Cargando…

A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection Molding

Many challenges are associated with the injection molding process for forming a rib-structured pallet (1100 mm × 1100 mm × 140 mm, length × width × height) because greater flowing resistance through the rib channels within the pallet can induce insufficient filling. Essentially, multi-gate filling i...

Descripción completa

Detalles Bibliográficos
Autores principales: Liao, Yi-Ling, Tsai, Hsi-Hsun
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2022
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9031278/
https://www.ncbi.nlm.nih.gov/pubmed/35458381
http://dx.doi.org/10.3390/polym14081631
_version_ 1784692350963941376
author Liao, Yi-Ling
Tsai, Hsi-Hsun
author_facet Liao, Yi-Ling
Tsai, Hsi-Hsun
author_sort Liao, Yi-Ling
collection PubMed
description Many challenges are associated with the injection molding process for forming a rib-structured pallet (1100 mm × 1100 mm × 140 mm, length × width × height) because greater flowing resistance through the rib channels within the pallet can induce insufficient filling. Essentially, multi-gate filling involves a sequential valve gate system, which helps to spread the filling front with fewer weld lines. Based on the presetting of the sequential scheme of the valve gates, actual measurements of pallet flatness using the ATOS scan system were compared to numerical warpage measurements of a pallet derived by Moldex3D 2020. In this study, we propose a sequential scheme by actuating the valve gates to open once the flow front spreads towards them; then, actual warpage measurements of a pallet are compared with numerical measurements. The results show that the warpage of the top surface of the pallet is 5.144 mm in actual measurements and 5.729 mm in simulation. The results all indicated small warpage with respect to the pallet size. The simulation and actual measurements of flatness are in excellent agreement; the difference in top flatness between the simulated and actual pallet is 0.59 mm, while the bottom flatness difference is 0.035 mm. By adjusting the cooling water temperature, increasing the mold temperature, and decreasing the material temperature, overall flatness and warpage displacement can be reduced.
format Online
Article
Text
id pubmed-9031278
institution National Center for Biotechnology Information
language English
publishDate 2022
publisher MDPI
record_format MEDLINE/PubMed
spelling pubmed-90312782022-04-23 A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection Molding Liao, Yi-Ling Tsai, Hsi-Hsun Polymers (Basel) Article Many challenges are associated with the injection molding process for forming a rib-structured pallet (1100 mm × 1100 mm × 140 mm, length × width × height) because greater flowing resistance through the rib channels within the pallet can induce insufficient filling. Essentially, multi-gate filling involves a sequential valve gate system, which helps to spread the filling front with fewer weld lines. Based on the presetting of the sequential scheme of the valve gates, actual measurements of pallet flatness using the ATOS scan system were compared to numerical warpage measurements of a pallet derived by Moldex3D 2020. In this study, we propose a sequential scheme by actuating the valve gates to open once the flow front spreads towards them; then, actual warpage measurements of a pallet are compared with numerical measurements. The results show that the warpage of the top surface of the pallet is 5.144 mm in actual measurements and 5.729 mm in simulation. The results all indicated small warpage with respect to the pallet size. The simulation and actual measurements of flatness are in excellent agreement; the difference in top flatness between the simulated and actual pallet is 0.59 mm, while the bottom flatness difference is 0.035 mm. By adjusting the cooling water temperature, increasing the mold temperature, and decreasing the material temperature, overall flatness and warpage displacement can be reduced. MDPI 2022-04-18 /pmc/articles/PMC9031278/ /pubmed/35458381 http://dx.doi.org/10.3390/polym14081631 Text en © 2022 by the authors. https://creativecommons.org/licenses/by/4.0/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 (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Liao, Yi-Ling
Tsai, Hsi-Hsun
A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection Molding
title A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection Molding
title_full A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection Molding
title_fullStr A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection Molding
title_full_unstemmed A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection Molding
title_short A Comparison of Numerical and Actual Measurements of Large-Scale Rib-Structured Pallet Flatness Using Recycled Polypropylene in Injection Molding
title_sort comparison of numerical and actual measurements of large-scale rib-structured pallet flatness using recycled polypropylene in injection molding
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9031278/
https://www.ncbi.nlm.nih.gov/pubmed/35458381
http://dx.doi.org/10.3390/polym14081631
work_keys_str_mv AT liaoyiling acomparisonofnumericalandactualmeasurementsoflargescaleribstructuredpalletflatnessusingrecycledpolypropyleneininjectionmolding
AT tsaihsihsun acomparisonofnumericalandactualmeasurementsoflargescaleribstructuredpalletflatnessusingrecycledpolypropyleneininjectionmolding
AT liaoyiling comparisonofnumericalandactualmeasurementsoflargescaleribstructuredpalletflatnessusingrecycledpolypropyleneininjectionmolding
AT tsaihsihsun comparisonofnumericalandactualmeasurementsoflargescaleribstructuredpalletflatnessusingrecycledpolypropyleneininjectionmolding