Tie-Bar Elongation Based Filling-To-Packing Switch

polymers
Article
Tie-Bar Elongation Based Filling-To-Packing
Switchover Control and Prediction of Injection
Molding Quality
Jian-Yu Chen 1 , Chun-Ying Liu 2 and Ming-Shyan Huang 2, *
1 Bachelor’s Program of Precision System Design, Feng Chia University, 100, Wenhwa Rd., Seatwen,
Taichung City 40724, Taiwan
2 Department of Mechatronics Engineering, National Kaohsiung University of Science and Technology,
1 University Rd., Yanchao Dist., Kaohsiung City 824, Taiwan
* Correspondence: mshuang@nkust.edu.tw; Tel.: +886-7-6011000 (ext. 32219); Fax: +886-7-6011066

Received: 15 June 2019; Accepted: 7 July 2019; Published: 9 July 2019
Abstract: Filling-to-packing switchover (also called V/P switchover) is critical for assuring injection
molding quality. An improper V/P switchover setting may result in various defects of injection-molded
parts, such as excessive residual stress, flash, short shot, and warpage, etc. To enhance a consistent
molding quality, recent V/P switchover approaches adopt cavity pressure profiles requiring sensors
embedded in mold cavities, which is invasive to mold cavities and more expensive. Instead of
using cavity pressure sensors, by working with the most popular screw position switchover control,
this study hereby proposes a novel approach of tuning V/P switchover timing using a tie-bar
elongation profile. In this investigation, a dumbbell testing specimen mold is applied to verify the
feasibility of the method proposed. The results show that the mold filling and packing stages can be
observed along the tie-bar elongation profile, detected by mounting strain gauges on the tie bars.
Also, the characteristics of the cavity pressure are similar to those of the tie-bar elongation profile
under a proper clamping force condition. Moreover, the varying process parameter settings which
include injection speed, V/P switchover point, and holding pressure, can be reflected in these profiles.
By extracting their characteristics, the application of the V/P switchover is proved to be realistic.
This research conducted an experiment to verify the proposed V/P switchover decision method
based on the tie-bar elongation profile. The result showed that the fluctuation of the part’s weight
corresponding to a slight change of the barrel’s temperature from 210 ◦ C to 215 ◦ C can be successfully
controlled with this method. Besides, the maximum clamping force increment extracted from the
tie-bar elongation profile was found to be a good indicator for online monitoring of the reground
material variation.
Keywords: clamping force; filling-to-packing switchover; injection molding; process control;

tie-bar elongation
1. Introduction
Injection molding has been broadly used to fabricate components in many industries, such as
in automobiles, electronics, sports goods, medical devices, and optical lenses. Injection molding is a
cyclic process that comprises of four stages: (1) mold closing and clamping; (2) filling, compressing,
and holding; (3) cooling and concurrently plasticizing for the next cycle; and (4) mold opening and
ejecting. In stages 2 and 3, the filling, compressing, holding and cooling of molten polymer within
cavities have been paid much attention in past studies, since they determine the quality of the injection
molding parts [1–3]. Particularly, this includes main process parameters such as injection speed and
Polymers 2019, 11, 1168; doi:10.3390/polym11071168 www.mdpi.com/journal/polymers

Polymers 2019, 11, 1168 2 of 18
Polymers 2019, 11, x FOR PEER REVIEW 2 of 18
molding qualities,
pressure, e.g., partand
holding pressure appearance,
time, meltgeometrical dimensions, dominate
and mold temperatures mechanicalthe properties, etc. The
injection molding
behaviorse.g.,
qualities, of molten polymer within
part appearance, cavitiesdimensions,
geometrical can be observed by investigating
mechanical properties,the etc.cavity pressure
The behaviors
profiles
of molten [4].polymer
Figure 1within
showscavities
a typicalcan cavity pressure by
be observed profile, the pattern
investigating thefrom Point
cavity A to Cprofiles
pressure represents[4].
the filling
Figure stage,aintypical
1 shows whichcavity
moltenpressure
polymerprofile,
enters the mold
pattern cavities, following
from Point A to this the cavitythe
C represents pressure
filling
is gradually
stage, in which increased
molten based
polymer on enters
the injection
the mold pressure applied.
cavities, followingThethis
filling
the phase
cavity is completed
pressure at Point
is gradually
C, where the
increased based cavity
on theis only volumetrically
injection filled by
pressure applied. the
The molten
filling phasepolymer without
is completed atbeing
Point compressed.
C, where the
The compression
cavity process then
is only volumetrically begins,
filled by theand the pressure
molten polymerincreases rapidly
without being to its peak value
compressed. at Point D,
The compression
which has the greatest impact on the resisting mold clamping force
process then begins, and the pressure increases rapidly to its peak value at Point D, which introduced by the clamping
has the
mechanism
greatest impact in the
on whole injection
the resisting moldmolding
clamping process.
force The molten by
introduced polymer within mechanism
the clamping the cavity isinthen the
maintained
whole at a molding
injection set pressure during
process. Thethe holding
molten phase.within
polymer Additional molten
the cavity polymer
is then can be packed
maintained at a set
into the cavity
pressure during to compensate
the holding for the plastic
phase. shrinkage
Additional caused
molten by cooling,
polymer can bethus ensuring
packed into that the mold
the cavity to
is completely
compensate forfilled. This shrinkage
the plastic process continues
caused byuntil thethus
cooling, gateensuring
is frozen, that asthe
shown
mold at Point E. This
is completely is
filled.
followed
This process by the final cooling
continues phase,
until the and
gate is it continues
frozen, as shown until the end
at Point of the
E. This is cycle.
followedDuring this
by the phase,
final the
cooling
melt solidifies
phase, gradually
and it continues as the
until the end
coolant
of thethat circulates
cycle. During within the the
this phase, cooling
melt channels in the mold
solidifies gradually as
removes
the coolant heat.
thatThe coolingwithin
circulates and solidification rates determine
the cooling channels in the mold the removes
rate while the The
heat. cavity pressure
cooling and
decreases.
solidification rates determine the rate while the cavity pressure decreases.
Figure 1. Typical cavity pressure profile.

Figure 1. Typical cavity pressure profile.
Due to increasing demand for injection molding quality, a proper setting of main processing
Due to increasing demand for injection molding quality, a proper setting of main processing
parameters such as injection speed and pressure, melt and mold temperature, holding pressure and
parameters such as injection speed and pressure, melt and mold temperature, holding pressure and
time as well as the cooling rate dominate the results. Particularly, the switching time from mold
time as well as the cooling rate dominate the results. Particularly, the switching time from mold filling
filling to molding holding, also called filling-to-packing switchover or V/P switchover, is crucial in
to molding holding, also called filling-to-packing switchover or V/P switchover, is crucial in
determining part quality. Notably, the control strategy of an injection molding machine to proceed
determining part quality. Notably, the control strategy of an injection molding machine to proceed
to mold filling and mold holding is distinct. For mold filling, molten polymer is compressed to fill
to mold filling and mold holding is distinct. For mold filling, molten polymer is compressed to fill
cavities with a constant flow rate beneath a limited injection pressure to protect machine and mold.
cavities with a constant flow rate beneath a limited injection pressure to protect machine and mold.
In contrast, in mold holding, molten polymer fills mold cavities with a constant holding pressure while
In contrast, in mold holding, molten polymer fills mold cavities with a constant holding pressure
the holding speed is limited. This holding stage aims to compensate for the volume shrinkage of the
while the holding speed is limited. This holding stage aims to compensate for the volume shrinkage
polymer due to cooling.
of the polymer due to cooling.
A proper V/P switchover time setting is essential in achieving good consistency of the
A proper V/P switchover time setting is essential in achieving good consistency of the injection-
injection-molded parts. If the V/P switchover time is too early, the injection pressure, as shown
molded parts. If the V/P switchover time is too early, the injection pressure, as shown in Figure 2a
in Figure 2a may be insufficient to compress the molten polymer into the mold’s cavities, resulting in
may be insufficient to compress the molten polymer into the mold’s cavities, resulting in a short shot,
a short shot, sink mark and warpage, etc. On the contrary, a later V/P switchover time may lead to
sink mark and warpage, etc. On the contrary, a later V/P switchover time may lead to overfilling and
overfilling and generate excessive cavity pressure as shown in Figure 2b. Improper switchover timing
generate excessive cavity pressure as shown in Figure 2b. Improper switchover timing may create
may create serious residual stress/flash on injection-molded part, or even a severe mold deformation
serious residual stress/flash on injection-molded part, or even a severe mold deformation and
excessive tie-bar elongation. Therefore, a proper V/P switchover time setting not only assures that the
molten polymer performs a complete mold filling, but also generates sufficient compression of the
Polymers 2019, 11, 1168 3 of 18
and excessive
Polymers 2019, 11, xtie-bar elongation.
FOR PEER Therefore, a proper V/P switchover time setting not only assures
REVIEW 3 ofthat
18
the molten polymer performs a complete mold filling, but also generates sufficient compression of the
molten
moltenpolymer
polymerininthe
thecavity.
cavity.The
Thecavity
cavitypressure
pressureprofile
profileunder
underaaproper
properV/P
V/Pswitchover
switchoverisissmooth,
smooth,
asasshown
shownininFigure
Figure2c.
2c.
Pressure peak
Pressure
Pressure
Time Time
(a) (b) (c)

Two typical
Figure2.2.Two
Figure typical cavity
cavity pressure
pressureprofiles
profilesbyby
filling-to-packing (V/P)
filling-to-packing switchover:
(V/P) (a) early;
switchover: (b) later;
(a) early; (b)
(c) proper.
later; (c) proper.
The cavity pressure profile and its repeatability clearly influence the quality of the molded part,
The cavity pressure profile and its repeatability clearly influence the quality of the molded part,
especially its mass, dimensional stability, mechanical behavior, and surface quality. Many studies have
especially its mass, dimensional stability, mechanical behavior, and surface quality. Many studies
proposed that the cavity pressure profile can be used to maintain product quality and help control
have proposed that the cavity pressure profile can be used to maintain product quality and help
the machine during the injection-molding process. Besides, other studies indicated that a method
control the machine during the injection-molding process. Besides, other studies indicated that a
to maintain
method a high ayield
to maintain highrate
yieldfrom
ratemolding
from molding is to reproduce
is to reproducethe cavity pressure
the cavity curvecurve
pressure in every shot.
in every
shot. Based on these studies, the ideal process parameters have been selected in the past study [4], the
Based on these studies, the ideal process parameters have been selected in the past study [4], so so
corresponding
the corresponding idealideal
cavity pressure
cavity profileprofile
pressure is explored and reproduced
is explored by the machine
and reproduced by theinmachine
subsequent in
shots. Seeing
subsequent thatSeeing
shots. inconsistent V/P switchover
that inconsistent settings can
V/P switchover significantly
settings affect theaffect
can significantly cavity thepressure
cavity
profile, they
pressure must
profile, be must
they controlled adequately.
be controlled adequately.
Eventhough
Even thoughthe theV/P
V/Pswitchover
switchovercontrol
controlbased basedon oncavity
cavitypressure
pressuresignals
signalsisisaawell-recognized
well-recognized
method, it is costly and inconvenient concerning the installation of
method, it is costly and inconvenient concerning the installation of pressure sensors in injectionpressure sensors in injectionmold.mold.
InIncomparison,
comparison,aastrain strainsensor
sensormounted
mountedon onthe
thetietiebar
barcan canpresent
presentthe thedynamics
dynamicsofofthe theclamping
clampingforce force
during injection molding process. Figure 3 shows a typical clamping
during injection molding process. Figure 3 shows a typical clamping force profile in the injection force profile in the injection
moldingprocess,
molding process, in in which
which thethecavity
cavitypressure
pressureinin thethe
packing
packing stage increases
stage increasessharply, resulting
sharply, resultingin mold
in
separation
mold separationand immediately
and immediately leading to additional
leading tie-bar elongation,
to additional generating
tie-bar elongation, a furtheraclamping
generating further
force increment
clamping on the clamping
force increment on theforce profile.force
clamping Choosing
profile. theChoosing
tie-bar elongation
the tie-bar profile for V/Pprofile
elongation switchover for
control has two major advantages: (1) the profile can be easily detected
V/P switchover control has two major advantages: (1) the profile can be easily detected by a strain by a strain sensor mounted
on themounted
sensor tie bar, which on theistie
free of which
bar, being invasive
is free ofto the injection
being invasive mold. Once themold.
to the injection sensorOnce is installed,
the sensor it is
applicable to various injection molds attached to the same clamping mechanism;
is installed, it is applicable to various injection molds attached to the same clamping mechanism; (2) (2) tie-bar elongation
enables
tie-bar the monitoring
elongation enablesofthe themonitoring
clamping of condition
the clampingand helps in identifying
condition and helpsain proper clamping
identifying force
a proper
value to set [5]. In injection molding, the magnitude of the clamping
clamping force value to set [5]. In injection molding, the magnitude of the clamping force may affect force may affect the quality
of the
the plastic
quality parts.
of the For instance,
plastic parts. Forainstance,
small clampinga small force may produce
clamping force may defects
produce such as flashes
defects suchand as
poor geometrical
flashes accuracy, whereas
and poor geometrical accuracy, a large
whereas forceacould
large result in insufficient
force could result in air venting during
insufficient air ventingmold
filling/packing,
during leading to theleading
mold filling/packing, generationto theof short shot. Traditionally,
generation of short shot.clamping force is
Traditionally, set at theforce
clamping highest
is
machine specification, which may lead to additional energy consumption.
set at the highest machine specification, which may lead to additional energy consumption. Moreover, Moreover, heavy loading
at the loading
heavy tie bars is at detrimental
the tie bars to is the durability
detrimental toof processed
the durability molds and the machine
of processed molds and itself.
the Therefore,
machine
itself. Therefore, the clamping force is suggested to be set at a proper value for assuringquality
the clamping force is suggested to be set at a proper value for assuring injection molding injectionand
preventing
molding potential
quality damage onpotential
and preventing the machine damage and mold
on the[6]. In this and
machine study, we [6].
mold aimIn to this
investigate
study, we the
aim to investigate the feasibility of quality monitoring based on the characteristics of tie-bara
feasibility of quality monitoring based on the characteristics of tie-bar elongation, further develops
decision rule
elongation, for V/P
further switchover
develops in injection
a decision rule for molding.
V/P switchover in injection molding.
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Figure 3. Typical clamping force profile during one cycle of injection molding.
Figure 3. Typical clamping force profile during one cycle of injection molding.
2. Literature Review
2. Literature Review
The rheological property of molten polymer in the injection molding process is dependent on
the The rheological
shear, temperature property of moltenand
and pressure polymer in the injection
is essentially manifestedmolding
in the process
viscosityis dependent
of the molten on
the shear, temperature
polymer. The viscosityand pressurethe
determines andflowis essentially
behavior ofmanifested in the viscosity
the resin through the mold,ofand the therefore
molten
polymer. The viscosity
has a significant effectdetermines
on the quality the flow
of the behavior
moldedofcomponents.
the resin through
Therethe aremold,
threeandmajortherefore
factorshas that
a determine
significantthe effect on the
viscosity of quality of the molded
molten polymer, namelycomponents. There are
(1) the raw material, three
e.g., major
the type of factors
material, thatthe
determine
rheological thecharacteristics
viscosity of molten of thepolymer,
material,namely (1) the raw
the humidity material,and
conditions, e.g.,batch-by-batch
the type of material, the
variations;
rheological characteristics
(2) the plasticizing effect, of the material,
which is affected thebyhumidity conditions,
the geometrical andofbatch-by-batch
design the injection screw,variations;
the screw(2)
the plasticizing
rotational speed, effect, which is affected
the back-pressure, theby the geometrical
feeding design
rate, the barrel of the injection
temperature and thescrew, the screw
metering time;
rotational
and (3) the speed, the back-pressure,
injection parameter settings, the feeding rate,injection
e.g., the the barrel temperature
speed, the mold and the metering
temperature, thetime;
melt
and (3) the injection
temperature, parameter
the pressure, and thesettings,
coolinge.g.,
time.theConventionally,
injection speed, thethe mold temperature,
behavior of molten polymer the melt flow
temperature,
to cavities isthe hard pressure, and the
to visualize, cooling
so the process time.of Conventionally,
injection molding theacts
behavior
as a blackof molten polymer
box to operators.
flow to cavities
However, withisadvanced
hard to visualize, so the process
sensing technology, much of injection
physical molding
information actsabout
as a black
moltenboxpolymer
to operators.within
However,
the cavities with
can advanced
be revealedsensing [7,8]. Fortechnology,
example, the much cavityphysical
pressure information aboutbymolten
profile detected a cavitypolymer
pressure
within
sensorthe cancavities
reflectcan thebe revealed of
variations [7,8]. For example,
molten polymerthe cavityduring
quality pressure theprofile detected
mold filling by a cavity
process [9–13].
pressure sensor can reflect the variations of molten polymer quality during
Regarding V/P switchover control, Kazmer et al. [14] compared the effects of the V/P switchover setting the mold filling process
[9–13].
point on Regarding
molded part V/Pquality
switchover control,
with seven Kazmer
different et al. including:
methods, [14] compared the position;
(1) screw effects of(2)the V/P
injection
switchover setting point
time; (3) machine pressure;on molded
(4) nozzlepart quality (5)
pressure; with seven
sprue different
pressure; (6)methods, including:
cavity pressure; and(1) (7)screw
cavity
position; (2) injection
temperature. time; (3) machine
They concluded that methodspressure;based(4)onnozzle
screwpressure;
position and(5) sprue
machine pressure;
pressure (6)arecavity
both
pressure;
sufficientand (7) cavity
in most injection temperature.
molding cases, They concluded
providing that consistency
quality methods based for the oninjection-molded
screw position and parts.
machine
Moreover, pressure are both sufficient
the application of cavity in most injection
pressure sensors molding cases, providing
and temperature transducers quality
are consistency
also feasible
for
to the injection-molded
develop a V/P switchover parts.decision
Moreover, forthe
theapplication
injection moldingof cavity pressure
quality sensors
control. and temperature
Huang [4] revealed a
transducers are also feasible
novel V/P switchover controltomethod
develop a V/P
based onswitchover decision profile
the cavity pressure for theby injection
integratingmolding
a simplequalitygrey
control. Huang [4] revealed a novel V/P switchover control method
model, GM (1,1), to immediately predict the volumetric-filling point in each shot. The experiment’s based on the cavity pressure
profile
resultsby integrating
proved a simple
the validity grey model,
of seeking a proper GMV/P (1,1), to immediately
switchover. To obtain predict the volumetric-filling
a precise switchover control,
point
manyinfactors
each shot. The experiment’s
concerning resultsand
sensor locations proved
expensethe validity of seeking a proper V/P switchover.
are involved.
To obtain a precise
As molten switchover
polymer control,
fills the cavity,many factors pressure
the cavity’s concerning sensor locations
increases. When the and
melt expense
nearlyare fills
involved.
up the cavity and finally transfers to the compression phase, cavity pressure increases sharply.
ThisAs molten polymer
phenomenon fillsin
results themold
cavity,separation
the cavity’sand pressure increases.
immediately When
leads tothe melt nearly
tie-bar elongation fills up[5].
the cavity andthere
Accordingly, finallyis a transfers
clamping to theincrement
force compression on the phase, cavity
measured pressureforce
clamping increases
profile sharply. This
[5], a sufficient
phenomenon
clamping force results in moldtoseparation
is required prevent mold and separation
immediately leads tofrom
resulting tie-bar elongation
excessive cavity[5]. Accordingly,
pressure as melt
there is acavity.
fills the clamping force increment
Basically, the extent of onmold
the measured
separationclamping force profile
can be classified [5], astatuses
into three sufficient clamping
(S1–S3) under
force is required
various clamping to force
preventset mold
valuesseparation
(Figure 4).resulting
High clamping from excessive cavity
force setting pressure
results as melt
in mold fills the
compression
cavity.
(S1) and Basically,
may then thelead
extent of moldventing
to possible separation can be
problems and classified into threemold
further potential statuses (S1–S3) under
deterioration, tie bar
various
breakage,clamping
as wellforce
as wear set values (Figure 4).component.
in the clamping High clamping force setting
In contrast, a low results
clamping in mold
force compression
setting creates
(S1) and may then lead to possible venting problems and further potential mold deterioration, tie bar
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18
breakage, as well as wear in the clamping component. In contrast, a low clamping force setting creates
significant mold separation (S3) during mold filling and packing and then generates possible flash
breakage, as well as wear in the clamping component. In contrast, a low clamping force setting creates
defects. Hence, aseparation
significant proper clamping force which generatespacking
slight moldthen
separation (S2) in injection
significant mold
mold separation (S3) (S3) during
during mold
mold filling
filling and
and packing and
and thengenerates
generates possible
possible flash
flash
molding
defects. is necessary.
Hence, aa proper
defects. Hence, proper clamping
clamping force
force which
which generates
generates slight
slight mold
mold separation
separation (S2)
(S2) in
in injection
injection
molding
moldingisisnecessary.
necessary.
Figure 4. The extent of mold separation under various clamping force set values.
Huang etFigureFigure
al. [5]4.4.investigated
The extent
The extent of
of mold
moldeffects
the separation
separation underseparation
under
of mold variousclamping
various clamping forceset
force
on molded set values.
values.
part quality through
various melt filling patterns, and found that the molded part quality is crucially affected by whether
Huang
Huangetetal.al.[5][5]
investigated
investigated the the
effects of mold
effects separation
of mold on molded
separation part quality
on molded part through various
quality through
or not the clamping force is appropriately set (Figure 5). They also founded a method to seek an
melt filling patterns, and found that the molded part quality is crucially affected
various melt filling patterns, and found that the molded part quality is crucially affected by whether by whether or not the
appropriate clamping force setting based on tie-bar elongation, and verified this with application in
clamping
or not theforce is appropriately
clamping set (Figure 5).
force is appropriately setThey also5).founded
(Figure They also a method
founded to aseek an appropriate
method to seek an
a real molding process (Figure 6) [6]. Chen et al. [15,16] investigated the effect of mold separation on
clamping
appropriate force setting based
clamping on tie-bar
force setting elongation,
based and
on tie-bar verified this
elongation, andwith application
verified in aapplication
this with real molding in
molded part quality through a precise linear displacement transducer installed outside the mold
process (Figure 6) [6]. Chen et al. [15,16] investigated the effect of mold separation
a real molding process (Figure 6) [6]. Chen et al. [15,16] investigated the effect of mold separation on on molded part
plates, and found that the maximum mold separation occurring in the V/P switchover is highly
quality
moldedthrough a precise
part quality linear adisplacement
through precise linear transducer installed
displacement outside the
transducer mold plates,
installed outsideand thefound
mold
correlated with part weight. Chen et al. [17] conducted an experimental verification of several quality
that the and
plates, maximum
found moldthat the separation
maximum occurring in the V/Poccurring
mold separation switchover in isthe
highly correlated with
V/P switchover part
is highly
indexes, including peak pressure, viscosity extracted pressure profiles from the system, the nozzle,
weight. Chen et al. [17] conducted an experimental verification of several
correlated with part weight. Chen et al. [17] conducted an experimental verification of several quality quality indexes, including
and the cavity, as well as the clamping force increment extracted from the tie-bar elongation profile.
peak pressure,
indexes, viscosity
including peakextracted
pressure,pressure
viscosityprofiles frompressure
extracted the system, the nozzle,
profiles from theandsystem,
the cavity,
the as well
nozzle,
They found that these quality indexes, especially the clamping force increment index, have a strong
as the clamping force increment extracted from the tie-bar elongation profile.
and the cavity, as well as the clamping force increment extracted from the tie-bar elongation profile. They found that these
correlation with the part quality. They also suggested that the clamping force increment index can be
quality
They foundindexes,
thatespecially
these quality the clamping force increment
indexes, especially index, have
the clamping forcea strong
increment correlation with the
index, have part
a strong
used to predict part quality, as it is sensitive enough to indicate the slightly varied V/P switchover
quality.
correlationTheywith
alsothe
suggested that the
part quality. Theyclamping force increment
also suggested that theindex can beforce
clamping usedincrement
to predictindex
part quality,
can be
and the melt quality fluctuation.
as it isto
used sensitive
predictenough to indicate
part quality, as it isthesensitive
slightly varied
enoughV/P switchover
to indicate theand the melt
slightly quality
varied V/P fluctuation.
switchover
and the melt quality fluctuation.
Figure 5.
Figure Clamping force
5. Clamping force set
set value
value versus
versus part
part weight
weight [5].
[5].
Figure 5. Clamping force set value versus part weight [5].

Polymers 2019, 11, 1168
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Figure 6. A proper clamping force set value [6].

Figure 6. A proper clamping force set value [6].
Conventional V/P switchover control in an injection molding machine is mainly based on screw
Conventional
position. Theoretically,V/P switchover
the part qualitycontrol isin an injection
consistent from molding
shot tomachine
shot when is mainly
the motionbasedcontrol
on screw of
position. Theoretically, the part quality is consistent from shot to
injection molding machine is accurate and repeatable. However, the melt quality is often disturbed shot when the motion control of
injection molding machine is accurate and repeatable. However, the
and interfered by extrinsic factors, so the consistency of the molded part from shot to shot proceeding melt quality is often disturbed
and
on a interfered by extrinsic
precise injection molding factors, so theisconsistency
machine of theInmolded
still insufficient. part from
other words, shot to shot
a precisely proceeding
determined V/P
on a precise injection molding machine is still insufficient. In other
switchover control is essential in compensating for defects of the molded part in order to realize highwords, a precisely determined
V/P switchover
quality consistency. control is essential
In recent in compensating
applications, V/P switchoverfor defects
control ofbased
the molded
on cavity part in ordersignals
pressure to realize
is a
high quality consistency. In recent applications, V/P switchover control
well-recognized method, but is highly costed and inconvenient in terms of the installation of pressure based on cavity pressure
signals
sensors is inathewell-recognized
injection mold.method, but isa highly
In contrast, tie-bar costed
elongationand sensor
inconvenient
is simple in terms
to mount of the
oninstallation
the surface
of pressure sensors in the injection mold. In contrast, a tie-bar elongation
of the tie-bar without invading the mold cavity. Currently, sensors on tie bars are used to measure sensor is simple to mountthe
on the surface
surface strain withof thea tie-bar
press-on without
sensorinvading
directly at thethemold cavity. location
mounting Currently, [16]sensors on tie bars
or ultrasonic are used
sensors [18].
to measure
The the surface
tie-bar strain sensors, strain
which with
are asimilar
press-on sensor strain
to bonded directly at thecan
gauges, mounting
be usedlocation
to measure [16]the
or
ultrasonic
clamping force. sensorsThe [18]. The tie-bar
strain gaugesstrain sensors, which
are compressed under areasimilar to bonded
stainless-steel strain gauges,
protective can be
foil wrapped
used to measure the clamping force. The strain gauges are compressed
tightly on the cylindrical surface of the tie bar to be measured. Based on an accurate measurement under a stainless-steel
protective
of the clamping foil wrapped
force acting tightly on thehalves
on mold cylindrical
during surface
injectionof the tie barwith
molding to bethe measured. Based
tie-bar strain on an
sensors,
accurate
an injection measurement
molding machine of the clamping
can detectforce acting onofmold
the variation tie-barhalves duringonline.
elongation injection moldingofwith
Estimation the
the tie-bar strain sensors, an injection molding machine can detect
minimal clamping force for achieving high injection quality with low energy consumption and the variation of tie-bar elongation
machine
online.
and mold Estimation
damage of is the minimal
feasible. Thisclamping force for achieving
study investigates high injection
the feasibility of quality quality with low
monitoring energy
based on
consumption
the characteristics and machine
of tie-barand mold damage
elongation, furtherisdeveloping
feasible. This study investigates
a decision rule for V/Pthe feasibility in
switchovers of
quality monitoring
injection molding. based on the characteristics of tie-bar elongation, further developing a decision
rule for V/P switchovers in injection molding.
3. Experimental Setup
3. Experimental Setup
The device applied in this research contains an all-electric driven injection molding machine
with The
100 device
tonnageapplied
clamping in this
forceresearch
and a 28-mmcontainsscrewan all-electric
diameter,driven made by injection
Fanuc molding
Company, machine
Japan.
with 100 tonnage clamping force and a 28-mm screw diameter, made by
Tie-bar elongation sensors and cavity pressure sensors are separately installed on the injection molding Fanuc Company, Japan. Tie-
bar elongation
machine and mold sensors and cavity
(Figure pressure
7), while sensors
the strain are separately
gauge sensor used installed
to detect onthethe tie-bar
injection molding
elongation
machine
is shownand mold (Figure
in Figure 8. The 7), while the strain
specification of the gauge
sensors sensor
appliedused into detect
this the tie-bar
research is listedelongation
in Table is 1.
shown in Figure 8. The specification of the sensors applied in this
The tie-bar strain sensors (GE1029) applied to measure clamping force are manufactured by GEFRAN research is listed in Table 1. The
tie-bar strain sensors
Corp., Germany. (GE1029)and
The accuracy applied to measure
repeatability clamping
are smaller thanforce are full
±0.5% manufactured
scale and 0.1% by GEFRAN
full scale,
Corp., Germany. The accuracy and repeatability are smaller than
respectively. The strain gauges were pressed under a stainless protective foil wrapped tightly on ±0.5% full scale and 0.1% full scale,
the
respectively. The strain gauges were
cylindrical surface of the tie bar to be measured. pressed under a stainless protective foil wrapped tightly on the
cylindrical surface of the tie bar to be measured.
F
ε = ε = EA (1) (1)
×
𝐹= ×4 (2)
.
Polymers 2019,
Polymers 11, x1168
2019, 11, FOR PEER REVIEW 77of
of 18
18
Polymersε2019,
where 11, x FORthe
represents PEER REVIEW
strain of a tie bar in micrometers, E is the Young’s modulus of the tie bar7 and of 18
EAε × 1010
F = × 4
its value is 210,000 kgf/cm , A is the cross-sectional area of a single tie bar in mm , and F is the
2 2 (2)
where ε represents the strain of a tie bar in 9.81
micrometers, E is the Young’s modulus of the tie bar and
clamping force in kNs.
where ε represents
its value is 210,000the strain2,ofAa is
kgf/cm tiethe
barcross-sectional E is the
in micrometers,area of aYoung’s modulus
single tie bar inofmm
the2,tie
andbarFand its
is the
value is 210,000
clamping force in kNs.2 , A is the cross-sectional area of a single tie bar in mm2 , and F is the clamping
kgf/cm
force in kNs.
Figure 7. Diagram of the measuring equipment.

Figure 8. Measurement of clamping force.

Figure 8. Measurement of clamping force.
Table 1. Specifications of sensors.
Figure 8. Measurement
Figure 9 shows that the configuration of clamping
of an injection mold force.
has two cavities, allowing molding
Sensor Supplier Type
for a dumbbell-shaped specimen (Figure 10). The geometry of the 1.2 mm thick specimen follows the
Figure of
regulations 9 shows
ASTM that
Cavity
D638.the configuration
pressure
The
sensor of an injection
raw material
Kistler mold has two
used in this research
6159A cavities, butadiene
is acrylonitrile allowing molding
styrene
for a dumbbell-shaped Tie-bar strain(Figure
specimen sensor 10). TheGEFRAN
geometry of the 1.2GE1029
mm thick specimen follows the
(ABS) made by CHI-MEI Corporation, Taiwan (PA756 with melt flow index (MFI) 4.4 g/10 min). The
National
regulations of processing
recommended ASTM D638. Thecard
DAQ rawfor
operation material used in thisand
melt temperature research is acrylonitrile butadiene styrene
USB-6343
Instruments mold temperature settings are 180–230
(ABS) made by CHI-MEI Corporation, Taiwan (PA756 with melt
°C and 40–80 °C respectively. In this research, through different level settings flow index (MFI) 4.4 g/10speed,
of injection min). V/P
The
recommended
switchover and processing
holding operation for melt temperature and mold temperature settings are 180–230
°C andFigure 9 shows
40–80 °Care thatpressure,
respectively. In
the effect of
the configuration
this research,
of an
process
through
parameters
injection mold level
different hasontwo
clamping
cavities,
settings
force increment
allowing
of injection
and
molding
speed, V/P
cavity
for pressure
a dumbbell-shaped observed.
specimenIn addition,
(Figure compared
10). The to the
geometry characteristic
of theon of
1.2clamping cavity
mm thick pressure
specimen profile,
follows
switchover
the and
determination holding
of pressure,
V/P switchover the effect of process parameters force increment and
the regulations
cavity pressure of
areASTM
observed.D638.In Thebased
addition,
on the characteristic
raw material
compared used
to the thisof clamping
in characteristic
research is
of
force increment
acrylonitrile
cavity pressure
profile
butadiene
profile,
was developed.
styrene Theby
(ABS) made experimental
CHI-MEI parameter Taiwan
Corporation, settings(PA756
in thiswith
studymeltareflow
listed in Table
index (MFI) 2, whereas
4.4 a
g/10profile
min).
the determination
proper of V/P
clamping force switchover
is set to be 600 based on the to
kN referring characteristic
[6]. of clamping force increment
was developed. The experimental parameter settings in this study are listed in Table 2, whereas a
proper clamping force is set to be 600 kN referring to [6].
Polymers 2019,
Polymers 11,11,
2019, x FOR
1168PEER REVIEW 8 of8 of
18 18
Polymers 2019, 11, x FOR PEER REVIEW Table 1. Specifications of sensors. 8 of 18

The recommended processing operation for melt temperature and mold temperature settings are
Sensor Table
180–230 ◦ C and 40–80 ◦ C respectively. In this Supplier
1. Specifications
research, of sensors.
through Typesettings of injection speed,
different level
V/P switchover and Cavity
holdingpressure sensor
pressure, Kistler parameters6159A
the effect of process on clamping force increment
Sensor Supplier Type
Tie-bar
and cavity pressure are strain
observed. sensor
In addition, GEFRAN
compared to the GE1029of cavity pressure profile,
characteristic
Cavity pressure sensor Kistler 6159A
the determination of V/P DAQ card based on
switchover National Instruments USB-6343force increment profile
the characteristic
Tie-bar strain sensor GEFRAN of clamping GE1029
was developed. The experimental
DAQ card parameterNational
settings in this study are
Instruments listed in Table 2, whereas a
USB-6343
proper clamping force is set to be 600 kN referring to [6].
Figure 9. Injection tool with two cavities.

Figure 10. Geometry of dumbbell-shaped specimen.

Figure 10. Geometry of dumbbell-shaped specimen.
Table 2. Process condition settings in this research.
Figure
Table 10. Geometry
2. Process of dumbbell-shaped
condition specimen.
settings in this research.
Fixed Parameters
Table 2. (mm)
Process Fixed Parameters
condition
Feeding stroke 40 settingsHolding
in this research.
time (s) 5
Feeding stroke (mm)◦
Barrel temperature ( C) Fixed 210 40 Holding
Coolingtime (s) (s)
time 5 15
Barrel temperature Parameters
Screw rotational speed (°C)
(rpm) 210
100 Cooling
Mold time (s) (◦ C) 15 60
temperature
Screw Feeding stroke
rotational speed (mm)
(rpm) 100 40 Holding time (°C)
(s) 5
InjectionpPressure (MPa) 180 Mold temperature
Clamping force (kN) 60 600
Barrel temperature
InjectionpPressure (MPa) (°C) 180210 Cooling time
Clamping force (kN) (s) 15
600
Screw rotational speedVaried Varied Parameters
(rpm) 100 Mold temperature (°C) 60
Parameters
InjectionpPressure
Injection
Injection speed
speed(mm/s)
(mm/s) (MPa) 180 60,60,
Clamping
80,80, 100,
100, force
120,
120, (kN)
140,
140, 160160 600
V/P switchover
V/P switchover (mm)(mm) Varied Parameters11, 12, 13, 14, 15,
11, 12, 13, 14, 15, 16 16
Holding pressure
Injection speed(MPa)
(mm/s) 80,80,
60, 100, 120, 140, 160
Holding pressure (MPa) 80, 100,100,
120,120,
140,140,
160 160
V/P switchover (mm) 11, 12, 13, 14, 15, 16
Holding pressure (MPa) 80, 100, 120, 140, 160
4. 4. Results
Results andand Discussion
Discussion
4.
4.1. Results
4.1. Cavity
Cavity and
Pressure Discussion
Pressure Profiles
Profiles Affected
Affected byby V/PSwitchover
V/P SwitchoverTiming
Timing
To better describe the cavity pressure profiles affected
byby V/P switchover timing inin
thethe following
4.1.To better
Cavity describe
Pressure the cavity
Profiles pressure
Affected by V/Pprofiles affected
Switchover Timing V/P switchover timing following
experimental results, we summarize that there are generally three types
experimental results, we summarize that there are generally three types of pressure profiles which of pressure profiles which
To
representbetter
the describe
flowing the cavity
behaviors pressure profiles affected by V/P switchover timing in the following
represent the flowing behaviors ofof polymer
polymer melt
melt during
during mold
mold filling,
filling, packing,
packing, and
and holding
holding process
process
experimental
(Figure 11). Inresults,
Segment weA-B,
summarize
the that there
polymer melt are generally
fills the cavity three
before types of pressure
arriving at the profiles
V/P which
switchover
(Figure 11). In Segment A-B, the polymer melt fills the cavity before arriving at the V/P switchover
represent
point, and the
the flowing
pressure behaviors
rises, of polymer
representing melt
the during
polymer mold
melt filling,
filling thepacking,
mold and
cavity holding
with process
a constant
point, and the pressure rises, representing the polymer melt filling the mold cavity with a constant
(Figure
flow 11).
rate at In Segment
the filling A-B,After
stage. the polymer
passing melt fills point
through the cavity
B, the before arriving
so-called ideal at
V/Ptheswitchover
V/P switchoverpoint,
flow rate at the filling stage. After passing through point B, the so-called ideal V/P switchover point,
point,
the and themelt
polymer pressure rises,torepresenting
continues fill in the the polymer
cavity with melt filling
constant pressurethe mold
and cavity with
limited a constant
injection speed
the polymer melt continues to fill in the cavity with constant pressure and limited injection speed
flow rate at the filling stage. After passing through point B, the so-called ideal V/P switchover point,
until arriving at point C. From point B to C, the pressure profile rises slowly, whereas segment B-C
the polymer melt continues to fill in the cavity with constant pressure and limited injection speed
until arriving at point C. From point B to C, the pressure profile rises slowly, whereas segment B-C
Polymers 2019, 11, 1168 9 of 18
represents the polymer

until arriving melt
at point C. filling
From theBcavity
point to C, from the beginning
the pressure profileof the slowly,
rises holdingwhereas
stage. Notably,
segment point
B-C
C represents
represents the polymer
the polymer melt the
melt filling volumetrically filling
cavity from the in theofmold
beginning cavitystage.
the holding followed by point
Notably, acting
C
compression. After the polymer melt passes point C, the cavity pressure profiles can be classified
represents the polymer melt volumetrically filling in the mold cavity followed by acting compression. into
three
After patterns:
the polymer melt passes point C, the cavity pressure profiles can be classified into three patterns:
(1) Pattern A: Polymer melt performs insufficient or just complete mold filling, in which the
(1) Pattern A: Polymer melt performs insufficient or just complete mold filling, in which the
compression phenomenon does not clearly exist at the holding stage (Figure 11a). Accordingly,
compression phenomenon does not clearly exist at the holding stage (Figure 11a). Accordingly,
there is no obvious piecewise point appearing after point C in the pressure profile.
there is no obvious piecewise point appearing after point C in the pressure profile.
(2) Pattern B: Polymer melt sufficiently fills up the whole cavity at the holding stage and performs
(2) Pattern B: Polymer melt sufficiently fills up the whole cavity at the holding stage and performs
compression after point C (Figure 11b). Consequently, an obvious piecewise point exists at point
compression after point C (Figure 11b). Consequently, an obvious piecewise point exists at point
C that reflects the compression behavior of the polymer melt.
C that reflects the compression behavior of the polymer melt.
(3) Pattern C: Polymer melt excessively fills up the cavity after point C in the holding stage, leading
(3) Pattern C: Polymer melt excessively fills up the cavity after point C in the holding stage, leading to
to a sudden rise in segment C–D along the pressure profile (Figure 11c). Hence, an obvious
a sudden rise in segment C–D along the pressure profile (Figure 11c). Hence, an obvious piecewise
piecewise appears at point C, also reflecting an excessive compression behavior among the
appears at point C, also reflecting an excessive compression behavior among the polymer melt.
polymer melt.
Pressure
D
C
B
A E
Time
(a)
D
Pressure
C
B
A Time E
(b)
D
Pressure
C
B
A Time E
(c)
Figure
Figure 11. Patterns
Patterns of
ofcavity
cavitypressure
pressure profile
profile affected
affected by V/P
by the the switchover
V/P switchover
timing.timing.
PatternPattern (a),
(a), Pattern
(b), Pattern
Pattern (c).
(b), Pattern (c).
Therefore, the
Therefore, the slope
slope at
at segment
segment C-D
C-D varies
varies with
with respect
respect to
to the
the level
level of
of compression
compression among
among the the
polymer melt. Meanwhile, the mold separation reflected is also distinct and consistent
polymer melt. Meanwhile, the mold separation reflected is also distinct and consistent with tie-bar with tie-bar
elongation. Thus,
elongation. Thus,segment
segmentC-D C-Dininthis
thisresearch
researchisisdefined
definedasasthe
thepolymer
polymermelt meltcompression
compressionphase.phase.
After point D, the cavity pressure curve drops smoothly to point E in the cooling stage,
After point D, the cavity pressure curve drops smoothly to point E in the cooling stage, in which the in which
the polymer
polymer meltmelt is cooled
is cooled downdown andand shrinks
shrinks volumetrically
volumetrically in in thecavity.
the cavity.Segment
SegmentD-ED-Eisis therefore
therefore
defined as the volumetric shrinkage phase of the polymer melt. As the holding stage is completed,
Polymers 2019, 11, 1168 10 of 18
defined
the cavity aspressure
the volumetric
at pointshrinkage
E reflectsphase of the polymer
the over-packing melt. As the
characteristic holding stage
if excessive is completed,
compression of the
the cavity pressure
polymer melt occurs. at point E reflects the over-packing characteristic if excessive compression of the
polymer melt occurs.
4.2. Effect of Injection Speed, Switchover Point and Holding Pressure on Cavity Pressure and Clamping
4.2. Effect
Force of Injection Speed, Switchover Point and Holding Pressure on Cavity Pressure and Clamping
Increment
Force Increment
Figure 12a,b show the experimental results of varied injection speeds under identical V/P
Figure 12a,b show the experimental results of varied injection speeds under identical V/P
switchover (referring to screw position at 15 mm) and holding pressure (100 MPa) settings. Notably,
switchover (referring to screw position at 15 mm) and holding pressure (100 MPa) settings. Notably,
these sensed pressure and clamping force increment signals at the starting time have shifted to the
these sensed pressure and clamping force increment signals at the starting time have shifted to the
same starting time for subsequent comparisons (Figures 12–14). Comparing the patterns of
same starting time for subsequent comparisons (Figures 12–14). Comparing the patterns of measuring
measuring profiles obtained by the cavity pressure sensor and the tie-bar strain sensor, the patterns
profiles obtained by the cavity pressure sensor and the tie-bar strain sensor, the patterns of segments
of segments A-B, B-C, C-D are most concerned with the V/P switchover in this study (referring to
A-B, B-C, C-D are most concerned with the V/P switchover in this study (referring to Section 4.1),
Section 4.1), and the peak value at point D is visually similar to each other. Figure 12a,b show that a
and the peak value at point D is visually similar to each other. Figure 12a,b show that a higher pressure
higher pressure that forces the polymer melt to fill in the mold cavity appears when the injection
that forces the polymer melt to fill in the mold cavity appears when the injection speed is increased at
speed is increased at the filling phase. Consequently, the slope at segment A-B becomes sharper with
the filling phase. Consequently, the slope at segment A-B becomes sharper with increasing injection
increasing injection speed. If the mold cavity is not volumetrically filled at the holding phase, the
speed. If the mold cavity is not volumetrically filled at the holding phase, the slope at segment B-C
slope at segment B-C with respect to varied injection speed changes insignificantly. When the
with respect to varied injection speed changes insignificantly. When the polymer melt compression
polymer melt compression phase is executed at a low injection speed (60 and 80 mm/s in this case),
phase
the slopeis executed
at segment at aC-D
lowshowing
injectionthe speed (60 and 80behavior
compression mm/s inisthis case), the slope
insignificant, whichatissegment C-D
classified as
showingAthe
Pattern compression
in Figure 11a. The behavior
compressionis insignificant,
phenomenon which is classified
is relatively as Pattern
obvious with a A in Figure
higher 11a.
injection
The
speedcompression
(100 and 120 phenomenon
mm/s in this is relatively obvious
case), which is with a higher
identified as injection
Pattern B speed (100 and
in Figure 11b.120Also,
mm/sthein
this case), which is identified as Pattern B in Figure 11b. Also, the piecewise
piecewise point C appears earlier because more polymer melt is injected into the mold cavity which point C appears earlier
because
is due tomorea largepolymer
inertia melt is injected
of injection screwintomotion
the mold cavity
in high which
speed. is due to
Besides, thea peak
largepressure
inertia ofappeared
injection
screw motion in high speed. Besides, the peak pressure appeared at
at point D is also higher. As the injection speed significantly increases to 140 and 160 mm/s, point D is also higher. As the
the
injection speed significantly increases to 140 and 160 mm/s, the sudden
sudden compression behavior may lead to overshot and the pattern is similar to Pattern C in Figure compression behavior may
lead In
11c. to overshot
these cases, andthethepatterns
pattern is ofsimilar
clamping to Pattern C in Figure
force increment 11c. In
which these cases,reflect
successfully the patterns
the mold of
clamping force increment which successfully reflect the mold separation
separation are similar to those of cavity pressure. Table 3 shows quantitative evidence of the are similar to those of cavity
pressure. Tablesimilarities
characteristic 3 shows quantitative
between cavityevidence of the characteristic
pressure and clampingsimilarities betweenwith
force increments cavityrespect
pressure
to
and clamping force increments with respect to varied injection speeds. Except
varied injection speeds. Except for the negative slope of segment B-C in the clamping force increment for the negative slope
of segment
which B-C in the
is obscured clamping
in this study, the force increment
other slopes ofwhich is obscured
segments, the peakin this study,
values thecavity
of the other pressure,
slopes of
segments, the peak values of the cavity pressure, and the clamping
and the clamping force increment are all increased with increasing injection speed. force increment are all increased
with increasing injection speed.
(a)
Figure 12. Cont.

Polymers 2019, 11, 1168 11 of 18
(b)
Figure
Figure12.
12.Effect
Effectof
ofinjection
injectionspeed
speedon
on(a)
(a)cavity
cavitypressure
pressureand
and(b)
(b)clamping
clamping force
force increment.
increment.
Table 3. Quantitative characteristics of cavity pressure and clamping force increment with respect to
varied injection speeds.
varied injection speeds.
Cavity Pressure Clamping Force Increment
Injection Cavity Pressure Clamping Force Increment
Injection Slope of Slope of Slope of Peak Slope of Slope of Slope of Peak
Speed
Speed Slope
seg. A-B of Slope
seg. B-C of Slope
Seg. C-Dof Peak
Value Slope
Seg. A-Bof Slope
Seg. of
B-C Slope
Seg. of
C-D Peak
Value
(mm/s) seg. A-B (MPa/s)seg. B-C (MPa/s)
Seg. C-D (MPa)Value Seg. A-B Seg. B-C Seg. C-D Value
(mm/s) (MPa/s) (MPa/s) (MPa/s) (MPa/s) (kN)
60 (MPa/s)
183.76 (MPa/s)
14.43 * (MPa/s)
14.43 * (MPa)
28.86 (MPa/s)
2.46 (MPa/s)
0.01 (MPa/s)
0.32 (kN)
0.78
80 60 288.67
183.76 17.88
14.43* * 17.88
14.43** 32.10
28.86 2.73
2.46 0.61
0.01 0.52
0.32 0.85
0.78
10080 288.67
348.06 17.88 *
40.79 17.88 *
36.60 32.10
41.46 2.73
3.07 0.61
–0.10 0.52
1.18 0.85
1.01
120100 348.06
378.37 40.79
65.06 36.60
56.90 41.46
46.10 3.07
4.65 –0.10
–0.19 1.18
1.62 1.01
1.12
140120 378.37
448.68 65.06
74.93 56.90
67.41 46.10
49.18 4.65
5.37 –0.19
–1.14 1.62
2.52 1.12
1.16
160140 448.68
485.35 74.93
85.72 67.41
95.43 49.18
51.58 5.37
6.07 –1.14
–1.02 2.52
2.84 1.16
1.28
160 485.35 85.72 95.43 51.58 6.07 –1.02 2.84 1.28
* Point C is not significant, and the slopes of segments B-C and C-D are approximated with the slope
* Point C is not significant, and the slopes of segments B-C and C-D are approximated with the slope of segment B-D.
of segment B-D.
Figure
Figure 13a,b
13a,b show
show thethe experiment
experiment results
results regarding
regarding different
different V/P V/P switchover
switchover point point that
that isis
referring
referring to toscrew
screwposition
positionwithwiththethesame
sameinjection
injectionspeed
speed(60 (60mm/s)
mm/s)and andholding
holdingpressure
pressure(100(100MPa).
MPa).
By
By comparing
comparing the the patterns
patternsof ofthe
thecavity
cavitypressure
pressureprofile
profileand andthethe clamping
clampingforce forceincrement
incrementprofile,
profile,
their trends are identical to the assumptions mentioned in Section
their trends are identical to the assumptions mentioned in Section 4.1, i.e., Pattern A for4.1, i.e., Pattern A fora aswitchover
switchover at
at 16 mm, Pattern B at 13, 14 and 15 mm, and Pattern C at 11 and 12 mm.
16 mm, Pattern B at 13, 14 and 15 mm, and Pattern C at 11 and 12 mm. To further investigate the effect To further investigate the
effect
of theof theswitchover
V/P V/P switchover setting setting
on theon the profiles
profiles detecteddetected
by theby the cavity
cavity pressure pressure
sensorsensor and tie-bar
and tie-bar strain
strain sensor, the slopes of segment A-B from measuring cavity pressure
sensor, the slopes of segment A-B from measuring cavity pressure profiles are visually identical, profiles are visually identical,
as an
as an equivalent pressure is required to drive molten polymer to maintain
equivalent pressure is required to drive molten polymer to maintain a constant injection speed at the a constant injection speed
at the filling
filling phase despite
phase despite of variousof various V/P switchover
V/P switchover points.
points. Point B isPoint
gettingB is getting
higher higher
as the V/P as the V/P
switchover
switchover pointgradually.
point is delayed is delayedItgradually.
is due to theIt is due
fact to an
that theincrease
fact thatofan increase
screw moving of screw moving
produces moreproduces
polymer
more polymer melt packing within the mold’s cavity, so cavity pressure
melt packing within the mold’s cavity, so cavity pressure increases. Meanwhile, segment B-C with increases. Meanwhile,
segment B-C with various
various switchover point switchover
settings becomes point settings
shorter, becomes
reflectingshorter,
a quicker reflecting
beginninga quicker
of thebeginning
following
of the following compression phase. As for segment C-D, its slope
compression phase. As for segment C-D, its slope and peak pressure at point D increases when and peak pressure at pointtheD
increases when the delay of V/P switchover point is increased. It
delay of V/P switchover point is increased. It is because the compression phenomenon of the polymeris because the compression
phenomenon
melt after the of V/Pthe polymer point
switchover melt after theobvious
is more V/P switchover
since the point
bufferisatmore
the end obvious
of the since
cavitythe buffer
in the at
filling
the
phaseendis of the cavity
shortened. in the
Table fillingquantitative
4 shows phase is shortened.
evidence ofTable 4 shows quantitative
the characteristic similaritiesevidence
betweenof the
cavity
characteristic similarities between cavity pressure and clamping force
pressure and clamping force increments with respect to varied V/P switchovers referring to screw increments with respect to
varied
position. V/PThe
switchovers referringB-C
slopes of segment to screw position.
of the cavity The slopes
pressure, of segment
the slope of segment B-C C-D,
of thethe
cavity
peakpressure,
values of
the slope of segment C-D, the peak values of the cavity pressure, and the
the cavity pressure, and the clamping force increment are all increased with delaying V/P switchovers. clamping force increment
are all increased with delaying V/P switchovers.
Polymers 2019, 11, 1168 12 of 18
(a)
(b)
Figure
Figure 13.
13. Effect
Effectof
ofV/P
V/P switchover
switchover on
on (a)
(a) cavity
cavity pressure
pressure and (b) clamping force increment.
varied V/P switchover.
varied V/P switchover.
V/P Cavity Pressure Clamping Force Increment
V/P
Switchover Slope of of Slope
Slope of of Slope
Slope Slopeofof PeakPeak Slope
Slopeof of Slope
Slope of Slope of
of Slope of Peak
Peak
(mm) Seg. A-B Seg. B-C Seg. C-D Value Seg. A-B seg.
Switchover(mm) Seg. A-B Seg. B-C Seg. C-D Value Seg. A-B seg. B-C Seg. C-D Value B-C Seg. C-D Value
(MPa/s) (MPa/s) (MPa/s) (MPa) (MPa/s) (MPa/s) (MPa/s) (kN)
11
11 334.94 ** ** 334.94
334.94 ** ** 304.46
334.94 304.46 70.94
70.94 4.74
4.74** 4.74
4.74 **
** 32.77 3.83
12
12 333.24 ** ** 333.24
333.24 ** ** 176.30
333.24 176.30 61.92
61.92 4.90
4.90** 4.90
4.90 **
** 13.91
13.91 2.09
2.09
13
13 363.63
363.63 103.77
103.77 92.96
92.96 53.48
53.48 3.92
3.92 0.37
0.37 4.45
4.45 1.34
1.34
14 369.81 59.09 73.06 48.35 3.64 −3.86 2.19 1.18
14 369.81 59.09 73.06 48.35 3.64 −3.86 2.19 1.18
15 340.56 39.26 42.01 41.44 3.53 −0.50 1.28 1.00
15 340.56 39.26 42.01 41.44 3.53 −0.50 1.28 1.00
16 331.23 22.01 * 22.01 * 29.48 2.79 −0.04 0.37 0.79
16 331.23 22.01 * 22.01 * 29.48 2.79 −0.04 0.37 0.79
***Point
Point BCisisnot
not significant,
significant, andand the slopes
the slopes of segments
of segments A-B and B-C andapproximated
B-C are C-D are approximated
with the slopewith the slope
of segment A-C.
of segment B-D. ** Point B is not significant, and the slopes of segments A-B and B-C are approximated
with the slope of segment A-C.
Figure 14a,b show the experiment results of varied holding pressures set with constant injection
speed (60 mm/s)
Figure and V/P
14a,b show switchoverresults
the experiment point of
(referring to screw
varied holding positionset
pressures atwith
15 mm). The
constant profile
injection
characteristic
speed of clamping
(60 mm/s) and V/Pforce incrementpoint
switchover is similar with that
(referring to of cavity
screw pressure.
position at In
15addition,
mm). Thetheprofile
profile
characteristic of clamping force increment is more significant than cavity pressure. From the measuring
characteristic of clamping force increment is similar with that of cavity pressure. In addition, the
profile,characteristic
profile the slope andoflength of segment
clamping A-B withisdifferent
force increment holding than
more significant pressure settings
cavity are From
pressure. the same,
the
measuring profile, the slope and length of segment A-B with different holding pressure settings are
Polymers 2019, 11, 1168 13 of 18
the same, and point B also overlapped with identical injection speeds and switchover point settings.
After pointB B,
and point theoverlapped
also slopes of segment B-C and
with identical C-D become
injection speedssharper as the holding
and switchover pressureAfter
point settings. increases.
point
Notably,
B, the slopes of segment B-C and C-D become sharper as the holding pressure increases. injection
the holding phase is engaged with controlled pressure and limited speed in Notably,
molding
the holdingmachines. The peak
phase is engaged with pressure at point
controlled D and
pressure alsolimited
becomes higher
speed as the molding
in injection holding machines.
pressure
increases.
The peak pressure at point D also becomes higher as the holding pressure increases. After pointinD,
After point D, the excessive holding pressure setting leads to over-packing and results a
residual pressure
the excessive at point
holding E (holding
pressure settingpressure is larger than and
leads to over-packing 120 MPa
resultsin in
this case). Table
a residual 5 alsoatshows
pressure point
quantitative evidence of the characteristic similarities between cavity pressure and
E (holding pressure is larger than 120 MPa in this case). Table 5 also shows quantitative evidence of clamping force
the
increment with respect to varied holding pressures. The slopes of segment A-B are slightly
characteristic similarities between cavity pressure and clamping force increment with respect to varied changed
due to identical
holding pressures.V/PThe
switchover
slopes ofsettings
segmentinA-Bthese
arecases. Aschanged
slightly to the slopes
due to ofidentical
segmentsV/P B-C, C-D, the
switchover
peak values of cavity pressure, and clamping force increment, all increased with
settings in these cases. As to the slopes of segments B-C, C-D, the peak values of cavity pressure,increasing holding
and
pressure as expected.
clamping force increment, all increased with increasing holding pressure as expected.
(a)
(b)
Figure
Figure 14.
14. Effects
Effects of
of holding
holding pressure
pressure on (a) cavity pressure and (b) clamping force increment.
By introducing
Table the three
5. Quantitative major process
characteristics parameters,
of cavity namely
pressure and injection
clamping force speed, V/Pwith
increment switchover
respect topoint,
and holding pressure,
varied holding factors affecting part quality in injection molding, such as changes of the cavity
pressures.
pressure profile and clamping force increment profile is proved to be correlated in this study. Table 6
shows quantitative evidence in which most characteristics are all highly correlated except for the slope
Holding Slope of Slope of
of segment B-C being
Slope ofobscure,
Slopeparticularly
of when Peak
the clamping
Slopeforce
of increment
Slope of profiles are reflecting
Peak
Pressure Seg. C- Seg. C-
with varied injection speeds.
Seg. A-B Seg. B-C Generally, the cavity pressure profile,
Value Seg. A-B Seg. B-C which is identified as a good
Value
(MP) D D
indicator of the variation (MPa/s)
(MPa/s) of injection-molded part quality, (MPa/s)
(MPa) can also be (MPa/s)
reflected in the clamping force
(kN)
(MPa/s) (MPa/s)
increment profile. To seek a consistent injection molding quality, the peak value of the clamping force
80
increment 362.15
can also be used8.00
as a*quality8.00 *
indicator 22.97 3.28 by adjusting
and controlled −0.86 the process
0.27 parameters.
0.64
100 361.69 42.06 40.87 42.18 3.15 −0.11 1.51 1.05
Polymers 2019, 11, 1168 14 of 18

120 361.68 87.41 65.93 55.93 3.40 1.15 2.56 1.68
140 361.55 134.35 84.99 68.11 3.53 ** 3.53 ** 6.09 3.21
The 160
following paragraphs
361.48 will describe77.45
143.88 an example of using3.90
77.19 the **
V/P switchover
3.90 ** point to shot-by-shot
9.50 5.83
control the peak value of clamping force increment to maintain a consistent part weight.
* Point C is not significant, and the slopes of segments B-C and C-D are approximated with the slope
of segment B-D. ** Point B is not significant, and the slopes of segments A-B and B-C are approximated
with the slope of segment A-C.
varied holding pressures.
By introducing the three major process parameters, namely injection speed, V/P switchover
point, and holding pressure,Cavity
Holding factorsPressure
affecting part quality in injection Clamping Force
molding, Increment
such as changes of the
cavity pressure Slope
Pressure profile ofandSlope of
clamping Slopeincrement
force of Slope
Peakprofile of
is proved Slope Slope of
to beofcorrelated Peak
in this study.
Seg. A-B Seg. B-C Seg. C-D Value Seg. A-B Seg. B-C Seg. C-D Value
Table (MP)
6 shows quantitative evidence in which most characteristics are all highly correlated except for
the slope of segment B-C being obscure, particularly when the clamping force increment profiles are
80 362.15 8.00 * −0.86
reflecting with varied injection speeds. 8.00 *
Generally, 22.97 3.28
the cavity pressure profile, which0.27 0.64
is identified as a
100 361.69 42.06 40.87 42.18 3.15 −0.11 1.51 1.05
good indicator of the variation of injection-molded part quality, can also be reflected in the clamping
120 361.68 87.41 65.93 55.93
force increment profile. To seek a consistent injection molding3.40quality, the1.15
peak value 2.56 1.68
of the clamping
140 361.55 134.35 84.99 68.11 3.53 ** 3.53 ** 6.09 3.21
force increment
160 can also be
361.48 used as a77.45
143.88 quality indicator
77.19 and controlled
3.90 ** by adjusting
3.90 ** 9.50 the 5.83process
parameters. The following paragraphs will describe an example of using the V/P switchover point to
shot-by-shot
** Point B iscontrol the peak
not significant, value
and the ofofclamping
slopes force
segments A-B andincrement to maintain
B-C are approximated a consistent
with the partA-C.
slope of segment weight.
Table 6.
Table Correlation analysis
6. Correlation analysis between
between cavity
cavity pressure
pressure and
and clamping
clamping force
force increment.
increment.
Varied
Varied Parameters Slope
Parameters SlopeofofSeg.
Seg.A-B
A-B Slope of Seg. B-C
B-C Slope
SlopeofofSeg.
Seg.C-D
C-D Peak Value
Peak Value
Injection speed
Injection speed 0.93
0.93 -0.83
−0.83 0.94
0.94 0.99
0.99
V/PV/P switchover
switchover 0.82
0.82 0.58
0.58 0.99
0.99 0.88
0.88
Holding pressure
Holding pressure n/a
n/a 1.00
1.00 0.76
0.76 0.89
0.89
4.3.
4.3. Control
Control of
of Part
Part Weight
Weight by
by Changing
Changing V/P
V/P Switchover Point
Switchover Point
Initially, the sensitivity
Initially, the sensitivity of
of changing
changing V/P
V/P switchover point to
switchover point to part
part weight
weight is
is proved
proved by
by experiment
experiment
conducted
conducted in this study, whereas the V/P switchover point referring to screw position is purposely
in this study, whereas the V/P switchover point referring to screw position is purposely
changed
changed inin aa sequence
sequence of of 15
15 mm,
mm, 1414 mm,
mm, 16
16 mm,
mm, 15
15 mm,
mm, 14.2
14.2 mm,
mm, 1515 mm,
mm, 15.8
15.8 mm,
mm, 1515 mm,
mm, 14.4
14.4 mm,
mm,
15 mm, 15.6 mm, 15 mm, 14.6 mm, 15 mm, 15.4 mm, 15 mm, 14.8 mm, 15 mm,
15 mm, 15.6 mm, 15 mm, 14.6 mm, 15 mm, 15.4 mm, 15 mm, 14.8 mm, 15 mm, 15.2 mm, and 15 mm. 15.2 mm, and 15 mm.
Figure 15shows
Figure 15 showsa aslight
slight change
change in the
in the partpart weight
weight is reflected
is reflected by changing
by changing the V/P the V/P switchover
switchover position,
position,
in which in
thewhich
maximalthe maximal
clampingclamping force increment
force increment and part
and part weight areweight
highlyare highly correlated.
correlated.
Figure 15. Sensitivity of V/P switchover point to part weight.

Figure 15. Sensitivity of V/P switchover point to part weight.
To further prove the feasibility of changing V/P switchover point to part weight, this study
conducted an experiment which slightly changed the barrel temperature from 210 ◦ C to 215 ◦ C.
To further prove the feasibility of changing V/P switchover point to part weight, this study
Polymers 2019, 11, 1168 15 of 18
conducted
To further an experiment
prove the which slightly
feasibility changed the
of changing V/Pbarrel temperature
switchover point to from 210weight,
part °C to 215 this°C. The
study
part weightan
conducted is experiment
expected to which increase, since changed
slightly a higher barrel temperature
the barrel temperature enhances the °C
from 210 flowing
to 215ability
°C. The of
molten
part polymer
weight is when
expected filling
to the
increase, cavity.
since Figure
a higher16 shows
barrel the change
temperature of part
enhances
The part weight is expected to increase, since a higher barrel temperature enhances the flowing ability weight
the corresponding
flowing ability to
of
varied
molten
of moltenbarrel
polymer temperatures,
polymer when
when filling inthe
filling which
thecavity. both
cavity. the product
Figure
Figure1616shows weight
shows the and clamping
thechange
change ofofpart force
partweight
weight increment increase
corresponding
corresponding to
to
and
variedrun out
barrel of the specification
temperatures, in which (bluebothblock).
the Figure
product 17 shows
weight and the result
clamping
varied barrel temperatures, in which both the product weight and clamping force increment increase of reducing
force increment part weight
increase
variation
and
and run
run out with
out of the
of the proposed
the specification
specification V/P(blueswitchover
(blue block). control
block). Figure
Figure 17 method.
17 showsThe
shows the screw-position
the result
result ofof reducing
reducing V/Ppart
switchover
part weight
weight
point is further
variation
variation withthe
with related
the to theV/P
proposed
proposed value
V/P of the clamping
switchover
switchover force
control
control increment,
method.
method. The The i.e., when a continuous
screw-position
screw-position shotpoint
V/P switchover
V/P switchover with
over
point clamping
is further force
relatedincrement
to the is
value detected,
of the an earlier
clamping V/P
force switchover
increment, is
i.e., performed.
is further related to the value of the clamping force increment, i.e., when a continuous shot with overwhen a In contrast,
continuous shota later
with
V/P switchover
over clamping
clamping forceforceis adjusted.
increment
increment isTheis figure
detected,
detected, alsoearlier
an andescribes
earlier
V/PV/Phow both the
switchover
switchover is part
is weight and
performed.
performed. clampingaa force
Incontrast,
In contrast, later
later
increment
V/P switchoverare tuned
is back
adjusted. within
The the
figure specification
also after
describes a
how few
bothshots.
the
V/P switchover is adjusted. The figure also describes how both the part weight and clamping forceFurthermore,
part weight in
and a series
clamping of barrel
force
temperature
increment
increment arevariations
are tuned
tuned back
back in within
a sequence
within the of 210 °C, 215
the specification
specification °C,aa210
after
after few°C,
few 205Furthermore,
shots.
shots. °C, and 210 °C,
Furthermore, in aFigure
in series18
a series of shows
of barrel
barrel
that the fluctuation
temperature
temperature variations
variations of in
part weight can
in aa sequence
sequence of be successfully
of 210
210 °C,
◦ C, 215
215 °C,
◦ reduced
C, 210
210 °C,
◦ 205with
C, 205 °C,
◦ this 210
C, and
and method,
210 °C,
◦ as the18
C, Figure
Figure 18original
shows
shows
weight
that
that therange
the 0.048 of
fluctuation
fluctuation gofis decreased
part
part weight
weight to can
can 0.027beg.successfully
be successfully reducedreduced
with with this method,
this method, as the as the original
original weight
weight range
range 0.048 g 0.048 g is decreased
is decreased to 0.027to g. 0.027 g.
Figure 16. Part weight corresponding to varied barrel temperatures.

Figure Reduction
17.Reduction
Figure 17. of weight
of part part weight
variationvariation by V/P switchover
by V/P switchover point relatedpoint related
to clamping to increment.
force clamping
force increment.
Figure 17. Reduction of part weight variation by V/P switchover point related to clamping force increment.
Polymers 2019, 11, 1168 16 of 18
(a)
(b)
Figure 18. Reduction of part weight variation corresponding a series of barrel temperature change by
V/P switchover
V/P switchover point
point referring
referringto
toclamping
clampingforce
forceincrement:
increment: (a)
(a) original;
original;(b)
(b)control
controlengaged.
engaged.
4.4. A Potential
4.4. A Potential Indicator
Indicator of
of Clamping
Clamping Force
Force Increment
Increment to
to Material
Material Fluctuation
Fluctuation
This
This study
study further
further conducted
conducted an an experiment
experiment to to verify
verify whether
whether clamping
clamping force
force increment
increment cancan
indicate batch-to-batch variation of the material property. In the experiment, the PA756
indicate batch-to-batch variation of the material property. In the experiment, the PA756 pellets (ABS pellets (ABS
polymer
polymer made
made by
by Chi-Mei
Chi-Mei Co.) with an
Co.) with an MFI
MFI value
value of
of 40
40 mL/10min
mL/10min werewere gradually
gradually replaced
replaced with
with
PA756H,
PA756H, which has superior flowing ability with 80 mL/10min MFI. Figure 19 shows the
which has superior flowing ability with 80 mL/10min MFI. Figure 19 shows the change
change ofof
the viscosity of the molten polymer induced by a change in the raw material, which can
the viscosity of the molten polymer induced by a change in the raw material, which can be indicated be indicated
with
with the
the varied
varied clamping
clamping force
force increments.
increments. This
This result
result proves
proves that
that the
the clamping
clamping force
force increment
increment isis aa
possible
possible indicator
indicator for
for online
online monitoring
monitoring of of the
the reground
regroundmaterial
materialvariation.
variation.
Polymers 2019, 11, 1168 17 of 18
Figure 19.
Figure Potential melt
19. Potential melt quality
quality fluctuations
fluctuations using
using clamping
clamping force
force increment.
increment.
5. Conclusions
5. Conclusions
Although injection molding technology has been developed for more than one hundred years,
Although injection molding technology has been developed for more than one hundred years,
developing an intelligent process parameter setting is crucial in satisfying an increasing demand
developing an intelligent process parameter setting is crucial in satisfying an increasing demand for
for injection molding quality. An appropriate molding parameter setting dominates part quality.
injection molding quality. An appropriate molding parameter setting dominates part quality.
Particularly, it is critical for the V/P switchover point to be free of defects. Hence, this research
Particularly, it is critical for the V/P switchover point to be free of defects. Hence, this research has
has developed a novel V/P switchover decision method based on the tie-bar elongation profile.
developed a novel V/P switchover decision method based on the tie-bar elongation profile. Our
Our experimental studies found that the V/P switchover is crucial in affecting the quality of parts.
experimental studies found that the V/P switchover is crucial in affecting the quality of parts. Defects
Defects of over-packing and flashes appeared in injection-molded parts due to late switchover point
of over-packing and flashes appeared in injection-molded parts due to late switchover point settings.
settings. In contrast, short shot and low density resulted from an early switchover setting. Furthermore,
In contrast, short shot and low density resulted from an early switchover setting. Furthermore,
injection speed, V/P switchover point, and holding pressure are most influential to cavity pressure
injection speed, V/P switchover point, and holding pressure are most influential to cavity pressure
profiles and clamping force increment profiles. In particular, characteristics of clamping force increment
profiles and clamping force increment profiles. In particular, characteristics of clamping force
profile is found to be similar to that of the cavity pressure profile. Therefore, the decision rule for
increment profile is found to be similar to that of the cavity pressure profile. Therefore, the decision
the V/P switchover point has the potential to be successful based on the tie-bar elongation profile.
rule for the V/P switchover point has the potential to be successful based on the tie-bar elongation
In addition, the online fluctuation of batch-to-batch processed material can be detected online by
profile. In addition, the online fluctuation of batch-to-batch processed material can be detected online
monitoring the clamping force increment, calculated from the tie bar elongation profile. It is essential
by monitoring the clamping force increment, calculated from the tie bar elongation profile. It is
for assuring processing quality and is practical for injection molding.
essential for assuring processing quality and is practical for injection molding.
Author Contributions: Conceptualization, M.-S.H.; Methodology, J.-Y.C. and C.-Y.L.; Software, C.-Y.L.; Validation,
Author Contributions:
J.-Y.C. and M.-S.H.; Formal Conceptualization, M.-S.H.;
Analysis, J.-Y.C. and Methodology,
C.-Y.L.; Investigation,J.-Y.C.
J.-Y.C.and Software, M.-S.H.;
and C.-Y.L.; Resources, C.-Y.L.;
Data Curation,
Validation, J.-Y.C.
J.-Y.C. and and C.-Y.L.;
M.-S.H.; Writing-Original
Formal Draft
Analysis, J.-Y.C. andPreparation, J.-Y.C.; Writing-Review
C.-Y.L.; Investigation, & Editing,
J.-Y.C. and C.-Y.L.; M.-S.
Resources,
Huang; Visualization,
M.-S.H.; Data Curation,M.-S.H.;
J.-Y.C. Supervision,
and C.-Y.L.; M.-S.H.; Project Administration,
Writing-Original Draft Preparation,M.-S.H.; Funding
J.-Y.C.; Acquisition,
Writing-Review &
M.-S.H.
Editing, M.-S. Huang; Visualization, M.-S.H.; Supervision, M.-S.H.; Project Administration, M.-S.H.; Funding
Funding: This
Acquisition, research was funded by the Frontier Mould and Die Research and Development Center from
M.-S.H.
The Featured Areas Research Center Program within the framework of the Higher Education Sprout Project
Funding: This research
by the Ministry was funded
of Education by the
(MOE), Frontier
Taiwan, andMould and Dieof
the Ministry Research
Scienceand
andDevelopment Center from
Technology (Project The
number:
107-2221-E-992-041-MY2),
Featured Taiwan.
Areas Research Center Program within the framework of the Higher Education Sprout Project by the
Ministry
ConflictsofofEducation (MOE),
Interest: The Taiwan,
authors and
declare nothe Ministry
conflict of Science and Technology (Project number: 107-2221-
of interest.
E-992-041-MY2), Taiwan.
References
Conflicts of Interest: The authors declare no conflict of interest.
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© 2019 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access
article distributed under the terms and conditions of the Creative Commons Attribution
(CC BY) license (http://creativecommons.org/licenses/by/4.0/).

Tie-Bar Elongation Based Filling-To-Packing Switch

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Tie-Bar Elongation Based Filling-To-Packing Switch

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polymers

Keywords: clamping force; filling-to-packing switchover; injection molding; process control;

Polymers 2019, 11, 1168; doi:10.3390/polym11071168 www.mdpi.com/journal/polymers

Figure 1. Typical cavity pressure profile.

(a) (b) (c)

Figure 5. Clamping force set value versus part weight [5].

Figure 6. A proper clamping force set value [6].

Figure 7. Diagram of the measuring equipment.

Figure 8. Measurement of clamping force.

Polymers 2019, 11, x FOR PEER REVIEW Table 1. Specifications of sensors. 8 of 18

Figure 9. Injection tool with two cavities.

Figure 10. Geometry of dumbbell-shaped specimen.

represents the polymer

Figure 12. Cont.

Polymers 2019, 11, 1168 14 of 18

Figure 15. Sensitivity of V/P switchover point to part weight.

Figure 16. Part weight corresponding to varied barrel temperatures.

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