Improving the Melt Flow Length of Acrylonitrile Butadiene Styrene in Thin-Wall Injection Molding by External Induction Heating with the Assistance of a Rotation Device
Abstract
:1. Introduction
2. Simulation and Experimental Method
2.1. The External Induction Heating with the Assistance of a Rotation Device
2.2. Simulation Method
2.3. Experiment Method
3. Results and Discussion
3.1. Effect of the Gap between the Heating Surface and the Induction Coil
3.2. Effect of the Heating Time on the Temperature Distribution
3.3. Improving the Melt Flow Length of Front Cover Part by External Induction Heating for the Gate Temperature Control
4. Conclusions
- For an initial mold temperature of 30 °C and a gap (G) of 5 mm, it can be seen that the magnetic heating process can heat the plate to 290 °C in 5 s. However, at a distance of 15 mm, it took up to 8 s to reach 270 °C. The heating time results show that this heating strategy has almost no impact on the cycle time, which often varied from around 10 to 20 s. Therefore, depending on the cycle time, the gap (G) could be set to the greatest possible value to ensure that the heating rate is not too high and to prolong the lifetime of the coil and the insert surface.
- The temperature of line L clearly increased with a longer heating time. Due to the edge effect, the temperature on two sides of the insert quickly increased. In addition, this effect also allowed the temperature at the holding area to increase quickly. Varying the heating time from 1 to 8 s, the result shows that a lower heating rate could reduce overheating at the edge of the insert plate.
- The temperature profile of line L undergoes a change after the heating for 3 s is completed. The temperature was more uniform, and the high temperature at the two sides was clearly reduced due to the heat transfer from the higher temperature to the lower temperature. With the heating time of 5 s, the experimental results show that the temperature of line L varies around 168.0, 210, and 280 °C with a gap of 5, 10, and 15 mm, respectively. This result also demonstrates that Ex-IH could support the heating process for a cavity area of 35 mm × 95 mm and has great potential for application in the field of mold temperature control.
- According to the measurement results, when the mold heating time was increased from 0 to 5 s during the molding process, the flow length significantly increased from 71.5 to 168.1 mm, and the filling percentage of the thin-wall product also increased from 10.2% to 100%. In general, when the Ex-IH was applied during the molding cycle, the total cycle time was similar to that in the traditional case.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Material | Property | Value | Unit |
---|---|---|---|
Copper | Relative permeability (μ/μ0) | 1 | 1 |
Electrical conductivity | 5.87 × 107 | S/m | |
Coefficient of thermal expansion | 17 × 10−6 | 1/K | |
Heat capacity at constant pressure | 387 | J/(kg·K) | |
Density | 8940 | kg/m3 | |
Thermal conductivity | 398 | W/(m·K) | |
Young’s modulus | 128 × 109 | Pa | |
Poisson’s ratio | 0.34 | 1 | |
Reference resistivity | 1.72 × 10−8 | Ω·m | |
Resistivity temperature coefficient | 3.9 × 10−3 | 1/K | |
Reference temperature | 273.15 | K | |
Steel | Electrical conductivity | 1 × 107 | S/m |
Relative permeability (μ/μ0) | 100 | 1 | |
Thermal conductivity | 68 | W/(m·K) | |
Density | 7210 | kg/m3 | |
Heat capacity at constant pressure | 448 | J/(kg·K) |
Molding Parameters | Unit | Melt Flow Length Testing | Thin-Wall Product |
---|---|---|---|
Injection speed | cm3/sec | 23 | 25 |
Injection pressure | Bar | 38 | 42 |
Injection time | s | 1.5 | 1.0 |
Packing time | s | 2.5 | 3.0 |
Packing pressure | Bar | 35 | 40 |
Cooling time | s | 12 | |
Initial mold temperature | °C | 35 | |
Melt temperature | °C | 260 | 270 |
Preheating time by Ex-IH | s | 2–5 |
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Minh, P.S.; Le, M.-T. Improving the Melt Flow Length of Acrylonitrile Butadiene Styrene in Thin-Wall Injection Molding by External Induction Heating with the Assistance of a Rotation Device. Polymers 2021, 13, 2288. https://doi.org/10.3390/polym13142288
Minh PS, Le M-T. Improving the Melt Flow Length of Acrylonitrile Butadiene Styrene in Thin-Wall Injection Molding by External Induction Heating with the Assistance of a Rotation Device. Polymers. 2021; 13(14):2288. https://doi.org/10.3390/polym13142288
Chicago/Turabian StyleMinh, Pham Son, and Minh-Tai Le. 2021. "Improving the Melt Flow Length of Acrylonitrile Butadiene Styrene in Thin-Wall Injection Molding by External Induction Heating with the Assistance of a Rotation Device" Polymers 13, no. 14: 2288. https://doi.org/10.3390/polym13142288