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Related Experiment Video

Updated: Jan 22, 2026

A Soft Tooling Process Chain for Injection Molding of a 3D Component with Micro Pillars
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Tie-Bar Elongation Based Filling-To-Packing Switchover Control and Prediction of Injection Molding Quality.

Jian-Yu Chen1, Chun-Ying Liu2, Ming-Shyan Huang3

  • 1Bachelor's Program of Precision System Design, Feng Chia University, 100, Wenhwa Rd., Seatwen, Taichung City 40724, Taiwan.

Polymers
|July 21, 2019
PubMed
Summary

This study introduces a new method for injection molding quality control using tie-bar elongation profiles instead of invasive cavity pressure sensors. This approach accurately monitors the filling-to-packing switchover (V/P switchover) and material variations for consistent part production.

Keywords:
clamping forcefilling-to-packing switchoverinjection moldingprocess controltie-bar elongation

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Polymer Processing

Background:

  • Injection molding quality is heavily reliant on precise filling-to-packing switchover (V/P switchover).
  • Current V/P switchover methods often use invasive and costly cavity pressure sensors.
  • Improper V/P switchover settings lead to defects like residual stress, flash, short shots, and warpage.

Purpose of the Study:

  • To propose and verify a novel, non-invasive method for tuning V/P switchover timing using tie-bar elongation profiles.
  • To demonstrate an alternative to expensive and invasive cavity pressure sensors for injection molding quality control.
  • To establish a realistic and effective approach for V/P switchover using readily available data.

Main Methods:

  • Utilized a dumbbell testing specimen mold for experimental verification.
  • Mounted strain gauges on tie bars to detect tie-bar elongation profiles.
  • Analyzed tie-bar elongation profiles to observe mold filling and packing stages.
  • Correlated tie-bar elongation profiles with cavity pressure characteristics under proper clamping force.

Main Results:

  • Tie-bar elongation profiles successfully mirrored mold filling and packing stages.
  • Cavity pressure characteristics showed similarity to tie-bar elongation profiles with adequate clamping force.
  • Process parameter variations (injection speed, V/P switchover point, holding pressure) were reflected in the profiles.
  • The method demonstrated control over part weight fluctuations due to minor temperature changes.
  • Maximum clamping force increment from tie-bar elongation served as an indicator for reground material variation.

Conclusions:

  • The proposed tie-bar elongation profile method is a feasible and realistic approach for V/P switchover in injection molding.
  • This non-invasive technique offers a cost-effective alternative to cavity pressure sensors for consistent molding quality.
  • Tie-bar elongation profiles provide valuable insights for online monitoring of process parameters and material variations.