This paper presents a systematic approach to model and simulate the influence that the variation of process parameters has on the final quality of an injection moulded component. In the first phase, we define a multi-steps procedure to develop a reliable digital model of the injection moulding process by the fine-tuning of the part cavity and the mould elements (e.g. detail simplification, discretization and mesh density, elements modelling, etc.) using real data as validation. In the second phase, we investigate the correlation between selected process parameters and the final tolerances of the moulded component, based on a Design of Experiments. As a case study, we selected the body of a mass airflow sensor for an automotive high performance engines, made of polybutylene terephthalate reinforced with glass-fibre, which presents roundness issues on functional features. The effects of the injection velocity and packing pressure on the deformation of the component are investigated, identifying the best combination of their values that leads to compliance with the roundness tolerances on its functional features. The injection moulding Computer Aided Engineering (CAE) software Moldex3D (CoreTech) is used to run the simulations, and the results are finally validated by comparing the experimental data obtained from the injection moulding machine that produces the component.

Investigation of Warpage and Tolerances in Injection Moulding Components Based on Simulation and Experimental Validation / Garlaschelli, G.; Gherardini, F.; Malagola, S.; Leali, F.. - (2022), pp. 342-353. ((Intervento presentato al convegno 2nd International Conference on Design Tools and Methods in Industrial Engineering, ADM 2021 tenutosi a ita nel 2021 [10.1007/978-3-030-91234-5_35].

Investigation of Warpage and Tolerances in Injection Moulding Components Based on Simulation and Experimental Validation

Gherardini F.
;
Leali F.
2022

Abstract

This paper presents a systematic approach to model and simulate the influence that the variation of process parameters has on the final quality of an injection moulded component. In the first phase, we define a multi-steps procedure to develop a reliable digital model of the injection moulding process by the fine-tuning of the part cavity and the mould elements (e.g. detail simplification, discretization and mesh density, elements modelling, etc.) using real data as validation. In the second phase, we investigate the correlation between selected process parameters and the final tolerances of the moulded component, based on a Design of Experiments. As a case study, we selected the body of a mass airflow sensor for an automotive high performance engines, made of polybutylene terephthalate reinforced with glass-fibre, which presents roundness issues on functional features. The effects of the injection velocity and packing pressure on the deformation of the component are investigated, identifying the best combination of their values that leads to compliance with the roundness tolerances on its functional features. The injection moulding Computer Aided Engineering (CAE) software Moldex3D (CoreTech) is used to run the simulations, and the results are finally validated by comparing the experimental data obtained from the injection moulding machine that produces the component.
2nd International Conference on Design Tools and Methods in Industrial Engineering, ADM 2021
ita
2021
342
353
Garlaschelli, G.; Gherardini, F.; Malagola, S.; Leali, F.
Investigation of Warpage and Tolerances in Injection Moulding Components Based on Simulation and Experimental Validation / Garlaschelli, G.; Gherardini, F.; Malagola, S.; Leali, F.. - (2022), pp. 342-353. ((Intervento presentato al convegno 2nd International Conference on Design Tools and Methods in Industrial Engineering, ADM 2021 tenutosi a ita nel 2021 [10.1007/978-3-030-91234-5_35].
File in questo prodotto:
File Dimensione Formato  
2022_Investigation ofWarpage and Tolerances in Injection Moulding.pdf

non disponibili

Tipologia: Versione dell'editore (versione pubblicata)
Dimensione 1.43 MB
Formato Adobe PDF
1.43 MB Adobe PDF   Visualizza/Apri   Richiedi una copia
ADM_IM_warpage_final_postprint.pdf

embargo fino al 01/12/2024

Descrizione: Versione postprint (accettata)
Tipologia: Post-print dell'autore (bozza post referaggio)
Dimensione 473.33 kB
Formato Adobe PDF
473.33 kB Adobe PDF   Visualizza/Apri   Richiedi una copia
Pubblicazioni consigliate

Caricamento pubblicazioni consigliate

Licenza Creative Commons
I metadati presenti in IRIS UNIMORE sono rilasciati con licenza Creative Commons CC0 1.0 Universal, mentre i file delle pubblicazioni sono rilasciati con licenza Attribuzione 4.0 Internazionale (CC BY 4.0), salvo diversa indicazione.
In caso di violazione di copyright, contattare Supporto Iris

Utilizza questo identificativo per citare o creare un link a questo documento: http://hdl.handle.net/11380/1274528
Citazioni
  • ???jsp.display-item.citation.pmc??? ND
  • Scopus 0
  • ???jsp.display-item.citation.isi??? ND
social impact