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Engineering Analysis for Plastic Molding Quality Assurance and Productivity

  • Author / Creator
    Fu,Junyu
  • The injection molding process has been widely used to manufacture various plastic products featuring complex geometry. Product quality and productivity are conflicting requirements which are hard to achieve simultaneously. Some molding simulation packages are available which can accurately simulate the injection molding process based on process parameters, material data and mold configuration, and can help engineers to understand the molding process and evaluate the quality of the parts. However, due to the complexity of the molding process, producing high-quality plastic parts in less cycle time is still difficult, even with the help of advanced simulation technology.
    This thesis analyzes the gaps between the real injection molding process and the current available technology, and proposes a finite element analysis method to ensure that high-quality plastic parts are produced in less cycle time. First, a simulation workflow is proposed that aims to analyze the causes of warpage after pilot molding, and four possible methods are suggested to resolve such problems. Next, a molding simulation and structural analysis integrated method is proposed to predict the ejection-induced deformation and the shrinkage resulting from air-cooling. Finally, a new mold design strategy is proposed to facilitate early ejection upon partial solidification. By accurately predicting the molding behavior of plastic parts throughout the molding process, the parts, the mold and the process itself can be better designed to ensure the quality of plastic parts in less cycle time.

  • Subjects / Keywords
  • Graduation date
    Fall 2018
  • Type of Item
    Thesis
  • Degree
    Doctor of Philosophy
  • DOI
    https://doi.org/10.7939/R3TX35P0S
  • License
    Permission is hereby granted to the University of Alberta Libraries to reproduce single copies of this thesis and to lend or sell such copies for private, scholarly or scientific research purposes only. Where the thesis is converted to, or otherwise made available in digital form, the University of Alberta will advise potential users of the thesis of these terms. The author reserves all other publication and other rights in association with the copyright in the thesis and, except as herein before provided, neither the thesis nor any substantial portion thereof may be printed or otherwise reproduced in any material form whatsoever without the author's prior written permission.