Theorical and Experimental Study of the Manufacture of Polymeric Parts by

Injection Molding
Fábio Duarte Nóbrega Rodrigues

Instituto Superior Técnico – Universidade Técnica de Lisboa – Portugal

October 2010

Secção de Tecnologia Mecânica, Instituto Superior Técnico, Avenida Rovisco Pais, 1049-001 Lisboa, Portugal

Abstract
This work gave an analysis of the fabrication process of polymeric parts by injection with reference to a single part conceived in an
industrial environment. The use of finite element software, namely the Autodesk Moldflow Insight®, brought numerical simulated
answers with real processing characteristics. The intent of this approach was to get results translating in the main features of the
part in question. Taking these results into account, an evaluation was done on the control method of the fabrication process of this
part, complying with the normal guidelines of the technology of plastic transformation. With this in mind and the effect caused by
each variable, a new and more suitable definition was advised in this work, concerning the main variables on the injection mold
process, with the products’ ultimate standard in mind. The goals achieved illustrate the benefits of the numerical simulation process
and the appropriate definition of all parameters.

Keywords: Injection Molding, Thermoplastics, Finite Element Method, Injection Process Control.

1 Introduction The process variables depend not only on

machine parameters, but also the combination of
Nowadays, industries face increasingly
three other factors: polymer, mold and machine used.
demanding high standards, finding themselves
Although process control has been widely studied and
obliged to deliver quality products on a global market,
reported on several publications, it hasn’t been mostly
where competitive final costs are seen as
applied in industry [2].
prerequisites.
Countless defects may appear in injected parts,
Within this scenario, injection molding
causing potential problems regarding mechanical
technology presents itself as a manufacturing process
strength and surface quality, which directly affect
of great prominence and importance regards the
commercialization. Efforts are made in order to
processing of polymeric components. Through their
reduce problems in the production process from
research and experience, several researchers study
injection mold design to the conception of the part to
and try to explain the technological and
be molded. In this context, it’s most important to call
phenomenological aspects of this process [1].
upon both sophisticated analysis tools and
computational simulations to firmly sustain a project
Hereupon, it appears that some of the difficulties
[3].
experienced by companies using the injection molding
technology are due to lack of both systematization
Understanding how the process parameters are
and optimization, not only in building tools, as is the
controlled requires high acquaintance of all
case of mold, but also the definition of control
phenomena related to injection phase, particularly
variables of the entire injection process. Due to large
regarding flow characteristics during fill, shear
capital investment needed in machinery, molds and
stresses, temperatures and pressures developed. In
auxiliary equipment, it is crucial to have prior deep
this context, it is essential to understand how
knowledge of all aspects related to process
polymeric materials behave, not only in terms of its
operations, since they are directly related to both
mechanical strength but also in terms of its
feasibility and quality of injected parts.
rheological properties and their performance as a

1
function of pressure, specific volume and temperature effect of the most influential parameters, with the aim
[4]. of improving some quality aspects of process.

Taking this into account, it is useful to apply a

numerical simulation software, as their tools allow us 2.1 Processing Conditions Study
to predict and eliminate potential production problems
After each molding cycle two parts are extracted
and optimize the design of both part and mold, while
enabling it to perform experiments in order to observe simultaneously (Figure 2.2).
the behavior of diverse process parameters, allowing
thus to acquire skill in manipulating input variables
involved in the whole process of injection molding.

Within the purpose of this work, it’s also

included the reproduction of actual conditions of
processing an injection molding part and the
validation of studies’ results in order to understand
and improve the process variables, using the Figure 2.2 – Ejection parts after a cycle
numerical simulations. With this in mind, the aim is to
find an improved set of definitions for the manufacture Although both parts seem to have total
of such polymeric part, using the injection molding
symmetry in terms of final characteristics, upon closer
process and evaluating the decisions through the
study of numerical simulation software Moldflow examination, there are small differences. Those can
Autodesk Insight ®. be explained by the simple fact of the mold cavities or
runners were not machined precisely the same way
2 Theorical and Experimental Work on both sides, since it is difficult to achieve that
perfection [5].
The study refers to a part (Figure 2.1) manufactured
in series by injection molding in an industrial
environment in order to be marketed. Observe, for example, the difference in a
characteristic welding line of the part (Figure 2.3).

Figure 2.1 – Part manufactured by injection molding Figure 2.3 – (a) Part extracted of the cavity #1. (b) Part
extracted of the cavity #2.
The first goal of this study is to reproduce as
faithfully as possible the conditions used in the
The filling control is made by a velocity
company, using the numerical simulation software
Moldflow Autodesk Insight ®. To do that, a survey profile of ram set in relation to its position,
was carried out to gather all the characteristics of the whose values are graphically presented in
equipment used in the process, the part’s material Figure 2.4
and all the parameters programmed into the control
system in order to proceed to the corresponding
computer simulation.

This case study ends with suggesting new

process conditions taking into account the combined

2
 It appears that the flow front velocity is variable.
This is shown by the different spacing in the predicted
filling contours. (Figure 2.7). This issue is usually
damaging to the final part quality [4].

Figure 2.7 – Spacing in the predicted filling contours.

Observe Figure 2.8, which illustrates the

Figure 2.4 – (a) Ram stroke. (b) Profile of speeds used in
evolution of maximum pressure versus filling time.
filling control.

Reproduction of the computational process was

carried out using the parameters collected in an
industrial environment (Figure 2.5).

Figure 2.5 – cooling system.

It follows that the welding line obtained in Figure 2.8 – Pressure injection as a function of filling time.
computer simulation is comparable with the part
shown in Figure 2.3b (corresponding to the part
extracted from the cavity mold # 2), as exposed in
Figure 2.6. 2.2 Rating the Real Process

The target aspects of possible changes in order

to give more quality to the part are:

1. Gate: wrong dimensioning of the fan gate

(not maintaining constant section area) and
opt for a disadvantaged location taking into
account the effect of fiber orientation, which
causes greater warping.

2. Velocity profile: unbalanced profile which

Figure 2.6 – Welding line obtained in the computer
simulation. causes an inconstant melt front velocity

3
 during filling phase, originating different
orientations of the fibers along the part.

3. V/P Switchover: Switchover at 87.17% of the

volume filled, which is premature as it
originates about 13% of total volume to be
filled under different conditions from the rest
of the part, that is, variable flow front velocity.

4. Compensation pressure: excessive

compensation pressure, which may call into
Figure 2.9 – Ram speed profile recommended.
question the integrity of the equipment,
causing high clamp force and lead to defects It’s estimated that the nominal flow rate which
3
in the part. Moreover, there is a sudden minimizes total deflection is the about Qn ≈390cm /s
change of pressure in the passage of the (Figure 2.10).
filling phase to the pressurization phase,
which should not happen.

The first critical point mentioned corresponds to

a variable related exclusively with mold design, which
means it cannot be modified through the control
system of the process, that’s why it will not be
considered for improvement henceforth.

Regarding the three remaining points, it will be

made a deeper study in order to illustrate the
individual effect of each variable. This evaluation is
always performed in accordance with the processing
Figure 2.10 – Total deflection as a function of nominal flow
variables used in the simulation to reproduce real rate.
conditions, i.e. in each study only one parameter is
With this methodology it is possible to obtain a
going to be considered and then it will be discussed
constant flow front velocity, as filling contours are
its influence regarding part’s final quality.
equally spaced (Figure 2.11).

The recommended profile is given by the

analysis in which real processing conditions were
reproduced, which was iterated until the convergence
of values that is presented in Figure 2.9, which
induces a constant flow front velocity.

Figure 2.11 – Spacing in the predicted filling contours.

It also appears that total deflection decreases

when V/P switchover is changed to a value near
100% (Figure 2.12).

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 Figure 2.12 – Total deflection as a function of V/P
switchover.
Figure 2.14 – (a) Ram Stroke. (b) Speed profile suggested
Finally, the total deflection also decreases with for the filling control.
increasing compensation pressure (Figure 2.13).
The maximum pressure evolution during fill
phase is shown in Figure 2.15, where V/P switchover
has carried out with 98.5% of shot volume and with a
compensation pressure equal to 80% of the value
immediately before switchover.

Figure 2.13 – Total deflection as a function of compensation

pressure.

2.3 Alterations Suggested for the Process

Control

However, the overall effect of all variables is

complex and difficult to predict. Therefore, in order to Figure 2.15 – Maximum injection pressure as a function of
adjust to each variable, there were several iterative filling time.
numerical analysis of trial and error in order to obtain
the lowest possible deflection. Figure 2.16 illustrates total deflection suggested
control is inputted.
The suggested speed profile is shown in Figure
2.14.

5

Figure 2.16 – Total deflection by the suggested control.
Figure 2.17 allows us to observe differences in clamp
force between real control and suggested control.
Figure 2.17 – Clamp force as a time function.
3 Results and Discussions
Using suggested process control, it appears that
total deflection obtained fits in the same order of
magnitude. However, with this control, compensation
pressure is used in the recommended range and this
is a key factor to safeguard the integrity of all
equipment, as it prevents excessive compensation
pressures and rapid changes in V/P switchover, i.e.
factors contributing to the quality of process.
It appears that using the variables suggested for
improving the process, a maximum clamp force of
125 tons is needed, while in real processing is
required a maximum of 224 tons, which means an
increase of about 80%. This can be considered a
great advantage because energy consumption is
significantly reduced and therefore a smaller capacity
injection machine is required.
As all deflection graphics are analyzed, it
becomes clear that maximum values are
systematically restricted in the ribs’ zone. This proves
that part’s geometry is also a preponderant factor to
take into account in its design. Alternatively, if other
ribs were added perpendicularly to those existing
(originating small squares), for example, part’s
geometry effect on total deflection could possibly be
lower.
4 Conclusions
The study on injection molding process allowed us to
realize the influence of the main control parameters.
Using Autodesk Moldflow Insight, it was possible to
efficiently reproduce real conditions in a number of
polymer processing. Thus, it was possible to make an
assessment of the processing conditions and highlight
a few critical points related to control settings adopted
by the company.
One of the most important factors in controlling
the injection process is the proper definition of ram
speed. Finding this profile should be, mostly, the first
step regarding all input variables in programming the
control unit of the injection machine. Due to lack of a
systematic approach for the determination of this
profile, a methodology was needed. Taking into
account the recommended velocity profile given by
the software, which is defined by the percentage shot
volume as function of percentage flow rate. Given this
method of controlling ram speed, different flow rate
were tested in order to discover which is the most
advantageous for the quality of the part. After
determining flow rate, the previously determined
profile is converted into another equivalent, through
simple analytical calculations, but now defined by the
ram speed according to its position, in order to be
comparable to the profile used in the real processing.
This methodology proved to be very consistent in a
way that it provided a mold filled with constant melt
front velocity, as intended.
6
 It was found that the parameters suggested for
the control of the process were appropriate, given that
the final results showed a number of benefits.
In addition to highlighting the importance of a
proper definition process control system variables, it
[4] Shoemaker, J. Moldflow Design Guide: A
Resource for Plastics Engineers, Hanser Gardner
Publications, USA, 2006.
[5] Harada, J. Moldes para Injeção de
Termoplásticos: Projetos e Principios. Artiliber, São
Paulo, 2004

was stressed also the importance of a consistent

mold design and factors related to part’s geometry,
since these may determine the total deflection of the
part. Benefits of a favorable gate location were
shown, taking into account the induced orientation to
the fibers. Nevertheless, there are other factors
prevailing in that decision, namely the constructive
aspects of mold and economic factor. It’s also
important to mention that the computational
simulation isn’t, by itself, the solver of all the
problems, still it’s a powerful tool that can generate
great advantage for businesses and enable their rapid
technological evolution.

This work showed that when solutions are

needed, namely for design and programming control
variables, knowledge is not efficiently gathered in a
simple and effective way, since injection molding
technology is a very wide area and with complex
phenomena and interdisciplinary. Thus, the studies
developed during this work somehow allowed creating
methodologies towards a consistent approach of the
main factors inherent in the technology of plastics
processing.

References

[1] Hassan, H., Regnier, N., e Defaye, G. (2009). A

3D study on the effect of gate location on the cooling
of polymer by injection molding. International Journal
of Heat and Fluid Flow, 30: 1218-1229.

[2] Beaumont, J.P. Runner and Gating Design

Handbook: Tools for Successful Injection Molding,
Carl Hanser Verlag, 2º edição, Munich, 2007.

[3] Osswald, T.A., Turng, L. S. e Gramann, P. J.

Injection Molding Handbook, Hanser Gardner
Publications, Munich, 2008