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Modeling and Experimental Studies on Polymer Melting and Flow in Injection Molding.

Krzysztof Wilczyński1, Krzysztof J Wilczyński2, Kamila Buziak1

  • 1Polymer Processing Department, Faculty of Mechanical and Industrial Engineering, Warsaw University of Technology, Narbutta 85, 02-524 Warsaw, Poland.

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Summary

This study addresses polymer processing challenges in injection molding. New experiments reveal the impact of processing conditions on polymer flow and melting, observing previously undocumented screw starving phenomena.

Keywords:
injection moldingmeltingmodelingpolymers

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Area of Science:

  • Polymer Science and Engineering
  • Manufacturing Technology

Background:

  • Injection molding is a critical polymer processing technology alongside extrusion.
  • Accurate modeling requires integrating solid polymer transport, melting, and melt flow.
  • Existing mathematical models for injection molding lack robust experimental validation.

Purpose of the Study:

  • To present and discuss the state-of-the-art in modeling and experimentation for polymer flow and melting in injection molding.
  • To address the experimental deficit in current mathematical models.
  • To investigate the influence of processing parameters on the injection molding cycle.

Main Methods:

  • Experimental investigation of polymer flow and melting within an injection molding machine.
  • Analysis of the effects of screw speed, plasticating stroke, and back pressure on the process.
  • Comparison of experimental findings with existing modeling approaches.

Main Results:

  • Observed starving phenomena in the initial screw sections, a novel finding not previously reported.
  • Quantified the impact of varying screw speed, plasticating stroke, and back pressure.
  • Identified limitations in current mathematical models due to lack of experimental basis.

Conclusions:

  • Experimental data is crucial for advancing injection molding models.
  • The observed starving phenomenon requires further investigation and model incorporation.
  • Novel concepts for improved injection molding modeling have been proposed based on experimental findings.