Verfügbarkeit: Molding Simulation: Theory and Practice

Molding Simulation: Theory and Practice:

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Bibliographische Detailangaben
Hauptverfasser:	Wang, Maw-Ling (VerfasserIn), Chang, Rong-Yeu (VerfasserIn), Hsu, Chia-Hsiang (VerfasserIn)
Format:	Buch
Sprache:	English
Veröffentlicht:	Munich Carl Hanser Verlag [2022]
Ausgabe:	2nd Edition
Schlagworte:	Spritzgießen Computersimulation Kunststoff Modellierung assisted injection molding computer assisted engineering fiber orientation foam injection molding gates injection molding Kunststoffverarbeitung manufacturing melt flow mold cooling mold design Moldex3D plastics plastics processing resin transfer molding rheology runners simulation warpage FBKTSPRI: Spritzgießen PLAS2022 Lehrbuch
Online-Zugang:	Inhaltsverzeichnis
Beschreibung:	XX, 599 Seiten Illustrationen, Diagramme 25 cm
ISBN:	9781569908846

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653			\|a rheology
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Datensatz im Suchindex

_version_	1804184131220799488
adam_text	CONTENTS ACKNOWLEDGMENTS ................................................................................. V PREFACE ..................................................................................................... VII 1 OVERVIEW OF PLASTICS MOLDING ..................................................... 1 CHE-PING (BARTON) LIN 1.1 INTRODUCTION TO INJECTION MOLDING ........................................................... 1 1.1.1 THE SYSTEMS OF INJECTION MOLDING ............................................... 3 1.1.1.1 THE CYCLE OF INJECTION MOLDING .................................... 3 1.1.1.2 INJECTION MACHINE .......................................................... 4 1.1.2 DEFECTS IN INJECTION MOLDED PRODUCTS ........................................ 10 1.1.2.1 SHORT SHOT ...................................................................... 10 1.1.2.2 WARP ................................................................................ 11 1.1.2.3 FLASH ................................................................................ 11 1.1.2.4 SINK MARK AND VOID ....................................................... 12 1.1.2.5 AIR TRAP .......................................................................... 13 1.1.2.6 BURN MARK ..................................................................... 13 1.1.2.7 DELAMINATION .................................................................. 14 1.1.2.8 FISH EYE .......................................................................... 14 1.1.2.9 FLOW MARK ..................................................................... 14 1.1.2.10 STRESS MARK ................................................................... 15 1.1.2.11 HESITATION ....................................................................... 15 1.1.2.12 JETTING ............................................................................. 16 1.1.2.13 SPLAY ............................................................................... 16 1.1.2.14 WELD LINE ....................................................................... 17 1.2 CORE VALUES OF MOLDING SIMULATION ......................................................... 18 1.2.1 APPLICATION OF CAE TECHNOLOGY IN INJECTION MOLDING ................ 19 2 MATERIAL PROPERTIES OF PLASTICS ................................................... 23 CHEN-CHIEH (JYE) WANG 2.1 OVERVIEW ..................................................................................................... 23 2.2 RHEOLOGICAL PROPERTIES .............................................................................. 25 2.2.1 VISCOSITY ......................................................................................... 26 2.2.1.1 EFFECTS OF NON-NEWTONIAN AND MOLECULAR CONFORMATION ................................................................. 27 2.2.1.2 EFFECTS OF SHEAR RATE ..................................................... 28 2.2.1.3 EFFECTS OF TEMPERATURE .................................................. 30 2.2.1.4 EFFECTS OF PRESSURE ........................................................ 31 2.2.1.5 THEORETICAL MODELS ........................................................ 31 2.2.1.6 VISCOSITY PROPERTIES OF PLASTICS ................................... 33 2.2.2 VISCOELASTIC FLUIDS ......................................................................... 35 2.2.2.1 VISCOELASTIC BEHAVIOR .................................................... 35 2.2.2.2 THEORETICAL MODELS ........................................................ 37 2.2.2.3 MEASUREMENT OF VISCOELASTICITY ................................... 41 2.3 THERMODYNAMIC AND THERMAL PROPERTIES ................................................ 46 2.3.1 SPECIFIC HEAT CAPACITY ................................................................... 46 2.3.2 MELTING POINT AND GLASS TRANSITION TEMPERATURES ..................... 48 2.3.3 PVT EQUATION OF STATE ................................................................... 49 2.3.3.1 DEFINITION ........................................................................ 49 2.3.3.2 DATA INTERPRETATION ........................................................ 50 2.3.3.3 THEORETICAL MODELS ........................................................ 51 2.3.3.4 EFFECTS OF NON-EQUILIBRIUM STATE ON PVT .................... 54 2.3.4 THERMAL CONDUCTIVITY AND HEAT TRANSFER COEFFICIENT .............. 56 2.3.4.1 DEFINITION ........................................................................ 56 2.3.4.2 THEORETICAL MODELS ........................................................ 57 2.3.4.3 DATA INTERPRETATION ........................................................ 57 2.3.4.4 MOLD-MELT CONTACT AND HEAT TRANSFER COEFFICIENT (HTC) ........................................................... 58 2.4 MECHANICAL PROPERTIES .............................................................................. 59 2.4.1 STRESS AND STRAIN OF PLASTICS ........................................................ 59 2.4.2 SOLID-LIKE VISCOELASTICITY ............................................................ 60 2.4.3 THEORETICAL MODEL ........................................................................ 61 2.4.4 DATA INTERPRETATION ...................................................................... 62 2.5 KINETIC PROPERTIES ...................................................................................... 64 2.5.1 CRYSTALLINE ..................................................................................... 64 2.5.2 THEORETICAL MODELS ........................................................................ 64 2.5.3 EFFECTS OF COOLING RATE ON CRYSTALLIZATION .................................. 65 2.6 CURING KINETICS .......................................................................................... 66 2.6.1 CURING PHENOMENON .................................................................... 66 2.6.2 THEORETICAL MODELS ........................................................................ 67 2.6.3 CURING EFFECT ON VISCOSITY ............................................................ 68 2.6.4 DATA INTERPRETATION ...................................................................... 70 3 PART AND MOLD DESIGN ................................................................... 73 TSAI-HSIN (SAM) HSIEH, TAO-CHEN (CLOUD) TSAI, YAO-WEI (WILLIE) CHUANG 3.1 PART DESIGN ................................................................................................ 73 3.1.1 GOLDEN RULE: UNIFORM WALL THICKNESS ........................................ 73 3.1.2 WALL THICKNESS VERSUS FLOW LENGTH ............................................ 76 3.1.3 RADIUS/FILLETS AND CHAMFER ANGLE .............................................. 78 3.1.4 RIB AND BOSS .................................................................................. 79 3.1.5 DRAFT ANGLE .................................................................................... 84 3.1.6 DESIGN FOR MANUFACTURING (DFM) ................................................ 85 3.1.7 SUMMARY ...................................................................................... 86 3.2 MOLD DESIGN ............................................................................................... 87 3.2.1 BASICS ............................................................................................ 88 3.2.2 GATE DESIGN .................................................................................... 91 3.2.2.1 GATE NUMBER .................................................................. 91 3.2.2.2 GATE LOCATION .................................................................. 92 3.2.2.3 GATE TYPES ...................................................................... 95 3.2.3 RUNNER DESIGN .............................................................................. 97 3.2.3.1 RUNNER SHAPE AND DIMENSION ...................................... 98 3.2.3.2 MULTI-CAVITY RUNNER DESIGN ........................................ 99 3.2.4 COOLING DESIGN .............................................................................. 100 3.2.5 OTHERS ............................................................................................ 102 3.2.5.1 EJECTOR SYSTEM ................................................................ 102 3.2.5.2 VENTING DESIGN .............................................................. 102 4 PROCESS CONDITIONS ....................................................................... 105 CHUAN-WEI (ARVID) CHANG 4.1 INTRODUCTION TO THE INJECTION MOLDING CYCLE ............................................ 105 4.1.1 BRIEF INTRODUCTION TO INJECTION MOLDING MACHINE UNITS ........... 105 4.1.2 INJECTION MOLDING CYCLE .............................................................. 107 4.1.3 MOLDING WINDOW .......................................................................... 110 4.1.4 PVT VARIATIONS DURING INJECTION STAGES .................................... ILL 4.2 PLASTICIZING CONDITIONS ............................................................................. 122 4.2.1 NOZZLE TEMPERATURE AND CYLINDER TEMPERATURES ..................... 122 4.2.2 BACK PRESSURE, SCREW RPM, SUCK BACK, AND METERING STROKE .. 123 4.3 FILLING CONDITIONS ..................................................................................... 129 4.3.1 FILLING TIME VERSUS INJECTION VELOCITY ........................................ 129 4.3.2 INJECTION PRESSURE ........................................................................ 133 4.3.3 VP SWITCH ...................................................................................... 136 4.4 PACKING CONDITIONS .................................................................................... 138 4.5 COOLING CONDITIONS .................................................................................... 140 4.5.1 COOLING TIME ................................................................................ 140 4.5.2 COOLANT FLOW RATE ......................................................................... 141 4.5.3 MOLD TEMPERATURE ......................................................................... 141 4.6 CONNECTING SMART DESIGN TO SMART MANUFACTURING ............................. 142 4.6.1 MACHINE CHARACTERIZATION ............................................................. 143 4.6.2 THE CAE SETTING MODE IN COMBINATION WITH INJECTION MACHINE ON SITE ................................................. 148 4.6.3 CASE STUDY ..................................................................................... 150 5 MOLDING SIMULATION METHODOLOGY ............................................... 157 HSIEN-SEN (ETHAN) CHIU 5.1 THE GOAL OF MOLDING SIMULATION .............................................................. 157 5.1.1 DESIGN VERIFICATION AND OPTIMIZATION ......................................... 158 5.1.1.1 OVERVIEW OF DESIGN FOR MANUFACTURE (DFM) ............. 158 5.1.1.2 CAE AND DFM: A PRACTICAL CASE STUDY ....................... 160 5.1.2 PROCESS CONDITIONS OPTIMIZATION .................................................. 167 5.1.2.1 MOLDING STABILITY ........................................................... 167 5.1.2.2 REAL CASE ....................................................................... 169 5.2 BASICS OF SIMULATION EQUATIONS ................................................................ 173 5.2.1 GOVERNING EQUATIONS ....................................................................... 174 5.2.2 NUMERICAL APPROXIMATION .............................................................. 175 5.2.2.1 FINITE DIFFERENCE METHOD (FDM) ................................. 175 5.2.2.2 FINITE VOLUME METHOD (FVM) ....................................... 178 5.2.2.3 FINITE ELEMENT METHOD (FEM) ..................................... 180 5.3 WHAT IS MOLDING SIMULATION? ................................................................... 182 5.3.1 BRIEF HISTORY OF MOLDING SIMULATION ............................................ 182 5.3.2 SIMULATION WORKFLOW ....................................................................... 189 6 FLOW CONSIDERATION VERSUS PART FEATURES ................................ 193 WEN-HSIN (DEBBIE) WENG 6.1 BASICS .......................................................................................................... 193 6.1.1 FLOW BEHAVIOR OF PLASTIC MELT IN THE CAVITY .................................. 193 6.1.2 EFFECTS OF FILLING TIME ................................................................... 198 6.1.3 FLOW RATE VERSUS INJECTION PRESSURE ............................................ 199 6.1.3.1 FLOW RATE CURVE SETTING ............................................... 199 6.1.3.2 RELATIONSHIP OF INJECTION RATE AND INJECTION PRESSURE ......................................................... 203 6.1.4 VP SWITCH AND CAVITY PRESSURE ................................................... 209 6.1.5 EFFECTS OF PART THICKNESS ............................................................... 218 6.1.6 MATERIAL VISCOSITY AN FLOW BEHAVIOUR ........................................... 223 6.1.7 SUMMARY ........................................................................... 227 6.2 PRACTICAL APPLICATIONS ............................................................................... 228 6.2.1 CAE SOLUTION TO STRESS MARK IN A PHONE SHELL .......................... 228 6.2.2 FLOW RATE EFFECT ON INJECTION PRESSURE OF LAPTOP PRODUCT ........ 232 6.3 CAE CASE STUDY ........................................................................... 234 7 RUNNER AND GATE DESIGN ................................................................ 239 YAO-CHEN (CLOUD) TSAI, YAO-WEI (WILLIE) CHUANG 7.1 BASICS ........................................................................................................... 239 7.1.1 GENERAL DESIGN GUIDE OF RUNNERS ................................................ 239 7.1.2 GENERAL DESIGN GUIDE OF GATES ..................................................... 244 7.1.3 GATE SEALING .................................................................................... 256 7.1.4 FLOW BALANCE .................................................................................... 258 7.2 PRACTICAL APPLICATIONS ................................................................................ 265 7.2.1 CAE VERIFICATION ON MELTFLIPPER DESIGN .................................... 265 7.2.2 CAE VERIFICATION OF MULTI-CAVITY SYSTEMS .................................... 271 7.3 CAE CASE STUDY .......................................................................................... 275 8 COOLING OPTIMIZATION ..................................................................... 279 HUNG-CHOU (KENT) WANG 8.1 BASICS .......................................................................................................... 279 8.1.1 HEAT TRANSFER MECHANISM ............................................................. 280 8.1.2 DESIGN GOLDEN RULE: UNIFORM MOLD TEMPERATURE ....................... 283 8.1.3 GENERAL DESIGN GUIDE OF COOLING CHANNEL ................................. 287 8.1.4 COOLING EFFICIENCY: COOLANT FLOW CONSIDERATION ......................... 291 8.1.5 COOLING TIME ESTIMATE ................................................................... 294 8.1.6 USE CAE COOLING ANALYSIS ............................................................. 296 8.1.7 CONFORMAL COOLING APPLICATION ................................................... 299 8.2 PRACTICAL APPLICATIONS ................................................................................ 303 8.2.1 DIGITAL CAMERA COVER ..................................................................... 303 8.2.2 CARTRIDGE ........................................... : ............................................ 308 8.3 CAE CASE STUDY .......................................................................................... 312 9 WARPAGE CONTROL ............................................................................ 315 SHIH-PO (TOBER) SUN, WEN-HSIN (DEBBIE) WENG 9.1 BASICS .......................................................................................................... 315 9.1.1 THE CAUSES OF WARPAGE .................................................................. 318 9.1.2 MATERIAL EFFECTS .............................................................................. 321 9.1.3 GEOMETRICAL EFFECTS ........................................................................ 324 9.1.4 PROCESS CONDITION EFFECTS .............................................................. 326 9.1.5 CRITERIA OF CAE WARP ANALYSIS ..................................................... 328 9.1.6 METHODS TO MINIMIZE WARPAGE ..................................................... 332 9.2 PRACTICAL APPLICATIONS ................................................................................ 338 9.3 CAE CASE STUDY .......................................................................................... 343 10 FIBER ORIENTATION CONTROL .............................................................. 347 HUAN-CHANG (IVOR) TSENG 10.1 BASICS .......................................................................................................... 348 10.1.1 PROCESS PRINCIPLE ........................................................................... 350 10.1.2 THEORY MODELS ............................................................................... 351 10.1.3 ADVANTAGES AND CHALLENGES ......................................................... 361 10.2 PRACTICAL APPLICATIONS ................................................................................ 362 10.2.1 USING THE IARD-RPR MODEL FOR AN INJECTION MOLDED CENTER-GATED DISK WITH FIBER-REINFORCED THERMOPLASTICS .......... 362 10.2.2 COMPARISON OF IARD-RPR MODELS UNDER GNF DECOUPLING AND IISO COUPLING .............................................................. 366 10.2.3 THE INFLUENCES OF MATERIAL FLOW AND FIBER INTERACTION ON FIBER ORIENTATION AND PRODUCT QUALITY DURING INJECTION MOLDING ............................................................... 369 10.3 CAE CASE STUDY .......................................................................................... 374 11 HOT RUNNER OPTIMIZATION ............................................................. 379 TSAI-HSIN (SAM) HSIEH 11.1 BASICS .......................................................................................................... 379 11.1.1 PROCESS PRINCIPLE ........................................................................... 380 11.1.2 TEMPERATURE CONTROL IN A HOT RUNNER SYSTEM .......................... 384 11.1.3 ADVANTAGES AND CHALLENGES ......................................................... 386 11.2 PRACTICAL APPLICATIONS ............................................................................... 395 11.2.1 CAE VERIFICATION ON A SINGLE-GATE HOT RUNNER SYSTEM ............ 395 11.2.2 CAE PIN MOVEMENT CONTROL OF VALVE GATE ................................... 404 11.3 CAE CASE STUDY ......................................................................................... 408 12 CO-/BI-INJECTION MOLDING .............................................................. 411 CHIH-CHUNG (JIM) HSU, YU-SHENG (TIM) CHOU 12.1 BASICS .......................................................................................................... 412 12.1.1 PROCESS PRINCIPLE ........................................................................... 412 12.1.2 ADVANTAGES AND CHALLENGES ......................................................... 415 12.1.3 THEORY MODELS ............................................................................... 417 12.2 PRACTICAL APPLICATIONS ................................................................................ 418 12.2.1 CO-INJECTION MOLDING OF FORK MODEL ............................................. 418 12.2.2 CO-INJECTION MOLDING: CORE BREAKTHROUGH AND FLOW IMBALANCE ................................................................. 420 12.2.3 CO-INJECTION MOLDING: FIBER ORIENTATION PREDICTIONS ................ 424 12.2.4 CAE CASE OF BI-INJECTION MOLDING ............................................... 426 12.3 CAE CASE STUDY ........................................................................................ 430 13 GAS-/WATER-ASSISTED INJECTION MOLDING .................................. 433 CHIH-CHUNG (JIM) HSU, YU-SHENG (TIM) CHOU 13.1 BASICS .......................................................................................................... 433 13.1.1 PROCESS PRINCIPLE ........................................................................... 434 13.1.1.1 SHORT-SHOT PROCESS ....................................................... 434 13.1.1.2 FULL-SHOT PROCESS ........................................................... 436 13.1.2 ADVANTAGES AND CHALLENGES ......................................................... 438 13.2 PRACTICAL APPLICATIONS .............................................................................. 446 13.2.1 CAE VERIFICATION ON GAIM ............................................................. 446 13.2.2 CAE VERIFICATION ON WAIM ........................................................... 449 13.2.3 CAE VERIFICATION ON GAIM: FINGERING EFFECT ............................... 452 13.3 CAE CASE STUDY ........................................................................................ 454 14 FOAM INJECTION MOLDING .............................................................. 457 YUAN-JUNG (DAN) CHANG, LI-YANG (ROBERT) CHANG, CHIH-WEI (JOE) WANG 14.1 BASICS ......................................................................................................... 457 14.1.1 MICROCELLULAR PROCESS PRINCIPLE .................................................. 458 14.1.2 ADVANTAGES AND CHALLENGES ........................................................ 462 14.1.3 THEORY MODELS .............................................................................. 464 14.2 PRACTICAL APPLICATIONS ............................................................................... 466 14.2.1 CAE VERIFICATION ON MICROCELLULAR INJECTION MOLDING: CASE 1 .. 466 14.2.2 CAE VERIFICATION OF MICROCELLULAR INJECTION MOLDING: CASE 2 .. 473 14.2.3 CAE VERIFICATION ON CHEMICAL FOAMING INJECTION MOLDING .... 480 14.2.4 CAE VERIFICATION OF POLYURETHANE REACTIVE FOAMING MOLDING . 483 14.2.5 SUMMARY ....................................................................................... 491 14.3 CAE CASE STUDY ........................................................................................ 492 15 POWDER INJECTION MOLDING .......................................................... 495 HUAN-CHANG (IVOR) TSENG 15.1 BASICS ........................................................................................................ 495 15.1.1 PROCESS PRINCIPLE ........................................................................... 496 15.1.2 ADVANTAGES AND CHALLENGES ......................................................... 497 15.1.3 THEORY MODELS ............................................................................... 500 15.2 PRACTICAL APPLICATIONS .............................................................................. 505 15.3 CAE CASE STUDY ........................................................................................ 508 16 RESIN TRANSFER MOLDING ................................................................ 511 HSUN (FRED) YANG, YU-HE (ZOE) CHEN 16.1 BASICS ........................................................................................................ 512 16.1.1 PROCESS PRINCIPLE ........................................................................... 516 16.1.2 ADVANTAGES AND CHALLENGES ......................................................... 520 16.2 THEORY MODELS .......................................................................................... 521 16.2.1 2.5D ANALYSIS ................................................................................. 521 16.2.2 3D ANALYSIS ..................................................................................... 523 16.2.3 MEASUREMENT OF PERMEABILITY ..................................................... 525 16.2.4 POROSITY ........................................................................................... 528 16.2.5 MEASUREMENT OF CHEMORHEOLOGICAL PROPERTIES .......................... 529 16.2.6 SIMULATION PARAMETERS ................................................................. 530 16.3 PRACTICAL APPLICATIONS .............................................................................. 531 16.3.1 CAE VERIFICATION ON EDGE EFFECTS ................................................. 531 16.3.2 CAE VERIFICATION ON THICKNESS-DIRECTION FLOW .......................... 533 16.3.3 CAE VERIFICATION ON A WIND TURBINE BLADE ................................ 538 16.3.4 CAE VERIFICATION ON MAT EFFECTS .................................................. 540 16.3.5 CAE VERIFICATION ON FLYBRIDGE ..................................................... 543 16.4 CAE CASE STUDY ......................................................................................... 547 17 INTEGRATED CIRCUIT PACKAGING ...................................................... 549 CHIH-CHUNG (JIM) HSU, CHIA-PENG (VICTOR) SUN, CHEN-AN (JENNAN) WANG, YU-EN (JOSEPH) LIANG 17.1 BASICS ........................................................................................................... 549 17.1.1 PROCESS PRINCIPLE ........................................................................... 554 17.1.2 ADVANTAGES AND CHALLENGES ......................................................... 557 17.1.3 THEORETICAL MODELS ......................................................................... 559 17.2 PRACTICAL APPLICATIONS ................................................................................ 563 17.2.1 CAE VERIFICATION ON VOID PREDICTION ........................................... 563 17.2.2 FLUID-STRUCTURE INTERACTIONS: WIRE SWEEP ANALYSIS .................. 567 17.2.3 FLUID-STRUCTURE INTERACTIONS: PADDLE SHIFT AND CHIP DEFORMATION ANALYSIS ................................................................... 569 17.2.4 WARPAGE PREDICTION FOR A BILAMINATE ........................................... 577 17.2.5 WARPAGE PREDICTION FOR A BI-MATERIAL COMPONENT MODEL ........ 580 17.2.6 WARPAGE OF BI-MATERIAL STRIP ....................................................... 583 17.2.7 THE EFFECT OF DISPENSING CONTROL AND CREEPING BEHAVIOR ON THE UNDERFILL PROCESS ................................................... 586 17.3 CAE CASE STUDY ........................................................................................... 591 INDEX ......................................................................................................... 595
adam_txt	CONTENTS ACKNOWLEDGMENTS . V PREFACE . VII 1 OVERVIEW OF PLASTICS MOLDING . 1 CHE-PING (BARTON) LIN 1.1 INTRODUCTION TO INJECTION MOLDING . 1 1.1.1 THE SYSTEMS OF INJECTION MOLDING . 3 1.1.1.1 THE CYCLE OF INJECTION MOLDING . 3 1.1.1.2 INJECTION MACHINE . 4 1.1.2 DEFECTS IN INJECTION MOLDED PRODUCTS . 10 1.1.2.1 SHORT SHOT . 10 1.1.2.2 WARP . 11 1.1.2.3 FLASH . 11 1.1.2.4 SINK MARK AND VOID . 12 1.1.2.5 AIR TRAP . 13 1.1.2.6 BURN MARK . 13 1.1.2.7 DELAMINATION . 14 1.1.2.8 FISH EYE . 14 1.1.2.9 FLOW MARK . 14 1.1.2.10 STRESS MARK . 15 1.1.2.11 HESITATION . 15 1.1.2.12 JETTING . 16 1.1.2.13 SPLAY . 16 1.1.2.14 WELD LINE . 17 1.2 CORE VALUES OF MOLDING SIMULATION . 18 1.2.1 APPLICATION OF CAE TECHNOLOGY IN INJECTION MOLDING . 19 2 MATERIAL PROPERTIES OF PLASTICS . 23 CHEN-CHIEH (JYE) WANG 2.1 OVERVIEW . 23 2.2 RHEOLOGICAL PROPERTIES . 25 2.2.1 VISCOSITY . 26 2.2.1.1 EFFECTS OF NON-NEWTONIAN AND MOLECULAR CONFORMATION . 27 2.2.1.2 EFFECTS OF SHEAR RATE . 28 2.2.1.3 EFFECTS OF TEMPERATURE . 30 2.2.1.4 EFFECTS OF PRESSURE . 31 2.2.1.5 THEORETICAL MODELS . 31 2.2.1.6 VISCOSITY PROPERTIES OF PLASTICS . 33 2.2.2 VISCOELASTIC FLUIDS . 35 2.2.2.1 VISCOELASTIC BEHAVIOR . 35 2.2.2.2 THEORETICAL MODELS . 37 2.2.2.3 MEASUREMENT OF VISCOELASTICITY . 41 2.3 THERMODYNAMIC AND THERMAL PROPERTIES . 46 2.3.1 SPECIFIC HEAT CAPACITY . 46 2.3.2 MELTING POINT AND GLASS TRANSITION TEMPERATURES . 48 2.3.3 PVT EQUATION OF STATE . 49 2.3.3.1 DEFINITION . 49 2.3.3.2 DATA INTERPRETATION . 50 2.3.3.3 THEORETICAL MODELS . 51 2.3.3.4 EFFECTS OF NON-EQUILIBRIUM STATE ON PVT . 54 2.3.4 THERMAL CONDUCTIVITY AND HEAT TRANSFER COEFFICIENT . 56 2.3.4.1 DEFINITION . 56 2.3.4.2 THEORETICAL MODELS . 57 2.3.4.3 DATA INTERPRETATION . 57 2.3.4.4 MOLD-MELT CONTACT AND HEAT TRANSFER COEFFICIENT (HTC) . 58 2.4 MECHANICAL PROPERTIES . 59 2.4.1 STRESS AND STRAIN OF PLASTICS . 59 2.4.2 SOLID-LIKE VISCOELASTICITY . 60 2.4.3 THEORETICAL MODEL . 61 2.4.4 DATA INTERPRETATION . 62 2.5 KINETIC PROPERTIES . 64 2.5.1 CRYSTALLINE . 64 2.5.2 THEORETICAL MODELS . 64 2.5.3 EFFECTS OF COOLING RATE ON CRYSTALLIZATION . 65 2.6 CURING KINETICS . 66 2.6.1 CURING PHENOMENON . 66 2.6.2 THEORETICAL MODELS . 67 2.6.3 CURING EFFECT ON VISCOSITY . 68 2.6.4 DATA INTERPRETATION . 70 3 PART AND MOLD DESIGN . 73 TSAI-HSIN (SAM) HSIEH, TAO-CHEN (CLOUD) TSAI, YAO-WEI (WILLIE) CHUANG 3.1 PART DESIGN . 73 3.1.1 GOLDEN RULE: UNIFORM WALL THICKNESS . 73 3.1.2 WALL THICKNESS VERSUS FLOW LENGTH . 76 3.1.3 RADIUS/FILLETS AND CHAMFER ANGLE . 78 3.1.4 RIB AND BOSS . 79 3.1.5 DRAFT ANGLE . 84 3.1.6 DESIGN FOR MANUFACTURING (DFM) . 85 3.1.7 SUMMARY . 86 3.2 MOLD DESIGN . 87 3.2.1 BASICS . 88 3.2.2 GATE DESIGN . 91 3.2.2.1 GATE NUMBER . 91 3.2.2.2 GATE LOCATION . 92 3.2.2.3 GATE TYPES . 95 3.2.3 RUNNER DESIGN . 97 3.2.3.1 RUNNER SHAPE AND DIMENSION . 98 3.2.3.2 MULTI-CAVITY RUNNER DESIGN . 99 3.2.4 COOLING DESIGN . 100 3.2.5 OTHERS . 102 3.2.5.1 EJECTOR SYSTEM . 102 3.2.5.2 VENTING DESIGN . 102 4 PROCESS CONDITIONS . 105 CHUAN-WEI (ARVID) CHANG 4.1 INTRODUCTION TO THE INJECTION MOLDING CYCLE . 105 4.1.1 BRIEF INTRODUCTION TO INJECTION MOLDING MACHINE UNITS . 105 4.1.2 INJECTION MOLDING CYCLE . 107 4.1.3 MOLDING WINDOW . 110 4.1.4 PVT VARIATIONS DURING INJECTION STAGES . ILL 4.2 PLASTICIZING CONDITIONS . 122 4.2.1 NOZZLE TEMPERATURE AND CYLINDER TEMPERATURES . 122 4.2.2 BACK PRESSURE, SCREW RPM, SUCK BACK, AND METERING STROKE . 123 4.3 FILLING CONDITIONS . 129 4.3.1 FILLING TIME VERSUS INJECTION VELOCITY . 129 4.3.2 INJECTION PRESSURE . 133 4.3.3 VP SWITCH . 136 4.4 PACKING CONDITIONS . 138 4.5 COOLING CONDITIONS . 140 4.5.1 COOLING TIME . 140 4.5.2 COOLANT FLOW RATE . 141 4.5.3 MOLD TEMPERATURE . 141 4.6 CONNECTING SMART DESIGN TO SMART MANUFACTURING . 142 4.6.1 MACHINE CHARACTERIZATION . 143 4.6.2 THE CAE SETTING MODE IN COMBINATION WITH INJECTION MACHINE ON SITE . 148 4.6.3 CASE STUDY . 150 5 MOLDING SIMULATION METHODOLOGY . 157 HSIEN-SEN (ETHAN) CHIU 5.1 THE GOAL OF MOLDING SIMULATION . 157 5.1.1 DESIGN VERIFICATION AND OPTIMIZATION . 158 5.1.1.1 OVERVIEW OF DESIGN FOR MANUFACTURE (DFM) . 158 5.1.1.2 CAE AND DFM: A PRACTICAL CASE STUDY . 160 5.1.2 PROCESS CONDITIONS OPTIMIZATION . 167 5.1.2.1 MOLDING STABILITY . 167 5.1.2.2 REAL CASE . 169 5.2 BASICS OF SIMULATION EQUATIONS . 173 5.2.1 GOVERNING EQUATIONS . 174 5.2.2 NUMERICAL APPROXIMATION . 175 5.2.2.1 FINITE DIFFERENCE METHOD (FDM) . 175 5.2.2.2 FINITE VOLUME METHOD (FVM) . 178 5.2.2.3 FINITE ELEMENT METHOD (FEM) . 180 5.3 WHAT IS MOLDING SIMULATION? . 182 5.3.1 BRIEF HISTORY OF MOLDING SIMULATION . 182 5.3.2 SIMULATION WORKFLOW . 189 6 FLOW CONSIDERATION VERSUS PART FEATURES . 193 WEN-HSIN (DEBBIE) WENG 6.1 BASICS . 193 6.1.1 FLOW BEHAVIOR OF PLASTIC MELT IN THE CAVITY . 193 6.1.2 EFFECTS OF FILLING TIME . 198 6.1.3 FLOW RATE VERSUS INJECTION PRESSURE . 199 6.1.3.1 FLOW RATE CURVE SETTING . 199 6.1.3.2 RELATIONSHIP OF INJECTION RATE AND INJECTION PRESSURE . 203 6.1.4 VP SWITCH AND CAVITY PRESSURE . 209 6.1.5 EFFECTS OF PART THICKNESS . 218 6.1.6 MATERIAL VISCOSITY AN FLOW BEHAVIOUR . 223 6.1.7 SUMMARY . 227 6.2 PRACTICAL APPLICATIONS . 228 6.2.1 CAE SOLUTION TO STRESS MARK IN A PHONE SHELL . 228 6.2.2 FLOW RATE EFFECT ON INJECTION PRESSURE OF LAPTOP PRODUCT . 232 6.3 CAE CASE STUDY . 234 7 RUNNER AND GATE DESIGN . 239 YAO-CHEN (CLOUD) TSAI, YAO-WEI (WILLIE) CHUANG 7.1 BASICS . 239 7.1.1 GENERAL DESIGN GUIDE OF RUNNERS . 239 7.1.2 GENERAL DESIGN GUIDE OF GATES . 244 7.1.3 GATE SEALING . 256 7.1.4 FLOW BALANCE . 258 7.2 PRACTICAL APPLICATIONS . 265 7.2.1 CAE VERIFICATION ON MELTFLIPPER DESIGN . 265 7.2.2 CAE VERIFICATION OF MULTI-CAVITY SYSTEMS . 271 7.3 CAE CASE STUDY . 275 8 COOLING OPTIMIZATION . 279 HUNG-CHOU (KENT) WANG 8.1 BASICS . 279 8.1.1 HEAT TRANSFER MECHANISM . 280 8.1.2 DESIGN GOLDEN RULE: UNIFORM MOLD TEMPERATURE . 283 8.1.3 GENERAL DESIGN GUIDE OF COOLING CHANNEL . 287 8.1.4 COOLING EFFICIENCY: COOLANT FLOW CONSIDERATION . 291 8.1.5 COOLING TIME ESTIMATE . 294 8.1.6 USE CAE COOLING ANALYSIS . 296 8.1.7 CONFORMAL COOLING APPLICATION . 299 8.2 PRACTICAL APPLICATIONS . 303 8.2.1 DIGITAL CAMERA COVER . 303 8.2.2 CARTRIDGE . : . 308 8.3 CAE CASE STUDY . 312 9 WARPAGE CONTROL . 315 SHIH-PO (TOBER) SUN, WEN-HSIN (DEBBIE) WENG 9.1 BASICS . 315 9.1.1 THE CAUSES OF WARPAGE . 318 9.1.2 MATERIAL EFFECTS . 321 9.1.3 GEOMETRICAL EFFECTS . 324 9.1.4 PROCESS CONDITION EFFECTS . 326 9.1.5 CRITERIA OF CAE WARP ANALYSIS . 328 9.1.6 METHODS TO MINIMIZE WARPAGE . 332 9.2 PRACTICAL APPLICATIONS . 338 9.3 CAE CASE STUDY . 343 10 FIBER ORIENTATION CONTROL . 347 HUAN-CHANG (IVOR) TSENG 10.1 BASICS . 348 10.1.1 PROCESS PRINCIPLE . 350 10.1.2 THEORY MODELS . 351 10.1.3 ADVANTAGES AND CHALLENGES . 361 10.2 PRACTICAL APPLICATIONS . 362 10.2.1 USING THE IARD-RPR MODEL FOR AN INJECTION MOLDED CENTER-GATED DISK WITH FIBER-REINFORCED THERMOPLASTICS . 362 10.2.2 COMPARISON OF IARD-RPR MODELS UNDER GNF DECOUPLING AND IISO COUPLING . 366 10.2.3 THE INFLUENCES OF MATERIAL FLOW AND FIBER INTERACTION ON FIBER ORIENTATION AND PRODUCT QUALITY DURING INJECTION MOLDING . 369 10.3 CAE CASE STUDY . 374 11 HOT RUNNER OPTIMIZATION . 379 TSAI-HSIN (SAM) HSIEH 11.1 BASICS . 379 11.1.1 PROCESS PRINCIPLE . 380 11.1.2 TEMPERATURE CONTROL IN A HOT RUNNER SYSTEM . 384 11.1.3 ADVANTAGES AND CHALLENGES . 386 11.2 PRACTICAL APPLICATIONS . 395 11.2.1 CAE VERIFICATION ON A SINGLE-GATE HOT RUNNER SYSTEM . 395 11.2.2 CAE PIN MOVEMENT CONTROL OF VALVE GATE . 404 11.3 CAE CASE STUDY . 408 12 CO-/BI-INJECTION MOLDING . 411 CHIH-CHUNG (JIM) HSU, YU-SHENG (TIM) CHOU 12.1 BASICS . 412 12.1.1 PROCESS PRINCIPLE . 412 12.1.2 ADVANTAGES AND CHALLENGES . 415 12.1.3 THEORY MODELS . 417 12.2 PRACTICAL APPLICATIONS . 418 12.2.1 CO-INJECTION MOLDING OF FORK MODEL . 418 12.2.2 CO-INJECTION MOLDING: CORE BREAKTHROUGH AND FLOW IMBALANCE . 420 12.2.3 CO-INJECTION MOLDING: FIBER ORIENTATION PREDICTIONS . 424 12.2.4 CAE CASE OF BI-INJECTION MOLDING . 426 12.3 CAE CASE STUDY . 430 13 GAS-/WATER-ASSISTED INJECTION MOLDING . 433 CHIH-CHUNG (JIM) HSU, YU-SHENG (TIM) CHOU 13.1 BASICS . 433 13.1.1 PROCESS PRINCIPLE . 434 13.1.1.1 SHORT-SHOT PROCESS . 434 13.1.1.2 FULL-SHOT PROCESS . 436 13.1.2 ADVANTAGES AND CHALLENGES . 438 13.2 PRACTICAL APPLICATIONS . 446 13.2.1 CAE VERIFICATION ON GAIM . 446 13.2.2 CAE VERIFICATION ON WAIM . 449 13.2.3 CAE VERIFICATION ON GAIM: FINGERING EFFECT . 452 13.3 CAE CASE STUDY . 454 14 FOAM INJECTION MOLDING . 457 YUAN-JUNG (DAN) CHANG, LI-YANG (ROBERT) CHANG, CHIH-WEI (JOE) WANG 14.1 BASICS . 457 14.1.1 MICROCELLULAR PROCESS PRINCIPLE . 458 14.1.2 ADVANTAGES AND CHALLENGES . 462 14.1.3 THEORY MODELS . 464 14.2 PRACTICAL APPLICATIONS . 466 14.2.1 CAE VERIFICATION ON MICROCELLULAR INJECTION MOLDING: CASE 1 . 466 14.2.2 CAE VERIFICATION OF MICROCELLULAR INJECTION MOLDING: CASE 2 . 473 14.2.3 CAE VERIFICATION ON CHEMICAL FOAMING INJECTION MOLDING . 480 14.2.4 CAE VERIFICATION OF POLYURETHANE REACTIVE FOAMING MOLDING . 483 14.2.5 SUMMARY . 491 14.3 CAE CASE STUDY . 492 15 POWDER INJECTION MOLDING . 495 HUAN-CHANG (IVOR) TSENG 15.1 BASICS . 495 15.1.1 PROCESS PRINCIPLE . 496 15.1.2 ADVANTAGES AND CHALLENGES . 497 15.1.3 THEORY MODELS . 500 15.2 PRACTICAL APPLICATIONS . 505 15.3 CAE CASE STUDY . 508 16 RESIN TRANSFER MOLDING . 511 HSUN (FRED) YANG, YU-HE (ZOE) CHEN 16.1 BASICS . 512 16.1.1 PROCESS PRINCIPLE . 516 16.1.2 ADVANTAGES AND CHALLENGES . 520 16.2 THEORY MODELS . 521 16.2.1 2.5D ANALYSIS . 521 16.2.2 3D ANALYSIS . 523 16.2.3 MEASUREMENT OF PERMEABILITY . 525 16.2.4 POROSITY . 528 16.2.5 MEASUREMENT OF CHEMORHEOLOGICAL PROPERTIES . 529 16.2.6 SIMULATION PARAMETERS . 530 16.3 PRACTICAL APPLICATIONS . 531 16.3.1 CAE VERIFICATION ON EDGE EFFECTS . 531 16.3.2 CAE VERIFICATION ON THICKNESS-DIRECTION FLOW . 533 16.3.3 CAE VERIFICATION ON A WIND TURBINE BLADE . 538 16.3.4 CAE VERIFICATION ON MAT EFFECTS . 540 16.3.5 CAE VERIFICATION ON FLYBRIDGE . 543 16.4 CAE CASE STUDY . 547 17 INTEGRATED CIRCUIT PACKAGING . 549 CHIH-CHUNG (JIM) HSU, CHIA-PENG (VICTOR) SUN, CHEN-AN (JENNAN) WANG, YU-EN (JOSEPH) LIANG 17.1 BASICS . 549 17.1.1 PROCESS PRINCIPLE . 554 17.1.2 ADVANTAGES AND CHALLENGES . 557 17.1.3 THEORETICAL MODELS . 559 17.2 PRACTICAL APPLICATIONS . 563 17.2.1 CAE VERIFICATION ON VOID PREDICTION . 563 17.2.2 FLUID-STRUCTURE INTERACTIONS: WIRE SWEEP ANALYSIS . 567 17.2.3 FLUID-STRUCTURE INTERACTIONS: PADDLE SHIFT AND CHIP DEFORMATION ANALYSIS . 569 17.2.4 WARPAGE PREDICTION FOR A BILAMINATE . 577 17.2.5 WARPAGE PREDICTION FOR A BI-MATERIAL COMPONENT MODEL . 580 17.2.6 WARPAGE OF BI-MATERIAL STRIP . 583 17.2.7 THE EFFECT OF DISPENSING CONTROL AND CREEPING BEHAVIOR ON THE UNDERFILL PROCESS . 586 17.3 CAE CASE STUDY . 591 INDEX . 595
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any_adam_object_boolean	1
author	Wang, Maw-Ling Chang, Rong-Yeu Hsu, Chia-Hsiang
author_GND	(DE-588)1261910265
author_facet	Wang, Maw-Ling Chang, Rong-Yeu Hsu, Chia-Hsiang
author_role	aut aut aut
author_sort	Wang, Maw-Ling
author_variant	m l w mlw r y c ryc c h h chh
building	Verbundindex
bvnumber	BV048294752
classification_tum	CIT 735
ctrlnum	(OCoLC)1288570091 (DE-599)DNB1247123391
discipline	Werkstoffwissenschaften Chemie-Ingenieurwesen
discipline_str_mv	Werkstoffwissenschaften Chemie-Ingenieurwesen
edition	2nd Edition
format	Book
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owner	DE-210 DE-12 DE-91G DE-BY-TUM
owner_facet	DE-210 DE-12 DE-91G DE-BY-TUM
physical	XX, 599 Seiten Illustrationen, Diagramme 25 cm
publishDate	2022
publishDateSearch	2022
publishDateSort	2022
publisher	Carl Hanser Verlag
record_format	marc
spelling	Wang, Maw-Ling Verfasser aut Molding Simulation: Theory and Practice Maw-Ling Wang, Rong-Yeu Chang, Chia-Hsiang (David) Hsu 2nd Edition Munich Carl Hanser Verlag [2022] © 2022 XX, 599 Seiten Illustrationen, Diagramme 25 cm txt rdacontent n rdamedia nc rdacarrier Spritzgießen (DE-588)4056561-0 gnd rswk-swf Computersimulation (DE-588)4148259-1 gnd rswk-swf Kunststoff (DE-588)4033676-1 gnd rswk-swf Modellierung (DE-588)4170297-9 gnd rswk-swf assisted injection molding computer assisted engineering fiber orientation foam injection molding gates injection molding Kunststoffverarbeitung manufacturing melt flow mold cooling mold design Moldex3D plastics plastics processing resin transfer molding rheology runners simulation Spritzgießen warpage FBKTSPRI: Spritzgießen PLAS2022 (DE-588)4123623-3 Lehrbuch gnd-content Spritzgießen (DE-588)4056561-0 s Computersimulation (DE-588)4148259-1 s Modellierung (DE-588)4170297-9 s DE-604 Kunststoff (DE-588)4033676-1 s Chang, Rong-Yeu Verfasser aut Hsu, Chia-Hsiang Verfasser (DE-588)1261910265 aut Hanser Publications (DE-588)1064064051 pbl Erscheint auch als Online-Ausgabe 978-1-56990-885-3 DNB Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=033674653&sequence=000001&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis 1\p vlb 20211208 DE-101 https://d-nb.info/provenance/plan#vlb
spellingShingle	Wang, Maw-Ling Chang, Rong-Yeu Hsu, Chia-Hsiang Molding Simulation: Theory and Practice Spritzgießen (DE-588)4056561-0 gnd Computersimulation (DE-588)4148259-1 gnd Kunststoff (DE-588)4033676-1 gnd Modellierung (DE-588)4170297-9 gnd
subject_GND	(DE-588)4056561-0 (DE-588)4148259-1 (DE-588)4033676-1 (DE-588)4170297-9 (DE-588)4123623-3
title	Molding Simulation: Theory and Practice
title_auth	Molding Simulation: Theory and Practice
title_exact_search	Molding Simulation: Theory and Practice
title_exact_search_txtP	Molding Simulation: Theory and Practice
title_full	Molding Simulation: Theory and Practice Maw-Ling Wang, Rong-Yeu Chang, Chia-Hsiang (David) Hsu
title_fullStr	Molding Simulation: Theory and Practice Maw-Ling Wang, Rong-Yeu Chang, Chia-Hsiang (David) Hsu
title_full_unstemmed	Molding Simulation: Theory and Practice Maw-Ling Wang, Rong-Yeu Chang, Chia-Hsiang (David) Hsu
title_short	Molding Simulation: Theory and Practice
title_sort	molding simulation theory and practice
topic	Spritzgießen (DE-588)4056561-0 gnd Computersimulation (DE-588)4148259-1 gnd Kunststoff (DE-588)4033676-1 gnd Modellierung (DE-588)4170297-9 gnd
topic_facet	Spritzgießen Computersimulation Kunststoff Modellierung Lehrbuch
url	http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=033674653&sequence=000001&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA
work_keys_str_mv	AT wangmawling moldingsimulationtheoryandpractice AT changrongyeu moldingsimulationtheoryandpractice AT hsuchiahsiang moldingsimulationtheoryandpractice AT hanserpublications moldingsimulationtheoryandpractice

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