality at lower cost. To do so successfully, significant innovations in manufacturing process technology need to be developed and implemented. The present paper describes a new research concept targeted at the development of “intelligent” or “adaptive” injection molding technology. More specifically, the effort is focused on the establishment of a capability to improve injection molding processing by monitoring shot to shot product quality and controlling the filling of multi-cavity molds in real time. During the first phase of the research, a target product having features and dimensional characteristics matching anticipated future requirements was selected. A two-cavity mold with which to manufacture the target product was then designed and fabricated. Candidate methodologies through which to implement control and assure proper filling of all product cavities at the individual cavity level were identified and evaluated. Based on this analysis, several types of mechanical valves for inclusion in runner systems were designed and fabricated. The resultant valve systems were tested on the prototype two-cavity mold, with important process as well as product quality variables monitored and/or measured during testing. All initial testing was performed using a liquid crystal polymer (LCP) material from Hoechst Celanese. The results of the testing trials were analyzed to both validate the concept of individual cavity filling modification and identify an optimal valve type through which this can be accomplished. It was concluded that the flow control concept developed was experimentally validated, and that a custom characterized valve type appears most promising for future utilization at industrial manufacturing facilities. The future directions for the continuing project are also discussed.
Sponsorship	Materials Division
Starting Page	83
Ending Page	94
Page Count	12
File Format	PDF
ISBN	079183719X
DOI	10.1115/IMECE2003-55360
Volume Number	Materials
Conference Proceedings	ASME 2003 International Mechanical Engineering Congress and Exposition
Language	English
Publisher Date	2003-11-15
Publisher Place	Washington, DC, USA
Access Restriction	Subscribed
Subject Keyword	Product quality Cavities Injection molding Flow control Valves Production facilities Manufacturing Liquid crystalline polymers Flow (dynamics) Engineering prototypes Testing
Content Type	Text
Resource Type	Article

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