Study on the Influence of Runner and Overflow Area Design on Flow–Fiber Coupling in a Multi-Cavity System
Abstract
:1. Introduction
2. Theoretical Background
2.1. Model for Polymer Melt Flow
2.2. Models for Fiber Orientations
2.3. Model for Viscosity by Flow–Fiber Coupling
3. Systems and Information
3.1. System of Simulation
3.2. System of Experimentation
3.3. Dimensional Measurement of the Injected Parts
4. Results
4.1. Flow Behavior Validation
4.2. Fiber Orientation Distribution from Cavity to Cavity
4.2.1. Simulation Result with Flow–Fiber Coupling Effect
4.2.2. Simulation Result without Flow–Fiber Coupling Effect
4.3. Discover the Evidence of the Flow–Fiber Coupling Effect in a Single Cavity S1
4.3.1. Sprue Pressure
4.3.2. Theoretical Investigation into the Impact of the Overflow Area on the Flow–Fiber Coupling Effect
4.4. The Relationship between Fiber Orientations and Geometrical Shrinkage
4.4.1. Numerical Prediction of the Average Fiber Orientation along Flow Direction
4.4.2. Numerical prediction of the geometrical shrinkage
4.4.3. Experimental Validation of the Geometrical Shrinkage
5. Discussion
5.1. Flow–Fiber Coupling Effect Validation
5.2. The Influence of Overflow Area on the Occurrence of Flow–Fiber Coupling
5.3. Validation of the Flow–Fiber Coupling Effect on the Asymmetrical Shrikange Behavior from Upstream to Downstream
6. Conclusions
- Irrespective of the consideration of the flow–fiber coupling effect, the theoretical fiber orientation of each cavity remains consistent.
- When examining the flow–fiber coupling effect, two observations can demonstrate this phenomenon: (1) the sprue pressure in the system exhibiting flow–fiber coupling was higher than in the system without this coupling, and (2) the core layer area in the system with flow–fiber coupling was observed to be enlarged compared to the system lacking such coupling.
- In a geometric system featuring an overflow area design, the presence of these overflow areas serves to postpone the onset of the flow–fiber coupling effect in contrast to a system lacking such design elements.
- Through the integration of fiber orientation distribution data, it is possible to examine the consequences of the delayed flow–fiber coupling effect in the overflow area, particularly in the EFR. This phenomenon leads to a significant transfer of A11 fiber orientation to A22 and A33 in the final filling zone (H4 to H5), resulting in an asymmetrical arrangement of fiber orientation.
- By analyzing the geometric dimensions of the final part from the 1 × 4 multi-cavity system with overflow area, it is evident that there are noticeable variations in size and shrinkage between the upstream and downstream sections within the EFR. These differences align with the asymmetrical distribution of fiber orientation induced by the flow–fiber coupling effect.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Region | Material | Shrinkage | ||||||
---|---|---|---|---|---|---|---|---|
Unit | (Lx)U | (Lx)D | (Ly)L | (Ly)R | (Lz)L | (Lz)R | ||
EFR | PP | mm | 18.440 | 18.440 | 9.317 | 9.333 | 3.440 | 3.450 |
±0.000 | ±0.000 | ±0.006 | ±0.006 | ±0.010 | ±0.010 | |||
% | −0.753 | −0.753 | −2.239 | −2.064 | −1.714 | −1.429 | ||
30SFPP | mm | 18.703 | 18.700 | 9.353 | 9.427 | 3.437 | 3.487 | |
±0.006 | ±0.000 | ±0.006 | ±0.006 | ±0.006 | ±0.006 | |||
% | 0.664 | 0.646 | −1.854 | −1.084 | −1.810 | −0.381 |
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Hsieh, F.-L.; Chen, C.-T.; Hwang, S.-S.; Hwang, S.-J.; Huang, P.-W.; Peng, H.-S.; Jien, M.-Y.; Huang, C.-T. Study on the Influence of Runner and Overflow Area Design on Flow–Fiber Coupling in a Multi-Cavity System. Polymers 2024, 16, 1279. https://doi.org/10.3390/polym16091279
Hsieh F-L, Chen C-T, Hwang S-S, Hwang S-J, Huang P-W, Peng H-S, Jien M-Y, Huang C-T. Study on the Influence of Runner and Overflow Area Design on Flow–Fiber Coupling in a Multi-Cavity System. Polymers. 2024; 16(9):1279. https://doi.org/10.3390/polym16091279
Chicago/Turabian StyleHsieh, Fang-Lin, Chuan-Tsen Chen, Shyh-Shin Hwang, Sheng-Jye Hwang, Po-Wei Huang, Hsin-Shu Peng, Ming-Yuan Jien, and Chao-Tsai Huang. 2024. "Study on the Influence of Runner and Overflow Area Design on Flow–Fiber Coupling in a Multi-Cavity System" Polymers 16, no. 9: 1279. https://doi.org/10.3390/polym16091279