In-line steady shear flow characteristics of polymer melt in rectangular slit cavities during thin-wall/micro injection molding

Both scale and temperature field effects have a considerable impact on polymer melt viscosity during thin-wall/micro injection molding. In this work, an in-line rheological test with similar dynamic test conditions to thin-wall/micro injection molding was adopted to further analyze the rheological p...

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Main Authors: Wangqing Wu, Baishun Zhao, Fan Mo, Binbin Li, Bingyan Jiang
Format: Article
Language:English
Published: Elsevier 2022-11-01
Series:Materials & Design
Subjects:
Online Access:http://www.sciencedirect.com/science/article/pii/S0264127522008887
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author Wangqing Wu
Baishun Zhao
Fan Mo
Binbin Li
Bingyan Jiang
author_facet Wangqing Wu
Baishun Zhao
Fan Mo
Binbin Li
Bingyan Jiang
author_sort Wangqing Wu
collection DOAJ
description Both scale and temperature field effects have a considerable impact on polymer melt viscosity during thin-wall/micro injection molding. In this work, an in-line rheological test with similar dynamic test conditions to thin-wall/micro injection molding was adopted to further analyze the rheological properties and improve the simulation accuracy. An injection mold with rectangular slit cavity and storage region was designed to obtain a steady flow. The effects of factors such as the cavity size, viscous dissipation and melt temperature on polymer melt viscosity were studied. The results demonstrate that the injection molding conditions have a significant influence on the in-line rheological properties. When the cavity thickness (h) was 0.5 mm, the average percentage reductions of viscosity were 8.86 % (200 to 220 °C) and 4.07 % (220 to 240 °C) as the melt temperature rose. They were 57.13 % (200 to 220 °C) and 38.86 % (220 to 240 °C) when the cavity thickness was reduced to 0.2 mm. The test results show that the average prediction errors of pressure drop based on the capillary rheometer viscosity and in-line viscosity are 29.78 % (die: 5/0.2 mm) and 16.61 % (slit:h = 0.2 mm), respectively. In-line rheological viscosity shows potential for application in mold flow simulation.
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spelling doaj.art-24dbeabe3d6b417db3e3277d924b5dcc2022-12-22T03:56:15ZengElsevierMaterials & Design0264-12752022-11-01223111266In-line steady shear flow characteristics of polymer melt in rectangular slit cavities during thin-wall/micro injection moldingWangqing Wu0Baishun Zhao1Fan Mo2Binbin Li3Bingyan Jiang4Corresponding authors at: Central South University, School of Mechanical and Electrical Engineering, Lushan South Road 932, 410083 Changsha, Hunan, China.; State Key Laboratory of High-Performance Complex Manufacturing, School of Mechanical and Electrical Engineering, Central South University, Changsha 410083, ChinaState Key Laboratory of High-Performance Complex Manufacturing, School of Mechanical and Electrical Engineering, Central South University, Changsha 410083, ChinaState Key Laboratory of High-Performance Complex Manufacturing, School of Mechanical and Electrical Engineering, Central South University, Changsha 410083, ChinaState Key Laboratory of High-Performance Complex Manufacturing, School of Mechanical and Electrical Engineering, Central South University, Changsha 410083, ChinaCorresponding authors at: Central South University, School of Mechanical and Electrical Engineering, Lushan South Road 932, 410083 Changsha, Hunan, China.; State Key Laboratory of High-Performance Complex Manufacturing, School of Mechanical and Electrical Engineering, Central South University, Changsha 410083, ChinaBoth scale and temperature field effects have a considerable impact on polymer melt viscosity during thin-wall/micro injection molding. In this work, an in-line rheological test with similar dynamic test conditions to thin-wall/micro injection molding was adopted to further analyze the rheological properties and improve the simulation accuracy. An injection mold with rectangular slit cavity and storage region was designed to obtain a steady flow. The effects of factors such as the cavity size, viscous dissipation and melt temperature on polymer melt viscosity were studied. The results demonstrate that the injection molding conditions have a significant influence on the in-line rheological properties. When the cavity thickness (h) was 0.5 mm, the average percentage reductions of viscosity were 8.86 % (200 to 220 °C) and 4.07 % (220 to 240 °C) as the melt temperature rose. They were 57.13 % (200 to 220 °C) and 38.86 % (220 to 240 °C) when the cavity thickness was reduced to 0.2 mm. The test results show that the average prediction errors of pressure drop based on the capillary rheometer viscosity and in-line viscosity are 29.78 % (die: 5/0.2 mm) and 16.61 % (slit:h = 0.2 mm), respectively. In-line rheological viscosity shows potential for application in mold flow simulation.http://www.sciencedirect.com/science/article/pii/S0264127522008887In-line metrologyThin-wall/micro injection moldingSteady flowShear viscosityNon-isothermal effect
spellingShingle Wangqing Wu
Baishun Zhao
Fan Mo
Binbin Li
Bingyan Jiang
In-line steady shear flow characteristics of polymer melt in rectangular slit cavities during thin-wall/micro injection molding
Materials & Design
In-line metrology
Thin-wall/micro injection molding
Steady flow
Shear viscosity
Non-isothermal effect
title In-line steady shear flow characteristics of polymer melt in rectangular slit cavities during thin-wall/micro injection molding
title_full In-line steady shear flow characteristics of polymer melt in rectangular slit cavities during thin-wall/micro injection molding
title_fullStr In-line steady shear flow characteristics of polymer melt in rectangular slit cavities during thin-wall/micro injection molding
title_full_unstemmed In-line steady shear flow characteristics of polymer melt in rectangular slit cavities during thin-wall/micro injection molding
title_short In-line steady shear flow characteristics of polymer melt in rectangular slit cavities during thin-wall/micro injection molding
title_sort in line steady shear flow characteristics of polymer melt in rectangular slit cavities during thin wall micro injection molding
topic In-line metrology
Thin-wall/micro injection molding
Steady flow
Shear viscosity
Non-isothermal effect
url http://www.sciencedirect.com/science/article/pii/S0264127522008887
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