A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection Molding
Many challenges are associated with the injection molding process for forming a rib-structured pallet (1100 mm × 1100 mm × 140 mm, length × width × height) because greater flowing resistance through the rib channels within the pallet can induce insufficient filling. Essentially, multi-gate filling i...
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-04-01
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| Series: | Polymers |
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| Online Access: | https://www.mdpi.com/2073-4360/14/8/1631 |
| _version_ | 1797434304003833856 |
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| author | Yi-Ling Liao Hsi-Hsun Tsai |
| author_facet | Yi-Ling Liao Hsi-Hsun Tsai |
| author_sort | Yi-Ling Liao |
| collection | DOAJ |
| description | Many challenges are associated with the injection molding process for forming a rib-structured pallet (1100 mm × 1100 mm × 140 mm, length × width × height) because greater flowing resistance through the rib channels within the pallet can induce insufficient filling. Essentially, multi-gate filling involves a sequential valve gate system, which helps to spread the filling front with fewer weld lines. Based on the presetting of the sequential scheme of the valve gates, actual measurements of pallet flatness using the ATOS scan system were compared to numerical warpage measurements of a pallet derived by Moldex3D 2020. In this study, we propose a sequential scheme by actuating the valve gates to open once the flow front spreads towards them; then, actual warpage measurements of a pallet are compared with numerical measurements. The results show that the warpage of the top surface of the pallet is 5.144 mm in actual measurements and 5.729 mm in simulation. The results all indicated small warpage with respect to the pallet size. The simulation and actual measurements of flatness are in excellent agreement; the difference in top flatness between the simulated and actual pallet is 0.59 mm, while the bottom flatness difference is 0.035 mm. By adjusting the cooling water temperature, increasing the mold temperature, and decreasing the material temperature, overall flatness and warpage displacement can be reduced. |
| first_indexed | 2024-03-09T10:30:17Z |
| format | Article |
| id | doaj.art-8fbb8bcbb0754523b6e321a380a77c06 |
| institution | Directory Open Access Journal |
| issn | 2073-4360 |
| language | English |
| last_indexed | 2024-03-09T10:30:17Z |
| publishDate | 2022-04-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Polymers |
| spelling | doaj.art-8fbb8bcbb0754523b6e321a380a77c062023-12-01T21:20:27ZengMDPI AGPolymers2073-43602022-04-01148163110.3390/polym14081631A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection MoldingYi-Ling Liao0Hsi-Hsun Tsai1Department of Mechanical Engineering, Ming Chi University of Technology, New Taipei City 24301, TaiwanDepartment of Mechanical Engineering, Ming Chi University of Technology, New Taipei City 24301, TaiwanMany challenges are associated with the injection molding process for forming a rib-structured pallet (1100 mm × 1100 mm × 140 mm, length × width × height) because greater flowing resistance through the rib channels within the pallet can induce insufficient filling. Essentially, multi-gate filling involves a sequential valve gate system, which helps to spread the filling front with fewer weld lines. Based on the presetting of the sequential scheme of the valve gates, actual measurements of pallet flatness using the ATOS scan system were compared to numerical warpage measurements of a pallet derived by Moldex3D 2020. In this study, we propose a sequential scheme by actuating the valve gates to open once the flow front spreads towards them; then, actual warpage measurements of a pallet are compared with numerical measurements. The results show that the warpage of the top surface of the pallet is 5.144 mm in actual measurements and 5.729 mm in simulation. The results all indicated small warpage with respect to the pallet size. The simulation and actual measurements of flatness are in excellent agreement; the difference in top flatness between the simulated and actual pallet is 0.59 mm, while the bottom flatness difference is 0.035 mm. By adjusting the cooling water temperature, increasing the mold temperature, and decreasing the material temperature, overall flatness and warpage displacement can be reduced.https://www.mdpi.com/2073-4360/14/8/1631plastic palletinjection moldingflatnesssequential valve gate systemmolding flow analysis |
| spellingShingle | Yi-Ling Liao Hsi-Hsun Tsai A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection Molding Polymers plastic pallet injection molding flatness sequential valve gate system molding flow analysis |
| title | A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection Molding |
| title_full | A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection Molding |
| title_fullStr | A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection Molding |
| title_full_unstemmed | A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection Molding |
| title_short | A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection Molding |
| title_sort | comparison of numerical and actual measurements of large scale rib structured pallet flatness using recycled polypropylene in injection molding |
| topic | plastic pallet injection molding flatness sequential valve gate system molding flow analysis |
| url | https://www.mdpi.com/2073-4360/14/8/1631 |
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