The Experts below are selected from a list of 360 Experts worldwide ranked by ideXlab platform
Yanjin Guan - One of the best experts on this subject based on the ideXlab platform.
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thermal response of an Electric Heating rapid heat cycle molding mold and its effect on surface appearance and tensile strength of the molded part
Journal of Applied Polymer Science, 2012Co-Authors: Guilong Wang, Guoqun Zhao, Yanjin GuanAbstract:Rapid heat cycle molding (RHCM) is a newly developed injection molding technology in recent years. In this article, a new Electric Heating RHCM mold is developed for rapid Heating and cooling of the cavity surface. A data acquisition system is constructed to evaluate thermal response of the cavity surfaces of the Electric Heating RHCM mold. Thermal cycling experiments are implemented to investigate cavity surface temperature responses with different Heating time and cooling time. According to the experimental results, a mathematical model is developed by regression analysis to predict the highest temperature and the lowest temperature of the cavity surface during thermal cycling of the Electric Heating RHCM mold. The verification experiments show that the proposed model is very effective for accurate control of the cavity surface temperature. For a more comprehensive analysis of the thermal response and temperature distribution of the cavity surfaces, the numerical-method-based finite element analysis (FEA) is used to simulate thermal response of the Electric Heating RHCM mold during thermal cycling process. The simulated cavity surface temperature response shows a good agreement with the experimental results. Based on simulations, the influence of the power density of the cartridge heaters and the temperature of the cooling water on thermal response of the cavity surface is obtained. Finally, the effect of RHCM process on surface appearance and tensile strength of the part is studied. The results show that the high-cavity surface temperature during filling stage in RHCM can significantly improve the surface appearance by greatly improving the surface gloss and completely eliminating the weld line and jetting mark. RHCM process can also eliminate the exposing fibers on the part surface for the fiber-reinforced plastics. For the high-gloss acrylonitrile butadiene styrene/polymethyl methacrylate (ABS/PMMA) alloy, RHCM process reduces the tensile strength of the part either with or without weld mark. For the fiber-reinforced plastics of polypropylene (PP) + 20% glass fiber, RHCM process reduces the tensile strength of the part without weld mark but slightly increases the tensile strength of the part with weld mark. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013
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thermal and stress analysis of rapid Electric Heating injection mold for a large lcd tv panel
Applied Thermal Engineering, 2011Co-Authors: Ningning Gong, Yanjin Guan, Guangming ChengAbstract:Abstract Rapid Electric Heating cycle injection molding technology has been used widely in injection engineering application. Using this technology, excellent products with no weld marks, flow marks and other surface defects can be produced. However, as the special mold structure and its worse working process, the rapid Electric heated injection (EHI) mold is easy to fail than that of the conventional injection mold along with the injection process carried out repeatedly. In this paper, an EHI mold for a large liquid crystal display (LCD) TV panel was first presented. Then the heat transfer process of the mold during the working process was studied. Lastly, through finite element simulation, the reasons that cause the large thermal stress and deformation of the mold were analyzed. The practical failure of the mold proved that the analysis presented in the paper was right.
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research and application of a new rapid heat cycle molding with Electric Heating and coolant cooling to improve the surface quality of large lcd tv panels
Polymers for Advanced Technologies, 2011Co-Authors: Guoqun Zhao, Guilong Wang, Yanjin Guan, Huiping LiAbstract:The usage of rapid heat cycle molding (RHCM) has gained increasing attention in overcoming the limits of conventional injection molding (CIM) and improving the surface quality and mechanical properties of molded plastic products. In RHCM, the vario-thermal mold temperature control system is the key technique because it directly affects the molding cycle time and the final part quality. In this study, a new RHCM technology with Electric Heating and coolant cooling was studied in detail. Two different RHCM mold structures for a large LCD TV panel were proposed and designed. The numerical simulation method was used to analyze the thermal response of the mold cavity surface at the Heating stage and the thermal response of the resin melt at the cooling stage. The Heating/cooling efficiency of the proposed Electric Heating RHCM system was evaluated. The thermal expansion analysis of mold cavity was implemented and the fixation of the cavity in molds was also optimized. The results showed that the Electric-Heating mold with a separate cooling plate can efficiently enhance the Heating efficiency. The thermal expansion of the cavity surface can be reduced by increasing the alleviating-gap between the cavity and the cavity-retainer plate. Then, the service lifetime of the Electric-Heating mold can be improved. A RHCM production line with Electric Heating for the large LCD TV panel was constructed. Both the simulation and test production results indicate that the proposed Electric Heating RHCM technique can realize high-temperature injection molding without increasing the molding cycle time. The surface appearance of the LCD TV panels was dramatically improved and the surface marks that usually occur in CIM process were eliminated completely. Copyright © 2009 John Wiley & Sons, Ltd.
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research on optimum Heating system design for rapid thermal response mold with Electric Heating based on response surface methodology and particle swarm optimization
Journal of Applied Polymer Science, 2011Co-Authors: Guilong Wang, Guoqun Zhao, Yanjin GuanAbstract:A new Electric-Heating rapid thermal response (RTR) mold with floating cavity/core for rapid heat cycle molding is investigated in this study. Process principles of Rapid heat cycle molding (RHCM) with such new Electric-Heating mold are discussed and presented. Response surface methodology (RSM) is employed to develop mathematical relationships between layout of the Heating elements and Heating efficiency, temperature uniformity and structural strength of the floating cavity. Three explanatory variables including half distance between two adjacent Heating rods, spacing between Heating rods and cavity surface, and the diameter of the Heating rod are used to describe the layout and scale of the Heating elements. The response variables involving required Heating time, maximum cavity surface temperature, and maximum von-Mises stress are used to characterize Heating efficiency, temperature uniformity, and structural strength of the floating cavity, respectively. Central composite design (CCD) method is used for factorial experiments. Finite element analyses are conducted for combination of explanatory parameters to acquire the corresponding values of the response variables. Three predictive models for the response variables are created by regression analysis. Analysis of variance (ANOVA) is used to check their accuracy. These response surface models are interfaced with an effective particle swarm algorithm for the optimum Heating system design of the Electric-Heating RTR mold. The developed optimum method is then used for the design of the floating Electric-Heating cavity for an actual industrial product. The following heat transfer analysis results show that the temperature distribution uniformity of the cavity surface is greatly improved with the optimal cavity structure and layout of Heating rods. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011
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research of thermal response simulation and mold structure optimization for rapid heat cycle molding processes respectively with steam Heating and Electric Heating
Materials & Design, 2010Co-Authors: Guilong Wang, Huiping Li, Guoqun Zhao, Yanjin GuanAbstract:The dynamic mold temperature control system is the key of rapid heat cycle molding (RHCM) technology because it significantly affects the stability of the process, productivity and the quality of the final polymer part. For this reason, the approaches and techniques for dynamic mold temperature control were discussed in this study and two different dynamic mold temperature control methods, respectively, with steam Heating and Electric Heating were found to be very feasible in mass production. The methods and principles of mold design for the two RHCM technologies were also discussed and then several different kinds of mold structures were designed. By constructing the corresponding thermal response analytical models for these RHCM molds, the temperature responses of the molding systems in the Heating and cooling process of RHCM were simulated and studied. The effects of the mold design parameters such as the insulation layer between mold plate and mold inert, and mold material, on thermal response efficiency and temperature uniformity of the two RHCM processes were analyzed based on the simulation results. The results show that the insulation layer can increase the upper limit temperature of RHCM with steam Heating and improve the Heating speed of RHCM with Electric Heating. It can also greatly decrease the energy consumption of the two RHCM processes. The Heating efficiency of RHCM with steam Heating can be effectively improved by increasing the thermal conductivity of the cavity/core material, while the situation is diametrically opposite for RHCM with Electric Heating. Therefore, we acquired an optimized mold design principle and method for RHCM with steam Heating and Electric Heating, respectively. Finally, a new Electric Heating mold with a cooling plate was proposed to enhance the cooling efficiency. The thermal response of this new Electric Heating mold was also simulated. The simulation results show that the cooling plate can significantly improve the cooling and Heating efficiency.
Hanxiong Huang - One of the best experts on this subject based on the ideXlab platform.
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development and application of rapid thermal cycling molding with Electric Heating for improving surface quality of microcellular injection molded parts
Applied Thermal Engineering, 2016Co-Authors: Chenglong Xiao, Hanxiong Huang, Xing YangAbstract:Abstract A rapid thermal cycling molding (RTCM) technology with Electric Heating and water cooling was developed to eliminate the surface defects of microcellular injection molded parts. To verify its effectiveness, an RTCM mold for producing microcellular cover plates was constructed. Experiments and simulations were conducted to evaluate the mold thermal response. The results show that the mold cavity surface temperature (TM) can be rapidly adjusted in a large range. Moreover, empirical correlations for predicting the TMs were proposed and validated, and then can be used as an effective tool to accurately control the TMs in actual molding. Finally, microcellular polyformaldehyde (POM) cover plates were molded. The effect of the TM on their surface roughness was investigated and relevant mechanism was analyzed. It is found that the part surface roughness can be effectively reduced by increasing the TM. When raising the TM close to or above 150 °C, the microcellular POM cover plates with glossy appearance comparable to the solid counterpart can be molded within an accepted molding cycle time, demonstrating the effectiveness of the developed molding technology.
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multiobjective optimization design of Heating system in Electric Heating rapid thermal cycling mold for yielding high gloss parts
Journal of Applied Polymer Science, 2014Co-Authors: Chenglong Xiao, Hanxiong HuangAbstract:An optimization design method is developed for the Electric Heating system in rapid thermal cycling molding (RTCM) mold. First, a multiobjective optimization model is established, in which the distance between the mold cavity surface and the center of Heating elements and the number and power density of Heating elements are the design variables, the required Heating time th and the highest cavity surface temperature Tmax at time th are the objective functions. Then, an optimization strategy consisting of design of experiment, finite element analysis, artificial neural network (ANN) and response surface methodology (RSM) models, and Pareto-based genetic algorithm is proposed to solve the multiobjective optimization model. Finally, the optimization strategy is applied for the design of the Heating system for an automotive spoiler blow mold. The results show that the temperature distribution uniformity on the blow mold cavity surface is obviously improved and high Heating efficiency is also ensured with the optimized design parameters. Moreover, the ANN model exhibits its superiority over the RSM model in terms of modeling and predictive abilities. A RTCM blow mold with the optimized Electric Heating system is constructed and successfully utilized to mold high gloss automotive spoiler. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2014, 131, 39976.
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optimal design of Heating system for rapid thermal cycling mold using particle swarm optimization and finite element method
Applied Thermal Engineering, 2014Co-Authors: Chenglong Xiao, Hanxiong HuangAbstract:Abstract Heating efficiency and cavity surface temperature distribution are two key factors for the design of Heating system in rapid thermal cycling molding (RTCM) mold. Aiming at high Heating efficiency and uniform cavity surface temperature distribution, an optimization method combining particle swarm optimization (PSO) with finite element method (FEM) is proposed to design the Heating system for RTCM mold in this work. The proposed optimization design method is applied to design the Electric-Heating system for an RTCM blow mold of automotive spoiler to verify its effectiveness. The results demonstrate that the method can be used to effectively obtain the optimal design parameters compared with the simulation-based trial and error design method. Based on the optimal results, the RTCM spoiler blow mold with Electric Heating is constructed. Then, both infrared thermal imaging system and numerical simulation method are used to evaluate the mold thermal response and cavity surface temperature distribution. It is found that the simulated results are in good agreement with the measured ones. The blow molding experiments conducted using the constructed RTCM mold show that the surface quality of molded spoilers is dramatically improved.
Chenglong Xiao - One of the best experts on this subject based on the ideXlab platform.
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development and application of rapid thermal cycling molding with Electric Heating for improving surface quality of microcellular injection molded parts
Applied Thermal Engineering, 2016Co-Authors: Chenglong Xiao, Hanxiong Huang, Xing YangAbstract:Abstract A rapid thermal cycling molding (RTCM) technology with Electric Heating and water cooling was developed to eliminate the surface defects of microcellular injection molded parts. To verify its effectiveness, an RTCM mold for producing microcellular cover plates was constructed. Experiments and simulations were conducted to evaluate the mold thermal response. The results show that the mold cavity surface temperature (TM) can be rapidly adjusted in a large range. Moreover, empirical correlations for predicting the TMs were proposed and validated, and then can be used as an effective tool to accurately control the TMs in actual molding. Finally, microcellular polyformaldehyde (POM) cover plates were molded. The effect of the TM on their surface roughness was investigated and relevant mechanism was analyzed. It is found that the part surface roughness can be effectively reduced by increasing the TM. When raising the TM close to or above 150 °C, the microcellular POM cover plates with glossy appearance comparable to the solid counterpart can be molded within an accepted molding cycle time, demonstrating the effectiveness of the developed molding technology.
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multiobjective optimization design of Heating system in Electric Heating rapid thermal cycling mold for yielding high gloss parts
Journal of Applied Polymer Science, 2014Co-Authors: Chenglong Xiao, Hanxiong HuangAbstract:An optimization design method is developed for the Electric Heating system in rapid thermal cycling molding (RTCM) mold. First, a multiobjective optimization model is established, in which the distance between the mold cavity surface and the center of Heating elements and the number and power density of Heating elements are the design variables, the required Heating time th and the highest cavity surface temperature Tmax at time th are the objective functions. Then, an optimization strategy consisting of design of experiment, finite element analysis, artificial neural network (ANN) and response surface methodology (RSM) models, and Pareto-based genetic algorithm is proposed to solve the multiobjective optimization model. Finally, the optimization strategy is applied for the design of the Heating system for an automotive spoiler blow mold. The results show that the temperature distribution uniformity on the blow mold cavity surface is obviously improved and high Heating efficiency is also ensured with the optimized design parameters. Moreover, the ANN model exhibits its superiority over the RSM model in terms of modeling and predictive abilities. A RTCM blow mold with the optimized Electric Heating system is constructed and successfully utilized to mold high gloss automotive spoiler. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2014, 131, 39976.
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optimal design of Heating system for rapid thermal cycling mold using particle swarm optimization and finite element method
Applied Thermal Engineering, 2014Co-Authors: Chenglong Xiao, Hanxiong HuangAbstract:Abstract Heating efficiency and cavity surface temperature distribution are two key factors for the design of Heating system in rapid thermal cycling molding (RTCM) mold. Aiming at high Heating efficiency and uniform cavity surface temperature distribution, an optimization method combining particle swarm optimization (PSO) with finite element method (FEM) is proposed to design the Heating system for RTCM mold in this work. The proposed optimization design method is applied to design the Electric-Heating system for an RTCM blow mold of automotive spoiler to verify its effectiveness. The results demonstrate that the method can be used to effectively obtain the optimal design parameters compared with the simulation-based trial and error design method. Based on the optimal results, the RTCM spoiler blow mold with Electric Heating is constructed. Then, both infrared thermal imaging system and numerical simulation method are used to evaluate the mold thermal response and cavity surface temperature distribution. It is found that the simulated results are in good agreement with the measured ones. The blow molding experiments conducted using the constructed RTCM mold show that the surface quality of molded spoilers is dramatically improved.
Young Gyu Jeong - One of the best experts on this subject based on the ideXlab platform.
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carbon nanotube polyimide bilayer thin films with high structural stability optical transparency and Electric Heating performance
RSC Advances, 2016Co-Authors: Youngju Kim, Young Gyu JeongAbstract:Structurally stable and optically transparent multiwalled carbon nanotube/polyimide (MWCNT/PI) bilayer thin films with different MWCNT thicknesses of 56–155 nm are manufactured by a facile spin-coating of MWCNT aqueous solution and poly(amic acid) (PAA) solution on a glass substrate, followed by thermal treatment for imidization. For this purpose, PAA as a PI precursor is synthesized by the reaction of pyromellitic dianhydride and 4,4′-diaminodiphenylether. The MWCNT layer thickness in the bilayer films is controlled by the cycle number of the spin-coating process of the MWCNT aqueous solution on the glass substrate. SEM images of the bilayer films reveal that neat MWCNT layers are uniformly coated on glass substrates and they are covered well with a PI layer. Accordingly, the MWCNT/PI bilayer films are mechanically and structurally stable owing to the presence of a PI layer on the MWCNT layer, compared to neat MWCNT films on glass substrates. With the increase of the MWCNT layer thickness in the bilayer films from 56 nm to 155 nm, the sheet resistance decreases from ∼1.97 × 105 Ω sq−1 to ∼3.89 × 103 Ω sq−1 and the optical transparency at 550 nm wavelength also decreases from ∼78% to ∼52%. The MWCNT/PI bilayer thin films exhibit a high Electric Heating performance in view of the rapid Heating/cooling response time of 13.8–16.8 s, high Electric power efficiency of 11.5–14.8 mW per °C, and high steady-state maximum temperatures up to 219 °C as a function of the applied voltage of 20–100 V.
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investigation of microstructure and Electric Heating behavior of hybrid polymer composite films based on thermally stable polybenzimidazole and multiwalled carbon nanotube
Polymer, 2015Co-Authors: Jinho Park, Young Gyu JeongAbstract:Abstract Thermally stable polybenzimidazole (PBI)-based composite films filled with different pristine multiwalled carbon nanotube (MWCNT) contents of 0.0–10.0 wt% were manufactured by a facile solution casting, and their microstructural features, thermal and Electrical properties were investigated as a function of the MWCNT content. Electron microscopic images and FT-IR spectra of the composite films confirmed that each MWCNT was wrapped with PBI chains by π–π interaction and thus they were well dispersed in the PBI matrix. Thus, the Electrical resistivity of the composite films decreased considerably from ∼107 Ω cm to ∼10−1 Ω cm with the increment of the MWCNT content, especially at a certain percolation threshold of ∼0.25 wt% MWCNT. The composite films containing above 0.3 wt% MWCNT contents exhibited excellent Electric Heating performance. For instance, the composite film with 10.0 wt% MWCNT exhibited low temperature growth/decay time constant of ∼1 s, stable maximum temperatures of 40–220 °C, and high Electric power efficiency of ∼7.32 mW/°C under the relatively low applied voltages of 5–25 V. Thermogravimetric analysis revealed that the composite films were thermally stable up to ∼450 °C under air environment. It is thus reasonable to contend that PBI/MWCNT composite films can be used as high performance Electric Heating materials in emerging application areas.
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microstructure and performance of multiwalled carbon nanotube m aramid composite films as Electric Heating elements
ACS Applied Materials & Interfaces, 2013Co-Authors: Young Gyu Jeong, Gil Woo JeonAbstract:We report microstructure of thermomechanically stable multiwalled carbon nanotube (MWCNT)/poly(m-phenylene isophthalamide) (m-aramid) composite films containing 0.0-10.0 wt % MWCNTs and their performance as Electric Heating elements. FE-SEM images show that the MWCNTs are well dispersed in the composite films and are wrapped with m-aramid chains and that the interfacial thickness of m-aramid wrapped MWCNTs decreases with the MWCNT content. The Electrical resistivity of films varies from ∼10(13) Ω cm for the neat m-aramid to ∼10(0) Ω cm of the film with 10.0 wt % MWCNT owing to the formation of a conductive three-dimensional network of MWCNTs. Accordingly, the performance of MWCNT/m-aramid films as Electric Heating elements is strongly dependent on MWCNT content as well as applied voltage. For the composite film with 10.0 wt % MWCNT, a maximum temperature of ∼176 °C is attained even at a low applied voltage of 10 V. The excellent performance such as rapid temperature response and high Electric power efficiency at given applied voltages is found to be related with the microstructural features of the MWCNT/m-aramid films.
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structure and Electric Heating performance of graphene epoxy composite films
European Polymer Journal, 2013Co-Authors: Young Gyu JeongAbstract:Abstract We have prepared a series of graphene/epoxy composite films by thermal curing of diglycidyl ether of bisphenol-A with an amine-functionalized agent casted on a polyimide film, and investigated their structures and Electrical properties as a function of graphene content of 0.0–10.0 wt%. X-ray diffraction patterns and TEM images show that graphene nanoplatelets are well dispersed in the epoxy resin matrix. The Electrical resistance of the composite films varies dramatically from ∼10 13 to ∼10 3 Ω with increasing the graphene content, especially at a certain graphene content between 1.0 and 2.0 wt%. Accordingly, Electric Heating behavior of the composite films with 2.0–10.0 wt% graphene is strongly dependent on graphene content as well as applied voltage. For the composite film with 10.0 wt% graphene, a maximum temperature of ∼126 °C is stably maintained over a cyclic voltage variation of 30 V. The excellent Electric Heating performance such as rapid temperature response, high Electric power efficiency, and operational stability at applied voltages is believed to be owing to the presence of highly conductive graphene sheets interconnected in the thermosetting epoxy matrix.
Guilong Wang - One of the best experts on this subject based on the ideXlab platform.
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thermal response of an Electric Heating rapid heat cycle molding mold and its effect on surface appearance and tensile strength of the molded part
Journal of Applied Polymer Science, 2012Co-Authors: Guilong Wang, Guoqun Zhao, Yanjin GuanAbstract:Rapid heat cycle molding (RHCM) is a newly developed injection molding technology in recent years. In this article, a new Electric Heating RHCM mold is developed for rapid Heating and cooling of the cavity surface. A data acquisition system is constructed to evaluate thermal response of the cavity surfaces of the Electric Heating RHCM mold. Thermal cycling experiments are implemented to investigate cavity surface temperature responses with different Heating time and cooling time. According to the experimental results, a mathematical model is developed by regression analysis to predict the highest temperature and the lowest temperature of the cavity surface during thermal cycling of the Electric Heating RHCM mold. The verification experiments show that the proposed model is very effective for accurate control of the cavity surface temperature. For a more comprehensive analysis of the thermal response and temperature distribution of the cavity surfaces, the numerical-method-based finite element analysis (FEA) is used to simulate thermal response of the Electric Heating RHCM mold during thermal cycling process. The simulated cavity surface temperature response shows a good agreement with the experimental results. Based on simulations, the influence of the power density of the cartridge heaters and the temperature of the cooling water on thermal response of the cavity surface is obtained. Finally, the effect of RHCM process on surface appearance and tensile strength of the part is studied. The results show that the high-cavity surface temperature during filling stage in RHCM can significantly improve the surface appearance by greatly improving the surface gloss and completely eliminating the weld line and jetting mark. RHCM process can also eliminate the exposing fibers on the part surface for the fiber-reinforced plastics. For the high-gloss acrylonitrile butadiene styrene/polymethyl methacrylate (ABS/PMMA) alloy, RHCM process reduces the tensile strength of the part either with or without weld mark. For the fiber-reinforced plastics of polypropylene (PP) + 20% glass fiber, RHCM process reduces the tensile strength of the part without weld mark but slightly increases the tensile strength of the part with weld mark. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013
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research and application of a new rapid heat cycle molding with Electric Heating and coolant cooling to improve the surface quality of large lcd tv panels
Polymers for Advanced Technologies, 2011Co-Authors: Guoqun Zhao, Guilong Wang, Yanjin Guan, Huiping LiAbstract:The usage of rapid heat cycle molding (RHCM) has gained increasing attention in overcoming the limits of conventional injection molding (CIM) and improving the surface quality and mechanical properties of molded plastic products. In RHCM, the vario-thermal mold temperature control system is the key technique because it directly affects the molding cycle time and the final part quality. In this study, a new RHCM technology with Electric Heating and coolant cooling was studied in detail. Two different RHCM mold structures for a large LCD TV panel were proposed and designed. The numerical simulation method was used to analyze the thermal response of the mold cavity surface at the Heating stage and the thermal response of the resin melt at the cooling stage. The Heating/cooling efficiency of the proposed Electric Heating RHCM system was evaluated. The thermal expansion analysis of mold cavity was implemented and the fixation of the cavity in molds was also optimized. The results showed that the Electric-Heating mold with a separate cooling plate can efficiently enhance the Heating efficiency. The thermal expansion of the cavity surface can be reduced by increasing the alleviating-gap between the cavity and the cavity-retainer plate. Then, the service lifetime of the Electric-Heating mold can be improved. A RHCM production line with Electric Heating for the large LCD TV panel was constructed. Both the simulation and test production results indicate that the proposed Electric Heating RHCM technique can realize high-temperature injection molding without increasing the molding cycle time. The surface appearance of the LCD TV panels was dramatically improved and the surface marks that usually occur in CIM process were eliminated completely. Copyright © 2009 John Wiley & Sons, Ltd.
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research on optimum Heating system design for rapid thermal response mold with Electric Heating based on response surface methodology and particle swarm optimization
Journal of Applied Polymer Science, 2011Co-Authors: Guilong Wang, Guoqun Zhao, Yanjin GuanAbstract:A new Electric-Heating rapid thermal response (RTR) mold with floating cavity/core for rapid heat cycle molding is investigated in this study. Process principles of Rapid heat cycle molding (RHCM) with such new Electric-Heating mold are discussed and presented. Response surface methodology (RSM) is employed to develop mathematical relationships between layout of the Heating elements and Heating efficiency, temperature uniformity and structural strength of the floating cavity. Three explanatory variables including half distance between two adjacent Heating rods, spacing between Heating rods and cavity surface, and the diameter of the Heating rod are used to describe the layout and scale of the Heating elements. The response variables involving required Heating time, maximum cavity surface temperature, and maximum von-Mises stress are used to characterize Heating efficiency, temperature uniformity, and structural strength of the floating cavity, respectively. Central composite design (CCD) method is used for factorial experiments. Finite element analyses are conducted for combination of explanatory parameters to acquire the corresponding values of the response variables. Three predictive models for the response variables are created by regression analysis. Analysis of variance (ANOVA) is used to check their accuracy. These response surface models are interfaced with an effective particle swarm algorithm for the optimum Heating system design of the Electric-Heating RTR mold. The developed optimum method is then used for the design of the floating Electric-Heating cavity for an actual industrial product. The following heat transfer analysis results show that the temperature distribution uniformity of the cavity surface is greatly improved with the optimal cavity structure and layout of Heating rods. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011
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research of thermal response simulation and mold structure optimization for rapid heat cycle molding processes respectively with steam Heating and Electric Heating
Materials & Design, 2010Co-Authors: Guilong Wang, Huiping Li, Guoqun Zhao, Yanjin GuanAbstract:The dynamic mold temperature control system is the key of rapid heat cycle molding (RHCM) technology because it significantly affects the stability of the process, productivity and the quality of the final polymer part. For this reason, the approaches and techniques for dynamic mold temperature control were discussed in this study and two different dynamic mold temperature control methods, respectively, with steam Heating and Electric Heating were found to be very feasible in mass production. The methods and principles of mold design for the two RHCM technologies were also discussed and then several different kinds of mold structures were designed. By constructing the corresponding thermal response analytical models for these RHCM molds, the temperature responses of the molding systems in the Heating and cooling process of RHCM were simulated and studied. The effects of the mold design parameters such as the insulation layer between mold plate and mold inert, and mold material, on thermal response efficiency and temperature uniformity of the two RHCM processes were analyzed based on the simulation results. The results show that the insulation layer can increase the upper limit temperature of RHCM with steam Heating and improve the Heating speed of RHCM with Electric Heating. It can also greatly decrease the energy consumption of the two RHCM processes. The Heating efficiency of RHCM with steam Heating can be effectively improved by increasing the thermal conductivity of the cavity/core material, while the situation is diametrically opposite for RHCM with Electric Heating. Therefore, we acquired an optimized mold design principle and method for RHCM with steam Heating and Electric Heating, respectively. Finally, a new Electric Heating mold with a cooling plate was proposed to enhance the cooling efficiency. The thermal response of this new Electric Heating mold was also simulated. The simulation results show that the cooling plate can significantly improve the cooling and Heating efficiency.