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Sample records for mold filling simulation

  1. Numerical recipes for mold filling simulation

    Energy Technology Data Exchange (ETDEWEB)

    Kothe, D.; Juric, D.; Lam, K.; Lally, B.

    1998-07-01

    Has the ability to simulate the filling of a mold progressed to a point where an appropriate numerical recipe achieves the desired results? If results are defined to be topological robustness, computational efficiency, quantitative accuracy, and predictability, all within a computational domain that faithfully represents complex three-dimensional foundry molds, then the answer unfortunately remains no. Significant interfacial flow algorithm developments have occurred over the last decade, however, that could bring this answer closer to maybe. These developments have been both evolutionary and revolutionary, will continue to transpire for the near future. Might they become useful numerical recipes for mold filling simulations? Quite possibly. Recent progress in algorithms for interface kinematics and dynamics, linear solution methods, computer science issues such as parallelization and object-oriented programming, high resolution Navier-Stokes (NS) solution methods, and unstructured mesh techniques, must all be pursued as possible paths toward higher fidelity mold filling simulations. A detailed exposition of these algorithmic developments is beyond the scope of this paper, hence the authors choose to focus here exclusively on algorithms for interface kinematics. These interface tracking algorithms are designed to model the movement of interfaces relative to a reference frame such as a fixed mesh. Current interface tracking algorithm choices are numerous, so is any one best suited for mold filling simulation? Although a clear winner is not (yet) apparent, pros and cons are given in the following brief, critical review. Highlighted are those outstanding interface tracking algorithm issues the authors feel can hamper the reliable modeling of today`s foundry mold filling processes.

  2. Computer simulation for centrifugal mold filling of precision titanium castings

    Institute of Scientific and Technical Information of China (English)

    2004-01-01

    Computer simulation codes were developed based on a proposed mathematical model for centrifugal mold filling processes and previous computer software for 3D mold filling and solidification of castings (CASM-3D for Windows). Sample simulations were implemented for mold filling processes of precision titanium castings under gravity and different centrifugal casting techniques. The computation results show that the alloy melt has a much stronger mold filling ability for thin section castings under a centrifugal force field than that only under the gravity. A "return back" mold filling manner is showed to be a reasonable technique for centrifugal casting processes, especially for thin section precision castings.

  3. Injection molding simulation with variothermal mold temperature control of highly filled polyphenylene sulfide

    Science.gov (United States)

    Birkholz, A.; Tschiersky, M.; Wortberg, J.

    2015-05-01

    For the installation of a fuel cell stack to convert chemical energy into electricity it is common to apply bipolar plates to separate and distribute reaction gases and cooling agents. For reducing manufacturing costs of bipolar plates a fully automated injection molding process is examined. The high performance thermoplastic matrix material, polyphenylene sulfide (PPS), defies against the chemical setting and the operation temperature up to 200 °C. To adjust also high electrical and thermal conductivity, PPS is highly filled with various carbon fillers up to an amount of 65 percentage by volume. In the first step two different structural plates (one-sided) with three different gate heights and molds are designed according to the characteristics of a bipolar plate. To cope with the approach that this plate should be producible on standard injection molding machines with variothermal mold temperature control, injection molding simulation is used. Additionally, the simulation should allow to formulate a quality prediction model, which is transferrable to bipolar plates. Obviously, the basis for a precise simulation output is an accurate description of the material properties and behavior of the highly filled compound. This, the design of the structural plate and mold and the optimization via simulation is presented, as well. The influence of the injection molding process parameters, e.g. injection time, cycle times, packing pressure, mold temperature, and melt temperature on the form filling have been simulated to determine optimal process conditions. With the aid of the simulation and the variothermal mold temperature control it was possible to reduce the required melt temperature below the decomposition temperature of PPS. Thereby, hazardous decomposition products as hydrogen sulfide are obviated. Thus, the health of the processor, the longevity of the injection molding machine as well as the material and product properties can be protected.

  4. Numerical Simulation and Water Analog of Mold Filling Processes

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    This paper demonstrates the potential of a computer code, developed by the authors, in shaping gating systems by modeling the fluid flow phenomena through a complex gating system during mold filling. A plate casting with dimension 200 mm×200 mm×50 mm was chosen as the verifying problem. Water analog studies were carried out on this casting. The comparison indicates that computer simulation could be a powerful tool in shaping gating systems.

  5. Computer precision simulation for titanium casting centrifugal mold filling of prescision titanium castings

    Directory of Open Access Journals (Sweden)

    Daming XU

    2004-08-01

    Full Text Available Computer simulation codes were developed based on proposed mathematical model for centrifugal mold filling processes and previous computer software for 3D mold filling and solidification of castings. Sample simulations were implemented for mold filling processes of precision titanium castings under gravity and different centrifugal casting techniques. The computation results show that the alloy melt has a much stronger mold filling ability for thin section castings unde a centrifugal force field than that only under the gravity. A "return back" mold filling manner is showed to be a reasonable technique for centrifugal casting processes, especially for thin section prcision castings.

  6. Modeling simulation and experimental validation for mold filling process

    Institute of Scientific and Technical Information of China (English)

    HOU Hua; JU Dong-ying; MAO Hong-kui; D. SAITO

    2006-01-01

    Based on the continuum equation, momentum conservation and energy conservation equations, the numerical model of turbulent flow filling was introduced; the 3-D free surface vof method was improved. Whether or not the numerical simulation results are reasonable, it needs corresponding experimental validations. General experimental techniques for casting fluid flow process include: thermocouple tracking location method, hydraulic simulating method, heat-resistant glass window method and X-ray observation etc. The hydraulic analogue experiment with DPIV technique is arranged to validate the fluent flow program for low-pressure casting with 0.1×105 Pa and 0.6×105 Pa pressure visually. By comparing the flow head, liquid surface, flow velocity, it is found that the filling pressure value influences the flow state strongly. With the increase of the filling pressure, the fluid flow state becomes unstable, the flow head becomes higher, and the filling time is reduced. The simulated results are accordant with the observed results approximately, which can prove the reasonability of our numerical program for filling process further.

  7. Study on Numerical Simulation of Mold Filling and HeatTransfer in Die Casting Process

    Institute of Scientific and Technical Information of China (English)

    2000-01-01

    A 3-D mathematical model considering turbulence phenomena has been established basedon a computational fluid dynamics technique, so called 3-D SOLA-VOF (Solution Algorithm-Volume of Fluid), to simulate the fluid flow of mold filling process of die casting. In addition, the mathematical model for simulating the heat transfer in die casting process has also been established.The computation program has been developed by the authors with the finite difference method (FDM) recently. As verification, the mold filling process of a S-shaped die casting has been simulated and the simulation results coincide with that of the benchmark test. Finally, as a practical application, the gating design of a motorcycle component was modified by the mold filling simulation and the dies design of another motorcycle component was optimized by theheat transfer simulation. All the optimized designs were verified by the production practice.

  8. Comparison of rheological analytic model with numerical simulation in powder injection molding filling process

    Institute of Scientific and Technical Information of China (English)

    刘跃军; 李祥刚; 黄宇刚; 魏珊珊; 曾广胜

    2008-01-01

    Mathematical model of filling disk-shaped mold cavity in steady state was studied.And the mathematical model under vibration field was developed from the model in steady state.According to the model of filling disk-shaped mold cavity in steady state,the filling time,the distribution of velocity field and the pressure field were obtained.The analysis results from rheological analytic model were compared with the numerical simulation results using Moldflow software in the powder injection molding filling process.Through the comparison,it is found that it is unreasonable to neglect the influence of temperature when calculated the pressure changing with the time at the cavity gate,while it can be neglected in other situations such as calculating the distribution of the velocity fields.This provides a theoretical reference for the establishment of correct model both in steady state and under vibration force field in the future.

  9. Flow visualization and simulation of the filling process during injection molding

    DEFF Research Database (Denmark)

    Guerrier, Patrick; Tosello, Guido; Hattel, Jesper Henri

    2017-01-01

    To directly compare experimental moldings from an injection molding machine with simulations, a special mold has been produced with a glass window. The injection plane is perpendicular to the opening and closing planes, in order for the 55. mm thick glass window to be easily visible from the side......, namely ABS and a high viscosity PC. Simulations were performed using the actual machine data as input, including the injection screw acceleration. Furthermore, the nozzle and barrel geometries were included as a hot runner to capture the effect of compressibility of the material in front of the screw....... These two had significant effects on the filling times and injection pressure calculated by the simulations. Other effects investigated included transient thermal management of the mold, pressure dependent viscosity and wall slip, but their effect were not remarkably large in this work. The obtained...

  10. Effect of normal stresses on the results of thermoplastic mold filling simulation

    Directory of Open Access Journals (Sweden)

    Bakharev Alexander

    2016-01-01

    Full Text Available The paper deals with the effect of the normal stresses on the predicted flow front during the filling stage of thermoplastic injection molding. The normal stresses are predicted using the non-linear Criminale-Ericksen-Filbey model (a variant of the second-order fluid rheological model with viscosity, first and second normal stress coefficients dependent upon magnitude of shear rate incorporated into a comprehensive 3D simulation software for mold-filling analysis. The additional stress term allows the prediction of the so called ear-flow effect (melt racing on the edges of the cavity.

  11. STUDY ON NUMERICAL SIMULATION OF MOLD-FILLING AND SOLIDIFICATION PROCESSES OF SHAPED CASTING

    Institute of Scientific and Technical Information of China (English)

    1999-01-01

    The latest progress on the study of numerical simulation of mold-filling and solidification process of shaped casting is reviewed. In mold-filling process simulation of castings, the SOLA-VOF algorithmis is improved in efficient free surface treatment and turbulence consideration, and parallel computational techniques are implemented to accelerate the fluid flow calculation time as well. Methods for predication of shrinkage defects of steel castings and S.G. iron castings are developed based on the solidification simulation. In order to reduce the residual stress and deformation of castings, a combined FDM/FEM method is implemented for the modelling of stresses. Numerical models for the simulation of micro-structure and prediction of mechanical properties of S.G. iron are developed. The verifications and applications of the simulation software show that the models and techniques adopted in current research work are efficient and appropriate for the numerical simulation of shaped castings.

  12. Analysis of Incomplete Filling Defect for Injection-Molded Air Cleaner Cover Using Moldflow Simulation

    Directory of Open Access Journals (Sweden)

    Hyeyoung Shin

    2013-01-01

    Full Text Available A large-sized cover part for air cleaner was injection molded with ABS resin, and its incomplete filling defect was analyzed using commercial Moldflow software. To investigate the effect of processing temperature on incomplete filling defect, tensile properties, weight loss, and phase separation behavior of ABS resin were evaluated. The tensile properties of dumbbell samples were not changed up to 250°C and decreased significantly thereafter. SEM micrographs indicated no significant changes in the status of polybutadiene rubber phase below 250°C. These different test results indicated that ABS resin little affected the thermal decomposition in processing temperature range. The Moldflow simulation was performed using measured thickness of molded cover and actual mold design with the defects. As expected, the cover part showed unbalanced filling and incomplete sections. To improve these defects, two possible cases of hot runner system have been simulated. When applying modified 5-gate system, the maximum injection pressure was decreased approximately 5.5% more than that of actual gate system. In case of 6-gate system, the maximum injection pressure reduced by 23%, and the injection pressure required to fill is well within the range of the molding equipment. The maximum clamping force of 6-gate system was also significantly reduced than that of actual and 5-gate system.

  13. Modeling and Simulation of Mold Filling with LIMS

    Science.gov (United States)

    2007-11-02

    reservedSimacek ONR Workshop - 13 Flexible Tekscan sensor Handle Serial interface box Force sensitive layer (changes resistance) Cover layers...2003 University of Delaware All rights reservedSimacek ONR Workshop - 24 Auto_RTM Experiment Simulation selected time Experimental Validation of TekScan ... Tekscan ™ F Visual (Camera) Resin Flat copper strips Time V ol ta ge 2 July 2003© 2003 University of Delaware All rights reservedSimacek ONR Workshop

  14. Numerical simulation of mold-filling capability for a thin- walled aluminum die casting

    Science.gov (United States)

    Sun, L.; Subasic, E.; Jakumeit, J.

    2015-06-01

    Mold-filling capability is an important property of casting materials. Especially in thin-walled die casting, fast cooling of the melt by contact to the die makes complete filling difficult to ensure. Simulation is an important tool enabling investigation of filling problems, even before the die is manufactured. However, the prediction of misruns is challenging. Flow and solidification have to be computed as closely coupled. The effects of surface tension, the wetting angle and reduced melt flow due to solidification must be modeled with high precision. To meet these requirements, a finite-volume method using arbitrary polyhedral control volumes is used to solve flow and solidification as closely coupled. The Volume-of-Fluid approach is used to capture the phase separation between gas, melt and solid in connection with a High-Resolution Interface-Capturing scheme to obtain sharp interfaces between phases. To model the resistance of the dendrite network to the melt flow, an additional source term in the momentum equation was implemented. The Bolt test was performed for A356 alloys at a range of different casting temperatures. Numerical prediction of incomplete filling in the bottleneck regions agreed well with experimental findings using 3D camera scanning. The simulation enables derivation of the dependence of critical wall-thickness, i.e. the thickness which is fillable, on casting temperature and metallostatic pressure. This could prove useful in predicting filling problems ahead of casting.

  15. Mensuration and simulation of mold filling process in semi-solid die-cast of aluminum alloy

    Institute of Scientific and Technical Information of China (English)

    YANG Yi-tao; WANG Jian-fu; ZHANG Heng-hua; SHAO Guang-jie

    2006-01-01

    To understand the flow trace of semi-solid slurry in mold cavity, some thermocouples were inserted in mold cavity, and the reaction timing of thermocouples showed the arrival of fluid. The filling time and rate were estimated by comparison between the experiment and calculation. The introduction of computer simulation technique based on ADSTEFAN was to predict injectionforming process and to prevent defects during trial manufacture of various parts. By comparing the formed appearance of parts in experiment and in simulation, and observing the relationship between internal defects inspected by X-ray or microscope and the flow field obtained in simulation, it was indicated that both have quite good agreement in simulation and experiment. Right predictions for cast defects resulted from mold filling can be carried out and proper direction was also proposed. The realization of numerical visualization for filling process during semi-solid die-cast process will play an important role in optimizing technology plan.

  16. Numerical Filling Simulation of Injection Molding Using Three-Dimensional Model

    Institute of Scientific and Technical Information of China (English)

    GengTie; LiDequn; ZhouHuamin

    2003-01-01

    Most injection molded parts are three-dimensional, with complex geometrical configurations and thick/thin wall sections. A 3D simulation model will predict more accurately the filling process than a 2.5D model. This paper gives a mathematical model and numeric method based on 3D model, in which an equal-order velocity-pressure interpolation method is employed successfully. The relation between velocity and pressure is obtained from the discretized momentum equations in order to derive the pressure equation. A 3D control volume scheme is employed to track the flow front. The validity of the model has been tested through the analysis of the flow in cavity.

  17. A New Method to Track Resin Flow Fronts in Mold Filling Simulation of RTM Process

    Institute of Scientific and Technical Information of China (English)

    Fuhong DAI; Shanyi DU; Boming ZHANG; Dianfu WAN

    2004-01-01

    A new method to track resin flow fronts, referred to as the topological interpolated method (TIM), which is based on filling states and topological relations of adjacent nodes was proposed. An experiment on the mould filling process was conducted. It was compared with exact solutions and the experimental results, and good agreements were observed. Numerical and experimental comparisons with the conventional contour method were also carried out, and it showed that TIM could enhance the local accuracy of flow front solutions with respect to the contour method when merging flow fronts and resin approaching the mold wall were involved.

  18. Numerical simulation of the filling stage in injection molding based on a 3D model

    Institute of Scientific and Technical Information of China (English)

    GENG Tie; LI De-qun; ZHOU Hua-min

    2005-01-01

    Most injection molded parts are three-dimensional, with complex geometrical configurations and thick/thin wall sections. The change of the thickness of parts has significant influence on flow during injection molding. This paper presents a 3D finite element model to deal with the three-dimensional flow, which can more accurately predict the filling process than a 2. 5D model. In this model, equal-order velocity-pressure interpolation method is successfully employed and the relation between velocity and pressure is obtained from the discretized momentum equation in order to derive the pressure equation. A 3D control volume scheme is employed to track the flow front. The validity of the model has been tested through the analysis of the flow in a cavity.

  19. An improved mathematical model to simulate mold filling process in high pressure die casting using CLSVOF method and CSF model

    Directory of Open Access Journals (Sweden)

    Cheng Bi

    2015-05-01

    Full Text Available A 3D mathematical model was proposed to simulate the mold filling process in high-pressure die casting (HPDC to improve accuracy considering the surface tension. Piecewise liner interface calculation (PLIC and volume of fluid (VOF methods were used to construct the pattern of the liquid interface. A coupled level-set and VOF method (CLSVOF was proposed to capture the interface pattern and obtain its normal vector. A continuum surface force (CSF model was used to consider the surface tension. Two water analogy experiments were carried out using the proposed model. Simulation and experimental results were analyzed and compared; and the effects of surface tension were also discussed. The simulation results agreed well with the experiments and the simulation accuracy was an improvement on interface geometries, liquid flows, and gas entrapments.

  20. The Elastic Mold Deformation During the Filling and Packing Stage of the Injection Molding Process

    Directory of Open Access Journals (Sweden)

    Stefan Kleindel

    2014-03-01

    Full Text Available The accurate numerical prediction of the mold filling process of long and thin walled parts is dependent on numerous factors. This paper investigates the effect of various influencing variables on the filling pattern by means of simulation and experimental validation. It was found that mold temperature, process settings and venting conditions have little effect on the predicted filling pattern. However, in the actual case study, the filling behavior observed during the experiments was significantly different compared to the numerical prediction. A structural finite element analysis of the moving mold half showed an unacceptable large deformation of the mold plates under injection pressure. A very good correlation between simulation and experiment was attained after improving the stiffness of the mold. Therefore it can be concluded, that the elasticity of the mold may have a significant influence on the filling pattern when long and thin walled products are considered. Furthermore, it was shown, that even an apparently stiff mold can exhibit a distinct deformation during filling and packing stage.

  1. Study on Antigravity Mold Filling by Conservative Scalar Method

    Institute of Scientific and Technical Information of China (English)

    李日; 王友序; 杨根仓; 毛协民

    2003-01-01

    By SIMPLE method and Van-Leer scheme, a program on numerical simulation for 3D mold filling has been developed. The fluid flow field of gas and liquid is calculated in couples by a single phase N-S equation using SIMPLE method, and free surface control equation is handied by Van-Leer scheme. Then it is verified by an anti-gravity mold filling of thin wall plate. In order to demonstrate its ability to simulate 3D casting, an anti-gravity mould filling of a cube is computed by the program.

  2. Modeling of Mold Filling and Solidification in Lost Foam Casting

    Institute of Scientific and Technical Information of China (English)

    Fengjun LI; Houfa SHEN; Baicheng LIU

    2003-01-01

    Based on the characteristics of the lost foam casting (LFC) and the artificial neural network technique, a mathematicalmodel for the simulation of the melt-pattern interface movement during the mold filling of LFC has been proposed andexperimentally verified. The simulation results are consistent with the experiments in both the shapes of melt frontand filling sequences. According to the calculated interface locations, the fluid flow and the temperature distributionsduring the mold filling and solidification processes were calculated, and the shrinkage defect of a lost foam ductileiron casting was predicted by considering the mold wall movement in LFC. The simulation method was applied tooptimize the casting design of lost foam ductile iron castings. It is shown that the model can be used for the defectsprediction and for casting design optimization in the practical LFC production.

  3. Flow channel design of a multi-cavity mold by filling simulation for thermosets. Netsu kokasei jushi ryudo kaiseki ni yoru cavity tasuko tori kanagata no ryuro sekkei

    Energy Technology Data Exchange (ETDEWEB)

    Saeki, J. (Hitachi Ltd., Tokyo (Japan)); Kaneda, A. (Hitachi Chemical Co. Ltd., Tokyo (Japan))

    1990-08-25

    A study was made on the flow channel design of a multi-cavity mold by filling simulation for thermosets. A practical analytic method was developed for the calculation of pressure losses at various locations in the channel following the estimation of viscosity change in the thermosets in the mold with optional shape. The runner and gate are designed for equal flow distribution to each cavity, and a newly developed model and a conventional type model were trially made for various evaluation using the conditions set at the time of designing. Ideal filling was achieved with the newly developed type model, and the design method of the type was confirmed to be reasonable. Characteristic values were studied which can be considered to give effect on the deformation of gold wires and void formation in molded devices. The effects on the prevention of gold wire deformation, decrease in void formation, and widening formation margin were confirmed. By the developed mold designing method, less diameter gold wire may be used without decreasing the quality of the package. 10 refs., 11 figs., 5 tabs.

  4. Mold Filling Analysis in Vacuum Infusion Molding Process Based on a High-Permeable Medium

    Institute of Scientific and Technical Information of China (English)

    Yingdan ZHU; Hua TAN; Jihui WANG

    2003-01-01

    The objective of this paper is to understand the flow mechanism through visualization experiments and discuss theinfluence of process parameters on mold filling process. A 2D leakage flow model is developed to simulate the moldingprocess, and the simulation results show good agreement with experiments.

  5. 立式离心铸造顶头模具设计及充型凝固模拟%Design of Vertical Centrifugal Casting Mold of Piercing Plug and It's Numerical Simulation of Mold-filling and Solidification Processes

    Institute of Scientific and Technical Information of China (English)

    章小峰; 凌兵; 黄贞益; 王萍

    2012-01-01

    Based on the shape of φ136 mm piercing plug, a vertical centrifugal casting mold of plug was designed. The process of mold filling and process of solidification were simulated by numerical simulation.The centrifugal casting process is centrifugal revolution 300 r/min ,casting temperature 1530℃ .casting velocity 0.25m/s. The simulation results show that the whole process of mold filling is stable and fast. The whole cavity is finished filling within 10.7 s.The temperature field of solidification accords with the sequence solidification principles. The casting is solidified within 1237 s. The solid fraction also proves that the solidification process of the casting is reasonable.%根据φ136mm的穿孔顶头外形,设计一种立式离心铸造顶头的模具.通过数值模拟软件模拟其充型过程及凝固过程,离心铸造工艺参数为离心转数300 r/min、浇注温度1530℃和充型速度0.25 m/s.模拟结果表明:铸件的充型过程基本平稳、快速,大概10.7s充型完毕;凝固过程中铸件温度场分布符合顺序凝固的要求,需1237s完全凝固.另外,固相分数也证实了铸件凝固过程是合理的.

  6. Process and part filling control in micro injection molding

    DEFF Research Database (Denmark)

    Tosello, Guido; Hansen, Hans Nørgaard; Schoth, Andreas

    2008-01-01

    The influence of process parameters on μ-injection molding (μIM) and on μ-injection molded parts has been investigated using Design of Experiments. A mold with a sensor applied at injection location was used to monitor actual injection pressure and to determine the cavity filling time. Flow markers...

  7. Diagnosis parameters of mold filling pattern for optimization of a casting system

    Directory of Open Access Journals (Sweden)

    Jun-Ho Hong

    2012-11-01

    Full Text Available For optimal design of a gating system, the setting of diagnosis parameters is very important. In this study, the permanent mold casting process was selected because most of the other casting processes have more complicated factors that influence the mold filling pattern compared to the permanent mold casting process, such as the surface roughness of mold, gas generation from the mold wash and binder of sand mold, and the gas permeability through a sand mold, etc. Two diagnosis parameters (flow rate difference and arrival time difference of molten metal flow pattern in the numerical simulation are suggested for design of an optimum casting system with a permanent mold. The results show that the arrival time difference can be used as one important diagnosis parameter of the complexity of the runner system and its usefulness has been verified via making aluminum parts using permanent mold casting (Fig. 9.

  8. Mold design with simulation for chalcogenide glass precision molding

    Science.gov (United States)

    Zhang, Yunlong; Wang, Zhibin; Li, Junqi; Zhang, Feng; Su, Ying; Wang, Zhongqiang

    2016-10-01

    Compare with the manufacturing of the traditional infrared material, such as signal crystal germanium, zinc sulfide, zinc selenide etc, chalcogenide infrared glass is suitable for precision molding for the low soften temperature to have large mass industry production. So the researches of precision glass molding are necessary, especially for the fast development of infrared product. The mold design is one of the key technologies of precision glass molding. In this paper, the mold processing of a sample chalcogenide glass from the technical drawing, mold design, molding to the lens are introduced. From the result of the precision molding, the technology of finite element simulation is a useful way to guiding the mold design. The molded lens by using mold process fit the design requirement.

  9. Turbulent Fluid Flow and Heat Transfer Calculation in Mold Filling and Solidification Processes of Castings

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    Based on the time-averaging equations and a modified engineering turbulence model, the mold filling and solidification processes of castings are approximately described. The algorithm for the control equations is briefly introduced, and some problems and improvement methods for the traditional method are also presented. Both calculation and tests proved that, comparing with the laminar fluid flow and heat transfer, the simulation results by using the turbulence model are closer to the real mold filling and solidification processes of castings.

  10. Mold Filling Behavior of Melts with Different Viscosity under Centrifugal Force Field

    Institute of Scientific and Technical Information of China (English)

    2002-01-01

    Recently proposed mathematical model for mold filling processes under centrifugal force field conditions and the computer codes were first tested through the sample simulation of gravity mold filling process for a benchmark plate-casting, which were compared with quoted experimental observations. The model and the developed computer program were then applied to the numerical simulation of centrifugal field mold filling processes for a thin-section casting with a titanium alloy melt of assumed viscosity of 1.2 and 12.0 mm2/s, respectively. The computation result comparison shows that the flow behaviors of the filling melts are basically similar to each other although the less viscous melt tends to fill into the thin section casting cavity faster.

  11. Characteristics and influence factors of mold filling process in permanent mold with a slot gating system

    Institute of Scientific and Technical Information of China (English)

    Chang Qingming; Chen Xia; Chen Changjun; Bao Siqian; David Schwam

    2009-01-01

    The main problems caused by improper gating are entrained aluminum oxide films and entrapped gas. In this study, the slot gating system is employed to improve mold filling behavior and therefore, to improve the quality of aluminum castings produced in permanent molds. An equipment as well as operation procedures for real-time X-ray radiography of molten aluminum flowing into permanent molds have been developed. Graphite molds transparent to X-rays are utilized which make it possible to observe the flow pattern through a number of vertically oriented gating systems. The investigation discovers that there are many influencing factors on the mold filling process. This paper focuses its research on some of the factors, such as the dimensions of the vertical riser and slot thickness, as well as roughness of the coating layer. The results indicate that molten metal can smoothly fill into casting cavity with a proper slot gating system. A bigger vertical riser, proper slot thickness and rougher coating can provide not only a better mold filling pattern, but also hot melt into the top of the cavity. A proper temperature gradient is obtainable, higher at the bottom and lower at the top of the casting cavity, which is in favor of feeding during casting solidification.

  12. Cavity air flow behavior during filling in microinjection molding

    DEFF Research Database (Denmark)

    Griffiths, C.A.; Dimov, S.S.; Scholz, S.

    2011-01-01

    Process monitoring of microinjection molding (μ-IM) is of crucial importance in understanding the effects of different parameter settings on the process, especially on its performance and consistency with regard to parts' quality. Quality factors related to mold cavity air evacuation can provide...... valuable information about the process dynamics and also about the filling of a cavity by a polymer melt. In this paper, a novel experimental setup is proposed to monitor maximum air flow and air flow work as an integral of the air flow over time by employing a microelectromechanical system gas sensor...... mounted inside the mold. The influence of four μIM parameters, melt temperature, mold temperature, injection speed, and resistance to air evacuation, on two air flow-related output parameters is investigated by carrying out a design of experiment study. The results provide empirical evidences about...

  13. Effects of centrifugal and Coriolis forces on the mold-filling behavior of titanium melts in vertically rotating molds

    Institute of Scientific and Technical Information of China (English)

    Xu Daming; Jia Limin; Fu Hengzhi

    2008-01-01

    The vertical centrifugal-casting technique is widely used in the manufacture of various irregularly-shaped castings of advanced structural alloys with thin walls, complex shapes and/or large sizes. These castings are used in the increasing applications in aero-space/aviation industries, human teeth/bone repairs with near-net shaped components, etc. In a vertically rotating casting system, the mold-filling processes of alloy melts, coupled with solidification-heat transfer, may be much more complicated, because they are driven simultaneously by gravity, centrifugal and Codolis forces. In the present work, an N-S/VOF-equations-based model, solved using a SOLA-VOF algorithm, under a rotating coordinate system was applied to numerically investigate the impacts of centrifugal and Coriolis forces on metallic melt mold-filling processes in different vertical centrifugal-casting configurations with different mold-rotation rates using an authors' computer-codes system. The computational results show that the Coriolis force may cause remarkable variations in the flow patterns in the casting-part-cavities of a large horizontal-section area and directly connected to the sprue via a short ingate in a vertical centrifugal-casting process. A "turn-back" mold-filling technique, which only takes advantage of the centrifugal force in a transient rotating melt system, has been confirmed to be a rational centrifugal-casting process in order to achieve smooth and layer-by-layer casting-cavities-filling control. The simulated mold-filling processes of Ti-6Al-4V alloy melt, in a vertical centrifugal-casting system with horizontally-connected plate-casting cavities, show reasonable agreement with experimental results from the literature.

  14. Evaluation of the mold-filling ability of alloy melt in squeeze casting

    Institute of Scientific and Technical Information of China (English)

    2006-01-01

    The mold-filling ability of alloy melt in squeeze casting process was evaluated by means of the maximum length of Archimedes spiral line. A theoretical evaluating model to predict the maximum filling length was built based on the flowing theory of the incompressible viscous fluid. It was proved by experiments and calculations that the mold-filling pressure and velocity are prominent influencing factors on the mold-filling ability of alloy melt. The mold-filling ability increases with the increase of the mold-filling pressure and the decrease of the proper mold-filling velocity. Moreover, the pouring temperature relatively has less effect on the mold-filling ability under the experimental conditions. The maximum deviation of theoretical calculating values with experimental results is less than 15%. The model can quantitatively estimate the effect of every factor on the mold-filling ability.

  15. Diagnosis parameters of mold filling pattern for optimization of a casting system

    OpenAIRE

    2012-01-01

    For optimal design of a gating system, the setting of diagnosis parameters is very important. In this study, the permanent mold casting process was selected because most of the other casting processes have more complicated factors that influence the mold filling pattern compared to the permanent mold casting process, such as the surface roughness of mold, gas generation from the mold wash and binder of sand mold, and the gas permeability through a sand mold, etc. Two diagnosis parameters (fl...

  16. Enhanced Injection Molding Simulation of Advanced Injection Molds

    Directory of Open Access Journals (Sweden)

    Béla Zink

    2017-02-01

    Full Text Available The most time-consuming phase of the injection molding cycle is cooling. Cooling efficiency can be enhanced with the application of conformal cooling systems or high thermal conductivity copper molds. The conformal cooling channels are placed along the geometry of the injection-molded product, and thus they can extract more heat and heat removal is more uniform than in the case of conventional cooling systems. In the case of copper mold inserts, cooling channels are made by drilling and heat removal is facilitated by the high thermal conductivity coefficient of copper, which is several times that of steel. Designing optimal cooling systems is a complex process; a proper design requires injection molding simulations, but the accuracy of calculations depends on how precise the input parameters and boundary conditions are. In this study, three cooling circuit designs and three mold materials (Ampcoloy 940, 1.2311 (P20 steel, and MS1 steel were used and compared using numerical methods. The effect of different mold designs and materials on cooling efficiency were examined using calculated and measured results. The simulation model was adjusted to the measurement results by considering the joint gap between the mold inserts.

  17. Effects of mold geometry and taper angles on the filling mechanism of a nanoimprinted polymer using molecular dynamics

    Science.gov (United States)

    Wu, Cheng-Da; Fang, Te-Hua; Lin, Jen-Fin

    2014-10-01

    Molecular dynamics simulations are used to investigate how the nanoimprint lithography mechanism influences the filling interaction and mechanical deformation on polymethylmethacrylate (PMMA) surfaces. The effects of two mold geometries and various taper angles were investigated using stress, slip vector, molecular trajectories, and applied force analysis. For the PMMA formation mechanism on a concave-like mold imprint, the molecules were extruded upward into the mold space after the molecules on two sides were downward compressed by the mold. The formation mechanism is opposite to that for the tip-like mold imprint because the molecules are firstly compressed downward by the tip. The results show that the slowest filled areas of the pattern were at the two corners of the tip where stress value was low. The filling speed in both the tip-like mold and the concave-like mold imprint increased with the taper angle increased due to filling space and smaller capillary flow. Due to the effect of capillary flow, the concave-like mold needs much more loading force to transfer the pattern than the tip-like mold. The loading force and curve oscillation increased with the taper angle in the tip-like mold imprint, but they significantly increased with decreasing taper angle in the concave-like mold. The high stress was mainly concentrated on the molecules near the tip and underneath the mold for the tip-like mold and the concave-like mold imprint, respectively. The relationship of the magnitude of taper angle to the loading force is similar to stress and slip vector.

  18. Development of Integrated Simulation System for Plastic Injection Molding

    Institute of Scientific and Technical Information of China (English)

    CHENGXue-wen; LIDe-qun; ZHOUHua-min

    2005-01-01

    Numerical simulation of injection molding have had success in predicting the behavior of polymer melt in extremely complicated geometries. Most of the current numerical solutions are based on finite-element/finite-difference/boundary-element/volume-control methods and the surface model. This paper discusses the development of an integrated CAE system for injection molding in detail, and presents the mathematics for numerical simulation of filling, packing,cooling, stress and warpage in injection molding. The developed system named as HsCAE3D is introduced at the end.

  19. Application of Artificial Vision in flow redirection during filling of Liquid Composite Molding processes

    Science.gov (United States)

    Montés, N.; Sanchez, F.; García, J. A.; Falcó, A.; Tornero, J.; Chinesta, F.

    2007-04-01

    The control techniques applied in Liquid Composite Molding processes have been extensively worked out by many different research groups abroad. In this work, the original use of artificial vision technology in order to redirect the flow path during mold filling appears as a major objective of online control strategy. In this study, a process performance index developed in a previous work is used to define the mold gate opening sequence. The Vacuum Assisted Resin Transfer Molding (VARTM) and Vacuum Assisted Resin Infusion (VARI) have been selected as the main processes of study. The expert system will make use of numerical simulation in order to obtain a previous physical understanding of the flow behaviour in different manufacturing conditions. Some examples of the installation are presented and discussed.

  20. Material flow data for numerical simulation of powder injection molding

    Science.gov (United States)

    Duretek, I.; Holzer, C.

    2017-01-01

    The powder injection molding (PIM) process is a cost efficient and important net-shape manufacturing process that is not completely understood. For the application of simulation programs for the powder injection molding process, apart from suitable physical models, exact material data and in particular knowledge of the flow behavior are essential in order to get precise numerical results. The flow processes of highly filled polymers are complex. Occurring effects are very hard to separate, like shear flow with yield stress, wall slip, elastic effects, etc. Furthermore, the occurrence of phase separation due to the multi-phase composition of compounds is quite probable. In this work, the flow behavior of a 316L stainless steel feedstock for powder injection molding was investigated. Additionally, the influence of pre-shearing on the flow behavior of PIM-feedstocks under practical conditions was examined and evaluated by a special PIM injection molding machine rheometer. In order to have a better understanding of key factors of PIM during the injection step, 3D non-isothermal numerical simulations were conducted with a commercial injection molding simulation software using experimental feedstock properties. The simulation results were compared with the experimental results. The mold filling studies amply illustrate the effect of mold temperature on the filling behavior during the mold filling stage. Moreover, the rheological measurements showed that at low shear rates no zero shear viscosity was observed, but instead the viscosity further increased strongly. This flow behavior could be described with the Cross-WLF approach with Herschel-Bulkley extension very well.

  1. The Simulation and Optimization of Aspheric Plastic Lens Injection Molding

    Institute of Scientific and Technical Information of China (English)

    WEN Jialing; WEN Pengfei

    2005-01-01

    For the purpose of reducing the volumetric shrinkage and volumetric shrinkage variation, the process in injection molding of aspheric plastic lens was simulated, and several process parameters which include holding pressure, melt temperature, mold temperature, fill time, holding pressure time and cooling time were optimized by using an orthogonal experimental design method. Finally, the optimum process parameters and the influence degree of process parameters on the average volumetric shrinkage and the volumetric shrinkage variation are obtained.

  2. Specific mold filling characteristics of highly filled phenolic injection molding compounds

    OpenAIRE

    Scheffler, Thomas; Englich, Sascha; Gehde, Michael

    2016-01-01

    Thermosets show excellent mechanical properties and chemical resistance (for most automotive fluids) even at high temperatures up to 300 °C. Furthermore they can be highly efficient processed by injection molding. So they should be particularly suited for e.g. under the bonnet applications. However, the reality shows that thermosets are, except fiber reinforced composites, heavily underrepresented in technical applications. E.g. thermosetting components only account 0,2 % to a vehicle’s weigh...

  3. Long fiber polymer composite property calculation in injection molding simulation

    Science.gov (United States)

    Jin, Xiaoshi; Wang, Jin; Han, Sejin

    2013-05-01

    Long fiber filled polymer composite materials have attracted a great attention and usage in recent years. However, the injection and compression molded long fiber composite materials possess complex microstructures that include spatial variations in fiber orientation and length. This paper presents the recent implemented anisotropic rotary diffusion - reduced strain closure (ARD-RSC) model for predicting fiber orientation distribution[1] and a newly developed fiber breakage model[2] for predicting fiber length distribution in injection and compression molding simulation, and Eshelby-Mori-Tanaka model[3,4] with fiber-matrix de-bonding model[5] have been implemented to calculate the long fiber composite property distribution with predicted fiber orientation and fiber length distributions. A validation study on fiber orientation, fiber breakage and mechanical property distributions are given with injection molding process simulation.

  4. Characteristics of mold filling and entrainment of oxide film in low pressure casting of A356 alloy

    Energy Technology Data Exchange (ETDEWEB)

    Liu, Shan-Guang; Cao, Fu-Yang; Zhao, Xin-Yi; Jia, Yan-Dong; Ning, Zhi-Liang; Sun, Jian-Fei, E-mail: jfsun_hit@263.net

    2015-02-25

    The effect of pressurizing speed of low pressure casting on mold filling and mechanical properties of A356 alloy was studied. The mold filling behavior was calculated by two phase flow model using VOF (Volume of Fluid) method. In order to evaluate the accuracy of simulated results, the real mold filling process observed by X-ray radiography was compared. The results show that during mold filling the gate velocity first increased dramatically, then kept unchanged under relatively low pressurizing speed, or increased slowly under relatively high pressurizing speed. High gate velocity causes melt falling back under gravity with high speed. The falling velocity and the resultant relative rotating vortex are the main causes of oxide film entrainment in low pressure casting. The mechanical properties of the as-cast A356 alloy were measured by four-point bend test. Weibull probability plots were used to assess the fracture mechanisms under different pressurizing speeds. The results obtained in this paper illuminate on designing suitable pressurizing speed for mold filling in low pressure casting.

  5. A TWO-PHASE FLOW MODEL FOR SIMULATING AIR ENTRAPMENT DURING MOLD FILLING OF HIGH PRESSURE DIE CASTING PROCESS%应用两相流模型模拟压铸充型过程的卷气现象

    Institute of Scientific and Technical Information of China (English)

    李帅君; 熊守美; Mei Li; John Allison

    2009-01-01

    通过对压铸充型过程中卷气缺陷形成机理的分析,认为型腔中空气的流动以及与金属液之间的相互作用是形成卷气现象的主要原因.为了考虑型腔中空气的流动,采用了一种不可压缩两相流数学模型来模拟压铸充型过程的卷气现象.通过计算流体力学中的两个基准算例,较为全面地验证了该模型的准确性和可靠性.在此基础上,设计了专门针对压铸充型过程的高速水模拟实验,通过对可视化实验结果与两相流模拟结果的比较,证实二者吻合较好,说明了该模型能够较好地模拟液体的充填行为和卷入其中的气泡.%The most common defect found in high pressure die casting (HPDC) process is the gas porosity which significantly affects the mechanical properties of the final components. The generation of gas porosity is known mainly due to the air entrapment in the liquid metal during the mold filling stage. Knowing the trapped-air location and amount could allow for a more accurate and objective analysis of casting quality. In the past few decades, extensive efforts have been made to develop simulation codes of casting flow. Most of these codes solve the velocity, pressure and fluid fraction only in the liquid phase with the assumption that the effect of air in the die cavity is negligible. As a matter of fact, the air in the die cavity has significant influence on the filling pattern of the molten metal and the gas porosity distribution of the die casts. Recently, following the development of computational fluid dynamics (CFD), two-phase flow models have drawn continuous attention in the numerical simulation of casting processes, but there are still few models and further studies are needed. In this study, the mechanism of the formation of air entrapment defects in the HPDC process was discussed and it turned out that the air flow in the die cavity as well as the interaction between air and liquid metal resulted in the final air

  6. Cooling simulation of plastic injection molding

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    Analyses the cooling of mold and plastic part during injectionmolding and the continued cooling of plastic part after being ejected from mold using the heat transfer theory and Boundary Element Method (BEM) to predict the temperature distribution in both mold and plastic part,and presents the experiments carried out with plates of ABS (Acrylonitrile-Butadiene-Styrene) to verify the validity of the cooling analysis software used to simulate the temperature distribution in ABS plate parts, and concludes that the analysis software agree qualitatively well with actual experimental findings.

  7. Characterization of fiberglass-filled diallyl phthalate plastic molding resins and molded parts

    Energy Technology Data Exchange (ETDEWEB)

    Whitaker, R.B.; Glaub, J.E.; Bonekowski, N.R.; Gillham, P.D.

    1980-12-01

    Characterization of diallyl phthalate (DAP) molding resins was undertaken by differential scanning calorimetry (DSC) and by combined size exclusion chromatography (SEC)/low angle laser light scattering (LALLS) in order to better predict moldability and storage life limits. Completeness of cure of molded parts, before and after any post-curing, was also determined by thermal analysis. Molecular weights and molecular weight distributions of the DAP molding resins by SEC/LALLS indicated that the better molding resins have lower M/sub w//M/sub n/ ratios. Association effects were observed, which could not be overcome by solvent modification alone. Determination of DAP molding resin heats of reaction by DSC indicated a linear relation between ..delta..H/sub R/ and weight percent filler for the good molding resins. DSC analyses of molded DAP parts showed that 95% cure was achieved in some as-molded parts, with a post-cure temperature of 165/sup 0/C being required to complete the cure to 100%. Thickness of the parts was a factor, with the thicker parts being 100% cured as molded. The glass transition temperature (T/sub g/) of the molded parts increased as cure was completed, to approx. 160 to 165/sup 0/C maximum. These results are consistent with a model of thermoset resin curing behavior which states that 100% cure can be achieved only if a post-curing operation is conducted above the T/sub g infinity/ (T/sub g/ at complete cure) of the polymer.

  8. Composite manufacturing: Simulation of 3-D resin transfer molding

    Science.gov (United States)

    Tan, Cheng Ping

    1998-10-01

    A technique was developed for simulating the resin transfer molding (RTM) process. The major feature of the technique is a computational steering system that enables the user to make changes during the simulation. Specifically, at any instance, the user can inspect the progress of the resin front. On the basis of the observed resin front position, the user can, as needed, change the port and vent locations, open and close ports and vents, adjust the inlet and exit pressures or flow rates, and reorient the mold with respect to the gravitational field. Additionally, the user can "rewind" the simulator to any previous time in the mold filling process, make any of the above changes and then continue the simulation. The technique is augmented by a computer code which has three main components, the Simulator, the Graphics User Interface (GUI), and the Global Data Storage. The Simulator is a finite element code that calculates the resin flow inside the fiber preform. The GUI serves as the interface between the user and the Simulator; it provides the commands to the Simulator and displays the results. The Global Data Storage is the module that manages the exchange of data between the GUI and the Simulator. The computer code (designated as SUPERTMsb-3D) is suitable for simulating the resin flow inside two-dimensional as well as three-dimensional fiber preforms of arbitrary shapes. The use of this computer code is illustrated through sample problems. These problems demonstrate how (with this code) the designer can establish the port and vent locations, opening and closing sequences of ports and vents such that the fiber preform is filled completely in the shortest time with the fewest number of vents.

  9. Determination of heat transfer coefficients at the polymer-mold-interface for injection molding simulation by means of calorimetry

    Science.gov (United States)

    Stricker, M.; Steinbichler, G.

    2014-05-01

    Appropriate modeling of heat transfer from the polymer material to the injection mold is essential to achieve accurate simulation results. The heat transfer is commonly modeled using convective heat transfer and applying heat transfer coefficients (HTC) to the polymer-mold-interface. The set HTC has an influence on the results for filling pressure, cooling performance and shrinkage, among others. The current paper, presents a new strategy to measure HTC in injection molding experiments using Newtons law of cooling. The heat flux is calculated out of demolding heat (measured by means of calorimetry), injection heat (measured by means of an IR-sensor), cooling time and part mass. Cavity surface area, average mold surface temperature and average part surface temperature lead to the HTC.

  10. Study on Antigravity Mold Filling by Conservative Scalar Method%薄壁铸件反重力充填的守恒标量法研究

    Institute of Scientific and Technical Information of China (English)

    李日; 王友序; 杨根仓; 毛协民

    2003-01-01

    By SIMPLE method and Van-Leer scheme, a program on numerical simulation for 3D mold filling has been developed. Thefluid flow field of gas and liquid is calculated in couples by a single phase N-S equation using SIMPLE method, and free surface controlequation is handled by Van-Leer scheme. Then it is verified by an anti-gravity mold filling of thin wall plate. In order to demonstrateits ability to simulate 3D casting, an anti-gravity mould filling of a cube is computed by the program.

  11. Relationship Between Casting Distortion, Mold Filling, and Interfacial Heat Transfer in Sand Molds

    Energy Technology Data Exchange (ETDEWEB)

    J. K. Parker; K. A. Woodbury; T. S. Piwonka; Y. Owusu

    1999-09-30

    This project sought to determine the relationship between casting dimensions and interfacial heat transfer in aluminum alloy sand castings. The program had four parts; measurement of interfacial heat transfer coefficients in resin bonded and green sand molds, the measurement of gap formation in these molds, the analysis of castings made in varying gatings, orientations and thicknesses, and the measurement of residual stresses in castings in the as-cast and gate removed condition. New values for interfacial heat transfer coefficients were measured, a novel method for gap formation was developed, and the variation of casting dimensions with casting method, gating, and casting orientation in the mold was documented.

  12. Analysis of cavity pressure and warpage of polyoxymethylene thin walled injection molded parts: Experiments and simulations

    Science.gov (United States)

    Guerrier, P.; Tosello, G.; Hattel, J. H.

    2015-05-01

    Process analysis and simulations on molding experiments of 3D thin shell parts have been conducted. Moldings were carried out with polyoxymethylene (POM). The moldings were performed with cavity pressure sensors in order to compare experimental process results with simulations. The warpage was characterized by measuring distances using a tactile coordinate measuring machine (CMM). Molding simulations have been executed taking into account actual processing conditions. Various aspects have been considered in the simulation: machine barrel geometry, injection speed profiles, cavity injection pressure, melt and mold temperatures, material rheological and pvT characterization. Factors investigated for comparisons were: injection pressure profile, short shots length, flow pattern, and warpage. A reliable molding experimental database was obtained, accurate simulations were conducted and a number of conclusions concerning improvements to simulation accuracy are presented regarding: pvT data, mesh, short shots, cavity pressure for process control validation as well as molding machine geometry modelling. Eventually, a methodology for improved molding simulations of cavity injection pressure, filling pattern and warpage was established.

  13. Comparative analysis of different process simulation settings of a micro injection molded part featuring conformal cooling

    DEFF Research Database (Denmark)

    Marhöfer, David Maximilian; Tosello, Guido; Islam, Aminul

    2015-01-01

    different simulation models are established: a version including the part without the surrounding mold block, an advanced version including the mold block and conventional cooling channels, and a third version alike the second with additional conformal cooling for efficient thermal management...... of the implementation of the actual mold block, conventional cooling, and conformal cooling. In the comparison, characteristic quality criteria for injection molding are studied, such as the filling behavior of the cavity, the injection pressure, the temperature distribution, and the resulting part warpage....... Additionally, the analysis of the cooling channels exploiting computational fluid dynamics is introduced as helpful tool for the mold design process. It is observed that the comprehensive implementation of the actual injection molding system and conditions is highly relevant at sub-mm/micro dimensional scales...

  14. Improvement Performance of the Filling Step in Injection Mold through Vibration

    Directory of Open Access Journals (Sweden)

    Trejo-Hernández M.

    2012-10-01

    Full Text Available This paper shows the flow improvement in the filling step of the polymer injection process due to the polymer excitation though vibration. This process can be split up into three main steps: filling, pocking and cooling. Several mechanical and aesthetic properties of the finished product can be changed in the filling step. The objective of this investigation is to demonstrate the improvement in the filling mold under vibration without adding chemical products. To reach this result, an experimental mold was designed and manufactured in which a vibration device was coupled; it was possible to demonstrate the vibration advantage through this process. Moreover, a heuristic methodology was proposed for the experiment which shows an improvement in the filling process with frequencies close to 3 Hz.

  15. Validation of three-dimensional micro injection molding simulation accuracy

    DEFF Research Database (Denmark)

    Tosello, Guido; Costa, F.S.; Hansen, Hans Nørgaard

    2011-01-01

    length, injection pressure profile, molding mass and flow pattern. The importance of calibrated micro molding process monitoring for an accurate implementation strategy of the simulation and its validation has been demonstrated. In fact, inconsistencies and uncertainties in the experimental data must...... be minimized to avoid introducing uncertainties in the simulation calculations. Simulations of bulky sub-100 milligrams micro molded parts have been validated and a methodology for accurate micro molding simulations was established.......Data analysis and simulations on micro-molding experiments have been conducted. Micro molding simulations have been executed taking into account actual processing conditions implementation in the software. Various aspects of the simulation set-up have been considered in order to improve...

  16. Visualization of mold filling stages in thermal nanoimprint by using pressure gradients

    DEFF Research Database (Denmark)

    Schift, H.; Bellini, S.; Mikkelsen, Morten Bo Lindholm;

    2007-01-01

    A method for the visualization of mold filling during a thermoplastic imprint at a microscopic level was developed, which is based on superposition of images of a series of different states of imprint. The animated movie sequence gives an insight into the complex flow of polymer and shows how voi...

  17. Composite materials molding simulation for purpose of automotive industry

    Science.gov (United States)

    Grabowski, Ł.; Baier, A.; Majzner, M.; Sobek, M.

    2016-08-01

    Composite materials loom large increasingly important role in the overall industry. Composite material have a special role in the ever-evolving automotive industry. Every year the composite materials are used in a growing number of elements included in the cars construction. Development requires the search for ever new applications of composite materials in areas where previously were used only metal materials. Requirements for modern solutions, such as reducing the weight of vehicles, the required strength and vibration damping characteristics go hand in hand with the properties of modern composite materials. The designers faced the challenge of the use of modern composite materials in the construction of bodies of power steering systems in vehicles. The initial choice of method for producing composite bodies was the method of molding injection of composite material. Molding injection of polymeric materials is a widely known and used for many years, but the molding injection of composite materials is a relatively new issue, innovative, it is not very common and is characterized by different conditions, parameters and properties in relation to the classical method. Therefore, for the purpose of selecting the appropriate composite material for injection for the body of power steering system computer analysis using Siemens NX 10.0 environment, including Moldex 3d and EasyFill Advanced tool to simulate the injection of materials from the group of possible solutions were carried out. Analyses were carried out on a model of a modernized wheel case of power steering system. During analysis, input parameters, such as temperature, pressure injectors, temperature charts have been analysed. An important part of the analysis was to analyse the propagation of material inside the mold during injection, so that allowed to determine the shape formability and the existence of possible imperfections of shapes and locations air traps. A very important parameter received from

  18. STRESS ANALYSIS OF INJECTION MOLDED PARTS IN POST-FILLING STAGE

    Institute of Scientific and Technical Information of China (English)

    2000-01-01

    The linear isothermo-viscoelastic constitutive equation is established according to the principle of viscoelastic mechanics. Given the boundary conditions of the temperature field, the linear themo-viscoelastic constitutive equation is established acording to the analysis of the thermorheologically simple. The stress analysis model is constructed on the base of some reasonable hypotheses which consider the restraint conditions of mold and the characteristics of injection molding in the post-filling stage. The mathematical model is calculated by the finite difference method. The results can help to predict the warpage of plastic products.

  19. In-Situ Real Time Monitoring and Control of Mold Making and Filling Processes: Final Report

    Energy Technology Data Exchange (ETDEWEB)

    Mohamed Abdelrahman; Kenneth Currie

    2010-12-22

    This project presents a model for addressing several objectives envisioned by the metal casting industries through the integration of research and educational components. It provides an innovative approach to introduce technologies for real time characterization of sand molds, lost foam patterns and monitoring of the mold filling process. The technology developed will enable better control over the casting process. It is expected to reduce scrap and variance in the casting quality. A strong educational component is integrated into the research plan to utilize increased awareness of the industry professional, the potential benefits of the developed technology, and the potential benefits of cross cutting technologies.

  20. Comparison Of Simulation Results When Using Two Different Methods For Mold Creation In Moldflow Simulation

    Directory of Open Access Journals (Sweden)

    Kaushikbhai C. Parmar

    2015-08-01

    Full Text Available Simulation gives different results when using different methods for the same simulation. Autodesk Moldflow Simulation software provide two different facilities for creating mold for the simulation of injection molding process. Mold can be created inside the Moldflow or it can be imported as CAD file. The aim of this paper is to study the difference in the simulation results like mold temperature part temperature deflection in different direction time for the simulation and coolant temperature for this two different methods.

  1. Mold Simulator Study of the Initial Solidification of Molten Steel in Continuous Casting Mold: Part II. Effects of Mold Oscillation and Mold Level Fluctuation

    Science.gov (United States)

    Zhang, Haihui; Wang, Wanlin

    2016-04-01

    The surface quality of the continuous casting strands is closely related to the initial solidification of liquid steel in the vicinity of the mold meniscus, and thus the clear understanding of the behavior of molten steel initial solidification would be of great importance for the control of the quality of final slab. With the development of the mold simulator techniques, the complex interrelationship between the solidified shell surface profile, heat flux, shell thickness, mold level fluctuation, and the infiltrated slag film was well illustrated in our previous study. As the second part, this article investigated the effect of the mold oscillation frequency, stroke, and mold level fluctuation on the initial solidification of the molten steel through the conduction of five different experiments. Results suggested that in the case of the stable mold level, the oscillation marks (OMs) exhibit equally spaced horizon depressions on the shell surface, where the heat flux at the meniscus area raises rapidly during negative strip time (NST) period and the presence of each OMs on the shell surface is corresponding to a peak value of the heat flux variation rate. Otherwise, the shell surface is poorly defined by the existence of wave-type defects, such as ripples or deep depressions, and the heat flux variation is irregular during NST period. The rising of the mold level leads to the longer-pitch and deeper OMs formation; conversely, the falling of mold level introduces shorter-pitch and shallower OMs. With the increase of the mold oscillation frequency, the average value of the low-frequency heat flux at the meniscus increases; however, it decreases when the mold oscillation stroke increases. Additionally, the variation amplitude of the high-frequency temperature and the high-frequency heat flux decreases with the increase of the oscillation frequency and the reduction of the oscillation stroke.

  2. Computational Simulation of VARI Fluid Process Molding for Stiffened Panel Structural Composites

    Directory of Open Access Journals (Sweden)

    XIAO Fei

    2016-08-01

    Full Text Available The resin filling time can be predicted and the flow pattern of resin can be simulated in Composites VARI Fluid Process Molding with simulation software PAM-RTM. The permeability is important parameter in VARI process. In-plane and transverse permeability are usually tested with complicate and expensive enclosed mold.A set of model with simple structure, easy operation, low cost, was built to obtain accurate permeability by using a process of vacuum-assisted resin infusion (VARI. Besides, the method of equivalent model was employed. The simulation results of effective model is compared with those of experimental VARI process. The filling times for simulation method is 254 s which is shorter than 301 s of the experimental process. Based on flow runner project with equivalent model, the stiffened panel structural composite is prepared to validate the selective process.

  3. Mold Simulator Study of Heat Transfer Phenomenon During the Initial Solidification in Continuous Casting Mold

    Science.gov (United States)

    Zhang, Haihui; Wang, Wanlin

    2017-01-01

    In this paper, mold simulator trials were firstly carried out to study the phenomena of the initial shell solidification of molten steel and the heat transfer across the initial shell to the infiltrated mold/shell slag film and mold. Second, a one-dimensional inverse heat transfer problem for solidification (1DITPS) was built to determine the temperature distribution and the heat transfer behavior through the solidifying shell from the measured shell thickness. Third, the mold wall temperature field was recovered by a 2DIHCP mathematical model from the measured in-mold wall temperatures. Finally, coupled with the measured slag film thickness and the calculations of 1DITPS and 2DIHCP, the thermal resistance and the thickness of liquid slag film in the vicinity of the meniscus were evaluated. The experiment results show that: the total mold/shell thermal resistance, the mold/slag interfacial thermal resistance, the liquid film thermal resistance, and the solid film thermal resistance is 8.0 to 14.9 × 10-4, 2.7 to 4.8 × 10-4, 1.5 to 4.6 × 10-4, and 3.9 to 6.8 × 10-4 m2 K/W, respectively. The percentage of mold/slag interfacial thermal resistance, liquid film thermal resistance, and solid film thermal resistance over the total mold/shell thermal resistance is 27.5 to 34.4, 17.2 to 34.0, and 38.5 to 48.8 pct, respectively. The ratio of radiation heat flux is around 14.1 to 51.9 pct in the liquid slag film.

  4. Wall-slip of highly filled powder injection molding compounds: Effect of flow channel geometry and roughness

    Energy Technology Data Exchange (ETDEWEB)

    Hausnerova, Berenika; Sanetrnik, Daniel [Dept. of Production Engineering, Faculty of Technology, Tomas Bata University in Zlin, nám. T.G. Masaryka 5555, 760 01 Zlín, Czech Republic and Centre of Polymer Systems, University Institute, Tomas Bata University in Zlin, Nad Ovc (Czech Republic); Paravanova, Gordana [Centre of Polymer Systems, University Institute, Tomas Bata University in Zlin, Nad Ovcírnou 3685, 760 01 Zlín (Czech Republic)

    2014-05-15

    The paper deals with the rheological behavior of highly filled compounds proceeded via powder injection molding (PIM) and applied in many sectors of industry (automotive, medicine, electronic or military). Online rheometer equipped with slit dies varying in surface roughness and dimensions was applied to investigate the wall-slip as a rheological phenomenon, which can be considered as a parameter indicating the separation of compound components (polymer binder and metallic powder) during high shear rates when injection molded.

  5. Investigation of gating parameter, temperature and density effects on mold filling in the lost foam casting (LFC process by direct observation method

    Directory of Open Access Journals (Sweden)

    A. Sharifi

    2013-03-01

    Full Text Available Mold filling sequence of A356 aluminum alloy was investigated with the aid of direct observation method (photography method. The results show that increase of the foam density causes decrease of the filling rate and increase of the filling time. Foam density has more pronounced effect on mold filling rate rather than pouring temperature. Gating design also affects the profile of molten metal advancement in the mold. The results show that the higher filling rate was obtained with G2 gating than with other gating system. Regarding the mold filling pattern, G3 gating system has more effective contact interface than G2 gating system and has lower filling time. Filling time in G4 gating and G1 gating system are nearly the same.

  6. Thermo-mechanical simulation of liquid-supported stretch blow molding

    Energy Technology Data Exchange (ETDEWEB)

    Zimmer, J.; Stommel, M. [Chair of Polymer Materials, Saarland University, Saarbruecken, Germany, – j.zimmer@mx.uni-saarland.de (Germany)

    2015-05-22

    Stretch blow molding is the well-established plastics forming method to produce Polyehtylene therephtalate (PET) bottles. An injection molded preform is heated up above the PET glass transition temperature (Tg∼85°C) and subsequently inflated by pressurized air into a closed cavity. In the follow-up filling process, the resulting bottle is filled with the final product. A recently developed modification of the process combines the blowing and filling stages by directly using the final liquid product to inflate the preform. In a previously published paper, a mechanical simulation and successful evaluation of this liquid-driven stretch blow molding process was presented. In this way, a realistic process parameter dependent simulation of the preform deformation throughout the forming process was enabled, whereas the preform temperature evolution during forming was neglected. However, the formability of the preform is highly reduced when the temperature sinks below Tg during forming. Experimental investigations show temperature-induced failure cases due to the fast heat transfer between hot preform and cold liquid. Therefore, in this paper, a process dependent simulation of the temperature evolution during processing to avoid preform failure is presented. For this purpose, the previously developed mechanical model is used to extract the time dependent thickness evolution. This information serves as input for the heat transfer simulation. The required material parameters are calibrated from preform cooling experiments recorded with an infrared-camera. Furthermore, the high deformation ratios during processing lead to strain induced crystallization. This exothermal reaction is included into the simulation by extracting data from preform measurements at different stages of deformation via Differential Scanning Calorimetry (DSC). Finally, the thermal simulation model is evaluated by free forming experiments, recorded by a high-speed infrared camera.

  7. Thermo-mechanical simulation of liquid-supported stretch blow molding

    Science.gov (United States)

    Zimmer, J.; Stommel, M.

    2015-05-01

    Stretch blow molding is the well-established plastics forming method to produce Polyehtylene therephtalate (PET) bottles. An injection molded preform is heated up above the PET glass transition temperature (Tg˜85°C) and subsequently inflated by pressurized air into a closed cavity. In the follow-up filling process, the resulting bottle is filled with the final product. A recently developed modification of the process combines the blowing and filling stages by directly using the final liquid product to inflate the preform. In a previously published paper, a mechanical simulation and successful evaluation of this liquid-driven stretch blow molding process was presented. In this way, a realistic process parameter dependent simulation of the preform deformation throughout the forming process was enabled, whereas the preform temperature evolution during forming was neglected. However, the formability of the preform is highly reduced when the temperature sinks below Tg during forming. Experimental investigations show temperature-induced failure cases due to the fast heat transfer between hot preform and cold liquid. Therefore, in this paper, a process dependent simulation of the temperature evolution during processing to avoid preform failure is presented. For this purpose, the previously developed mechanical model is used to extract the time dependent thickness evolution. This information serves as input for the heat transfer simulation. The required material parameters are calibrated from preform cooling experiments recorded with an infrared-camera. Furthermore, the high deformation ratios during processing lead to strain induced crystallization. This exothermal reaction is included into the simulation by extracting data from preform measurements at different stages of deformation via Differential Scanning Calorimetry (DSC). Finally, the thermal simulation model is evaluated by free forming experiments, recorded by a high-speed infrared camera.

  8. Application of statistical methods for analyzing the relationship between casting distortion, mold filling, and interfacial heat transfer in sand molds

    Energy Technology Data Exchange (ETDEWEB)

    Y. A. Owusu

    1999-03-31

    This report presents a statistical method of evaluating geometric tolerances of casting products using point cloud data generated by coordinate measuring machine (CMM) process. The focus of this report is to present a statistical-based approach to evaluate the differences in dimensional and form variations or tolerances of casting products as affected by casting gating system, molding material, casting thickness, and casting orientation at the mold-metal interface. Form parameters such as flatness, parallelism, and other geometric profiles such as angularity, casting length, and height of casting products were obtained and analyzed from CMM point cloud data. In order to relate the dimensional and form errors to the factors under consideration such as flatness and parallelism, a factorial analysis of variance and statistical test means methods were performed to identify the factors that contributed to the casting distortion at the mold-metal interface.

  9. Mold

    Centers for Disease Control (CDC) Podcasts

    2011-05-02

    This podcast answers a listener's question about the risks associated with mold after a natural disaster or severe weather.  Created: 5/2/2011 by National Center for Environmental Health (NCEH).   Date Released: 5/2/2011.

  10. Effect of yttrium on microstructure and mold filling capacity of a near-α high temperature titanium alloy

    Directory of Open Access Journals (Sweden)

    Zhao Ertuan

    2012-11-01

    Full Text Available The addition of rare earth yttrium (Y can improve the performances of high temperature titanium alloys, such as the tensile ductility, thermal stability and creep property, etc. However, few studies on the effect of Y on the castability of titanium alloys have been carried out, which is significant to fabrication of thin-walled complex titanium castings by investment casting. In this study, the microstructure and mold filling capacity of a Ti-1100 alloy with different Y additions (0, 0.1wt.%, 0.3wt.%, 0.5wt.% and 1.0wt.% were investigated systematically through investment casting experiments, and the casting experiments were carried out in a centrifugal titanium casting machine. The microstructures of the alloy were observed via the optical microscopy, scanning electron microscopy and transmission electron microscopy. The mold filling capacity was tested by using of a grid pattern and was evaluated by the number of segments completely filled by the cast alloy. The results indicate that the grain size is decreased and the mold filling capacity is improved significantly with increasing the addition of Y from 0 to 1.0wt.%. The average primary β grain size of Ti-1100 alloy is reduced from 250 μm to 50 μm and the mold filling capacity is increased from 61.5% to 100%. Considering the potential harmful effect on tensile properties of titanium alloys due to high concentrations of Y, it is suggested that Y addition should be about 0.3wt.%.

  11. Local mechanical properties of LFT injection molded parts: Numerical simulations versus experiments

    Science.gov (United States)

    Desplentere, F.; Soete, K.; Bonte, H.; Debrabandere, E.

    2014-05-01

    In predictive engineering for polymer processes, the proper prediction of material microstructure from known processing conditions and constituent material properties is a critical step forward properly predicting bulk properties in the finished composite. Operating within the context of long-fiber thermoplastics (LFT, length Autodesk Simulation Moldflow Insight 2014 software has been used. In this software, a fiber breakage algorithm for the polymer flow inside the mold is available. Using well known micro mechanic formulas allow to combine the local fiber length with the local orientation into local mechanical properties. Different experiments were performed using a commercially available glass fiber filled compound to compare the measured data with the numerical simulation results. In this investigation, tensile tests and 3 point bending tests are considered. To characterize the fiber length distribution of the polymer melt entering the mold (necessary for the numerical simulations), air shots were performed. For those air shots, similar homogenization conditions were used as during the injection molding tests. The fiber length distribution is characterized using automated optical method on samples for which the matrix material is burned away. Using the appropriate settings for the different experiments, good predictions of the local mechanical properties are obtained.

  12. Validation of precision powder injection molding process simulations using a spiral test geometry

    DEFF Research Database (Denmark)

    Marhöfer, Maximilian; Müller, Tobias; Tosello, Guido

    2015-01-01

    Like in many other areas of engineering, process simulations find application in precision injection molding to assist and optimize the quality and design of precise products and the molding process. Injection molding comprises mainly the manufacturing of plastic components. However, the variant ...

  13. Design optimization of clutch housing mold by fluid flow and solidification simulation

    Energy Technology Data Exchange (ETDEWEB)

    Hosseini, Seyedeh Maryam; Utlu, Zafer [Istanbul Aydin Univ., Istanbul (Turkmenistan)

    2016-06-15

    Aluminum die casting is so complex where flow momentum is critical matter in the mould filling process due the high velocity of the liquid metal. Actually, in complex parts the exact calculation of mould filling performance with using experimental knowledge is almost impossible. Aluminum die castings play a definitive role in the manufacturing of lightweight automobile bodies. Hence it is more essential today that these castings be produced with the high quality methods. In this condition the simulation is becoming more important in the designing procedure. This saves time and reduces the cost of the casting system design, which is an advantage of using simulation programs. Also, economical utilization of materials can be obtained when the quantity of test castings is decreased. This paper describes the advantages of the clutch housing die casting mold simulations to achieve better casting system design in High pressure die castings (HPDC). Filling analysis is used to determine the size and location of the gate as well as proper runner system design for ensuring a complete and balanced filling of the clutch housing part.

  14. Mold Simulator Study on the Initial Solidification of Molten Steel Near the Corner of Continuous Casting Mold

    Science.gov (United States)

    Lyu, Peisheng; Wang, Wanlin; Zhang, Haihui

    2016-11-01

    Corner cracks are one of the most widespread surface defects of continuous casting slabs, and they are especially severe for peritectic steels and low-alloy steels. Therefore, a clear understanding of molten steel initial solidification around mold corner would be of great importance for the inhibition of corner cracks. This paper has been conducted with the aim to elucidate this understanding, by using a novel mold simulator equipped with a right-angle copper mold. The responding temperatures and heat fluxes across the mold hot-face and corner were firstly calculated through a 2D-inverse heat conduction program mathematical model, and the results suggested that the cooling ability and the fluctuation of heat fluxes around the mold corner are stronger than those for mold hot-face. With the help of power spectral density analysis and fast Fourier transformation, the four characteristic signals of heat fluxes were discussed in this paper. Next, the relation between the thickness of solidified shell and solidification time was fitted with the solidification square root law; as a result, the average solidification factor bar{K} for the hot-face shell is 2.32 mm/s1/2, and it is 2.77 mm/s1/2 for the shell near-corner. For the same oscillation marks (OMs), it appeared that the OMs positions on the shell corner are lower than those on the shell hot-face along the casting direction, because the stronger shrinkage of shell at the corner allows the overflowing steel to penetrate deeper into the larger gap between the shell corner and mold, which is demonstrated through the heat transfer analysis and metallographic examination. Finally, the interrelation between shell profile, mold oscillation, variation rate of heat flux, high-frequency heat flux and high-frequency temperature was discussed for above two cases, and the results suggested that meniscus conditions (heat transfer and melt flow) around the mold corner are more unsteady.

  15. Mold Simulator Study on the Initial Solidification of Molten Steel Near the Corner of Continuous Casting Mold

    Science.gov (United States)

    Lyu, Peisheng; Wang, Wanlin; Zhang, Haihui

    2017-02-01

    Corner cracks are one of the most widespread surface defects of continuous casting slabs, and they are especially severe for peritectic steels and low-alloy steels. Therefore, a clear understanding of molten steel initial solidification around mold corner would be of great importance for the inhibition of corner cracks. This paper has been conducted with the aim to elucidate this understanding, by using a novel mold simulator equipped with a right-angle copper mold. The responding temperatures and heat fluxes across the mold hot-face and corner were firstly calculated through a 2D-inverse heat conduction program mathematical model, and the results suggested that the cooling ability and the fluctuation of heat fluxes around the mold corner are stronger than those for mold hot-face. With the help of power spectral density analysis and fast Fourier transformation, the four characteristic signals of heat fluxes were discussed in this paper. Next, the relation between the thickness of solidified shell and solidification time was fitted with the solidification square root law; as a result, the average solidification factor bar{K} for the hot-face shell is 2.32 mm/s1/2, and it is 2.77 mm/s1/2 for the shell near-corner. For the same oscillation marks (OMs), it appeared that the OMs positions on the shell corner are lower than those on the shell hot-face along the casting direction, because the stronger shrinkage of shell at the corner allows the overflowing steel to penetrate deeper into the larger gap between the shell corner and mold, which is demonstrated through the heat transfer analysis and metallographic examination. Finally, the interrelation between shell profile, mold oscillation, variation rate of heat flux, high-frequency heat flux and high-frequency temperature was discussed for above two cases, and the results suggested that meniscus conditions (heat transfer and melt flow) around the mold corner are more unsteady.

  16. Simulation of Jetting in Injection Molding Using a Finite Volume Method

    Directory of Open Access Journals (Sweden)

    Shaozhen Hua

    2016-05-01

    Full Text Available In order to predict the jetting and the subsequent buckling flow more accurately, a three dimensional melt flow model was established on a viscous, incompressible, and non-isothermal fluid, and a control volume-based finite volume method was employed to discretize the governing equations. A two-fold iterative method was proposed to decouple the dependence among pressure, velocity, and temperature so as to reduce the computation and improve the numerical stability. Based on the proposed theoretical model and numerical method, a program code was developed to simulate melt front progress and flow fields. The numerical simulations for different injection speeds, melt temperatures, and gate locations were carried out to explore the jetting mechanism. The results indicate the filling pattern depends on the competition between inertial and viscous forces. When inertial force exceeds the viscous force jetting occurs, then it changes to a buckling flow as the viscous force competes over the inertial force. Once the melt contacts with the mold wall, the melt filling switches to conventional sequential filling mode. Numerical results also indicate jetting length increases with injection speed but changes little with melt temperature. The reasonable agreements between simulated and experimental jetting length and buckling frequency imply the proposed method is valid for jetting simulation.

  17. Analysis of Cavity Pressure and Warpage of Polyoxymethylene Thin Walled Injection Molded Parts: Experiments and Simulations

    DEFF Research Database (Denmark)

    Guerrier, Patrick; Tosello, Guido; Hattel, Jesper Henri

    2014-01-01

    , melt and mold temperatures, material rheological and pvT characterization. Factors investigated for comparisons were: injection pressure profile, short shots length, flow pattern, and warpage. A reliable molding experimental database was obtained, accurate simulations were conducted and a number......Process analysis and simulations on molding experiments of 3D thin shell parts have been conducted. Moldings were carried out with polyoxymethylene (POM). The moldings were performed with cavity pressure sensors in order to compare experimental process results with simulations. The warpage...... was characterized by measuring distances using a tactile coordinate measuring machine (CMM). Molding simulations have been executed taking into account actual processing conditions. Various aspects have been considered in the simulation: machine barrel geometry, injection speed profiles, cavity injection pressure...

  18. EXPERIMENTAL RESEARCH AND NUMERICAL SIMULATION OF MOLD TEMPERATURE FIELD IN CONTINUOUS CASTING OF STEEL

    Institute of Scientific and Technical Information of China (English)

    X.S. Zheng; M.H. Sha; J.Z. Jin

    2006-01-01

    Mold is the heart of the continuous casting machine. Heat transfer and solidification in a watercooled mold are the most important factors during the continuous casting of steel. For studying the temperature distribution of a mold wall, a simulated apparatus of mold was designed and experiments were performed by it. The measured results indicated that the mold wall temperature approaches the temperature of cooling-water. An equivalent thermal-conductivity coefficient was proposed and deduced on the basis of the conclusion of the experiments. This coefficient was applied to solve the heat transfer between the melt and cooling water, and to characterize the heat transfer capacity of the mold. By this equivalent thermal-conductivity coefficient, it is very easy and convenient to numerically simulate the solidification process of continuous casting. And the calculation results are in agreement with the experiments. The effects of casting speed and water flow rate on the mold temperature field were also discussed.

  19. Numerical Analysis of Mold Deformation Including Plastic Melt Flow During Injection Molding

    Energy Technology Data Exchange (ETDEWEB)

    Jung, Joon Tae; Lee, Bong-Kee [Chonnam National University, Gwangju (Korea, Republic of)

    2014-07-15

    In the present study, a numerical analysis of an injection molding process was conducted for predicting the mold deformation considering non-Newtonian flow, heat transfer, and structural behavior. The accurate prediction of mold deformation during the filling stage is important to successfully design and manufacture a precision injection mold. While the local mold deformation can be caused by various factors, a pressure induced by the polymer melt is considered to be one of the most significant ones. In this regard, the numerical simulation considering both the melt filling and the mold deformation was carried out. A mold core for a 2D axisymmetric center-gated disk was used for the demonstration of the present study. The flow behavior inside the mold cavity and temperature distribution were analyzed along with the core displacement. Also, a Taguchi method was employed to investigate the influence of the relevant parameters including flow velocity, mold core temperature, and melt temperature.

  20. Gate design in injection molding of microfluidic components using process simulations

    DEFF Research Database (Denmark)

    Marhöfer, D. M.; Tosello, G.; Islam, A.;

    2015-01-01

    Just as in conventional injection molding of plastics, process simulations are an effective tool in the area of micro injection molding. They are applied in order to optimize and aid the design of the micro plastic part, the mold and the actual process. Available simulation software is actually...... made for macroscopic injection molding, but by means of the correct implementation and modelling strategy it can also be applied to micro plastic parts, as it is shown in the presented work. Process simulations are applied to two microfluidic devices (a micro distributor and a micro mixer) which shall...

  1. Influence of mold and substrate material combinations on nanoimprint lithography process: MD simulation approach

    Science.gov (United States)

    Yang, Seunghwa; Yu, Suyoung; Cho, Maenghyo

    2014-05-01

    A molecular dynamics (MD) study was performed to examine the effect of mold-substrate material composition on the pattern transferring and defects of the resist polymer in a thermal Nano Imprint Lithography (NIL) process. As candidate materials, single crystalline nickel (Ni), silicon (Si) and silica (SiO2, α-quartz) for the rigid mold substrate, and amorphous poly-(methylmethacrylate) (PMMA) thin film for the resist were considered for common applications in NIL processes. Three different material compositions of Si mold-Ni substrate, Ni mold-Si substrate, and quartz mold-Ni substrate were considered. In accordance with a real NIL process, a sequence of indentation-relaxation-release processes was quasi-statically simulated using isothermal ensemble simulation on tri-layer molecular structures consisting of a mold, resist, and substrate. To correlate the deformed shape and delamination of PMMA resist from the substrate in indentation and release processes, non-bond interaction energy between a rigid mold and resist was calculated for each combination of mold and substrate materials. The Si mold-Ni substrate combination shows successful pattern transfer to the resist polymer even without an anti-sticking layer as a result of the desirable balance of surface free energy for mold and substrate materials. However, Ni mold-Si substrate combination shows a critical delamination of the resist in the release process due to strong van der Waals adhesion between the resist and Ni mold. Similarly, the quartz mold-Ni substrate combination shows the same delamination in pattern transfer, but the adhesion of the resist to the quartz mold is attributed to electrostatic interaction. In order to provide guidelines for material selection in imprint-like processes where surface adsorption and wetting characteristics are critical design parameters, a simple PMMA-rigid plate model is proposed, with which consistent surface interaction characteristics in the full model NIL process

  2. Phenolic Molding Compounds

    Science.gov (United States)

    Koizumi, Koji; Charles, Ted; de Keyser, Hendrik

    Phenolic Molding Compounds continue to exhibit well balanced properties such as heat resistance, chemical resistance, dimensional stability, and creep resistance. They are widely applied in electrical, appliance, small engine, commutator, and automotive applications. As the focus of the automotive industry is weight reduction for greater fuel efficiency, phenolic molding compounds become appealing alternatives to metals. Current market volumes and trends, formulation components and its impact on properties, and a review of common manufacturing methods are presented. Molding processes as well as unique advanced techniques such as high temperature molding, live sprue, and injection/compression technique provide additional benefits in improving the performance characterisitics of phenolic molding compounds. Of special interest are descriptions of some of the latest innovations in automotive components, such as the phenolic intake manifold and valve block for dual clutch transmissions. The chapter also characterizes the most recent developments in new materials, including long glass phenolic molding compounds and carbon fiber reinforced phenolic molding compounds exhibiting a 10-20-fold increase in Charpy impact strength when compared to short fiber filled materials. The role of fatigue testing and fatigue fracture behavior presents some insight into long-term reliability and durability of glass-filled phenolic molding compounds. A section on new technology outlines the important factors to consider in modeling phenolic parts by finite element analysis and flow simulation.

  3. Minimization of variation in volumetric shrinkage and deflection on injection molding of Bi-aspheric lens using numerical simulation

    Energy Technology Data Exchange (ETDEWEB)

    Bensingh, R. Joseph [Central Institute of Plastics Engineering and Technology, Chennai (India); Boopathy, S. Rajendra [College of Engineering, Anna University, Chennai (India); Jebaraj, C. [Vellore Institutes of Technology, Chennai (India)

    2016-11-15

    The profile of a bi-aspheric lens is such a way that the thickness narrows down from center to periphery (convex). Injection molding of these profiles has high shrinkage in localized areas, which results in internal voids or sink marks when the part gets cool down to room temperature. This paper deals with the influence of injection molding process parameters such as mold surface temperature, melt temperature, injection time, V/P Switch over by percentage volume filled, packing pressure, and packing duration on the volumetric shrinkage and deflection. The optimal molding parameters for minimum variation in volumetric shrinkage and deflection of bi-aspheric lens have been determined with the application of computer numerical simulation integrated with optimization. The real experimental work carried out with optimal molding parameters and found to have a shallow and steep surface profile accuracy of 0.14 and 1.57 mm, 21.38-45.66 and 12.28-26.90 μm, 41.56-157.33 and 41.56-157.33 nm towards Radii of curvatures (RoC), surface roughness (Ra) and waviness of the surface profiles (profile error Pt), respectively.

  4. Precision Glass Molding: Validation of an FE Model for Thermo-Mechanical Simulation

    DEFF Research Database (Denmark)

    Sarhadi, Ali; Hattel, Jesper Henri; Hansen, Hans Nørgaard

    2014-01-01

    In precision glass molding process, the required accuracy for the final size and shape of the molded lenses as well as the complexity of this technology calls for a numerical simulation. The current paper addresses the development of an FE model for thermo-mechanical simulation of the precision...

  5. Phase Behaviors in Bi-phase Simulation of Powder Segregation in Metal Injection Molding

    Institute of Scientific and Technical Information of China (English)

    Liu Baosheng; Fan Xiaoxin; Cheng Zhiqiang

    2006-01-01

    Powder segregation induced by mold filling is an important phenomenon that affects the final quality of metal injection molding (MIM). The prediction of segregation in MIM requires a bi-phase flow model to describe distinctly the flows of metallic powder and polymer binder. Viscous behaviors for the flows of each phase should hence be determined. The coefficient of interaction between the flows of two phases should also be evaluated. However, only viscosity of the mixed feedstock is measurable by capillary tests. Wall sticking is supposed in the traditional model for capillary tests, while the wall slip is important to be taken into account in MIM injection. Objective of the present paper is to introduce the slip effect in bi-phase simulation, and search the suitable way to determine the viscous behaviors for each phase with the consideration of wall slip in capillary tests. Analytical and numerical methods were proposed to realize such a specific purpose. The proposed method is based on the mass conservation between the capillary flows in mono-phase model for the mixed feedstock and in bi-phase model for the flows of two phases. Examples of the bi-phase simulation in MIM were realized with the software developed by research team. The results show evident segregation, which is valuable for improving the mould designs.

  6. A two-dimensional simulation model for the molded underfill process in flip chip packaging

    Energy Technology Data Exchange (ETDEWEB)

    Guo, Xue Ru; Young, Wen Bin [National Cheng Kung University, Tainan (China)

    2015-07-15

    The flip chip process involves the deposition of solder bumps on the chip surface and their subsequent direct attachment and connection to a substrate. Underfilling traditional flip chip packaging is typically performed following a two-step approach. The first step uses capillary force to fill the gap between the chip and the substrate, and the second step uses epoxy molding compound (EMC) to overmold the package. Unlike traditional flip chip packaging, the molded underfill (MUF) concept uses a single-step approach to simultaneously achieve both underfill and overmold. MUF is a simpler and faster process. In this study, a 2D numerical model is developed to simulate the front movement of EMC flow and the void formation for different geometric parameters. The 2D model simplifies the procedures of geometric modeling and reduces the modeling time for the MUF simulation. Experiments are conducted to verify the prediction results of the model. The effect on void formation for different geometric parameters is investigated using a 2D model.

  7. Gate Design in Injection Molding of Microfluidic Components Using Process Simulations

    DEFF Research Database (Denmark)

    Marhöfer, David Maximilian; Tosello, Guido; Islam, Aminul

    2016-01-01

    Just as in conventional injection molding of plastics, process simulationsare an effective and interesting tool in the area of microinjection molding. They can be applied in order to optimize and assist the design of the microplastic part, the mold, and the actual process. Available simulation...... software is however actually made for macroscopic injection molding. By means of the correct implementation and careful modeling strategy though, it can also be applied to microplastic parts, as it is shown in the present work. Process simulations were applied to two microfluidic devices (amicrofluidic...

  8. Numerical simulation on inclusion transport in continuous casting mold

    Institute of Scientific and Technical Information of China (English)

    Lifeng Zhang; Brian G. Thomas

    2006-01-01

    Turbulent flow, the transport of inclusions and bubbles, and inclusion removal by fluid flow transport and by bubble flotation in the strand of the continuous slab caster are investigated using computational models, and validated through comparison with plant measurements of inclusions. Steady 3-D flow of steel in the liquid pool in the mold and upper strand is simulated with a finitedifference computational model using the standard k-ε turbulence model. Trajectories of inclusions and bubbles are calculated by integrating each local velocity, considering its drag and buoyancy forces. A "random walk" model is used to incorporate the effect of turbulent fluctuations on the particle motion. The attachment probability of inclusions on a bubble surface is investigated based on fundamental fluid flow simulations, incorporating the turbulent inclusion trajectory and sliding time of each individual inclusion along the bubble surface as a function of particle and bubble size. The change in inclusion distribution due to removal by bubble transport in the mold is calculated based on the computed attachment probability of inclusions on each bubble and the computed path length of the bubbles. The results indicate that 6%-10% inclusions are removed by fluid flow transport, 10% by bubble flotation, and 4% by entrapment to the submerged entry nozzle (SEN) walls. Smaller bubbles and larger inclusions have larger attachment probabilities. Smaller bubbles are more efficient for inclusion removal by bubble flotation, so long as they are not entrapped in the solidifying shell. A larger gas flow rate favors inclusion removal by bubble flotation. The optimum bubble size should be 2-4 mm.

  9. Optimized Injection Molding of Unfilled and Glass Filled PA6 Gears

    Directory of Open Access Journals (Sweden)

    Nik Mizamzul Mehat

    2014-01-01

    Full Text Available Shrinkage behavior is a crucial problem in manufacturing plastic molded gear. This is because it negatively affects the dimensional stability and accuracy of the involute profile, as well as the concentricity, roundness, tooth spacing uniformity, and size of the gear. By integrating the Taguchi robust design, Grey relational analysis, and principal component analysis, we investigated the dimensional stability related to the shrinkage of tooth thickness, addendum circle, and dedendum circle of molded gear via the optimization of processing parameters and glass fiber reinforcement. The results revealed that the optimal combination of the processing parameters of the molded gear to achieve minimum shrinkage is melt temperature of 260°C, packing pressure of 60%, packing time of 5 s, and cooling time of 30 s. The melt temperature showed the highest comparability sequence among the four key process parameters examined, followed by packing pressure, cooling time, and packing time. Meanwhile, the presence of glass fibers induced higher deviations of tooth thickness, addendum circle, and dedendum circle than those of the unfilled polyamide 6 gears.

  10. Numerical simulation of mould filling process for pressure plate and valve handle in LFC

    Directory of Open Access Journals (Sweden)

    Jiang Junxia

    2010-11-01

    Full Text Available In lost foam casting (LFC, the distribution of polymer beads during the bead filling process is not uniform, and the collision between polymer beads determines the distribution of two-phase flow of gas and solid. The interaction between the gas and solid phases reveals as coupling effect of the force that gas exerts on particles or vice versa, or that among particles. The gas-solid flow in filling process is nonlinearity, which makes the coupling effect an essential point to carry out a simulation properly. Therefore, information of each particle’s motion is important for acquiring the law of filling process. In bead filling process, compressed air is pressed into mold cavity, and discharged from gas vent, creating a pressure difference between outer and inner space near the gas vent. This pressure difference directly changes the spatial distribution and motion trace of gas and solid phases. In this paper, Discrete Element Method (DEM and Computational Fluid Dynamics (CFD are employed to simulate the fluid dynamic character based on Newton’s Third Law of Motion. The simulation results of some casting products such as pressure plate and valve handle are compared with the result obtained from practical experiment in order to test the feasibility of DEM. The comparison shows that this DEM method can be a very promising tool in the mould filling simulation of beads’ movement.

  11. Numerical Simulation of Injection Molding Cooling Process Based on 3D Surface Model

    Institute of Scientific and Technical Information of China (English)

    CUIShu-biao; ZHOUHua-min; LIDe-qun

    2004-01-01

    The design of the coohng system of injection molds directly affects both productivity and the quality of the final part. Using the cooling process CAE system to instruct the mold design, the efficiency and quality of design can be improved greatly. At the same time, it is helpful to confirm the cooling system structure and optimize the process conditions. In this paper, the 3D surface model of mold cavity is used to replace the middle-plane model in the simulation by Boundary Element Method, which break the bottleneck of the application of the injection molding simulation softwares base on the middle-plane model. With the improvements of this paper, a practical and commercial simulation software of injection molding cooling process named as HsCAE3D6.0 is developed.

  12. DEM simulations of die filling during pharmaceutical tabletting

    Institute of Scientific and Technical Information of China (English)

    2008-01-01

    The flow behaviour of powders from a stationary shoe into a moving die, which mimics the die filling process in a rotary tablet press, was analysed using a discrete element method (DEM), in which 2D irregular shaped particles were considered. The influence of the particle shape,size and size distribution, the number of particles used in the simulation, the initial height of powder bed in the shoe, and the filling speed on the average mass flow rate and the critical filling speed (the highest speed at which the die can be completely filled) were explored. It has been found that a maximum flow rate is obtained at the critical filling speed for all systems investigated and poly-disperse systems have higher mass flow rates and higher critical filling speeds than mono-disperse systems. In addition, the powder with particles which can tessellate generally has a lower filling rate and a lower critical filling speed.

  13. Numerical simulation of tungsten alloy in powder injection molding process

    Institute of Scientific and Technical Information of China (English)

    ZHENG Zhen-xing; XIA Wei; ZHOU Zhao-yao; ZHU Quan-li

    2008-01-01

    The flow behavior of feedstock for the tungsten alloy powder in the mold cavity was approximately described using Hele-Shaw flow model. The math model consisting of momentum equation, consecutive equation and thermo-conduction equation for describing the injection process was established. The equations are solved by the finite element/finite difference hybrid method that means dispersing the feedstock model with finite element method, resolving the model along the depth with finite difference methpd, and tracking the movable boundary with control volume method, then the pressure equation and energy equation can be resolved in turn. The numerical simulation of the injection process and the identification of the process parameters were realized by the Moldflow software. The results indicate that there is low temperature gradient in the cavity while the pressure and shear rate gradient are high at high flow rate. The selection of the flow rate is affected by the structure of the gate. The shear rate and the pressure near the gate can be decreased by properly widening the dimension of the gate. There is a good agreement between the process parameters obtained by the numerical simulation and the actual ones.

  14. Diallyl phthalate prepolymer characterization and testing in fiberglass filled molding compounds

    Energy Technology Data Exchange (ETDEWEB)

    Whitaker, R.B.; Schneider, R.E.; Schumacher, R.J.

    1983-02-21

    A program was undertaken to identify an acceptable alternative to Dapon 35, an o-diallyl phthalate (DAP) prepolymer no longer available. Three o-DAP prepolymers from the Osaka Soda Company and four laboratory-scale prepolymers from Bendix-Kansas city were characterized and evaluated in DAP-fiberglass molding compounds. Gel permeation chromatography results for the Osaka prepolymers showed all three to be very close to one another in molecular weights (mw) and mw distributions, but slightly lower in both than Dapon 35. They are also slightly higher in monomer content. All three processed readily into DAP-fiberglass molding compounds and passed required physical property tests. One Osaka prepolymer was compounded into both asbestos and Orlon-DAP compounds on a production scale. Both compounds have passed all certification tests. The Bendix prepolymers were deliberately varied in mw and mw distribution and higher in monomer content than Dapon 35. Processing difficulties were encountered with both the lowest and highest molecular weight compounds, and the lowest molecular weight compound failed a number of physical property tests. The two intermediate molecular weight compounds processed readily and passed property tests. Guidelines were established for acceptable o-DAP prepolymers: (1) weight average mw (relative to polystyrene standards): 30,000 to 150,000; (2) mw distribution: 3.0 to less than or equal to 18.0; and (3) DAP monomer content: 1.0 to less than or equal to 6.0%. 5 figures, 6 tables.

  15. Numerical simulation of temperature and strength distributions of mold(core) on heating

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    By using Visual C+ +, a model with post-processing was carried out to simulate the temperature and strength distributions of the mold(core). The results are shown in 256-color graphic mode. With this model, the temperature and strength distributions of the mold(core) both in case of heating process for core in the furnace and solidification process for a thin-wall aluminum alloy casting in the mold(core) are numerically simulated. The results show that the temperature and strength distributions of the mold(core) were uneven because the thermal conductivity of the resin sand was much small. This study laid a basis for the optimum design of the mold(core) properties.

  16. Effect of Melt Temperature and Hold Pressure on the Weld-Line Strength of an Injection Molded Talc-Filled Polypropylene

    Directory of Open Access Journals (Sweden)

    Yuanxin Zhou

    2014-01-01

    Full Text Available Tensile stress-strain behavior coupled with fractography was used to investigate the weld-line strength of an injection molded 40 w% talc-filled polypropylene. The relationship between processing conditions, microstructure, and tensile strength was established. Fracture surface of the weld line exhibited skin-core morphology with different degrees of talc particle orientations in the core and in the skin. Experimental results also showed that the thickness of the core decreased and the thickness of the skins increased with increasing melt temperature and increasing hold pressure, which resulted in an increase of yield strength and yield strain with increasing melt temperature and increasing hold pressure. Finally, a three-parameter nonlinear constitutive model was developed to describe the strain softening behavior of the weld-line strength of talc-filled polypropylene. The parameters in this model are the modulus E, the strain exponent m, and the compliance factor β. The simulated stress-strain curves from the model are in good agreement with the test data, and both m and β are functions of skin-core thickness ratio.

  17. Mould filling simulations during powder injection moulding

    NARCIS (Netherlands)

    Bilovol, V.V.

    2003-01-01

    Powder injection moulding (PIM) is a versatile technology capable of producing complex and near net shape parts. Significant help in optimisation of the PIM process can be obtained from the numerical simulation. To obtain realistic numerical results it is necessary to fulfil certain conditions. The

  18. Modeling and Fault Simulation of Propellant Filling System

    Science.gov (United States)

    Jiang, Yunchun; Liu, Weidong; Hou, Xiaobo

    2012-05-01

    Propellant filling system is one of the key ground plants in launching site of rocket that use liquid propellant. There is an urgent demand for ensuring and improving its reliability and safety, and there is no doubt that Failure Mode Effect Analysis (FMEA) is a good approach to meet it. Driven by the request to get more fault information for FMEA, and because of the high expense of propellant filling, in this paper, the working process of the propellant filling system in fault condition was studied by simulating based on AMESim. Firstly, based on analyzing its structure and function, the filling system was modular decomposed, and the mathematic models of every module were given, based on which the whole filling system was modeled in AMESim. Secondly, a general method of fault injecting into dynamic system was proposed, and as an example, two typical faults - leakage and blockage - were injected into the model of filling system, based on which one can get two fault models in AMESim. After that, fault simulation was processed and the dynamic characteristics of several key parameters were analyzed under fault conditions. The results show that the model can simulate effectively the two faults, and can be used to provide guidance for the filling system maintain and amelioration.

  19. Simulation of the aluminum alloy A356 solidification cast in cylindrical permanent molds

    OpenAIRE

    2008-01-01

    A mathematical model based on the control volume method with fixed mesh was selected in order to simulate the solidification of cylindrical castings poured in permanent steel mold. The latent heat was incorporated using the effective specific heat. The application of the model allowed us to obtain the solidification front and the temperature fields at any time from the pouring. The mold was made of the SAE 1010 steel. Two mold temperatures were evaluated: 25°C and 300°C. The mathematical mode...

  20. Interim Report on Mixing During the Casting of LEU-10Mo Plates in the Triple Plate Molds

    Energy Technology Data Exchange (ETDEWEB)

    Aikin, Jr., Robert M. [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

    2017-04-12

    LEU-10%Mo castings are commonly produced by down blending unalloyed HEU with a DU-12.7%Mo master-alloy. This work uses process modeling to provide insight into the mixing of the unalloyed uranium and U-Mo master alloy during melting and mold filling of a triple plate casting. Two different sets of situations are considered: (1) mixing during mold filling from a compositionally stratified crucible and (2) convective mixing of a compositionally stratified crucible during mold heating. The mold filling simulations are performed on the original Y-12 triple plate mold and the horizontal triple plate mold.

  1. Effect of reprocessing cycles on the degradation of polypropylene copolymer filled with talc or montmorillonite during injection molding process

    Energy Technology Data Exchange (ETDEWEB)

    Demori, R.; Mauler, R. S., E-mail: raquel.mauler@ufrgs.br [Chemistry Institute, Federal University of Rio Grande do Sul, UFRGS, Av. Bento Gonçalves, 9500, Porto Alegre, 91501-970 (Brazil); Ashton, E.; Weschenfelder, V. F.; Cândido, L. H. A.; Kindlein, W. [Laboratory of Design LDSM, Federal University of Rio Grande do Sul, UFRGS (Brazil)

    2015-05-22

    Mechanical recycling of polymeric materials is a favorable technique resulting in economic and environmental benefits, especially in the case of polymers with a high production volume as the polypropylene copolymer (PP). However, recycling by reprocessing techniques can lead to thermal, mechanical or thermo-oxidative degradation that can affect the structure of the polymer and subsequently the material properties. PP filled with montmorillonite (MMT) or talc are widely produced and studied, however, its degradation reactions by reprocessing cycles are poorly studied so far. In this study, the effects of reprocessing cycles in the structure and in the properties of the PP/MMT and PP/Talc were evaluated. The samples were mixed with 5% talc or MMT Cloisite C15A in a twin-screw extrusion. After extrusion, this filled material was submitted to five reprocessing cycles through an injection molding process. In order to evaluate the changes induced by reprocessing techniques, the samples were characterized by DSC, FT-IR, Izod impact and tensile strength tests. The study showed that Young modulus, elongation at brake and Izod impact were not affected by reprocessing cycles, except when using talc. In this case, the elongation at brake reduced until the fourth cycle, showing rigidity increase. The DSC results showed that melting and crystallization temperature were not affected. A comparison of FT-IR spectra of the reprocessed indicated that in both samples, between the first and the fifth cycle, no noticeable change has occurred. Thus, there is no evidence of thermo oxidative degradation. In general, these results suggest that PP reprocessing cycles using MMT or talc does not change the material properties until the fifth cycle.

  2. Numerical simulation method for weld line development in micro injection molding process

    Institute of Scientific and Technical Information of China (English)

    XIE Lei; ZIEGMANN Gerhard; JIANG Bing-yan

    2009-01-01

    In order to reduce the "trial-mold" risk and cost, numerical simulation method was applied to micro injection molding weld line development investigation. The micro tensile specimen which has the size of 0.1 mm (depth)×0.4 mm (width)× 12 mm(length) in test area was selected as the objective part, and polypropylene (PP) as the experimental material. Respectively with specific commercial software (Mold Flow~(R)) and general computational fluid dynamic (CFD) software (Comsol ~(R)Multiphysics), the simulation experiments for development of weld line in micro injection molding process were executed and the real comparison experiments were also carried out. The results show that during micro injection molding process, the specific commercial software for normal injection molding process is not valid to describe the micro flow process, the shape of flow front in micro cavity flowing which is important in weld line developing study and the contact angle clue to surface tension are not able to be simulated. In order to improve the simulation results for micro weld line development, the general CFD software, which is more flexible in user defining function, is applied. The results show better effects in describing micro fluid flow behavior. As a conclusion, as for weld line forming process, the numerical simulation method can give a characteristic analysis results for processing parameters optimizing in micro injection molding process; but for both kinds of softwares quantitative analysis cannot be obtained unless the boundary condition and micro fluid mathematic model are improved in the future.

  3. Performance Simulation and Verification of Vat Photopolymerization Based, Additively Manufactured Injection Molding Inserts with Micro-Features

    DEFF Research Database (Denmark)

    Mischkot, Michael; Hofstätter, Thomas; Michailidou, Ifigeneia

    2017-01-01

    . In this research, the thermal performance of a 20x20x2.7 mm3 injection molding insert was simulated. A thermal camera was used to assess the quality and accuracy of the simulation. Both, simulation and measurements showed that the temperature cycle during injection molding becomes stationary within 3 to 5 cycles...

  4. Modeling and flow analysis of pure nylon polymer for injection molding process

    Science.gov (United States)

    Nuruzzaman, D. M.; Kusaseh, N.; Basri, S.; Oumer, A. N.; Hamedon, Z.

    2016-02-01

    In the production of complex plastic parts, injection molding is one of the most popular industrial processes. This paper addresses the modeling and analysis of the flow process of the nylon (polyamide) polymer for injection molding process. To determine the best molding conditions, a series of simulations are carried out using Autodesk Moldflow Insight software and the processing parameters are adjusted. This mold filling commercial software simulates the cavity filling pattern along with temperature and pressure distributions in the mold cavity. In the modeling, during the plastics flow inside the mold cavity, different flow parameters such as fill time, pressure, temperature, shear rate and warp at different locations in the cavity are analyzed. Overall, this Moldflow is able to perform a relatively sophisticated analysis of the flow process of pure nylon. Thus the prediction of the filling of a mold cavity is very important and it becomes useful before a nylon plastic part to be manufactured.

  5. Study of Warpage in Injection MoldingUsing Rubber and Talc-filled Polypropylene— Influence of Molding Conditions on Corner Deformation —

    Science.gov (United States)

    Takahara, Tadayoshi; Furuhashi, Hiroshi; Maeda, Hidenori; Inoyama, Tatsuya; Koyama, Kiyohito

    The most popular resin material for automotive plastic parts is polypropylene, which includes talc for stiffness and heat-resistance. The anisotropic thermal expansion coefficient is well documented for talc reinforced polypropylene, but there are almost no technical papers for warpage. Therefore, using this kind of material and molding with an "L" shaped cross section, the influence of molding conditions on corner deformation is discussed in this study. The results of this study are as follows 1) Shrinkage rate in the thickness direction is a few times larger than that in the planar direction (flow direction and transverse direction). By SEM observation, talc orientation for planar direction was confirmed. This talc orientation can hinder shrinkage in the planar direction, so the shrinkage rate in the thickness direction is relatively larger. 2) Three relationships were confirmed; negative correlation between injected weight (i.e. specimen weight) and shrinkage rate in the thickness direction, positive correlation between shrinkage rate in the thickness direction and corner deformation, and injected weight was varied by molding condition. From the results above, corner deformation is examined when; molding condition changes the injected weight, injected weight varies the shrinkage rate in the thickness direction, and when the shrinkage rate in the thickness direction induces corner deformation.

  6. Numerical simulation for thermal flow filling process of casting

    Institute of Scientific and Technical Information of China (English)

    CHEN Ye; ZHAO Yu-hong; HOU Hua

    2006-01-01

    The solution algorithm (SOLA) method was used to solve the velocity and pressure field of the thermal flow filling process, and the volume of fluid (VOF) method for the free surface problem. Since the "donor-acceptor" rule often results in the free interface vague, the explicit difference method was adopted, and a method describing the free surface state at 0<F<1 was proposed to deal with this problem. In order to raise the computation efficiency, such algorithms were investigated and invalidated as: 1) internal and external area separation simplification algorithm; 2) the reducing necessary search area method. With the improved algorithms, the filling processes of the valve cover castings with gravity cast and an up cylinder block casting with low-pressure cast were simulated, the simulation results are believable and the computation efficiency is greatly improved. The SOLA-VOF model and its difference method for thermal fluid flow filling process were introduced.

  7. Experimental validation of viscous and viscoelastic simulations of micro injection molding process

    DEFF Research Database (Denmark)

    Gava, Alberto; Tosello, Guido; Lucchetta, Giovanni

    2009-01-01

    The effects of two different rheological models used in the simulation of the micro injection molding (µIM) process are investigated. The Cross-WLF viscous model and the Giesekus viscoelastic model are selected and their performance evaluated using 3D models implemented on two different commercia......The effects of two different rheological models used in the simulation of the micro injection molding (µIM) process are investigated. The Cross-WLF viscous model and the Giesekus viscoelastic model are selected and their performance evaluated using 3D models implemented on two different...

  8. Simulation of Light Propagation within Glass Fiber Filled Thermoplastics for Laser Transmission Welding

    Science.gov (United States)

    Hohmann, Martin; Devrient, Martin; Klämpfl, Florian; Roth, Stephan; Schmidt, Michael

    Laser transmission welding is a well-known joining technology for thermoplastics. Because of the needs of lightweight, cost effective and green production nowadays injection molded parts usually have to be welded. These parts are made out of semi-crystalline thermoplastics which are filled to a high amount with glass fibers. This leads to higher absorption and more scattering within the upper joining partner and hasa negative influence onto the welding process. Here a ray tracing model capable of considering every single glass fiber is introduced. Hence spatially not equally distributed glass fibers can be taken into account. Therefore the model is able to calculate in detail the welding laser intensity distribution after transmission through the upper joining partner. Data gained by numerical simulation is compared to data obtained by laser radiation scattering experiments. Thus observed deviation is quantified and discussed.

  9. LATTICE BGK MODEL SIMULATION OF ASYMMETRIC FLOW INSIDE A CONTINUOUS SLAB CASTING MOLD

    Institute of Scientific and Technical Information of China (English)

    ZHANG Xiao-jun; SHEN Hou-fa

    2006-01-01

    The incompressible lattice Bhatnager-Gross-Krook (BGK) model of computational fluid dynamics, from which the unsteady incompressible Navier-Stokes equations can be exactly derived with the limit of small Mach number, was established in continuous casting mold. An asymmetric flow pattern in the two-dimensional central plane of continuous slab casting mold was simulated, and the flow pattern is not stationary but changes over frequently if the Reynolds number is larger than 3000 or so. The results are found to be in excellent agreement with previous experimental results.

  10. System-level simulation of liquid filling in microfluidic chips.

    Science.gov (United States)

    Song, Hongjun; Wang, Yi; Pant, Kapil

    2011-06-01

    Liquid filling in microfluidic channels is a complex process that depends on a variety of geometric, operating, and material parameters such as microchannel geometry, flow velocity∕pressure, liquid surface tension, and contact angle of channel surface. Accurate analysis of the filling process can provide key insights into the filling time, air bubble trapping, and dead zone formation, and help evaluate trade-offs among the various design parameters and lead to optimal chip design. However, efficient modeling of liquid filling in complex microfluidic networks continues to be a significant challenge. High-fidelity computational methods, such as the volume of fluid method, are prohibitively expensive from a computational standpoint. Analytical models, on the other hand, are primarily applicable to idealized geometries and, hence, are unable to accurately capture chip level behavior of complex microfluidic systems. This paper presents a parametrized dynamic model for the system-level analysis of liquid filling in three-dimensional (3D) microfluidic networks. In our approach, a complex microfluidic network is deconstructed into a set of commonly used components, such as reservoirs, microchannels, and junctions. The components are then assembled according to their spatial layout and operating rationale to achieve a rapid system-level model. A dynamic model based on the transient momentum equation is developed to track the liquid front in the microchannels. The principle of mass conservation at the junction is used to link the fluidic parameters in the microchannels emanating from the junction. Assembly of these component models yields a set of differential and algebraic equations, which upon integration provides temporal information of the liquid filling process, particularly liquid front propagation (i.e., the arrival time). The models are used to simulate the transient liquid filling process in a variety of microfluidic constructs and in a multiplexer, representing a

  11. Improving the performance of a filling line based on simulation

    Science.gov (United States)

    Jasiulewicz-Kaczmarek, M.; Bartkowiak, T.

    2016-08-01

    The paper describes the method of improving performance of a filling line based on simulation. This study concerns a production line that is located in a manufacturing centre of a FMCG company. A discrete event simulation model was built using data provided by maintenance data acquisition system. Two types of failures were identified in the system and were approximated using continuous statistical distributions. The model was validated taking into consideration line performance measures. A brief Pareto analysis of line failures was conducted to identify potential areas of improvement. Two improvements scenarios were proposed and tested via simulation. The outcome of the simulations were the bases of financial analysis. NPV and ROI values were calculated taking into account depreciation, profits, losses, current CIT rate and inflation. A validated simulation model can be a useful tool in maintenance decision-making process.

  12. Numerical simulation for permanent mold centrifugal cast TiAl exhaust valve

    Institute of Scientific and Technical Information of China (English)

    SHENG Wen-bin; LI Dong

    2005-01-01

    The filling and solidification in centrifugal field, as well as the forming mechanism of off-center porosities were summarized, based on the mathematical model established for the centrifugal cast TiAl exhaust valves.The calculated results show that the centrifugal field results in the phenomenon that the flow in the valve cavity consists of forward flow and backward flow. The unsymmetrical initial temperature field causes continuous unsymmetrical variation in the following solidification, which makes the final solidified region depart from the cavity axis and then leads to the occurrence of off-center porosity. A series of optimized parameters, including the entrance velocity of 0.6 - 1.3 m/s, the rotation speed higher than 300 r/min, 80 mm or longer entrance length and 400 ℃ or higher preheated temperature of the mold, are suggested for the manufacture of permanent mold centrifugal cast TiAl exhaust valves.

  13. Finite-Element Simulation of Conventional and High-Speed Peripheral Milling of Hardened Mold Steel

    Science.gov (United States)

    Tang, D. W.; Wang, C. Y.; Hu, Y. N.; Song, Y. X.

    2009-12-01

    A finite-element model (FEM) with the flow stress and typical fracture is used to simulate a hard machining process, which before this work could not adequately represent the constitutive behavior of workpiece material that is usually heat treated to hardness levels above 50 Rockwell C hardness (HRC). Thus, a flow stress equation with a variation in hardness is used in the computer simulation of hard machining. In this article, the influence of the milling speed on the cutting force, chip morphology, effective stress, and cutting temperature in the deformation zones of both conventional and high-speed peripheral milling hardened mold steel is systematically studied by finite-element analysis (FEA). By taking into consideration the importance of material characteristics during the milling process, the similar Johnson-Cook’s constitutive equation with hardened mold steel is introduced to the FEM to investigate the peripheral milling of hardened mold steel. In comparison with the experimental data of the cutting force at various cutting speeds, the simulation result is identical with the measured data. The results indicate that the model can be used to accurately predict the behavior of hardened mold steel in both conventional and high-speed milling.

  14. Laser propagation in simulations of low fill density hohlraums

    Science.gov (United States)

    Meezan, Nathan; Berzak Hopkins, L. F.; Izumi, N.; Divol, L.; Hinkel, D. E.; Ralph, J. E.; Moody, J. D.; Callahan, D. A.

    2016-10-01

    We present analysis of laser propagation in simulations of low fill density hohlraums on the National Ignition Facility (NIF). Simulations using the radiation hydrodynamic code hydra are compared in 2D and 3D. The absorption of laser rays in different materials and spatial locations is extracted from the simulations to identify where and when the inner cone laser beams undergo significant absorption. Inner cone laser beams can be absorbed in the outer cone ``gold bubble'' or in the region where the ablator and hohlraum material interact. The simulations provide guidance on which hohlraum mitigation methods will be most effective at improving inner beam propagation. Prepared by LLNL under Contract DE-AC52-07NA27344.

  15. Simulation-Based Optimization of Cure Cycle of Large Area Compression Molding for LED Silicone Lens

    Directory of Open Access Journals (Sweden)

    Min-Jae Song

    2015-01-01

    Full Text Available Three-dimensional heat transfer-curing simulation was performed for the curing process by introducing a large area compression molding for simultaneous forming and mass production for the lens and encapsulants in the LED molding process. A dynamic cure kinetics model for the silicone resin was adopted and cure model and analysis result were validated and compared through a temperature measurement experiment for cylinder geometry with cure model. The temperature deviation between each lens cavity could be reduced by implementing a simulation model on the large area compression mold and by optimizing the location of heat source. A two-step cure cycle was constructed to reduce excessive reaction peak at the initial stage and cycle time. An optimum cure cycle that could reduce cycle time by more than 29% compared to a one-step cure cycle by adjusting dwell temperature, heating rate, and dwell time was proposed. It was thus confirmed that an optimization of large area LED lens molding process was possible by using the present experiment and the finite element method.

  16. Simulation of fluid flow induced by opposing ac magnetic fields in a continuous casting mold

    Energy Technology Data Exchange (ETDEWEB)

    Chang, F.C.; Hull, J.R. [Argonne National Lab., IL (United States); Beitelman, L. [J. Mulcahy Enterprises, Whitby, ON (Canada)

    1995-07-01

    A numerical simulation was performed for a novel electromagnetic stirring system employing two rotating magnetic fields. The system controls stirring flow in the meniscus region of a continuous casting mold independently from the stirring induced within the remaining volume of the mold by a main electromagnetic stirrer (M-EMS). This control is achieved by applying to the meniscus region an auxiliary electromagnetic field whose direction of rotation is opposite to that of the main magnetic field produced by the M-EMS. The model computes values and spatial distributions of electromagnetic parameters and fluid flow in the stirred pools of mercury in cylindrical and square geometries. Also predicted are the relationships between electromagnetics and fluid flows pertinent to a dynamic equilibrium of the opposing stirring swirls in the meniscus region. Results of the numerical simulation compared well with measurements obtained from experiments with mercury pools.

  17. New numerical algorithm of gas-liquid two-phase flow considering characteristics of liquid metal during mold filling%基于充型过程金属液流动特点的气-液两相流算法模型

    Institute of Scientific and Technical Information of China (English)

    牛晓峰; 方钊; 梁伟; 侯华; 王红霞

    2014-01-01

    A new program is developed for gas-liquid two-phase mold filling simulation in casting. The gas fluid, the superheated liquid metal and the liquid metal containing solid grains are assumed to be governed by Navier-Stokes equations and solved through Projection method. The Level set method is used to track the gas-liquid interface boundary. In order to demonstrate the correctness of this new program for simulation of gas-liquid two-phase mold filling in casting, a benchmark filling experiment is simulated (this benchmark test is designed by XU and the filling process is recorded by a 16-mm film camera). The simulated results agree very well with the experimental results, showing that this new program can be used to properly predicate the gas-liquid two-phase mold filling simulation in casting.%针对在铸件充型过程中,金属液表现出不同的流动特点,含有固体颗粒的金属液具有不可压缩非牛顿流的流动特性,而过热金属液具有不可压缩牛顿流的流动特点,采用 Projection 方法求解气体、过热金属液和含有固体颗粒的金属液的速度场,用Level set方法来追踪气-液界面边界。为了验证计算模型,将模拟结果与实验结果(采用16 mm摄像机记录充型过程)进行比对,从而证明计算模型的正确性。

  18. 注射成形填充模拟的修正算法%Modified Algorithm for Simulation of Injection Molding Process

    Institute of Scientific and Technical Information of China (English)

    石建军; 成志强; 柳葆生

    2012-01-01

    为提高注射成形过程数值模拟结果的准确性,采用类似迎风法的概念,通过对平流方程作为填充状态控制方程而导致模拟失真原因的分析,提出了相应的数值修正算法.该方法在高效显式数值模拟算法和有限元软件基础上,通过对模型内流体速度场的系统性操作,削弱空气流动速度场对喂料填充的不真实影响,使得填充状态的输送更基于流动前沿面后部的流场作用,并对⊥型和L型模腔进行了数值仿真.结果表明:该方法能有效抑制填充流的失真现象,实现了在流动过程中流向发生大角度变化模腔的正确填充过程.%In order to improve the accuracy of numerical simulation for injection molding process, a notion similar to upwind method was introduced. As the governing equation of the filling state takes the form of an advection equation, distorted simulation result may be induced by the flow of air in the mold cavity. To solve the problem, a numerical correction method was proposed. This method weakens the adverse effect of air flow velocity field on the filling process, by modifying the fluid velocity field through systematic operations based on an efficient explicit algorithm and finite element software. Thus, the advection of filling state mainly depends on the flow field behind the filling front. In addition, a numerical simulation was made in mold cavities of shapes ⊥ and L to verify the effectiveness of the method. The result shows that the proposed method can suppress the distortion phenomenon of filling flow effectively, and ensure a correct filling process in complex channels, in which the flow directions have large-angel changes.

  19. Prediction of fiber orientation in injection-molded parts using three-dimensional simulations

    Science.gov (United States)

    Wang, Jin; Cook, Peter; Bakharev, Alex; Costa, Franco; Astbury, David

    2016-03-01

    The Folgar-Tucker (F-T) model is widely used in most commercial software packages and research programs to predict the fiber orientation distribution in injection-molded fiber-reinforced composites. However, experimental measurements reveal that the F-T model normally results in much higher fiber alignment than observed because it tends to over-predict the orientation kinetics. The Reduced Strain Closure (RSC) model was developed, based on the F-T model, to capture the slow orientation kinetics in an objective fashion. Previous studies demonstrate that t he RSC model yields good agreement of fiber orientation with experimental measurements in shell element simulations using the Hele-Shaw flow approximation. This paper focuses on the RSC model in three-dimensional finite element simulations. The fiber orientation predictions were compared to the orientation measurements in a number of injection-molded parts of various shapes and dimensions and molded with various injection speeds. The RSC model is able to capture the orientation distribution through the part thickness and the average orientation trends along the flow length without the need to tailor the inlet orientation condition to pre-existing data.

  20. Analysis of filling process of Ti6Al4V alloy melt poured in permanent mold during centrifugal casting process

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    Ti6Al4V hip joint was foundered and the filling process of the melt poured in permanent mould during the centrifugal casting process was analyzed and the mathematical model of the filling process was established. Furthermore, the mathematical model was validated with a wax-model experiment. Calculating results show that the centrifugal field has an important influence on the filling process and the melt fills the mould with variational cross-sectional area and inclined angle. The cross-sectional area is in inverse proportion to the filling speed and its decreasing speed becomes fast with increasing rotating speed. The tangential value of the melt cross-sectional free-surface inclined angle is in direct proportion to the filling speed and the inclined angle increases with the filling length. Change curves of the cross-sectional inclined angle and area were obtained by the wax-model experiment when the rotating speeds were 60, 90 and 120  r/min respectively, which shows that the mathematical model is consistent with the experimental results.

  1. Numerical simulation and experimental investigation of two filling methods in vertical centrifugal casting

    Institute of Scientific and Technical Information of China (English)

    WU Shi-ping; LI Chang-yun; GUO Jing-jie; SU Yan-qing; LEI Xiu-qiao; FU Heng-zhi

    2006-01-01

    A mathematical model of the centrifugal filling process was established. The calculated results show that the centrifugal field has an important influence on the filling process. Moreover, the process of liquid flow and the location of free surface in sprue were simulated based on the Solution Algorithm-Volume of Fraction (SOLA-VOF) technique. In order to verify the mathematical model and computational results, hydraulic simulation experiment was carried out. The results of experiments and numerical simulation indicate the accuracy of mathematical model. Two kinds of filling methods were investigated and the results show that the bottom filling is better than the top filling that can achieve stable filling and reduce defects.

  2. Simulating Smoke Filling in Big Halls by Computational Fluid Dynamics

    Directory of Open Access Journals (Sweden)

    W. K. Chow

    2011-01-01

    Full Text Available Many tall halls of big space volume were built and, to be built in many construction projects in the Far East, particularly Mainland China, Hong Kong, and Taiwan. Smoke is identified to be the key hazard to handle. Consequently, smoke exhaust systems are specified in the fire code in those areas. An update on applying Computational Fluid Dynamics (CFD in smoke exhaust design will be presented in this paper. Key points to note in CFD simulations on smoke filling due to a fire in a big hall will be discussed. Mathematical aspects concerning of discretization of partial differential equations and algorithms for solving the velocity-pressure linked equations are briefly outlined. Results predicted by CFD with different free boundary conditions are compared with those on room fire tests. Standards on grid size, relaxation factors, convergence criteria, and false diffusion should be set up for numerical experiments with CFD.

  3. Numerical simulation of the interface molten metal air in the shot sleeve chambre and mold cavity of a die casting machine

    Science.gov (United States)

    Korti, Abdel Illah Nabil; Abboudi, Said

    2011-11-01

    The objective of this study relates to the numerical simulation of the free surface during the two-dimensional flow and solidification of aluminum in the horizontal cylinder and mold cavity of the high pressure die casting HPDC machine with cold chamber. The flow is governed by the Navier-Stokes equations (the mass and the momentum conservations) and solved in the two phase's liquid aluminum and air. The tracking of the free surface is ensured by the VOF method. The equivalent specific heat method is used to solve the phase change heat transfer problem in the solidification process. Considering the displacement of the plunger, the geometry of the problem is variable and the numerical resolution uses a dynamic grid. The study examines the influence of the plunger speed on the evolution of the interface aluminum liquid-air profile, the mass of air imprisoned and the stream function contours versus time. Filling of a mold is an essential part of HPDC process and affects significantly the heat transfer and solidification of the melt. For this reason, accurate prediction of the temperature field in the system can be achieved only by including simulation of filling in the analysis.

  4. Influence of Rubber Concentration on Angular deformation in Injection Molded Parts of Talc and Rubber Filled Polypropylene

    Science.gov (United States)

    Takahara, Tadayoshi; Koyama, Kiyohito

    The most popular resin material for automotive plastic parts is polypropylene, which includes talc for stiffness and heat-resistance and rubber for impact-resistance. The anisotropic thermal expansion coefficient is well documented for talc reinforced polypropylene, but there are very few technical papers for warpage. Therefore, using this kind of material and molding with an L-shaped cross section, the influence of rubber concentration on corner deformation was discussed in this study. The results of this study are as follows 1) L-shaped cross section specimens show that the corner deformation increases linearly in proportion to the increase of rubber concentration. 2) Plane shape specimens show that the shrinkage rates in the planar direction decrease linearly and the shrinkage rates in the thickness direction increase linearly. 3) The strains in each rubber concentration are calculated using Hooke's Law. This force that induces corner deformation is assumed as the shrinkage difference between the planar and thickness directions. The tendencies of calculated strains are qualitatively consistent with measured corner deformations. 4) The reason why corner deformation decreases linearly to rubber concentration is due to the fact that the shrinkage difference between the planar and thickness directions increases and the fact that the flexural modulus decreases linearly.

  5. Large Eddy Simulation of Transient Flow, Solidification, and Particle Transport Processes in Continuous-Casting Mold

    Science.gov (United States)

    Liu, Zhongqiu; Li, Linmin; Li, Baokuan; Jiang, Maofa

    2014-07-01

    The current study developed a coupled computational model to simulate the transient fluid flow, solidification, and particle transport processes in a slab continuous-casting mold. Transient flow of molten steel in the mold is calculated using the large eddy simulation. An enthalpy-porosity approach is used for the analysis of solidification processes. The transport of bubble and non-metallic inclusion inside the liquid pool is calculated using the Lagrangian approach based on the transient flow field. A criterion of particle entrapment in the solidified shell is developed using the user-defined functions of FLUENT software (ANSYS, Inc., Canonsburg, PA). The predicted results of this model are compared with the measurements of the ultrasonic testing of the rolled steel plates and the water model experiments. The transient asymmetrical flow pattern inside the liquid pool exhibits quite satisfactory agreement with the corresponding measurements. The predicted complex instantaneous velocity field is composed of various small recirculation zones and multiple vortices. The transport of particles inside the liquid pool and the entrapment of particles in the solidified shell are not symmetric. The Magnus force can reduce the entrapment ratio of particles in the solidified shell, especially for smaller particles, but the effect is not obvious. The Marangoni force can play an important role in controlling the motion of particles, which increases the entrapment ratio of particles in the solidified shell obviously.

  6. Modeling and Simulation of Fiber Orientation in Injection Molding of Polymer Composites

    Directory of Open Access Journals (Sweden)

    Jang Min Park

    2011-01-01

    Full Text Available We review the fundamental modeling and numerical simulation for a prediction of fiber orientation during injection molding process of polymer composite. In general, the simulation of fiber orientation involves coupled analysis of flow, temperature, moving free surface, and fiber kinematics. For the governing equation of the flow, Hele-Shaw flow model along with the generalized Newtonian constitutive model has been widely used. The kinematics of a group of fibers is described in terms of the second-order fiber orientation tensor. Folgar-Tucker model and recent fiber kinematics models such as a slow orientation model are discussed. Also various closure approximations are reviewed. Therefore, the coupled numerical methods are needed due to the above complex problems. We review several well-established methods such as a finite-element/finite-different hybrid scheme for Hele-Shaw flow model and a finite element method for a general three-dimensional flow model.

  7. Numerical simulation and analysis of mould filling process in lost foam casting

    Institute of Scientific and Technical Information of China (English)

    Jiang Junxia; Wu Zhichao; Chen Liliang; Hao Jing

    2008-01-01

    In lost foam casting (LFC) the foam pattern is the key criterion, and the filling process is crucial to ensure the high quality of the foam pattern. Filling which lacks uniformity and denseness will cause various defects and affect the surface quality of the casting. The influential factors of the filling process are realized in this research. Optimization of the filling process, enhancement of efficiency, decrease of waste, etc., are obtained by the numerical simulation of the filling process using a computer. The equations governing the dense gas-solid two-phase flow are established, and the physical significance of each equation is discussed. The Euler/Lagrange numerical model is used to simulate the fluid dynamic characteristics of the dense two-phase flow during the mould filling process in lost foam casting. The experiments and numerical results showed that this method can be a very promising tool in the mould filling simulation of beads' movement.

  8. 基于MoldFlow的手机后盖注射成型模拟分析%The Simulation Analysis of Injection Molding of Mobile Phone Back Cover Based on MoldFlow

    Institute of Scientific and Technical Information of China (English)

    刘玲; 王樑

    2012-01-01

    Along with the rapid development of electronic communication technology and the widely application of mobile phones, it is required to shorten the production period,to lower production cost and to increase the competitive power. The traditional design method obviously cannot satisfy the requirement of production, but the application of MoldFlow software can solve it,which can analysis the product structure reasonably, to realize the optimization design of the parts; which can formulate rational production process parameters, such as the filling time and the holding time etc; which can analyze the warping,bubble, lack of material common defects,to optimize mold design; which can design the mold structure, such as reasonable gating system, to shorten the cycle of mold design,to reduce production cost and enhance the competitiveness of enterprises.%随着电子通讯技术的飞速发展,手机的普遍应用,要求生产厂家缩短生产周期,降低生产成本提高竞争力。传统的设计方法显然不能满足生产的需要,应用MoldFlow软件对塑件结构进行合理性分析,实现塑件的优化设计;利用模拟成型制定合理的生产工艺参数如填充时间、保压时间等;对成型过程中出现的翘曲、气泡、缺料等常见缺陷进行分析,优化模具设计;设计出合理的浇注系统,缩短模具设计的周期,优化了模具设计,降低了生产成本,提高企业竞争力。

  9. Simulation of the Vacuum Assisted Resin Transfer Molding (VARTM) process and the development of light-weight composite bridging

    Science.gov (United States)

    Robinson, Marc J.

    A continued desire for increased mobility in the aftermath of natural disasters, or on the battlefield, has lead to the need for improved light-weight bridging solutions. This research investigates the development of a carbon/epoxy composite bridging system to meet the needs for light-weight bridging. The research focuses on two main topics. The first topic is that of processing composite structures and the second is the design and testing of these structures. In recent years the Vacuum Assisted Resin Transfer Molding (VARTM) process has become recognized as a low-cost manufacturing alternative for large Fiber Reinforced Polymer (FRP) composite structures for civil, military, and aerospace applications. The success of the VARTM process (complete wet-out) is very sensitive to the resin injection strategy used and the proper placement of flow distribution materials and inlet and vacuum ports. Predicting the flow front pattern, the time required for infusing a part with resin, and the time required to bleed excess resin at the end of filling, is critical to ensure that the part will become completely impregnated and desired fiber volume fractions achieved prior to the resin gelling (initiation of cure). In order to eliminate costly trial and error experiments to determine the optimal infusion strategy, this research presents a simulation model which considers in-plane flow as well as flow through the thickness of the preform. In addition to resin filling, the current model is able to simulate the bleeding of resin at the end of filling to predict the required bleeding time to reach desired fiber volume fractions for the final part. In addition to processing, the second portion of the dissertation investigates the design and testing of composite bridge deck sections which also serve as short-span bridging for gaps up to 4 m in length. The research focuses on the design of a light-weight core material for bridge decking as well as proof loading of short-span bridge

  10. CFD simulations of filling and emptying of hydrogen tanks

    OpenAIRE

    MELIDEO DANIELE; BARALDI DANIELE; ACOSTA IBORRA BEATRIZ; ORTIZ CEBOLLA RAFAEL; MORETTO PIETRO

    2016-01-01

    During the filling of hydrogen tanks high temperatures can be generated inside the vessel because of the gas compression while during the emptying low temperatures can be reached because of the gas expansion. The design temperature range goes from 40 C to 85 C. Temperatures outside that range could affect the mechanical properties of the tank materials. CFD analyses of the filling and emptying processes have been performed in the HyTransfer project. To assess the accuracy of the CFD model the...

  11. Influence of Talc Concentration on Angular Deformation in Injection Molded Parts of Talc and Rubber Filled Polypropylene

    Science.gov (United States)

    Takahara, Tadayoshi; Koyama, Kiyohito

    Polypropylene (PP), filled with talc and rubber, is one of the most popular resins used for automotive plastic parts. The influence of talc concentration in PP compounds on the angular deformation of L-shaped specimens is discussed. The experimental and analytical results are as follows 1) Angular deformation increases sharply with increasing talc concentration until approximately 10 wt% of talc. The angle reaches a maximum at 10 wt% of talc, and then decreases above the critical concentration. 2) The shrinkage in the in-plane direction of the plate specimens shows a decrease until the talc concentration reaches approximately 10 wt%, and then becomes constant above the critical concentration. On the other hand, the shrinkage in the thickness direction increases sharply until talc concentration approaches 5 %, and then decreases gradually above that concentration. 3) The strains for each sample are calculated using Hooke's Law. In this case, the force that induces angular deformation is assumed to be the difference of shrinkage between the thickness and in-plane directions. The tendencies of calculated strains are quite qualitatively consistent with measured angular deformations. 4) A deformation angle peak can be explained by the difference of shrinkage in the thickness and in-plane directions, which increase sharply until 5 wt% talc concentration. Above this concentration, shrinkage will remain constant despite an increasing flexural modulus.

  12. Large Eddy Simulation of Transient Flow and Inclusions Transport in Continuous Casting Mold under Different Electromagnetic Brakes

    Science.gov (United States)

    Liu, Zhongqiu; Li, Linmin; Li, Baokuan

    2016-08-01

    A mathematical model has been developed to analyze transient fluid flow and inclusions transport in a slab continuous casting mold, considering the effects of electromagnetic brake (EMBr) arrangement and magnetic field strength. Transient flow of molten steel in the mold is calculated by using the large eddy simulation. The electromagnetic force is incorporated into the Navier-Stokes equation. The transport of inclusion inside the mold is calculated using the Lagrangian approach based on the transient flow field. The predicted results of this model are compared with the measurements of the ultrasonic testing of the rolled steel plates and the water model experiments. The transient asymmetrical flow pattern and inclusion transport inside the mold exhibits satisfactory agreement with the corresponding measurements. With electromagnetic brake effect, the velocities around the braking region are significantly suppressed, and the recirculating flow in the lower part drops and tends to develop a plug-like flow. The EMBr arrangement has an insignificant effect on the overall removal fraction of inclusions, especially for larger inclusions. The inclusion removal rate for the flow-control mold (FCM arrangement) reduces instead compared with no EMBr, especially for smaller inclusions.

  13. Relevant Aspects in Modeling of Micro-injection Molding

    Science.gov (United States)

    Nguyen-Chung, Tham; Jüttner, Gábor; Pham, Tung; Mennig, Günter

    2008-07-01

    Growing demands in the manufacturing of micro and precision components in plastics require new concepts for molding machines and micro molds on the one hand. On the other hand, a deeper understanding of the filling and solidification process in a micro mold is indispensable. In this work, the filling process of a micro spiral was analyzed by modeling the compressible flow using pressure dependent viscosity and adjusted heat transfer coefficients. At the same time, experimental filling studies were carried out on an accurately controlled micro-injection molding machine. Based on the relationship between the injection pressure and the filling degree, essential factors for the quality of the simulation can be identified. It can be shown that the flow behavior of the melt in a micro cavity of high aspect ratio is extremely dependent on the melt compressibility in the injection cylinder which needs to be considered in the simulation in order to predict an accurate flow rate. Moreover, the heat transfer coefficients between the melt and the mold wall vary significantly when changing cavity thickness and processing conditions. It is believed that a pressure dependent model for the heat transfer coefficient would be able to improve the quality of the process simulation.

  14. Influence of the power law index on the fiber breakage during injection molding by numerical simulations

    Science.gov (United States)

    Desplentere, Frederik; Six, Wim; Bonte, Hilde; Debrabandere, Eric

    2013-04-01

    In predictive engineering for polymer processes, the proper prediction of material microstructure from known processing conditions and constituent material properties is a critical step forward properly predicting bulk properties in the finished composite. Operating within the context of long-fiber thermoplastics (LFT, length > 15mm) this investigation concentrates on the influence of the power law index on the final fiber length distribution within the injection molded part. To realize this, the Autodesk Simulation Moldflow Insight Scandium 2013 software has been used. In this software, a fiber breakage algorithm is available from this release on. Using virtual material data with realistic viscosity levels allows to separate the influence of the power law index on the fiber breakage from the other material and process parameters. Applying standard settings for the fiber breakage parameters results in an obvious influence on the fiber length distribution through the thickness of the part and also as function of position in the part. Finally, the influence of the shear rate constant within the fiber breakage model has been investigated illustrating the possibility to fit the virtual fiber length distribution to the possible experimentally available data.

  15. Silicon micro-mold

    Science.gov (United States)

    Morales, Alfredo M.

    2006-10-24

    The present invention describes a method for rapidly fabricating a robust 3-dimensional silicon-mold for use in preparing complex metal micro-components. The process begins by depositing a conductive metal layer onto one surface of a silicon wafer. A thin photoresist and a standard lithographic mask are then used to transfer a trace image pattern onto the opposite surface of the wafer by exposing and developing the resist. The exposed portion of the silicon substrate is anisotropically etched through the wafer thickness down to conductive metal layer to provide an etched pattern consisting of a series of rectilinear channels and recesses in the silicon which serve as the silicon micro-mold. Microcomponents are prepared with this mold by first filling the mold channels and recesses with a metal deposit, typically by electroplating, and then removing the silicon micro-mold by chemical etching.

  16. Computer Simulation on Low Pressure Plaster Mold Casting Process for ZL205A Alloy%铸铝ZL205A石膏型低压铸造工艺计算机模拟

    Institute of Scientific and Technical Information of China (English)

    王狂飞; 周志杰; 王有超; 历长云

    2011-01-01

    利用View Cast软件对某低压石膏型ZL205A铸件铸造过程进行了计算机模拟,获得了铸件充型、凝固过程温度随时间变化的分布图,并对可能产生缩孔、缩松缺陷的位置进行了预测.模拟结果显示,低压铸造充型过程中降温不明显,而熔液流经大截面时产生速度降;凝固过程中,熔体自顶向下形成逐层递增的温度梯度,利于熔体补缩.模拟结果与实际生产情况吻合较好.%The low pressure plaster mold casting process for ZL205A alloy was simulated by View Cast software, and the relationship between cast temperature and time were obtained in casting solidification and filling, and the location of the shrinkage defects were also forecasted. The results show that the temperature of liquid metal invisibly drops during mold filling, and the melt filling rate decreases with the increase of cross-section with the ingate, and increasing temperature gradient of melt from up to down can contribute to the shrinkage elimination of casting during solidifying. The simulations reasonably agree well with production results.

  17. Molded optics design and manufacture

    CERN Document Server

    Schaub, Michael

    2007-01-01

    While several available texts discuss molded plastic optics, none provide information on all classes of molded optics. Filling this gap, Molded Optics: Design and Manufacture presents detailed descriptions of molded plastic, glass, and infrared optics. Since an understanding of the manufacturing process is necessary to develop cost-effective, producible designs, the book extensively covers various manufacturing methods, design guidelines, trade-offs, best practices, and testing of critical parameters. It also discusses topics that often arise when designing systems with molded optics, such as

  18. Flexible Space-Filling Designs for Complex System Simulations

    Science.gov (United States)

    2013-06-01

    Systems Engineering Approved by: _________________________________________________________ Peter Denning, Chair, Department of Computer Science... Kirby , 2001; and Baker, Mavris, & Schrage, 2002). These meta-models approximate the underlying dependencies of the simulation output responses to the...Journal of Graphical and Statistics, 12, 512–530. Kirby , M. R. (2001). A methodology for technology identification, evaluation, and selection in

  19. Mold Allergy

    Science.gov (United States)

    ... Ask the Allergist Health Professionals Partners Media Donate Allergies Mold Allergy What Is a Mold Allergy? If you have an allergy that occurs over ... basement. What Are the Symptoms of a Mold Allergy? The symptoms of mold allergy are very similar ...

  20. Numerical simulation on heat transfer performance of vertical U-tube with different borehole fill materials

    Institute of Scientific and Technical Information of China (English)

    2006-01-01

    Heat exchange performance of vertical U-tube heat exchanger was studiedwith two different borehole fill materials and CFD software. Borehole surface temperature and water temperature distribution were simulated on the condition of continuous operation for 8 h in winter with inlet water temperature being 10 ℃. The results show that there is no obvious difference on heat exchanger performance between the two different borehole fill materials.

  1. Simulation of plasma filled hemispherical cavity as dielectric resonator antenna

    Science.gov (United States)

    Trenchev, G.; Kissóvski, Zh

    2016-10-01

    Plasma antennas are becoming an increasingly interesting research topic because of their uncommon characteristics. They are highly configurable, can be turned on and off rapidly, and exhibit lower thermal noise compared to metal antennas. In recent years, research has been conducted on cylindrical plasma columns sustained by DC, RF or microwave field, and their application as leaky wave antennas or as regular monopole antennas. Dielectric resonator antennas (DRA) with high dielectric permittivity are known for their small size and excellent operating characteristics for modern mobile communications (WiMAX, LTE). Hemispherical dielectric resonator antennas are characterized by simple shape, high radiation efficiency and wide bandwidth. Hemispherical DRA with a low density weakly ionized plasma as dielectric material will combine the positive features of plasma and dielectric antennas, and is particularly interesting, as antennas of this type have not been studied yet. The hemispherical plasma antenna is simulated with Ansoft HFSS in the microwave S-band. Obtained radiation pattern and bandwidth show the advantages of hemispherical plasma antennas for future communication technology.

  2. Simulation of mechanical behavior and optimization of simulated injection molding process for PLA based antibacterial composite and nanocomposite bone screws using central composite design.

    Science.gov (United States)

    Heidari, Behzad Shiroud; Oliaei, Erfan; Shayesteh, Hadi; Davachi, Seyed Mohammad; Hejazi, Iman; Seyfi, Javad; Bahrami, Mozhgan; Rashedi, Hamid

    2017-01-01

    In this study, injection molding of three poly lactic acid (PLA) based bone screws was simulated and optimized through minimizing the shrinkage and warpage of the bone screws. The optimization was carried out by investigating the process factors such as coolant temperature, mold temperature, melt temperature, packing time, injection time, and packing pressure. A response surface methodology (RSM), based on the central composite design (CCD), was used to determine the effects of the process factors on the PLA based bone screws. Upon applying the method of maximizing the desirability function, optimization of the factors gave the lowest warpage and shrinkage for nanocomposite PLA bone screw (PLA9). Moreover, PLA9 has the greatest desirability among the selected materials for bone screw injection molding. Meanwhile, a finite element analysis (FE analysis) was also performed to determine the force values and concentration points which cause yielding of the screws under certain conditions. The Von-Mises stress distribution showed that PLA9 screw is more resistant against the highest loads as compared to the other ones. Finally, according to the results of injection molding simulations, the design of experiments (DOE) and structural analysis, PLA9 screw is recommended as the best candidate for the production of biomedical materials among all the three types of screws.

  3. Die Casting Mold Design of the Thin-walled Aluminum Case by Computational Solidification Simulation

    Institute of Scientific and Technical Information of China (English)

    Young-Chan Kim; Chang-Seog Kang; Jae-Ik Cho; Chang-Yeol Jeong; Se-Weon Choi; Sung-Kil Hong

    2008-01-01

    Recently, demand for the lightweight alloy in electric/electronic housings has been greatly increased. However, among the lightweight alloys, aluminum alloy thin-walled die casting is problematic because it is quite difficult to achieve sufficient fluidity and feedability to fill the thin cavity as the wall thickness becomes less than 1 mm. Therefore, in this study, thin-walled die casting of aluminum (Al-Si-Cu alloy: ALDC 12) in size of notebook computer housing and thickness of 0.8 mm was investigated by solidification simulation (MAGMA soft) and actual casting experiment (Buhler Evolution B 53D). Three different types of gating design, finger, tangential and split type with 6 vertical runners, were simulated and the results showed that sound thin-walled die casting was possible with tangential and split type gating design because those gates allowed aluminum melt to flow into the thin cavity uniformly and split type gating system was preferable gating design comparing to tangential type gating system at the point of view of soundness of casting and distortion generated after solidification. Also, the solidification simulation agreed well with the actual die-casting and the casting showed no casting defects and distortion.

  4. Injection molding micro patterns with high aspect ratio using a polymeric flexible stamper

    Directory of Open Access Journals (Sweden)

    2011-11-01

    Full Text Available Poor filling occurs during the injection molding process of micro- or nano- scale patterns mainly because the hot polymer melt rapidly cools and its skin quickly solidifies upon contact with the mold surface. In this study, it is proposed to use Polyethylene terephthalate (PET film coated with patterned polyurethane acrylate (PUA as an effective thermal barrier. It can significantly hinder heat transfer into the mold during the molding process and thus may keep the melt viscosity low for longer duration. As a result, the replication would be improved not only during the filling phase but also during the packing phase. In order to verify the validity of the use of polymeric stamper, the melt-film interface temperature was evaluated by numerical simulation. Experimental results indicated that patterns possessing widths within the range of one to tens of micrometers and a height of approximately 10 µm were successfully filled and demolded.

  5. Numerical simulation of die filling behavior of AZ91D in the semisolid process

    Directory of Open Access Journals (Sweden)

    Zhu Guanglei

    2010-05-01

    Full Text Available In this work, numerical simulation of the die filling and solidification process of AZ91D semisolid alloy was investigated to produce a thin walled connecting rod demanding a high dimensional precision. The Carreau viscosity model was implemented to simulate the flow behavior of semisolid slurry during the filling. The fitted constants for the Carreau model were used to verify the simulation results. The predicted results from this model were in good agreement with the experimental results. Then the verified Carreau model was designed to predict die filling, casting defects and casting process. It was found that the predicted results had a good correlation with those in the experiment. The optimum parameters were obtained with a slurry temperature of 590 ℃, a die temperature of 250 ℃ and an injection velocity of 2 m/s.

  6. Simulations of indirectly driven gas-filled capsules at the National Ignition Facility

    Energy Technology Data Exchange (ETDEWEB)

    Weber, S. V.; Casey, D. T.; Eder, D. C.; Pino, J. E.; Smalyuk, V. A.; Remington, B. A.; Rowley, D. P.; Yeamans, C. B.; Tipton, R. E.; Barrios, M.; Benedetti, R.; Berzak Hopkins, L.; Bleuel, D. L.; Bond, E. J.; Bradley, D. K.; Caggiano, J. A.; Callahan, D. A.; Cerjan, C. J.; Clark, D. S.; Divol, L. [Lawrence Livermore National Laboratory, Livermore, California 94550 (United States); and others

    2014-11-15

    Gas-filled capsules imploded with indirect drive on the National Ignition Facility have been employed as symmetry surrogates for cryogenic-layered ignition capsules and to explore interfacial mix. Plastic capsules containing deuterated layers and filled with tritium gas provide a direct measure of mix of ablator into the gas fuel. Other plastic capsules have employed DT or D{sup 3}He gas fill. We present the results of two-dimensional simulations of gas-filled capsule implosions with known degradation sources represented as in modeling of inertial confinement fusion ignition designs; these are time-dependent drive asymmetry, the capsule support tent, roughness at material interfaces, and prescribed gas-ablator interface mix. Unlike the case of cryogenic-layered implosions, many observables of gas-filled implosions are in reasonable agreement with predictions of these simulations. Yields of TT and DT neutrons as well as other x-ray and nuclear diagnostics are matched for CD-layered implosions. Yields of DT-filled capsules are over-predicted by factors of 1.4–2, while D{sup 3}He capsule yields are matched, as well as other metrics for both capsule types.

  7. Simulation and Experimental Determination of Technological Liquid Molding Parameters of Tubing Basalt Insulation

    Directory of Open Access Journals (Sweden)

    Yu. V. Badanina

    2015-01-01

    Full Text Available The article is dedicated to one of the most important and urgent tasks in mechanical engineering development - the creation of low-density and environmentally-friendly thermoinsulation from available cheap basalt fibers for products to operate at temperatures up to 700°C.One of the most effective applications of such thermo-insulation is to develop and provide highly porous coatings from short basalt fibers by liquid filtration for tubing (T to supply superheated up to 420° C steam under pressure of 35 MPa in the deep layers with severe highviscosity oil. Tubing with the short low-density basalt insulation can be used for a greater depth than the vacuum-insulated tubing, which are also called "thermo-cases", and do not fully meet business needs for long-term reliability of oil vacuum tubes, too large mass per unit length of their design and, as a consequence, the impossibility to use such pipes for deep wells.The aim of the work is to simulate a liquid filtration process of short fibers and determine technological parameters of producing thermal insulation coatings of tubing pipes from basalt fibers and mineral binder shaped as cylinders and cylindrical shells. The paper proposes a mathematical model of free filtration deposition of short fibers from liquid slurry, which describes dynamics of creating thermal insulation products and allows us to determine the rational parameters of their manufacturing process. It shows methods to improve the products quality while forming the thermal insulation by filtration through additional vacuum deposition of a filtrate chamber and the final prepressing of sediment layer, giving dimensions and shape to the final product.The paper defines a prescription hydro mass composition. It shows that to increase the compressive strength of highly fibrous rings and cylindrical shells it is necessary to use based on oxide А12O3 5-7% by weight mineral binder, which fixes basalt fibers in places of their contacts. It

  8. A new approach for the validation of filling simulations in micro injection moulding

    DEFF Research Database (Denmark)

    Gava, Alberto; Tosello, Guido; Lucchetta, Giovanni;

    2007-01-01

    to be improved. The main objective of this work is to evaluate whether the present numerical codes are suitable to characterize melt flow patterns in a micro cavity. In order to test the accuracy of the software, real and simulated experiments were performed and used to investigate the filling of a micro moulded...

  9. Effect of filling on the compressibility of carbon nanotubes: predictions from molecular dynamics simulations.

    Science.gov (United States)

    Trotter, Heather; Phillips, Roshenda; Ni, Boris; Hu, Yanhong; Sinnott, Susan B; Mikulski, Paul T; Harrison, Judith A

    2005-04-01

    The compressibility of filled and empty (10, 10) carbon nanotubes (CNTs) is examined using classical molecular dynamics simulations. The filled nanotubes contain C60, CH4, Ne, n-C4H10, and n-C4H7 molecules that are covalently cross-linked to the inner CNT walls. In addition, nanotubes filled with either a hydrogen-terminated carbon nanowire or a carbon nanotube of comparable diameter is also considered. The forces on the atoms are calculated using a many-body reactive empirical bond-order potential and the adaptive intermolecular reactive empirical bond-order potential for hydrocarbons. The butane-filled system shows a unique yielding behavior prior to buckling that has not been observed previously. Cross-linking the molecules to the inner CNT walls is not predicted to affect the stiffness of the filled nanotube systems and removes the yielding response. The mechanical response of the nanowire filled CNT is remarkably similar to the response of the similarly sized multiwalled CNT.

  10. MECHANICAL PROPERTIES OF INJECTION-MOLDED FOAMED WHEAT STRAW FILLED HDPE BIOCOMPOSITES: THE EFFECTS OF FILLER LOADING AND COUPLING AGENT CONTENTS

    Directory of Open Access Journals (Sweden)

    Fatih Mengeloglu,

    2012-06-01

    Full Text Available This study investigated the effect of filler loading and coupling agent contents on the densities and mechanical properties of injection-molded foamed biocomposites. Biocomposite pellets were manufactured using wheat straw flour, maleic anhydrite grafted polyethylene (MAPE, paraffin wax, and high-density polyethylene (HDPE with an extrusion process. Pellets and the chemical foaming agent (azodicarbonamide were dry-mixed and foamed in an injection-molding machine. Densities and mechanical properties of the foamed biocomposites samples were measured and analyzed using central composite design (CCD. The results showed that both filler loading and coupling agent contents affected the density and mechanical properties of foamed biocomposites. Densities in the range of 0.57 to 0.81 gr cm-3 were achieved. Best results were obtained when less than 20% wheat straw flour and 1% coupling agent content were used. The flexural modulus and tensile modulus of foamed biocomposites were improved with increasing filler loading. However, flexural strength, tensile strength, elongation at break, and impact strength values were diminished. The tensile strength of the biocomposites was positively affected by CA contents, but other mechanical properties were not affected by it. Overall, injection molded foamed biocomposites with moderate mechanical properties were produced.

  11. Coupled discrete element and smoothed particle hydrodynamics simulations of the die filling process

    Science.gov (United States)

    Breinlinger, Thomas; Kraft, Torsten

    2016-11-01

    Die filling is an important part of the powder compaction process chain, where defects in the final part can be introduced—or prevented. Simulation of this process is therefore a goal for many part producers and has been studied by some researchers already. In this work, we focus on the influence of the surrounding air on the powder flow. We demonstrate the implementing and coupling of the discrete element method for the granular powder and the smoothed particle hydrodynamics method for the gas flow. Application of the method to the die filling process is demonstrated.

  12. Simulations of fill tube effects on the implosion of high-foot NIF ignition capsules

    Science.gov (United States)

    Dittrich, T. R.; Hurricane, O. A.; Berzak-Hopkins, L. F.; Callahan, D. A.; Casey, D. T.; Clark, D.; Dewald, E. L.; Doeppner, T.; Haan, S. W.; Hammel, B. A.; Harte, J. A.; Hinkel, D. E.; Kozioziemski, B. J.; Kritcher, A. L.; Ma, T.; Nikroo, A.; Pak, A. E.; Parham, T. G.; Park, H.-S.; Patel, P. K.; Remington, B. A.; Salmonson, J. D.; Springer, P. T.; Weber, C. R.; Zimmerman, G. B.; Kline, J. L.

    2016-05-01

    Encouraging results have been obtained using a strong first shock during the implosion of carbon-based ablator ignition capsules. These “high-foot” implosion results show that capsule performance deviates from 1D expectations as laser power and energy are increased. A possible cause of this deviation is the disruption of the hot spot by jets originating in the capsule fill tube. Nominally, a 10 μm outside diameter glass (SiO2) fill tube is used in these implosions. Simulations indicate that a thin coating of Au on this glass tube may lessen the hotspot disruption. These results and other mitigation strategies will be presented.

  13. Numerical simulation and analysis of mould filling process in lost foam casting

    OpenAIRE

    Jiang Junxia; Wu Zhichao; Chen Liliang

    2008-01-01

    In lost foam casting (LFC) the foam pattern is the key criterion, and the filling process is crucial to ensure the high quality of the foam pattern. Filling which lacks uniformity and denseness will cause various defects and affect the surface quality of the casting. The infl uential factors of the fi lling process are realized in this research. Optimization of the fi lling process, enhancement of effi ciency, decrease of waste, etc., are obtained by the numerical simulation of the fi lling p...

  14. Mechanical Behavior of Carbon Nanotubes Filled With Metal Nanowires By Atomistic Simulations

    Science.gov (United States)

    Danailov, Daniel; Keblinski, Pawel; Pulickel, Ajayan; Nayak, Saroj

    2002-03-01

    Using molecular dynamics simulations we studied mechanical behavior of (10,10) carbon nanotubes filled with a crystalline fcc metal wires. The interatomic interactions were described by a combination of Terfoff’s bond-order potential for carbon, embedded atom method (EAM) potential for metal and pair potential for carbon-metal interactions. The elastic properties, as well as failure mechanism were determined by simulating three point bending test, by pressing the center and the ends of relatively long tube in determined relatively small ring areas. We observed that following elastic response, at larger deformation, the metal wire yields well before the carbon bonding is affected. The behavior of filled tubes was compared with that of hollow tubes. Interesting is thet the hollow carbon (10,10) nanotube is more strong elastically than the same tube filled with Au-metal nanowire. We also simulated indentation of filled tubes residing on a hard flat surface. Similarly as in the bending test, metal wire yields first, is cut in between hard cylinder and hard plane and pushed away from under the indenter. Upon further increase of the indentation force, carbon tube is broken and forms two open ends that are rapidly zipped around the cut metal wire. Remarkably, the shape of the zipped tube ends strong depend of the speed of the punching of the tube. This result imply a possibility of designing tubes with various closed end shapes with applicationusing in the nanoscale manipulation procedures used for production.

  15. Simulation of beam-induced plasma in gas-filled rf cavities

    Science.gov (United States)

    Yu, Kwangmin; Samulyak, Roman; Yonehara, Katsuya; Freemire, Ben

    2017-03-01

    Processes occurring in a radio-frequency (rf) cavity, filled with high pressure gas and interacting with proton beams, have been studied via advanced numerical simulations. Simulations support the experimental program on the hydrogen gas-filled rf cavity in the Mucool Test Area (MTA) at Fermilab, and broader research on the design of muon cooling devices. space, a 3D electromagnetic particle-in-cell (EM-PIC) code with atomic physics support, was used in simulation studies. Plasma dynamics in the rf cavity, including the process of neutral gas ionization by proton beams, plasma loading of the rf cavity, and atomic processes in plasma such as electron-ion and ion-ion recombination and electron attachment to dopant molecules, have been studied. Through comparison with experiments in the MTA, simulations quantified several uncertain values of plasma properties such as effective recombination rates and the attachment time of electrons to dopant molecules. Simulations have achieved very good agreement with experiments on plasma loading and related processes. The experimentally validated code space is capable of predictive simulations of muon cooling devices.

  16. Transient Simulation of Mold Heat Transfer and Solidification Phenomena of Continuous Casting of Steel

    Science.gov (United States)

    El-Bealy, Mostafa Omar

    2016-10-01

    A comprehensive model of heat transfer and solidification phenomena has been developed including microstructure evolution and fluctuation macrosegregation in continuously cast steel slabs with an objective of evaluation of various mold cooling conditions. The study contains plant trials, metallographic examinations, and formulation of mathematical modeling. The plant trials involved sample collection from three slab casters in use at two different steel plants. The metallographic study combined measurements of dendrite arm spacings and macrosegregation analysis of collected samples. A one-dimensional mathematical model has been developed to characterize the thermal, solidification phases, microstructure evolution, interdendritic strain, and therefore, the macrosegregation distributions. Two cooling approaches were proposed in this study to evaluate the Newtonian heat transfer coefficient in various mold regions. The first approach is a direct estimation approach (DEA), whereas the second one is a coupled approach of the interfacial resistor model and direct estimation approach (CIR/DEA). The model predictions and standard analytical models as well as the previous measurements were compared to verify and to calibrate the model where good agreements were obtained. The comparison between the model predictions and the measurements of dendrite arm spacings and fluctuated carbon concentration profiles were performed to determine the model accuracy level with different cooling approaches. Good agreements were obtained by different accuracy levels with different cooling approaches. The model predictions of thermal parameters and isotherms were analyzed and discussed.

  17. Numerical simulation of fiber interaction in short-fiber injection-molded composite using different cavity geometries

    Science.gov (United States)

    Thi, Thanh Binh Nguyen; Yokoyama, Atsushi; Hamanaka, Senji; Yamashita, Katsuhisa; Nonomura, Chisato

    2016-03-01

    The theoretical fiber-interaction model for calculating the fiber orientation in the injection molded short fiber/thermoplastic composite parts was proposed. The proposed model included the fiber dynamics simulation in order to obtain an equation of the global interaction coefficient and accurate estimate of the fiber interacts at all orientation states. The steps to derive the equation for this coefficient in short fiber suspension as a function of the fiber aspect ratio, volume fraction and general shear rate are delineated. Simultaneously, the high-resolution 3D X-ray computed tomography system XVA-160α was used to observe fiber distribution of short-glass-fiber-reinforced polyamide specimens using different cavity geometries. The fiber orientation tensor components are then calculated. Experimental orientation measurements of short-glass-fiber-reinforced polyamide is used to check the ability of present theory for predicting orientation. The experiments and predictions show a quantitative agreement and confirm the basic understanding of fiber orientation in injection-molded composites.

  18. Compression of Carbon Nanotubes Filled with C60, CH4, or Ne: Predictions from Molecular Dynamics Simulations

    Science.gov (United States)

    Ni, Boris; Sinnott, Susan B.; Mikulski, Paul T.; Harrison, Judith A.

    2002-05-01

    The effect of filling nanotubes with C60, CH4, or Ne on the mechanical properties of the nanotubes is examined. The approach is classical molecular dynamics using the reactive empirical bond order (REBO) and the adaptive intermolecular REBO potentials. The simulations predict that the buckling force of filled nanotubes can be larger than that of empty nanotubes, and the magnitude of the increase depends on the density of the filling material. In addition, these simulations demonstrate that the buckling force of empty nanotubes depends on temperature. Filling the nanotube disrupts this temperature effect so that it is no longer present in some cases.

  19. Study of Shell-Mold Thermal Resistance: Laboratory Measurements, Estimation from Compact Strip Production Plant Data, and Observation of Simulated Flux-Mold Interface

    Science.gov (United States)

    González de la C., J. Manuel; Flores F., Tania M.; Castillejos E., A. Humberto

    2016-08-01

    The slag film that forms between the shell and mold in steel continuous casting is key in regulating the heat transfer between them. Generally, the mechanisms proposed are related to the phenomena associated with the formation of crystals in the solid layer of the film, such as the appearance of internal pores and surface roughness, which decrease phononic conduction through the layer and interfacial gap with the mold, respectively, and the emergence of crystals themselves, which reduce the transmissivity of infrared radiation across the layer. Due to the importance of the solid layer, this study investigates experimentally the effective thermal resistance, R T, between a hot Inconel surface and a cold Cu surface separated by an initially glassy slag disk, made from powders for casting low and medium-carbon steels, denoted as A and B, respectively. In the tests, an initially mirror-polished disk is sandwiched for 10,800 seconds while the Inconel temperature, away from the disk face, is maintained steady at a value, T c, between 973 K and 1423 K (700 °C and 1150 °C)-below the liquidus temperature of the slags. The disks have a thickness, d t, between ~0.7 and 3.2 mm. Over the range of conditions studied, mold slag B shows R T 33 pct larger than slag A, and microscopic observation of disks hints that the greater resistance arises from the larger porosity developed in B. This finding is supported by high-temperature confocal laser scanning microscope observations of the evolution of the surface of slag parallelepipeds encased between Pt sheets, which reveal that during devitrification the film surface moves outward not inward, contrary with what is widely claimed. This behavior would favor contact of the slag with the mold for both kinds of powders. However, in the case of slag A, the crystalline grains growing at or near the surface pack closely together, leaving only few and small empty spaces. In slag B, crystalline grains pack loosely and many and large empty

  20. CAE for Injection Molding — Past, Present and the Future

    Science.gov (United States)

    Wang, Kuo K.

    2004-06-01

    It is well known that injection molding is the most effective process for mass-producing discrete plastic parts of complex shape to the highest precision at the lowest cost. However, due to the complex property of polymeric materials undergoing a transient non-isothermal process, it is equally well recognized that the quality of final products is often difficult to be assured. This is particularly true when a new mold or material is encountered. As a result, injection molding has often been viewed as an art than a science. During the past few decades, numerical simulation of injection molding process based on analytic models has become feasible for practical use as computers became faster and cheaper continually. A research effort was initiated at the Cornell Injection Molding Program (CIMP) in 1974 under a grant from the National Science Foundation. Over a quarter of the century, CIMP has established some scientific bases ranging from materials characterization, flow analysis, to prediction of part quality. Use of such CAE tools has become common place today in industry. Present effort has been primarily aimed at refinements of many aspects of the process. Computational efficiency and user-interface have been main thrusts by commercial software developers. Extension to 3-dimensional flow analysis for certain parts has drawn some attention. Research activities are continuing on molding of fiber-filled materials and reactive polymers. Expanded molding processes such as gas-assisted, co-injection, micro-molding and many others are continually being investigated. In the future, improvements in simulation accuracy and efficiency will continue. This will include in-depth studies on materials characterization. Intelligent on-line process control may draw more attention in order to achieve higher degree of automation. As Internet technology continues to evolve, Web-based CAE tools for design, production, remote process monitoring and control can come to path. The CAE

  1. An Accurate Simulation Of Thermoforming And Blow-Molding Processes Using The Space Fiber Rotation (SFR) Concept

    Science.gov (United States)

    Ghomari, T.; Ayad, R.; Talbi, N.

    2007-05-01

    This work deals with a non-linear formulation of an axisymmetric hyperelastic solid model for thermoforming and blow-molding processes. It's based on a new kinematic concept labeled SFR (Space Fiber Rotation). The SFR-Axi element model uses a kinematic motion of a space linear fiber in order to obtain more accurate displacement field, without increasing the number of nodes. It improves in a significant way the precision of the linear element Q4 indeed. The corresponding numerical results are comparable and even better, in term of time CPU, with those of the 8-nodes higher order element Q8. A hyperelastic behavior law based on Mooney-Rivlin model has been implemented to allow the model better simulations of forming processes hollow plastic bodies. The numerical results, very promising, are given with considering or not the contact between the polymer.

  2. Thermal resistance of attic loose-fill insulations decreases under simulated winter conditions

    Energy Technology Data Exchange (ETDEWEB)

    Graves, R.S.; Wilkes, K.E.; McElroy, D.L.

    1994-05-01

    Two absolute techniques were used to measure the thermal resistance of attic loose-fill insulations: the Large Scale Climate Simulator (LSCS) and the Unguarded Thin-Heater Apparatus (UTHA). Two types of attic loose-fill insulations (unbonded and bonded/cubed) were tested under simulated winter conditions. To simulate winter conditions for an attic insulation, the specimens were tested with heat flow up, large temperature differences, and an air gap. The specimens were tested either with a constant mean temperature (30 or 21{degrees}C) and an increasing temperature difference or with a constant base temperature (21{degrees}C) and an increasing temperature difference (i.e., a decreasing mean temperature). The UTHA test specimens had a nominal thickness of 0.2 m of loose-fill insulation. The LSCS test specimens had a nominal thickness of 0.3 m of loose-fill insulation contained in a 4.2 by 5 m attic test module with a gypsum board base. The module had a gabled attic with a 5 in 12 slope roof. The tests yielded the surface-to-surface thermal resistance, R, which includes the thermal resistance due to gypsum, insulation, and any wood joists. Tests with and without an air gap were conducted in the UTHA. Surface-to-surface thermal resistance results from the LSCS and the UTHA show similar trends for these two types of loose-fill insulation when tested under simulated winter conditions. Tests with no air gap gave values of R that agreed with the bag label R-value for the insulations; R increased with lower mean temperatures. These no-gap values of R were 2 to 5% greater than the values of R obtained with an air gap for temperature differences of less than 22{degrees}C. For larger temperature differences R decreased, and at temperature differences of over 40{degrees}C, the R values were 50% less than those at small temperature differences.

  3. Relationship between Microcellular Foaming Injection Molding Process Parameters and Cell Size

    Institute of Scientific and Technical Information of China (English)

    HU Guang-hong; JIANG Chao-dong; CUI Zhen-shan

    2008-01-01

    In order to study the relationship between the main process parameters and the cell size, the mathematical model of cell growth of microcellular foaming injection process is built. Then numeric simulation is employed as experimental method, and the Taguchi method is used to analyze significance of effect of process parameters on the cell size. At last the process parameters are focused on melt temperature, injection time, mold temperature and pre- filled volume. The significance order from big to small of the effect of each process parameters on cell size is melt temperature, pre-filled volume, injection time, and mold temperature. On the basis of above research, the effect of each process parameter on cell size is further researched.Appropriate reduction of the melt temperature and increase of the we-filled volume can optimize the cell size effectively, while the effects of injection time and mold temperature on cell size are less significant.

  4. Implementation of Molding Constraints in Topology Optimization

    DEFF Research Database (Denmark)

    Marx, S.; Kristensen, Anders Schmidt

    2009-01-01

    In many cases the topology optimization method yield inadmissible solutions in respect to a particular manufacturing process, e.g. injection molding. In the present work it is chosen to focus on the most common injection molding parameters/factors determining the quality of the mold geometry, i.......e. uniform thickness, filling of the die and ejection of the molded item, i.e. extrusion. The mentioned injection mold parameters/factors are introduced in the topology optimization by defining a centerline of the initial domain and then penalize elements in respect to the distance to the defined centerline...

  5. Precision glass molding of complex shaped chalcogenide glass lenses for IR applications

    Science.gov (United States)

    Staasmeyer, Jan-Helge; Wang, Yang; Liu, Gang; Dambon, Olaf; Klocke, Fritz

    2016-09-01

    The use of chalcogenide glass in the thermal infrared domain is an emerging alternative to commonly used crystalline materials such as germanium. The main advantage of chalcogenide glass is the possibility of mass production of complex shaped geometries with replicative processes such as precision glass molding. Thus costly single point diamond turning processes are shifted to mold manufacturing and do not have to be applied to every single lens produced. The usage of FEM-Simulation is mandatory for developing a molding process for complex e.g. non rotational symmetric chalcogenide glass lenses in order to predict the flow of glass. This talk will present state of the art modelling of the precision glass molding process for chalcogenide glass lenses, based on thermal- and mechanical models. Input data for modelling are a set of material properties of the specific chalcogenide glass in conjunction with properties of mold material and wear protective coatings. Specific properties for the mold-glass interaction such as stress relaxation or friction at the glassmold interface cannot be obtained from datasheets and must be determined experimentally. A qualified model is a powerful tool to optimize mold and preform designs in advance in order to achieve sufficient mold filling and compensate for glass shrinkage. Application of these models in an FEM-Simulation "case study" for molding a complex shaped non-rotational symmetric lens is shown. The outlook will examine relevant issues for modelling the precision glass molding process of chalcogenide glasses in order to realize scaled up production in terms of multi cavity- and wafer level molding.

  6. Allergies, asthma, and molds

    Science.gov (United States)

    Reactive airway - mold; Bronchial asthma - mold; Triggers - mold; Allergic rhinitis - pollen ... Things that make allergies or asthma worse are called triggers. Mold is a common trigger. When your asthma or allergies become worse due to mold, you are ...

  7. Numerical simulation and analysis of mould filling process in lost foam casting

    Directory of Open Access Journals (Sweden)

    Jiang Junxia

    2008-08-01

    Full Text Available In lost foam casting (LFC the foam pattern is the key criterion, and the filling process is crucial to ensure the high quality of the foam pattern. Filling which lacks uniformity and denseness will cause various defects and affect the surface quality of the casting. The infl uential factors of the fi lling process are realized in this research. Optimization of the fi lling process, enhancement of effi ciency, decrease of waste, etc., are obtained by the numerical simulation of the fi lling process using a computer.The equations governing the dense gas-solid two-phase flow are established, and the physical significance of each equation is discussed. The Euler/Lagrange numerical model is used to simulate the fluid dynamic characteristics of the dense two-phase fl ow during the mould fi lling process in lost foam casting. The experiments and numerical results showed that this method can be a very promising tool in the mould fi lling simulation of beads' movement.

  8. A fluid-filled soft robot that exhibits spontaneous switching among versatile spatiotemporal oscillatory patterns inspired by the true slime mold.

    Science.gov (United States)

    Umedachi, Takuya; Idei, Ryo; Ito, Kentaro; Ishiguro, Akio

    2013-01-01

    Behavioral diversity is an essential feature of living systems, enabling them to exhibit adaptive behavior in hostile and dynamically changing environments. However, traditional engineering approaches strive to avoid, or suppress, the behavioral diversity in artificial systems to achieve high performance in specific environments for given tasks. The goals of this research include understanding how living systems exhibit behavioral diversity and using these findings to build lifelike robots that exhibit truly adaptive behaviors. To this end, we have focused on one of the most primitive forms of intelligence concerning behavioral diversity, namely, a plasmodium of true slime mold. The plasmodium is a large amoeba-like unicellular organism that does not possess any nervous system or specialized organs. However, it exhibits versatile spatiotemporal oscillatory patterns and switches spontaneously between these. Inspired by the plasmodium, we built a mathematical model that exhibits versatile oscillatory patterns and spontaneously transitions between these patterns. This model demonstrates that, in contrast to coupled nonlinear oscillators with a well-designed complex diffusion network, physically interacting mechanosensory oscillators are capable of generating versatile oscillatory patterns without changing any parameters. Thus, the results are expected to shed new light on the design scheme for lifelike robots that exhibit amazingly versatile and adaptive behaviors.

  9. Media-fill simulation tests in manual and robotic aseptic preparation of injection solutions in syringes.

    Science.gov (United States)

    Krämer, Irene; Federici, Matteo; Kaiser, Vanessa; Thiesen, Judith

    2016-04-01

    The purpose of this study was to evaluate the contamination rate of media-fill products either prepared automated with a robotic system (APOTECAchemo™) or prepared manually at cytotoxic workbenches in the same cleanroom environment and by experienced operators. Media fills were completed by microbiological environmental control in the critical zones and used to validate the cleaning and disinfection procedures of the robotic system. The aseptic preparation of patient individual ready-to-use injection solutions was simulated by using double concentrated tryptic soy broth as growth medium, water for injection and plastic syringes as primary packaging materials. Media fills were either prepared automated (500 units) in the robot or manually (500 units) in cytotoxic workbenches in the same cleanroom over a period of 18 working days. The test solutions were incubated at room temperature (22℃) over 4 weeks. Products were visually inspected for turbidity after a 2-week and 4-week period. Following incubation, growth promotion tests were performed with Staphylococcus epidermidis. During the media-fill procedures, passive air monitoring was performed with settle plates and surface monitoring with contact plates on predefined locations as well as fingerprints. The plates got incubated for 5-7 days at room temperature, followed by 2-3 days at 30-35℃ and the colony forming units (cfu) counted after both periods. The robot was cleaned and disinfected according to the established standard operating procedure on two working days prior to the media-fill session, while on six other working days only six critical components were sanitized at the end of the media-fill sessions. Every day UV irradiation was operated for 4 h after finishing work. None of the 1000 media-fill products prepared in the two different settings showed turbidity after the incubation period thereby indicating no contamination with microorganisms. All products remained uniform, clear, and light

  10. Gating of Permanent Molds for ALuminum Casting

    Energy Technology Data Exchange (ETDEWEB)

    David Schwam; John F. Wallace; Tom Engle; Qingming Chang

    2004-03-30

    This report summarizes a two-year project, DE-FC07-01ID13983 that concerns the gating of aluminum castings in permanent molds. The main goal of the project is to improve the quality of aluminum castings produced in permanent molds. The approach taken was determine how the vertical type gating systems used for permanent mold castings can be designed to fill the mold cavity with a minimum of damage to the quality of the resulting casting. It is evident that somewhat different systems are preferred for different shapes and sizes of aluminum castings. The main problems caused by improper gating are entrained aluminum oxide films and entrapped gas. The project highlights the characteristic features of gating systems used in permanent mold aluminum foundries and recommends gating procedures designed to avoid common defects. The study also provides direct evidence on the filling pattern and heat flow behavior in permanent mold castings.

  11. Numerical Simulation and Experimental Investigation of the Viscoelastic Heating Mechanism in Ultrasonic Plasticizing of Amorphous Polymers for Micro Injection Molding

    Directory of Open Access Journals (Sweden)

    Bingyan Jiang

    2016-05-01

    Full Text Available Ultrasonic plasticizing of polymers for micro-injection molding has been proposed and studied for its unique potential in materials and energy-saving. In our previous work, we have demonstrated the characteristics of the interfacial friction heating mechanism in ultrasonic plasticizing of polymer granulates. In this paper, the other important heating mechanism in ultrasonic plasticizing, i.e., viscoelastic heating for amorphous polymer, was studied by both theoretical modeling and experimentation. The influence mechanism of several parameters, such as the initial temperature of the polymer, the ultrasonic frequency, and the ultrasonic amplitude, was investigated. The results from both numerical simulation and experimentation indicate that the heat generation rate of viscoelastic heating can be significantly influenced by the initial temperature of polymer. The glass transition temperature was found to be a significant shifting point in viscoelastic heating. The heat generation rate is relatively low at the beginning and can have a steep increase after reaching glass transition temperature. In comparison with the ultrasonic frequency, the ultrasonic amplitude has much greater influence on the heat generation rate. In light of the quantitative difference in the viscoelastic heating rate, the limitation of the numerical simulation was discussed in the aspect of the assumptions and the applied mathematical models.

  12. Secondary protective seal of root canal fillings performed under simulated clinical conditions

    Directory of Open Access Journals (Sweden)

    Matthias Johannes Roggendorf

    2011-07-01

    Full Text Available Objective: This study evaluated sealing properties of root canal fillings with an additional composite barrier. The null hypothesis tested was that different sealers and different methods of sealer removal did not influence microleakage. Material and methods: Eighty extracted human molars with fully mature apices had root canal prepared to size 60 taper .02 and divided into eight groups: three experimental groups for each sealer and negative/positive control (n = 10 each. Teeth of experimental groups were mounted into the molar region of a training puppet to simulate clinical conditions. Root canals were filled with AH Plus or GuttaFlow and gutta-percha. Excess sealer was removed with: ethanol-moistened foam pellet only, additional preparation with a water-cooled diamond bur or additional etch-and-rinse procedure (37% phosphoric acid gel. All procedures were carried out until clean as judged by the naked eye. In all groups except the positive control Syntac was applied to the access cavity. Tetric flow was applied in two increments of 1 mm each. A dye penetration test was carried out by centrifugation for 3 min at 30 G within 5% methylene blue dye. Statistical evaluation was carried out with PASW 18.0 (α = 0.05. Results: Although the two sealers had different chemical composition, sealer exhibited no influence on the results, whereas technique of sealer removal did (Two-way-ANOVA, p < 0.001. Groups with “foam pellet” or “bur preparation” showed significantly more leakage than groups with “etch-and rinse” (SNK, p < 0.05. Conclusion: Applying an etch-and-rinse procedure prior to Syntac may be beneficial for the adhesive seal over root canal fillings.

  13. Gate design in injection molding of microfluidic components using process simulations

    DEFF Research Database (Denmark)

    Marhöfer, David Maximilian; Tosello, Guido; Islam, Aminul;

    for macroscopic plastic parts. By using the correct implementation and careful modelling though, it can also be applied to micro parts. In the present work, process simulations were applied to a microfluidic distributor and a microfluidic mixer of which features were in the 100 μm dimensional range. The meshing...

  14. Molds in the Environment

    Science.gov (United States)

    ... on Facebook Tweet Share Compartir Molds in the Environment What are molds? What are some of the ... molds found? Molds are found in virtually every environment and can be detected, both indoors and outdoors, ...

  15. Mold Testing or Sampling

    Science.gov (United States)

    In most cases, if visible mold growth is present, sampling is unnecessary. Since no EPA or other federal limits have been set for mold or mold spores, sampling cannot be used to check a building's compliance with federal mold standards.

  16. Stochastic resin transfer molding process

    CERN Document Server

    Park, M

    2016-01-01

    We consider one-dimensional and two-dimensional models of stochastic resin transfer molding process, which are formulated as random moving boundary problems. We study their properties, analytically in the one-dimensional case and numerically in the two-dimensional case. We show how variability of time to fill depends on correlation lengths and smoothness of a random permeability field.

  17. Numerical Simulations of Void Transport in Unidirectional Fiber Arrays in Resin Transfer Molding Process%RTM工艺中单向纤维排列中的缺陷迁移的数值模拟

    Institute of Scientific and Technical Information of China (English)

    LIU Hai-long; Wook Ryol Hwang

    2008-01-01

    Decreasing the amount of residual voids during the resin infiltration into fibrous porous media is an important aspect in manufacturing high performance composite materials.In order to better understand void transports and flow behaviors in filling process,which affects immediately the final void content,a finite-element scheme for transient simulations of the void migration in a transverse flow through the uniaxial micro-structured fibrous media is developed in this work.A volume-of-fluid (VOF) method has been incorporated in the Eulerian frame to capture the free surface of the resin flow.The implementation of periodic boundary condition to the vertical direction avoids unwanted wall effect.The void migration in a dual-scale fiber tow model was investigated.The voids are observed to be transported through the inter-tow region as well as entrapped into fiber tow.It is that the motion of void lagged behind macro flow front which implies that the adequate resin bleeding after mold filling is crucial to remove the entrapped air.

  18. Large Eddy Simulations of the Effects of EMBr and SEN Submergence Depth on Turbulent Flow in the Mold Region of a Steel Caster

    Science.gov (United States)

    Jin, Kai; Vanka, Surya P.; Thomas, Brian G.

    2017-02-01

    Transient turbulent flow in the mold region during continuous casting of steel is related to many quality problems, such as surface defects and slag entrainment. This work applies an efficient multi-GPU based code, CUFlow, to perform large eddy simulations (LES) of the turbulent flow in a domain that includes the slide gate, SEN, and mold region. The computations were first validated by comparing the predicted surface velocity with plant measurements. Then, seven LES simulations were conducted to study the effects of casting speed, electromagnetic braking (EMBr) field strength, and submerged entry nozzle (SEN) depth on the transient flow. The results show that EMBr has an important influence on flow inside the SEN, in addition to flow in the mold. With EMBr, an "M-shaped" flow profile is seen inside the SEN. The swirling flow behavior in the SEN and ports is more symmetrical at high casting speed and with higher EMBr strength. The position of the SEN ports relative to the peak magnetic field affects the EMBr performance. The results confirm and quantify how applying EMBr greatly lowers both the magnitude and turbulent variations of the surface velocity and level profile.

  19. Vertical root fracture resistance of simulated immature permanent teeth filled with MTA using different vehicles

    Science.gov (United States)

    Askerbeyli-Örs, Sevinc; Deniz-Sungur, Derya

    2017-01-01

    Background The aim of the study is to evaluate the resistance vertical root fracture (VRF) of mineral trioxide aggregate (MTA) filled-immature permanent roots by using three different vehicles. Material and Methods Forty-extracted human single-rooted mandibular premolars were selected and the root length was standardized to the length of 9 mm. For simulation of immature tooth apices, peeso reamers were introduced into the root canals and the prepared roots were assigned into three experimental groups according the used vehicle (distilled water-DW, prophylene glycol-PG, chlorhexidine-CHX) and control group (n=10). To simulate a periodontal membrane, the apical 7 mm of all roots was covered with wax to obtain a 0.2- to 0.3-mm-thick layer before embedding the roots into acrylic cylinders. A vertical force was applied (1mm/min) using a universal testing machine and the maximum load (F-max) that fracture occurred and the fracture mode (splint or comminuted) was recorded. Data were presented as mean and standard deviations. Statistical analysis was performed using Kruskal-Wallis, Mann-Whitney U Test was used for multiple comparisons. Results There were significant differences between fracture strength of experimental groups with that of control group (p0.05). In all groups, split fracture was the most common fracture mode. Conclusions MTA increases resistance of immature permanent teeth to VRF. Based on the results of this study, it can be concluded that mixing MTA with CHX or PG as the vehicle do not alter VRF resistance of simulated immature permanent roots. Key words:Immature teeth, MTA, vehicle, vertical root fracture. PMID:28210431

  20. IMAGE ANALYSIS DEDICATED TO POLYMER INJECTION MOLDING

    Directory of Open Access Journals (Sweden)

    David Garcia

    2011-05-01

    Full Text Available This work follows the general framework of polymer injection moulding simulation whose objectives are the mastering of the injection moulding process. The models of numerical simulation make it possible to predict the propagation of the molten polymer during the filling phase from the positioning of one point of injection or more. The objective of this paper is to propose a particular way to optimize the geometry of mold cavity in accordance with physical laws. A direct correlation is pointed out between geometric parameters issued from skeleton transformation and Hausdorff's distance and results provided by implementation of a classical model based on the Hele-Shaw equations which are currently used in the main computer codes of polymer injection.

  1. Design of the liquefied natural gas (LNG) vehicle gas cylinder filling semi-physical simulation training and assessment system

    Science.gov (United States)

    Gao, Jie; Zheng, Jianrong; Zhao, Yinghui

    2017-08-01

    With the rapid development of LNG vehicle in China, the operator's training and assessment of the operating skills cannot operate on material objects, because of Vehicle Gas Cylinder's high pressure, flammable and explosive characteristics. LNG Vehicle Gas Cylinder's filling simulation system with semi-physical simulation technology presents the overall design and procedures of the simulation system, and elaborates the realization of the practical analog machine, data acquisition and control system and the computer software, and introduces the design process of equipment simulation model in detail. According to the designed assessment system of the Vehicle Gas Cylinder, it can obtain the operation on the actual cylinder filling and visual effects for the operator, and automatically record operation, the results of real operation with its software, and achieve the operators' training and assessment of operating skills on mobile special equipment.

  2. Numerical simulation of casting processes: coupled mould filling and solidification using VOF and enthalpy-porosity method

    Science.gov (United States)

    Richter, Ole; Turnow, Johann; Kornev, Nikolai; Hassel, Egon

    2017-06-01

    Within the scope of industrial casting applications a numerical model for the simultaneous mould filling and solidification process has been formulated, implemented in a finite volume code and successfully validated using analytical and experimental data. In order to account for the developing of free surface flow and the liquid/solid phase change, respectively, the volume-of-fluid and enthalpy-porosity method have been coupled under a volume averaging framework on a fixed Eulerian grid. The coupled method captures the basic physical effects of a combined mould filling and solidification process and provides a trustful method for comprehensive casting simulations.

  3. Triple Plate Mold Final Report: Optimization of the Mold Design and Casting Parameters for a Thin U-10mo Fuel Casting

    Energy Technology Data Exchange (ETDEWEB)

    Aikin, Jr., Robert M. [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

    2017-01-04

    This work describes the experiments and modeling that have been performed to improve and try to optimize the simultaneous casting of three plates of U-10wt%Mo in a single coil vacuum induction melting (VIM) furnace. The plates of interest are 280 mm wide by 203 mm tall by 5 mm thick (11" x 8" x 0.2"). The initial mold design and processing parameters were supplied by Y-12. The mold and casting cavity were instrumented with a number of thermocouples, and the casting performed to determine the thermal history of the mold and casting. The resulting cast plates were radiographed and numerous defects identified. Metallography was performed to help identify the nature of the radiographically observed defects. This information was then used to validate a mold filling and solidification model of that casting. Based on the initial casting, good casting design practice, and process simulation of several design alternatives, a revised design was developed with the goal of minimizing casting defects such as porosity. The redesigned mold had a larger hot-top and had its long axis along the horizontal direction. These changes were to try to develop a strong thermal gradient conducive to good feeding and minimization of micro- and macroporosity in the cast plates. An instrumented casting was then performed with the revised mold design and a linear distributor. This design yielded cast plates with significantly less radiographically identified defects. Unfortunately, there was significant variation in plate weight and metal content in their hot-tops. Fluid flow simulations were then performed on this mold/distributor design. This helped identify the issue with this linear distributor design. Additional simulations were then performed on candidate distributor redesigns and a preferred distributor annular design was identified. This improved annular design was used to produce a third instrumented casting with favorable results. These refined designs and their radiographic

  4. Analysis of optical properties in injection-molded and compression-molded optical lenses.

    Science.gov (United States)

    Wang, Chung Yen; Wang, Pei Jen

    2014-04-10

    Numerical mold-flow simulations and experimental measurements for injection-molded lenses have been investigated in form accuracy on a two-cavity mold with various process conditions. First, form profiles of the molded lenses have been measured together with the corresponding simulated mold-temperature distribution and displacement distribution of the lens in the z direction. A flow-through type layout of cooling channels has been devised for balance of mold-temperature distribution in mold cavities with various parametric distances for assessments in uniformity of temperature distribution. Finally, a compression-molding process is proposed for the post-process of birefringence relaxation as well as adequate form accuracy of lenses. In conclusion, optimization of process parameters to achieve good form accuracy in a multicavity mold with symmetric geometry but nonuniform cooling conditions is difficult. A good design of cooling channels plus optimized process conditions could provide uniform mold-temperature distribution so that molded lenses of good quality would be possible. Then, the profile deviation of lenses could be further compensated by profile geometry corrections. In conclusion, the post-compression-molding process could make birefringence-free plastic lenses with good form accuracy.

  5. Casting defects of Ti-6Al-4V alloy in vertical centrifugal casting processes with graphite molds

    Science.gov (United States)

    Jia, Limin; Xu, Daming; Li, Min; Guo, Jingjie; Fu, Hengzhi

    2012-02-01

    Numerical simulation and experimental investigation are utilized to analyze the casting defects of Ti-6Al-4V alloy formed under different vertical centrifugal casting conditions in graphite molds. Mold rotating rates of 0, 110 and 210 rpm are considered in experimental process. Results show that centrifugal forces have significant effects on the quantity of both macropores and microdefects (micropores, microcracks and inclusions). The relative amount of all macro- and micro-scopic casting defects decreases from 62.4 % to 24.8 % with the increasing of the centrifugal force, and the macropore quantity in stepped casting decreases exponentially with the increase of the gravitation coefficient. The relative proportions of both micropores and microcracks decrease with the mold-rotating rate increase, but the relative proportion of inclusions increases significantly. Besides this, the mold-filling sequence is proved to be an important factor in casting quality control.

  6. Simulations of non-uniform embossing:the effect of asymmetric neighbor cavities on polymer flow during nanoimprint lithography.

    Energy Technology Data Exchange (ETDEWEB)

    Schunk, Peter Randall; King, William P. (Georgia Institute of Technology, Atlanta, GA); Sun, Amy Cha-Tien; Rowland, Harry D. (Georgia Institute of Technology, Atlanta, GA)

    2007-08-01

    This paper presents continuum simulations of viscous polymer flow during nanoimprint lithography (NIL) for embossing tools having irregular spacings and sizes. Simulations varied non-uniform embossing tool geometry to distinguish geometric quantities governing cavity filling order, polymer peak deformation, and global mold filling times. A characteristic NIL velocity predicts cavity filling order. In general, small cavities fill more quickly than large cavities, while cavity spacing modulates polymer deformation mode. Individual cavity size, not total filling volume, dominates replication time, with large differences in individual cavity size resulting in non-uniform, squeeze flow filling. High density features can be modeled as a solid indenter in squeeze flow to accurately predict polymer flow and allow for optimization of wafer-scale replication. The present simulations make it possible to design imprint templates capable of distributing pressure evenly across the mold surface and facilitating symmetric polymer flow over large areas to prevent mold deformation and non-uniform residual layer thickness.

  7. Influence of the local morphology on the surface tension of injection molded polypropylene

    Science.gov (United States)

    Gomes, M.; Pontes, A. J.; Viana, J. C.

    2014-05-01

    In this work, we investigate the development of the morphology of an injection molding polypropylene under the local thermomechanical environment imposed during processing, and its effect on the contact angle and, hence, on the surface tension of the moldings. Melt and mold temperatures were varied in two levels. The local thermomechanical environment was characterized by mold filling computational simulations that allow the calculation of thermomechanical variables (e.g., local temperatures, shear stresses) and indices (related to the local morphology development). In order to investigate the structural hierarchy variations of the moldings in the thickness direction, samples from skin to core were used. The molecular orientation and degree of crystallinity were determined as function of the thickness, as well as the contact angle. The variations of the degree of crystallinity were assessed by differential scanning calorimetry. The level of molecular orientation was evaluated by birefringence measurements. The contact angles were measured in deionized water by sessile drop (needle in) method at room temperature, to determine the wettability of the samples. The contact angles were found to vary along the molding thickness in the skin, transition and core layers. These variations are related to the local morphologies developed. Results suggest that water contact angle increases with the level of molecular orientation and for finer microstructures.

  8. Two-part silicone mold. A new tool for flexible ureteroscopy surgical training

    Directory of Open Access Journals (Sweden)

    Bruno Marroig

    Full Text Available ABSTRACT Introduction and objectives: Flexible ureteroscopy is a common procedure nowadays. Most of the training programs use virtual reality simulators. The aim of this study was to standardize the building of a three-dimensional silicone mold (cavity of the collecting system, on the basis of polyester resin endocasts, which can be used in surgical training programs. Materials and Methods: A yellow polyester resin was injected into the ureter to fill the collecting system of 24 cadaveric fresh human kidneys. After setting off the resin, the kidneys were immersed in hydrochloric acid until total corrosion of the organic matter was achieved and the collecting system endocasts obtained. The endocasts were used to prepare white color two-part silicone molds, which after endocasts withdrawn, enabled a ureteroscope insertion into the collecting system molds (cavities. Also, the minor calices were painted with different colors in order to map the access to the different caliceal groups. The cost of the materials used in the molds is $30.00 and two days are needed to build them. Results: Flexible ureteroscope could be inserted into all molds and the entire collecting system could be examined. Since some anatomical features, as infundular length, acute angle, and perpendicular minor calices may difficult the access to some minor calices, especially in the lower caliceal group, surgical training in models leads to better surgical results. Conclusions: The two-part silicone mold is feasible, cheap and allows its use for flexible ureteroscopy surgical training.

  9. Nonlinear Modeling of a High Precision Servo Injection Molding Machine Including Novel Molding Approach

    Institute of Scientific and Technical Information of China (English)

    何雪松; 王旭永; 冯正进; 章志新; 杨钦廉

    2003-01-01

    A nonlinear mathematical model of the injection molding process for electrohydraulic servo injection molding machine (IMM) is developed.It was found necessary to consider the characteristics of asymmetric cylinder for electrohydraulic servo IMM.The model is based on the dynamics of the machine including servo valve,asymmetric cylinder and screw,and the non-Newtonian flow behavior of polymer melt in injection molding is also considered.The performance of the model was evaluated based on novel approach of molding - injection and compress molding,and the results of simulation and experimental data demonstrate the effectiveness of the model.

  10. Validation of New Process Models for Large Injection-Molded Long-Fiber Thermoplastic Composite Structures

    Energy Technology Data Exchange (ETDEWEB)

    Nguyen, Ba Nghiep; Jin, Xiaoshi; Wang, Jin; Kunc, Vlastimil; Tucker III, Charles L.

    2012-02-23

    This report describes the work conducted under the CRADA Nr. PNNL/304 between Battelle PNNL and Autodesk whose objective is to validate the new process models developed under the previous CRADA for large injection-molded LFT composite structures. To this end, the ARD-RSC and fiber length attrition models implemented in the 2013 research version of Moldflow was used to simulate the injection molding of 600-mm x 600-mm x 3-mm plaques from 40% glass/polypropylene (Dow Chemical DLGF9411.00) and 40% glass/polyamide 6,6 (DuPont Zytel 75LG40HSL BK031) materials. The injection molding was performed by Injection Technologies, Inc. at Windsor, Ontario (under a subcontract by Oak Ridge National Laboratory, ORNL) using the mold offered by the Automotive Composite Consortium (ACC). Two fill speeds under the same back pressure were used to produce plaques under slow-fill and fast-fill conditions. Also, two gating options were used to achieve the following desired flow patterns: flows in edge-gated plaques and in center-gated plaques. After molding, ORNL performed measurements of fiber orientation and length distributions for process model validations. The structure of this report is as follows. After the Introduction (Section 1), Section 2 provides a summary of the ARD-RSC and fiber length attrition models. A summary of model implementations in the latest research version of Moldflow is given in Section 3. Section 4 provides the key processing conditions and parameters for molding of the ACC plaques. The validations of the ARD-RSC and fiber length attrition models are presented and discussed in Section 5. The conclusions will be drawn in Section 6.

  11. On the structural and mechanical properties of Fe-filled carbon nanotubes: a computer simulation approach.

    Science.gov (United States)

    Soldano, G; Mariscal, M M

    2009-04-22

    The structural and mechanical properties of single-and multi-walled carbon nanotubes filled with iron nanowires are studied using a recent parameterization of the modified embedded atom model. We have analyzed the effect of different crystal structures of iron (bcc and fcc) inside carbon nanotubes of different topographies. We have computed strain energy versus strain curves for pure systems: Fe nanowires, carbon and Fe-filled carbon nanotubes. A noticeable difference is found when these monatomic systems are joined to form iron-capped nanowires and where multi-layers of graphite are added to the nanotubes.

  12. EXPERIMENTAL INVESTIGATION AND COMPUTER SIMULATION ON DYNAMIC BUCKLING BEHAVIOR OF LIQUID-FILLED CYLINDRICAL SHELLS UNDER AXIAL IMPACT

    Institute of Scientific and Technical Information of China (English)

    Zhang Shanyuan; Lei Jianping; Zhao Longmao; Cheng Guoqiang; Lu Guoyun

    2000-01-01

    This article reports an experimental investigation on the axial impact buckling of thin metallic cylindrical shells fully filled with water. Low velocity impact tests are carried out by DHR-9401 drop hammer rig. The whole process of dynamic buckling is simulated using LS-DYNA computer code. The consistency between experimental observation and numerical simulation is quite satisfactory. The investigation indicates that quite high internal hydrodynamic pressure occurs inside the shell during the impact process. Under the combined action of the high internal pressure and axial compression plastic buckling occurs easily in the thin walled shells and buckling modes take on regular and axisymmetric wrinkles.

  13. Visualizing and simulating flow conditions in concrete form filling using pigments

    DEFF Research Database (Denmark)

    Jacobsen, Stefan; Cepuritis, Rolands; Peng, Ya

    2013-01-01

    Flow variation at surfaces and reinforcement during form filling was visualized with grey and black SCC. The border between grey and black (pigmented) SCC was captured as frozen images on hardened sawn- and formwork surfaces in a flow box experiment. Maximum velocity occurred at the centre of the...

  14. Simulation of Ultrasonic Cavitation Characteristics in Mold Cavity%模具异型腔内超声空化特性的仿真研究

    Institute of Scientific and Technical Information of China (English)

    吕婷; 李艺; 陶柏霖

    2014-01-01

    In order to further investigate the role of ultrasound on gas-liquid mixed phase in the mold cavity and im-prove the polishing result effectively,the software FLUENT6.3 is applied to establish ultrasonic polishing mold based on CFD.It is simulated for the distribution of polishing medium in the area of??low pressure and formation region,mecha-nism of cavitation bubbles by k-εmodel and gas-liquid mixed phase cavitation model.The study identifies that a cavita-tion phenomenon is able to improve the accuracy of ultrasonic polishing.%为进一步研究超声波对模具异型腔内气液混合相的作用,有效提高抛光效果,本文基于CFD,应用软件FLUENT6.3建立模具异型腔内超声抛光的模型。运用k-ε模型、气液两相流空化模型,模拟计算出模具异型腔内抛光介质在低压区的分布以及空化气泡的形成区域及其形成机理,确定了一定的空化现象的发生将有助于提高超声波抛光的精度。

  15. Computer simulation tool for predicting sound propagation in air-filled tubes with acoustic impedance discontinuities.

    Science.gov (United States)

    Albors, Gabriel O; Kyle, Aaron M; Wodicka, George R; Juan, Eduardo J

    2007-01-01

    A computer tool, based on an acoustic transmission line model, was developed for modeling and predicting sound propagation and reflections in cascaded tube segments. This subroutine considered the number of interconnected tubes, their dimensions and wall properties, as well as medium properties to create a network of cascaded transmission line model segments, from which the impulse response of the network was estimated. Acoustic propagation was examined in air-filled cascaded tube networks and model predictions were compared to measured acoustic pulse responses. The model was able to accurately predict the location and morphology of reflections. The developed code proved to be a useful design tool for applications such as the guidance of catheters through compliant air-filled biological conduits.

  16. Modeling injection molding of net-shape active ceramic components.

    Energy Technology Data Exchange (ETDEWEB)

    Baer, Tomas (Gram Inc.); Cote, Raymond O.; Grillet, Anne Mary; Yang, Pin; Hopkins, Matthew Morgan; Noble, David R.; Notz, Patrick K.; Rao, Rekha Ranjana; Halbleib, Laura L.; Castaneda, Jaime N.; Burns, George Robert; Mondy, Lisa Ann; Brooks, Carlton, F.

    2006-11-01

    To reduce costs and hazardous wastes associated with the production of lead-based active ceramic components, an injection molding process is being investigated to replace the current machining process. Here, lead zirconate titanate (PZT) ceramic particles are suspended in a thermoplastic resin and are injected into a mold and allowed to cool. The part is then bisque fired and sintered to complete the densification process. To help design this new process we use a finite element model to describe the injection molding of the ceramic paste. Flow solutions are obtained using a coupled, finite-element based, Newton-Raphson numerical method based on the GOMA/ARIA suite of Sandia flow solvers. The evolution of the free surface is solved with an advanced level set algorithm. This approach incorporates novel methods for representing surface tension and wetting forces that affect the evolution of the free surface. Thermal, rheological, and wetting properties of the PZT paste are measured for use as input to the model. The viscosity of the PZT is highly dependent both on temperature and shear rate. One challenge in modeling the injection process is coming up with appropriate constitutive equations that capture relevant phenomenology without being too computationally complex. For this reason we model the material as a Carreau fluid and a WLF temperature dependence. Two-dimensional (2D) modeling is performed to explore the effects of the shear in isothermal conditions. Results indicate that very low viscosity regions exist near walls and that these results look similar in terms of meniscus shape and fill times to a simple Newtonian constitutive equation at the shear-thinned viscosity for the paste. These results allow us to pick a representative viscosity to use in fully three-dimensional (3D) simulation, which because of numerical complexities are restricted to using a Newtonian constitutive equation. Further 2D modeling at nonisothermal conditions shows that the choice of

  17. Process-induced damage evolution and management in resin transfer molding of composite panels

    Science.gov (United States)

    Kuan, Yean-Der

    2000-10-01

    Woven fiber composites made by resin transfer molding process are currently used as the primary and secondary load bearing structures in automotive and aircraft industries. A variety of defects could be evolved during the injection stage and the curing stage of the process. Improper injection conditions or unsound tool design would result in process induced damage in the form of dry spots, incomplete filling, or displacement of the fiber. In the curing stage, the process parameters of heating and cooling rates, and the temperature level at each element of the curing cycle have direct effects on the development of internal residual stresses, and shape distortion due to warpage. The work in this dissertation aims at developing numerical models to predict, characterize, and minimize process-induced damage during both the injection stage and curing stage in RTM process for woven-fiber composites. A control volume technique based on the finite difference method is used to characterize the flow behavior in resin transfer molding (RTM) of composite structures. Resin flow through fiber mats is modeled as a two-phase flow through porous media. Experimental results on flow behavior of EPON 826 epoxy resin into irregular mold cavity with fiberglass mats agree well with the present numerical simulation. Parametric analysis of several case studies using developed model illustrates the effectiveness of the flow model in investigating the flow pattern, mold filling time, dry spots formulation, and pressure distribution inside the mold. A numerical model describing the evolution of process-induced damage during curing in molded composite panels was developed. The effects of thermo-mechanical and thermo-chemical responses of the material on the evolution of damage during resin transfer molding of the panels are quantified. The developed numerical model in conjunction with an optimization module based on Simulated Annealing (SA) scheme form a useful tool for conducting a parametric

  18. Molded underfill (MUF) encapsulation for flip-chip package: A numerical investigation

    Science.gov (United States)

    Azmi, M. A.; Abdullah, M. K.; Abdullah, M. Z.; Ariff, Z. M.; Saad, Abdullah Aziz; Hamid, M. F.; Ismail, M. A.

    2017-07-01

    This paper presents the numerical simulation of epoxy molding compound (EMC) filling in multi flip-chip packages during encapsulation process. The empty and a group flip chip packages were considered in the mold cavity in order to study the flow profile of the EMC. SOLIDWORKS software was used for three-dimensional modeling and it was incorporated into fluid analysis software namely as ANSYS FLUENT. The volume of fluid (VOF) technique was used for capturing the flow front profiles and Power Law model was applied for its rheology model. The numerical result are compared and discussed with previous experimental and it was shown a good conformity for model validation. The prediction of flow front was observed and analyzed at different filling time. The possibility and visual of void formation in the package is captured and the number of flip-chip is one factor that contributed to the void formation.

  19. Stability of FDTS monolayer coating on aluminum injection molding tools

    DEFF Research Database (Denmark)

    Cech, Jiri; Taboryski, Rafael J.

    2012-01-01

    The injection molding industry often employs prototype molds and mold inserts from melt spun (rapid solidification processing [1,2]) aluminum, especially for applications in optics [3,4], photonics [5] and microfludics. Prototypes are also used for verification of mold filling. The use of aluminum...... tools has reduced lead time (days instead of weeks) and manufacturing cost (30% of conventional mold). Moreover, for aluminum, a surface roughness (RMS) below 5 nm can be obtained with diamond machining [3,4,6]. Conventional mold coatings add cost and complexity, and coatings with thicknesses of a few...... trichloro-silane based coating deposited on aluminum or its alloys by molecular vapor deposition. We have tested the stability of this coating in challenging conditions of injection molding, an environment with high shear stress from the molten polymer, pressures up to 200 MPa, temperatures up to 250 ◦C...

  20. Shrinkage Behaviour of Spheroidal Graphite Cast Iron in Green and Dry Sand Molds for the Benchmarking of Solidification Simulation

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    The effects of metallurgical and processing parameters on the formation of shrinkage cavities and porosities in spheroidal graphite cast iron have been studied, considering the parameters of carbon equivalent, inoculation, casting modulus, mold type (green or dry) and pouring temperature within specific ranges of these variables. Based on the orthogonal experiments, the metallurgical and processing parameters of the minimum casting shrinkage and the maximum casting shrinkage were obtained, and the effects of metallurgical and processing parameters on the formation of shrinkage cavities and porosities in spheroidal graphite cast iron castings were discussed. Finally,two regression equations relating these variables to the formation of shrinkage porosity were derived based upon the orthogonal experiments conducted.

  1. The Multi-SAG project: filling the MultiDark simulations with semi-analytic galaxies

    Science.gov (United States)

    Vega-Martínez, C. A.; Cora, S. A.; Padilla, N. D.; Muñoz Arancibia, A. M.; Orsi, A. A.; Ruiz, A. N.

    2016-08-01

    The semi-analytical model sag is a code of galaxy formation and evolution which is applied to halo catalogs and merger trees extracted from cosmological -body simulations of dark matter. This contribution describes the project of constructing a catalog of simulated galaxies by adapting and applying the model sag over two dark matter simulations of the spanish MultiDark Project publicly available. Those simulations have particles, each, in boxes with sizes of 1000 Mpc and 400 Mpc respectively with Planck cosmological parameters. They cover a large range of masses and have halo mass resolutions of , therefore each simulation is able to produce more than 150 millions of simulated galaxies. A detailed description of the method is explained, and the first statistical results are shown.

  2. Numerical Simulation of Heat Transfer and Deformation of Initial Shell in Soft Contact Continuous Casting Mold Under High Frequency Electromagnetic Field

    Institute of Scientific and Technical Information of China (English)

    2007-01-01

    Heat transfer and deformation of initial solidification shell in soft contact continuous casting moldunder high frequency electromagnetic field were analyzed using numerical simulation method; the relative electromagnetic parameters were obtained from the previous studies. Owing to the induction heating of a high frequency electromagnetic field (20 kHz), the thickness of initial solidification shell decreases, and the temperature of strand surface and slit copper mold increases when compared with the case without the electromagnetic filed. The viscosity of flux decreases because of the induction heating of the high frequency electromagnetic field, and the dimension of the flux channel increases with electromagnetic pressure; thus, the deformation behavior of initial solidification shell was different before and after the action of high frequency electromagnetic field. Furthermore, the abatement mechanism of oscillation marks under high frequency electromagnetic field was explained.

  3. Vacuum Infusion Molding Process (Part 2 VIMP Based on Grooves)

    Institute of Scientific and Technical Information of China (English)

    ZHU Ying-dan; DENG Jing-lan; WANG Ji-hui; TAN Hua

    2003-01-01

    The optimal parameters for flow grooves and supply grooves were determined by a series of experiments , and the influences of various molding conditions on the mold filling process were analyzed. Furthermore ,the whole VIMP procedure based on grooves was introduced in detail taking the manufacture of a sandwich panel as an example.

  4. Study On The External Gas-Assisted Mold Temperature Control For Thin Wall Injection Molding

    Directory of Open Access Journals (Sweden)

    ThanhTrung Do

    2017-03-01

    Full Text Available Dynamic mold surface temperature control (DMTC has many advantages in micro-injection molding as well as thin-wall molding product. In this paper, DMTC will be applied for the thin-wall molding part with the observation of the weldline appearance and the weldline strength. The heating step of DMTC will be achieved by the hot air flow directly to the weldline area. The results show that the heating rate could be reached to 4.5C/s, which could raising the mold surface from 30C to over 120C within 15 s. The melt filling was operated with high temperature at the weldline area; therefore, the weldline appearance was eliminated. In addition, the weldline strength was also improved. The results show that the thinner part had the higher strength of the weldline

  5. Effect of mold treatment by solvent on PDMS molding into nanoholes

    Science.gov (United States)

    Con, Celal; Cui, Bo

    2013-09-01

    Polydimethylsiloxane (PDMS) is the most popular and versatile material for soft lithography due to its flexibility and easy fabrication by molding process. However, for nanoscale patterns, it is challenging to fill uncured PDMS into the holes or trenches on the master mold that is coated with a silane anti-adhesion layer needed for clean demolding. PDMS filling was previously found to be facilitated by diluting it with toluene or hexane, which was attributed to the great reduction of viscosity for diluted PDMS. Here, we suggest that the reason behind the improved filling for diluted PDMS is that the diluent solvent increases in situ the surface energy of the silane-treated mold and thus the wetting of PDMS to the mold surface. We treated the master mold surface (that was already coated with a silane anti-adhesion monolayer) with toluene or hexane, and found that the filling by undiluted PMDS into the nanoscale holes on the master mold was improved despite the high viscosity of the undiluted PDMS. A simple estimation based on capillary filing into a channel also gives a filling time on the millisecond scale, which implies that the viscosity of PMDS should not be the limiting factor. We achieved a hole filling down to sub-200-nm diameter that is smaller than those of the previous studies using regular Sylgard PDMS (not hard PDMS, Dow Corning Corporation, Midland, MI, USA). However, we are not able to explain using a simple argument based on wetting property why smaller, e.g., sub-100-nm holes, cannot be filled, for which we suggested a few possible factors for its explanation.

  6. Development of Metal Plate with Internal Structure Utilizing the Metal Injection Molding (MIM Process

    Directory of Open Access Journals (Sweden)

    Kwangho Shin

    2013-12-01

    Full Text Available In this study, we focus on making a double-sided metal plate with an internal structure, such as honeycomb. The stainless steel powder was used in the metal injection molding (MIM process. The preliminary studies were carried out for the measurement of the viscosity of the stainless steel feedstock and for the prediction of the filling behavior through Computer Aided Engineering (CAE simulation. PE (high density polyethylene (HDPE and low density polyethylene (LDPE and polypropylene (PP resins were used to make the sacrificed insert with a honeycomb structure using a plastic injection molding process. Additionally, these sacrificed insert parts were inserted in the metal injection mold, and the metal injection molding process was carried out to build a green part with rectangular shape. Subsequently, debinding and sintering processes were adopted to remove the sacrificed polymer insert. The insert had a suitable rigidity that was able to endure the filling pressure. The core shift analysis was conducted to predict the deformation of the insert part. The 17-4PH feedstock with a low melting temperature was applied. The glass transition temperature of the sacrificed polymer insert would be of a high grade, and this insert should be maintained during the MIM process. Through these processes, a square metal plate with a honeycomb structure was made.

  7. Reduction of Injection Pressure for Thin Walled Molding using the Laser Metal Sintered Mold

    OpenAIRE

    米山, 猛; 内藤, 圭亮; 阿部, 諭; 宮丸, 充

    2010-01-01

    Using milling combined laser metal sintering, porous surface has been fabricated on the thin walled cavity closed by the surrounded thick cavity in the injection mold. Resin flows into the cavity of 2mm thick at first around the thin part and then flows into the thin cavity of 0.2mm thick with 11mm square by packing pressure. The packing pressure for filling the thin part was compared among laser metal sintered mold with or without porous surface, steel mold with or without porous block. The ...

  8. Mathematical simulation of nonisothermal filling of plane channel with non-Newtonian fluid

    Science.gov (United States)

    Borzenko, E.; Ryltseva, K.; Frolov, O.; Shrager, G.

    2016-10-01

    In this paper, the fountain flow of a non-Newtonian fluid during the filling of a plane vertical channel with due account of dissipative heating is investigated. The rheological features of the medium are defined by Ostwald de Waele power-law with exponential temperature dependence of viscosity. The numerical solution of the problem is obtained using a finite-difference method, based on the SIMPLE algorithm, and the method of invariants for compliance with the natural boundary conditions on free surface. It was shown that the flow separates into a two-dimensional flow zone in the vicinity of the free surface and a onedimensional flow zone away from it. The parametrical investigations of kinematic and thermophysical properties of the flow and the dependence of the free surface behavior on the basic criteria and rheological parameters are implemented.

  9. CAE模拟分析在水龙头手柄压铸模设计中的应用%Application of CAE Simulation Analysis to the Design of Die Casting Mold for Faucet Handle

    Institute of Scientific and Technical Information of China (English)

    陈怀民

    2012-01-01

    针对传统压铸模具浇注系统设计采用试错法存在的缺陷,本文通过水龙头手柄压铸模设计,提出利用ProCAST铸造模拟分析功能,先确定内浇道合理位置,再进行浇注系统详细设计及模具设计,避免浇注系统对铸件成形过程不利影响,提高铸件质量,缩短模具制造周期.可为类似铸件浇注系统及压铸模具设计提供参考.%Aimed at the existing defects of traditional die casting mold gating system design by trial-and-error method, first the reasonable location of the ingate was determined and then the gating system and mold were designed in detail through designing the faucet handle die-casting mold, utilizing ProCAST casting simulation analysis capabilities, which avoid the adverse effects of the gating system for casting formation process, improve casting quality, and reduce mold manufacturing period. It can provide a reference for similar casting gating system and die casting mold design.

  10. Numerical simulation of an acoustic field generated by a phased arc array in a fluid-filled borehole

    Institute of Scientific and Technical Information of China (English)

    Che Xiaohua; Qiao Wenxiao

    2009-01-01

    The acoustic tools widely used in borehole well logging and being developed in borehole acoustic reflection imaging do not have the function of azimuthal measurement due to a symmetric source, so they can not be used to evaluate the azimuthal character of borehole formation. In this paper, a 3D finite difference method was used to simulate the acoustic fields in a fluid-filled borehole generated by a traditional monopole source and a phased arc array. Acoustic waveforms were presented for both cases. The analysis of the simulated waveforms showed that different from the monopole source, the acoustic energy generated by the phased arc array transmitter mainly radiated to the borehole in a narrow azimuthal range, which was the key technique to implement azimuthal acoustic well logging. Similar to the monopole source, the waveforms generated by the phased arc array in the fluid-filled borehole also contain compressional (P) waves and shear (S) waves refracted along the borehole, which is the theoretical foundation of phased arc array acoustic well logging.

  11. Study on Effects of Mold Temperature on the Injection Molded Article

    Directory of Open Access Journals (Sweden)

    Han J.-H.

    2017-06-01

    Full Text Available This is a study of the effects of temperature of injection mold on the injection molded article. By supplying water of the proper temperature in the cooling line of mold in the cooling process, the mold was the appropriate temperature, and the deformation of the injection molded article was examined according to the mold temperature. In this study, we conducted simulation analysis and experiments, and the results were analyzed. The minimum deformation of the injection molded article model obtained by supplying 50°C water in the cooling line is 0.003 mm, and the maximum deformation was 0.813 mm. Injection molded article models obtained by supplying 20°C water were found to be a minimum of 0.002 mm, with deformation of up to 0.761 mm. When comparing both conditions, the error rate of injection molded article obtained by supplying 20°C water in the mold cooling line was lower by about 0.18%.

  12. Floods and Mold Growth

    Science.gov (United States)

    Mold growth may be a problem after flooding. Excess moisture in the home is cause for concern about indoor air quality primarily because it provides breeding conditions for pests, molds and other microorganisms.

  13. JUSTIFICATION OF RATIONAL KINEMATIC CHARACTERISTICS OF MOLDING VIBRATING TABLE

    Directory of Open Access Journals (Sweden)

    P. G. Anofriev

    2016-12-01

    Full Text Available Purpose. One of the efficient ways to obtain castings of complex shape is lost foam casting (LFC in the evacuated molds (containers. Upgrading the quality of this casting method requires improvement of molding techniques. The molding process involves layer-by-layer vibratory compaction of sand in the containers. Most of the lines of LFC sections are equipped with vibrating tables with inertia oscillators driven by induction motors, operating at nominal speed. A promising way of improving the molding technique is the rational setting of the following parameters of vibrating table: vibration displacement, velocity and acceleration. These parameters are determined by the elastic-mass characteristics of the system «vibrating table – mold» and perturbing forces created by inertia oscillators. The aim of the study is to determine the rational range of setting the parameters of oscillators at which the qualitative layer-by-layer compaction of the molding sand in the mold takes place. Methodology. The efficiency criterion for setting characteristics of the vibrating table there were taken the values of averaged accelerations of 6.5 – 7.5 m/s2 corresponding to maximum compaction degree of dry molding sand and the range of acceleration values 9 – 9.5 m/s2 for giving the sand «pseudo-yielding». For the study it was developed a mathematical model of oscillations of the movable part of vibrating table with two types of casting containers for steady and transient operation modes. Findings. In the process of research of the mold oscillations it was calculated the natural frequencies of oscillations at different elastic-mass characteristics of the system using a mathematical model. It was constructed the frequency response of displacements and accelerations of the moving part of the table with container filled with molding sand layer-by-layer. Originality. The author proposes a method of determining the range of frequency setting of inertial

  14. Investigation of micro-injection molding based on longitudinal ultrasonic vibration core.

    Science.gov (United States)

    Qiu, Zhongjun; Yang, Xue; Zheng, Hui; Gao, Shan; Fang, Fengzhou

    2015-10-01

    An ultrasound-assisted micro-injection molding method is proposed to improve the rheological behavior of the polymer melt radically, and a micro-injection molding system based on a longitudinal ultrasonic vibration core is developed and employed in the micro-injection molding process of Fresnel lenses. The verification experiments show that the filling mold area of the polymer melt is increased by 6.08% to 19.12%, and the symmetric deviation of the Fresnel lens is improved 15.62% on average. This method improved the filling performance and replication quality of the polymer melt in the injection molding process effectively.

  15. Bleach Neutralizes Mold Allergens

    Science.gov (United States)

    Science Teacher, 2005

    2005-01-01

    Researchers at National Jewish Medical and Research Center have demonstrated that dilute bleach not only kills common household mold, but may also neutralize the mold allergens that cause most mold-related health complaints. The study, published in the Journal of Allergy and Clinical Immunology, is the first to test the effect on allergic…

  16. Numerical simulation of low pressure die-casting aluminum wheel

    Institute of Scientific and Technical Information of China (English)

    Mi Guofa; Liu Xiangyu; Wang Kuangfei; Fu Hengzhi

    2009-01-01

    The FDM numerical simulation software, ViewCast system, was employed to simulate the low pressure die casting (LPDC) of an aluminum wheel. By analyzing the mold-filling and solidification stage of the LPDC process, the distribution of liquid fraction, temperature field and solidification pattern of castings were studied. The potential shrinkage defects were predicted to be formed at the rim/spoke junctions, which is in consistence with the X-ray detection result. The distribution pattern of the defects has also been studied. A solution towards reducing such defects has been presented. The cooling capacity of the mold was improved by installing water pipes both in the side mold and the top mold. Analysis on the shrinkage defects under forced cooling mode proved that adding the cooling system in the mold is an effective method for reduction of shrinkage defects.

  17. IC chip stress during plastic package molding

    Energy Technology Data Exchange (ETDEWEB)

    Palmer, D.W.; Benson, D.A.; Peterson, D.W.; Sweet, J.N.

    1998-02-01

    Approximately 95% of the world`s integrated chips are packaged using a hot, high pressure transfer molding process. The stress created by the flow of silica powder loaded epoxy can displace the fine bonding wires and can even distort the metalization patterns under the protective chip passivation layer. In this study the authors developed a technique to measure the mechanical stress over the surface of an integrated circuit during the molding process. A CMOS test chip with 25 diffused resistor stress sensors was applied to a commercial lead frame. Both compression and shear stresses were measured at all 25 locations on the surface of the chip every 50 milliseconds during molding. These measurements have a fine time and stress resolution which should allow comparison with computer simulation of the molding process, thus allowing optimization of both the manufacturing process and mold geometry.

  18. Simulation of Femtosecond Pulse Propagation through Hollow Fibre Filled with Noble Gases of Gradient Temperature

    Institute of Scientific and Technical Information of China (English)

    SONG Zhen-Ming; ZHANG Guang-Xiao; CAO Shi-Ying; PANG Dong-Qing; CHAI Lu; WANG Qing-Yue; ZHANG Zhi-Gang

    2008-01-01

    We propose a novel technique for generating intense few to mono-cycle femtosecond pulses.The simulation demonstrate that for the temperature difference of 300K,the spectrum of the output pulses is increased by 67%and the transform limited pulse width is reduced almost by half,compared with those obtained with hollow fibres in uniform temperature.

  19. 机箱盖板金属型铸造工艺%Permanent Molding of Avionics Case Cover Plate

    Institute of Scientific and Technical Information of China (English)

    曾建民; 顾红; 路平; 沈成龙; 肖宪波

    2001-01-01

    In the permanent molding process, computer emulation technology is adopted to simulate the process of mould filling and solidification and to optimize the casting parameters.%采用计算机仿真技术对机箱盖板金属型铸造过程进行了充型和凝固模拟,并对铸造工艺进行了优化。

  20. Metamodel-based design optimization of injection molding process variables and gates of an automotive glove box for enhancing its quality

    Energy Technology Data Exchange (ETDEWEB)

    Kang, Gyung Ju [Pusan National University, Busan (Korea, Republic of); Park, Chang Hyun; Choi, Dong Hoon [Hanyang University, Seoul (Korea, Republic of)

    2016-04-15

    Injection molding process variables and gates of an automotive glove box were optimally determined to enhance its injection molding quality. We minimized warpage with satisfying constraints on clamp force, weldline, and profiles of filling and packing. Design variables concerning the injection molding process are temperatures of the mold and the resin, ram speeds, and packing pressures and durations; design variables concerning the gates are the shape of the center gate and locations of two side gates. To optimally determine the design variables in an efficient way, we adopted metamodel-based design optimization, sequentially using an optimal Latin hypercube design as a design of experiment, Kriging models as metamodels that replace time-consuming injection molding simulations, and a micro genetic algorithm as an optimization algorithm. In the optimization process, a commercial injection molding analysis software, MoldflowTM, was employed to evaluate the injection molding quality at design points specified. Using the proposed design approach, the warpage was found reduced by 20.5% compared to the initial warpage, while all the design constraints were satisfied, which clearly shows the validity of the proposed design approach.

  1. Evaluation of simulation learning materials use to fill the gap in Japanese dental English education.

    Science.gov (United States)

    Seki, Naoko; Moross, Janelle; Sunaga, Masayo; Hobo, Koki; Miyoshi, Tomoe; Nitta, Hiroshi; Kinoshita, Atsuhiro; Morio, Ikuko

    2016-01-01

    Even though English is most frequently the common language when the patient's native language differs from that of a dentist, the opportunities for Japanese undergraduate dental students to learn dental English are now quite limited. The purposes of our study were to investigate: the effectiveness and feasibility of the computer-assisted simulation materials as one solution strategy for dental English education in Japan, and the needs and demands for dental English from the learners' side. Interactive simulation materials for medical interviews in English and clinical cases which were translated to English, were delivered via Learning Management System (LMS) to nineteen trainee residents of dentistry (residents). Evaluation for the materials, learners' knowledge and interests in the contents, and ease of operation were obtained by post-questionnaire (response rates were 100% and 95%, respectively). Both questionnaire-surveys received positive feedback toward the materials, yet 47% answered that they lacked the level of knowledge about contents of the medical interview in English. Results were sufficient to suggest that the residents would like to have the opportunity to study or practice medical interview in English, or English related to dentistry, and that the simulation materials could be one of the solution strategies for opportunity provision.

  2. Vacuum Infusion Molding Process Part 1:VIMP Based on a High-Permeable Medium

    Institute of Scientific and Technical Information of China (English)

    ZHU Ying-dan; WANG Ji-hui; YANG Zui; TAN Hua

    2003-01-01

    The visualization experiments were carried out to investigate the permeability of the high-permeable medium (HPM) and the roles of the peel ply and the HPM in the mold filling.The influence of process parameters on mold filling is discussed.Furthermore,the whole vacuum infusion molding process (VIMP) procedure is introduced in detail taking the manufacture of a model boat for example.

  3. Integrated mold/surface-micromachining process

    Energy Technology Data Exchange (ETDEWEB)

    Barron, C.C.; Fleming, J.G.; Montague, S.; Sniegowski, J.J.; Hetherington, D.L.

    1996-03-01

    We detail a new monolithically integrated silicon mold/surface-micromachining process which makes possible the fabrication of stiff, high-aspect-ratio micromachined structures integrated with finely detailed, compliant structures. An important example, which we use here as our process demonstration vehicle, is that of an accelerometer with a large proof mass and compliant suspension. The proof mass is formed by etching a mold into the silicon substrate, lining the mold with oxide, filling it with mechanical polysilicon, and then planarizing back to the level of the substrate. The resulting molded structure is recessed into the substrate, forming a planar surface ideal for subsequent processing. We then add surface-micromachined springs and sense contacts. The principal advantage of this new monolithically integrated mold/surface-micromachining process is that it decouples the design of the different sections of the device: In the case of a sensitive accelerometer, it allows us to optimize independently the proof mass, which needs to be as large, stiff, and heavy as possible, and the suspension, which needs to be as delicate and compliant as possible. The fact that the high-aspect-ratio section of the device is embedded in the substrate enables the monolithic integration of high-aspect-ratio parts with surface-micromachined mechanical parts, and, in the future, also electronics. We anticipate that such an integrated mold/surface micromachining/electronics process will offer versatile high-aspect-ratio micromachined structures that can be batch-fabricated and monolithically integrated into complex microelectromechanical systems.

  4. Dynamics of pit filling in heteroepitaxy via phase-field simulations

    Science.gov (United States)

    Albani, Marco; Bergamaschini, Roberto; Montalenti, Francesco

    2016-08-01

    Heteroepitaxial growth on a pit-patterned substrate is investigated by phase-field simulations, tackling both film and substrate geometry and elastic properties. The dynamics results from material deposition and redistribution via surface diffusion according to the tendency toward free-energy minimization. The balance between surface energy, misfit strain, and wetting effects is taken into account. Numerical solution by finite-element method permits to properly account for the role played by the actual pit morphology in determining strain relaxation. The mechanisms leading to island growth into the pit are discussed. Different growth parameters and pattern geometries are considered and their effects on island ordering are explained and related to experimental evidences in literature.

  5. Measurement of $\\beta\\beta$ Decay-Simulating Events in Nuclear Emulsion with Molybdenum Filling

    CERN Document Server

    Ashitkov, V D; Bradnova, V Ya; Ditlov, V A; Dubinina, V V; Egorenkova, N P; Konovalov, S I; Pozharova, E A; Polukhina, N G; Smirnitsky, V A; Starkov, N I; Chernyavsky, M M; Shchedrina, T V; Umatov, V I

    2011-01-01

    The measurement of positron--nucleus collisions was used to estimate the possibility of suppressing background events that simulate $\\beta\\beta$ decay in the emulsion region adjacent to molybdenum conglomerates. The range of the escape of two relativistic particles from the interaction was found to be $ = (0.60\\pm 0.03) ~\\mu$m, which approximately corresponds to the grain size of developed nuclear emulsion. No correlation of the values of d with the angle between two relativistic particles was observed. It was shown that it was possible to exclude $\\beta\\beta$ decay background from electrons emerging in the decay of elements of naturally occurring radioactive chains. The background from $\\beta$ decays of $^{90}$Sr and $^{40}$K available in emulsion around Mo conglomerates was determined by the ratio of the volume $(\\sim d^3)$ to the total volume of emulsion and was found to be $1.5\\cdot 10^{-2}$. It was shown that the backgrounds from $^{40}$K, $^{90}$Sr and natural radioactivity could be significantly suppre...

  6. Mold deformation in soft UV-nanoimprint lithography

    Institute of Scientific and Technical Information of China (English)

    2009-01-01

    UV-nanoimprint lithography (UV-NIL) using a soft mold is a promising technique with low cost and high throughput for producing the submicron scale large-area patterns. However, the deformations of the soft mold during imprinting process which can cause serious consequences have to be understood for the practical application of the process. This paper investigated the deformation of the soft mold by theoretical analyses, numerical simulations, and experimental studies. We simulated the mold deformation using a simplified model and finite element method. The simulation and the related experimental results agree well with each other. Through the investigation, the mechanism and affected factors of the mold deformation are revealed, and some useful conclusions have been achieved. These results will be valuable in optimizing the imprinting process conditions and mold design for improving the quality of transferred patterns.

  7. Ultra-precision molding of chalcogenide glass aspherical lens

    Science.gov (United States)

    Zhang, Feng; Wang, Zhibin; Zhang, Yunlong; Su, Ying; Guo, Rui; Xu, Zengqi; Liu, Xuanmin

    2016-10-01

    With the development of infrared optical systems in military and civil areas, chalcogenide glass aspherical lens possess some advantages, such as large infrared transmission, good thermal stability performance and image quality. Aspherical lens using chalcogenide glass can satisfy the requirements of modern infrared optical systems. Therefore, precision manufacturing of chalcogenide glass aspheric has received more and more attention. The molding technology of chalcogenide glass aspheric has become a research hotspot, because it can achieve mass and low cost manufacturing. The article of molding technology is focusing on a kind of chalcogenide glass aspherical lens. We report on design and fabrication of the mold that through simulation analysis of molding. Finally, through molding test, the fabrication of mold's surface and parameters of molding has been optimized, ensuring the indicators of chalcogenide glass aspherical lens meet the requirements.

  8. Fracture resistance of simulated immature teeth filled with Biodentine and white mineral trioxide aggregate - an in vitro study.

    Science.gov (United States)

    Elnaghy, Amr M; Elsaka, Shaymaa E

    2016-04-01

    The purpose of this study was to evaluate the long-term fracture resistance of simulated immature teeth filled with Biodentine (BD) and white mineral trioxide aggregate (WMTA) as pulp space barriers for regenerative endodontic procedures (REPs). Sixty extracted human maxillary anterior teeth were divided into four groups of 15 teeth each. Positive control teeth received no treatment. The remaining teeth were prepared until a size 6 Peeso (1.7 mm) could be passed 1 mm beyond the apex. Then, an engineering twist drill of 3 mm diameter was used to extend the preparation of the canal 3 mm below CEJ. The root canals were irrigated and disinfected according to AAE considerations for REPs. The canals were filled with either BD or WMTA. The negative control canals were left unfilled. The coronal access cavities were restored with glass ionomer followed by composite resin. The teeth were placed in phosphate-buffered saline solution and stored for 12 months. Each specimen was then subjected to fracture testing using a universal testing machine. The peak load to fracture and the fracture resistance were recorded, and the data were analysed statistically. The positive control group had the highest fracture resistance and differed significantly (P  0.05). Considering the risk of cervical root fracture for pulpless infected immature teeth treated with REPs, after 12 months, there was no difference between WMTA and BD regarding the resistance to root fracture. © 2015 John Wiley & Sons A/S. Published by John Wiley & Sons Ltd.

  9. Numerical Simulation Analysis on Filling Process of Lost Foam Casting%消失模铸造充型过程的数值模拟分析

    Institute of Scientific and Technical Information of China (English)

    彭静; 郭玲宏

    2012-01-01

    Based on numerical simulation software, the filling process of lost foam casting was simulated and the changes of vacuum were analyzed. The producing process and reasons of defects in the fill process such as coanda effect, wrapped gas and anti -spray were studied.%应用计算机数值模拟技术对消失模铸造充型过程仿真,对充型过程中真空度的变化进行分析,研究充型过程中附壁效应、裹气和反喷缺陷的产生过程及原因。

  10. Operative simulation of anterior clinoidectomy using a rapid prototyping model molded by a three-dimensional printer.

    Science.gov (United States)

    Okonogi, Shinichi; Kondo, Kosuke; Harada, Naoyuki; Masuda, Hiroyuki; Nemoto, Masaaki; Sugo, Nobuo

    2017-05-15

    As the anatomical three-dimensional (3D) positional relationship around the anterior clinoid process (ACP) is complex, experience of many surgeries is necessary to understand anterior clinoidectomy (AC). We prepared a 3D synthetic image from computed tomographic angiography (CTA) and magnetic resonance imaging (MRI) data and a rapid prototyping (RP) model from the imaging data using a 3D printer. The objective of this study was to evaluate anatomical reproduction of the 3D synthetic image and intraosseous region after AC in the RP model. In addition, the usefulness of the RP model for operative simulation was investigated. The subjects were 51 patients who were examined by CTA and MRI before surgery. The size of the ACP, thickness and length of the optic nerve and artery, and intraosseous length after AC were measured in the 3D synthetic image and RP model, and reproducibility in the RP model was evaluated. In addition, 10 neurosurgeons performed AC in the completed RP models to investigate their usefulness for operative simulation. The RP model reproduced the region in the vicinity of the ACP in the 3D synthetic image, including the intraosseous region, at a high accuracy. In addition, drilling of the RP model was a useful operative simulation method of AC. The RP model of the vicinity of ACP, prepared using a 3D printer, showed favorable anatomical reproducibility, including reproduction of the intraosseous region. In addition, it was concluded that this RP model is useful as a surgical education tool for drilling.

  11. MOLECULAR DYNAMICS SIMULATIONS OF FILLED AND EMPTY CAGE-LIKE WATER CLUSTERS IN LIQUID WATER AND THEIR SIGNIFICANCE TO GAS HYDRATE FORMATION MECHANISMS

    Institute of Scientific and Technical Information of China (English)

    GUO Guangjun; ZHANG Yigang; ZHAO Yajuan

    2003-01-01

    Molecular dynamics simulations are performed to observe the evolutions of 512 and 51262 cage-like water clusters filled with or without a methane molecule immersed in bulk liquid water at 250 K and 230 K. The lifetimes of these clusters are calculated according to their Lindemann index δ (t) using the criteria of δ≥0.07. For both the filled and empty clusters, we find the dynamics of bulk water determines the lifetimes of cage-like water clusters, and that the lifetime of 512 62 cage-like cluster is the same as that of 512 cage-like cluster. Although the methane molecule indeed makes the filled cage-like cluster more stable than the empty one, the empty cage-like cluster still has chance to be long-lived compared with the filled clusters. These observations support the labile cluster hypothesis on the formation mechanisms of gas hydrates.

  12. Characterization of preform permeability and flow behavior for liquid composite molding

    Science.gov (United States)

    Sommerlot, Stephen Joseph

    Preform characterization is an important step in the processing of high-performance parts with liquid composite molding. A better understanding of preform compressibility and permeability creates more accurate process models, ultimately leading to high-quality finished composites. Without characterization, mold design and processing parameters are subject to guess-work and ad hoc optimization methods, which can result in poor infusions and inconsistent part quality. In this study, a complex architecture fiber reinforcement was characterized in compaction and permeability for liquid composite molding. Preforms of a four-harness satin carbon fabric were assembled with and without a novel inter-layer tackifier for experimentation. Compaction and permeability were measured to investigate the effects of the tackifier system, debulking, preform layup, and other processing parameters. Permeability and flow behavior was measured through saturated and unsaturated techniques, including investigations of fluid effects and high-flow rate infusions. The tackifier was seen to decrease permeability in both saturated and unsaturated cases, while notably influencing the orientation of first principal permeability. Tackified preforms also displayed a sensitivity to fluid type that non-tackified samples did not. Experimentally derived permeability was also used to generate numerical mold fill simulations of radially injected infusions, which produced favorable results.

  13. Polymer microlens array integrated with imaging sensors by UV-molding technique

    Science.gov (United States)

    Lai, Jianjun; Zhao, Yue; Ke, Caijun; Yi, Xinjian; Zhang, TianXu

    2005-01-01

    Fabrication of Polymer microlens array based on UV-molding techniques is presented. UV-molding enables for the integration of polymer microlens array on top of arbitrary substrates like glass, silicon other polymeric films. In this technique, photoresist or glass mold is first fabricated by conventional photolithnic method and subsequently served as transparent replication tool. UV curable polymer resin is then coated on patterned or unpatterned substrates and a contact mask aligner is used to align substrates and replication mold tool and then make the mold immersed into the resin. Replication of polymer on substrates is achieved by UV photopolymerisation of the resin. Resin thickness and gap distance between mold and substrate are carefully controlled in order to obtain acceptable thickness of cured polymer base. The UV molding technique was used to molding of a polymer film carring microlens array on the surface of an experimental CCD imaging sensor chip in this paper to enhance its fill factor and sensitivity.

  14. Method and mold for casting thin metal objects

    Energy Technology Data Exchange (ETDEWEB)

    Pehrson, Brandon P; Moore, Alan F

    2014-04-29

    Provided herein are various embodiments of systems for casting thin metal plates and sheets. Typical embodiments include layers of mold cavities that are oriented vertically for casting the metal plates. In some embodiments, the mold cavities include a beveled edge such that the plates that are cast have a beveled edge. In some embodiments, the mold cavities are filled with a molten metal through an open horizontal edge of the cavity. In some embodiments, the mold cavities are filled through one or more vertical feed orifices. Further disclosed are methods for forming a thin cast metal plate or sheet where the thickness of the cast part is in a range from 0.005 inches to 0.2 inches, and the surface area of the cast part is in a range from 16 square inches to 144 square inches.

  15. THE DURABILITY OF LARGE-SCALE ADDITIVE MANUFACTURING COMPOSITE MOLDS

    Energy Technology Data Exchange (ETDEWEB)

    Post, Brian K [ORNL; Love, Lonnie J [ORNL; Duty, Chad [University of Tennessee (UTK) and Oak Ridge National Laboratory (ORNL); Vaidya, Uday [University of Tennessee, Knoxville (UTK); Pipes, R. Byron [Purdue University; Kunc, Vlastimil [ORNL

    2016-01-01

    Oak Ridge National Laboratory s Big Area Additive Manufacturing (BAAM) technology permits the rapid production of thermoplastic composite molds using a carbon fiber filled Acrylonitrile-Butadiene-Styrene (ABS) thermoplastic. Demonstration tools (i.e. 0.965 m X 0.559 m X 0.152 m) for composite part fabrication have been printed, coated, and finished with a traditional tooling gel. We present validation results demonstrating the stability of thermoplastic printed molds for room temperature Vacuum Assisted Resin Transfer Molding (VARTM) processes. Arkema s Elium thermoplastic resin was investigated with a variety of reinforcement materials. Experimental results include dimensional characterization of the tool surface using laser scanning technique following demolding of 10 parts. Thermoplastic composite molds offer rapid production compared to traditionally built thermoset molds in that near-net deposition allows direct digital production of the net geometry at production rate of 45 kg/hr.

  16. Injection-molded nanocomposites and materials based on wheat gluten.

    Science.gov (United States)

    Cho, S-W; Gällstedt, M; Johansson, E; Hedenqvist, M S

    2011-01-01

    This is, to our knowledge, the first study of the injection molding of materials where wheat gluten (WG) is the main component. In addition to a plasticizer (glycerol), 5 wt.% natural montmorillonite clay was added. X-ray indicated intercalated clay and transmission electron microscopy indicated locally good clay platelet dispersion. Prior to feeding into the injection molder, the material was first compression molded into plates and pelletized. The filling of the circular mold via the central gate was characterized by a divergent flow yielding, in general, a stronger and stiffer material in the circumferential direction. It was observed that 20-30 wt.% glycerol yielded the best combination of processability and mechanical properties. The clay yielded improved processability, plate homogeneity and tensile stiffness. IR spectroscopy and protein solubility indicated that the injection molding process yielded a highly aggregated structure. The overall conclusion was that injection molding is a very promising method for producing WG objects.

  17. Numerical Simulation of the Thermal Conductivity of Thermal Insulation Pipe by Vacuum and High Pressure Argon Pre-filled

    Institute of Scientific and Technical Information of China (English)

    2014-01-01

    [Abstract]By analyzing the insulation effect of argon-filled tubing and vacuum-insulated tubing before and after hydrogen permeation respectively, a conclusion can be drawn that the insulated tubing filled with high pressure argon is better than the vacuum insulated tubing considering the lifetime and heat insulation effect.

  18. CAE analysis of filling and weld line of injection molded polypropylene auto bumper%PP注射成型汽车保险杠填充及熔接痕CAE分析

    Institute of Scientific and Technical Information of China (English)

    李永泉; 李峰; 孙晋

    2011-01-01

    借助Moldflow软件,通过最佳浇口位置分析并结合制件结构,确定了汽前保险杠的两种浇口位置方案.对采用的汽车保险杠专用树脂高抗冲聚丙烯1215C进行了流变性能、压力-体积-温度关系曲线及热传导系数等的测定.通过Moldflow软件比较了两种浇口位置对制品产生熔接痕的位置、数量的影响以及熔体遇合角度与温度对熔接痕质量的影响.确定了当制品采用方案2的浇口位置时、熔接痕对产品外观性能影响较小.%Two gate location schemes to produce auto bumper via injection molding were determined by means of Moldflow software based on the analysis of the optimal gate location and the structure of the parts. The rheological properties, pressure-volume-temperature curves and thermal conductivity of high impact polypropylene special resin for auto bumper, 1215C, were tested. The effect of the two gate locations on the position and amount of weld line of the parts and the effect of weld line converging angle and temperature on the quality of weld line were studied with Moldflow. The weld line had smaller influence on the appearance and properties of the parts in the case of scheme 2.

  19. Glass molding process with mold lubrication

    Science.gov (United States)

    Davey, Richard G.

    1978-06-27

    Improvements are provided in glass forming processes of the type wherein hot metal blank molds are employed by using the complementary action of a solid film lubricant layer, of graphite dispersed in a cured thermoset organopolysiloxane, along with an overspray of a lubricating oil.

  20. Gating of Permanent Molds for Aluminum Casting

    Energy Technology Data Exchange (ETDEWEB)

    David Schwam; John F. Wallace; Tom Engle; Qingming Chang

    2004-01-01

    This report summarizes a two-year project, DE-FC07-011D13983 that concerns the gating of aluminum castings in permanent molds. The main goal of the project is to improve the quality of aluminum castings produced in permanent molds. The approach taken was to determine how the vertical type gating systems used for permanent mold castings can be designed to fill the mold cavity with a minimum of damage to the quality of the resulting casting. It is evident that somewhat different systems are preferred for different shapes and sizes of aluminum castings. The main problems caused by improper gating are entrained aluminum oxide films and entrapped gas. The project highlights the characteristic features of gating systems used in permanent mold aluminum foundries and recommends gating procedures designed to avoid common defects. The study also provides direct evidence on the filling pattern and heat flow behavior in permanent mold castings. Equipment and procedure for real time X-Ray radiography of molten aluminum flow into permanent molds have been developed. Other studies have been conducted using water flow and behavior of liquid aluminum in sand mold using real time photography. This investigation utilizes graphite molds transparent to X-Rays making it possible to observe the flow pattern through a number of vertically oriented grating systems. These have included systems that are choked at the base of a rounded vertical sprue and vertical gating systems with a variety of different ingates into the bottom of a mold cavity. These systems have also been changed to include gating systems with vertical and horizontal gate configurations. Several conclusions can be derived from this study. A sprue-well, as designed in these experiments, does not eliminate the vena contracta. Because of the swirling at the sprue-base, the circulating metal begins to push the entering metal stream toward the open runner mitigating the intended effect of the sprue-well. Improved designs of

  1. Deformation analysis considering thermal expansion of injection mold

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Jun Hyung; Yi, Dae Eun; Jang, Jeong Hui; Lee, Min Seok [Samsung Electronics Co., LTD., Seoul (Korea, Republic of)

    2015-09-15

    In the design of injection molds, the temperature distribution and deformation of the mold is one of the most important parameters that affect the flow characteristics, flash generation, and surface appearance, etc. Plastic injection analyses have been carried out to predict the temperature distribution of the mold and the pressure distribution on the cavity surface. As the input loads, we transfer the temperature and pressure results to the structural analysis. We compare the structural analysis results with the thermal expansion effect using the actual flash and step size of a smartphone cover part. To reduce the flash problem, we proposed a new mold design, and verified the results by performing simulations.

  2. Three-Dimensional Modeling of Glass Lens Molding

    DEFF Research Database (Denmark)

    Sarhadi, Ali; Hattel, Jesper Henri; Hansen, Hans Nørgaard

    2015-01-01

    The required accuracy for the final dimensions of the molded lenses in wafer-based precision glass molding as well as the need for elimination of costly experimental trial and error calls for numerical simulations. This study deals with 3D thermo-mechanical modeling of the wafer-based precision...... glass lens molding process. First, a comprehensive 3D thermo-mechanical model of glass is implemented into a FORTRAN user subroutine (UMAT) in the FE program ABAQUS, and the developed FE model is validated with both a well-known sandwich seal test and experimental results of precision molding of several...... glass rings. Afterward, 3D thermo-mechanical modeling of the wafer-based glass lens manufacturing is performed to suggest a proper molding program (i.e., the proper set of process parameters including preset force-time and temperature-time histories) for molding a wafer to a desired dimension...

  3. Replication of optical microlens arrays using photoresist coated molds

    DEFF Research Database (Denmark)

    Chakrabarti, Maumita; Dam-Hansen, Carsten; Stubager, Jørgen

    2016-01-01

    A cost reduced method of producing injection molding tools is reported and demonstrated for the fabrication of optical microlens arrays. A standard computer-numerical-control (CNC) milling machine was used to make a rough mold in steel. Surface treatment of the steel mold by spray coating...... the light engine. Polymer injection molded microlens arrays were produced from both the rough and coated molds and have been characterized for lenslet parameters, surface quality, light scattering, and acceptance angle. The surface roughness (Ra) is improved approximately by a factor of two after...... the coating process and the light scattering is reduced so that the molded microlens array can be used for the color mixing application. The measured accepted angle of the microlens array is 40° which is in agreement with simulations....

  4. A study of interfacial heat transfer and process parameters in squeeze casting and low pressure permanent mold casting

    Science.gov (United States)

    Krishna, Prasad

    2001-08-01

    With the emerging demand for energy efficient and environment-friendly automobiles, cast aluminum alloys are increasingly being used in their manufacture. In this context, two permanent mold casting processes, namely, Squeeze Cast Permanent Mold and Low Pressure Permanent Mold (LPPM) have become very popular in the production of high integrity shape-cast aluminum components. However, many industries are yet to benefit from the full potential of these processes due to limited understanding of the effect of process parameters on casting quality and the necessary boundary conditions for computer modeling and simulation so as to minimize costly field trials. This dissertation attempts to address some of these concerns facing today's foundry industry. An experimental investigation of the Indirect Squeeze Casting Process was conducted by pouring molten Al-7Si-0.3Mg (A356) alloy into a specially designed and instrumented mold, mounted on a horizontal clamped-vertical shot squeeze caster (HVSC). Temperature measurements close to the metal/mold interface were made and compared with the results of the numerical simulation of heat flow during solidification and cooling of castings. The Heat Transfer Coefficient (HTC), a critical parameter essential for any solidification simulation, was estimated based on the simulation that gave the best fit to the experimental temperature data. During the solidification process, the HTC is relatively uniform over the entire casting and on reaching a critical solidification pressure, the HTC is close to 4500 W/m2 K. The work has also provided a correlation of Secondary Dendrite Arm Spacing (SDAS) with cooling rate for a modified A356 alloy. Low Pressure Permanent Mold Casting experiments were conducted by pouring a nearly identical aluminum alloy into an instrumented, coated mold mounted on a low pressure casting machine. The pressure levels, along with the time required to achieve complete filling, were microprocessor controlled in the

  5. Simulation and Optimization Analysis of Tank Fuel Filling%某乘用车燃油加注过程优化分析

    Institute of Scientific and Technical Information of China (English)

    刘洋; 刘志鹏; 何金平; 秦昊; 张昆

    2016-01-01

    The structure of fuel-filling pipe was very important for the smoothness in the fuel filling process,a bad design of oil-filling pipe could cause fuel spilling or injector shut-off.Simulation of fuel-filling base on one vehicle was performed using the CFD software in this paper.The fuel and gas distribution of filling pipe is obtained in this simulation.According the result,then,the design of fuel-filling pipe was improved,the smoothness was better,and decrease fuel spilling risk,providing a basis for optimization design of a fuel-tank system.%汽车的燃油加注管的结构决定了燃油加注过程的顺畅性,设计结构不好的燃油加注管容易引起反喷或提前“跳枪”现象。文章运用CFD软件对某一乘用车燃油加注过程进行模拟分析,获得了不同时刻加注管内油气分布的状态。根据分析结果对加注管结构进行优化,使加注过程更加顺畅,降低了跳枪和反喷的风险,为燃油系统优化设计提供了参考。

  6. Numerical Simulation on Seismic Response of the Filled Joint under High Amplitude Stress Waves Using Finite-Discrete Element Method (FDEM

    Directory of Open Access Journals (Sweden)

    Xiaolin Huang

    2016-12-01

    Full Text Available This paper numerically investigates the seismic response of the filled joint under high amplitude stress waves using the combined finite-discrete element method (FDEM. A thin layer of independent polygonal particles are used to simulate the joint fillings. Each particle is meshed using the Delaunay triangulation scheme and can be crushed when the load exceeds its strength. The propagation of the 1D longitude wave through a single filled joint is studied, considering the influences of the joint thickness and the characteristics of the incident wave, such as the amplitude and frequency. The results show that the filled particles under high amplitude stress waves mainly experience three deformation stages: (i initial compaction stage; (ii crushing stage; and (iii crushing and compaction stage. In the initial compaction stage and crushing and compaction stage, compaction dominates the mechanical behavior of the joint, and the particle area distribution curve varies little. In these stages, the transmission coefficient increases with the increase of the amplitude, i.e., peak particle velocity (PPV, of the incident wave. On the other hand, in the crushing stage, particle crushing plays the dominant role. The particle size distribution curve changes abruptly with the PPV due to the fragments created by the crushing process. This process consumes part of wave energy and reduces the stiffness of the filled joint. The transmission coefficient decreases with increasing PPV in this stage because of the increased amount of energy consumed by crushing. Moreover, with the increase of the frequency of the incident wave, the transmission coefficient decreases and fewer particles can be crushed. Under the same incident wave, the transmission coefficient decreases when the filled thickness increases and the filled particles become more difficult to be crushed.

  7. Mold Image Library

    Science.gov (United States)

    The image library contains mold-related images in seven categories. There are also animated images that you can choose to view and download. These photos may be used for presentations and educational purposes without contacting EPA.

  8. Diseño y construcción de un molde permanente utilizando un software por elementos finitos Design and construction of a permanent mold using finite element software

    Directory of Open Access Journals (Sweden)

    Fausto Oviedo Fierro

    2013-06-01

    -practicalapplication for a piece of aluminum that will be built, and consists in the analysis of the functionsand stresses to which it is submitted. The metal mold is designed specifically for the mentionedpieces using “VULCAN” which is based on the Finite Element Method (FEM. The simulation isperformed in three stages of the fusion process: filling, solidification and cooling. The filling isconsidered slow enough so that there are not expected to be greater turbulences and that thepieces are completely filled. Solidification is analyzed as an optimal process, avoiding defects oflack of material in the mold cavity (shrinkage. In the cooling stage, deformations and residualstresses are analyzed. At the same time, every result is validated analytically. With thisinformation the final geometry of the metal mold is defined and the alloy which will be used is confirmed. Subsequently, a CAD-CAM-CAE system is used for the design and development ofthe mold, and the aluminum pieces (knobs obtained are tested.

  9. Single gate optimization for plastic injection mold

    Institute of Scientific and Technical Information of China (English)

    LI Ji-quan; LI De-qun; GUO Zhi-ying; LV Hai-yuan

    2007-01-01

    This paper deals with a methodology for single gate location optimization for plastic injection mold. The objective of the gate optimization is to minimize the warpage of injection molded parts, because warpage is a crucial quality issue for most injection molded parts while it is influenced greatly by the gate location. Feature warpage is defined as the ratio of maximum displacement on the feature surface to the projected length of the feature surface to describe part warpage. The optimization is combined with the numerical simulation technology to find the optimal gate location, in which the simulated annealing algorithm is used to search for the optimum. Finally, an example is discussed in the paper and it can be concluded that the proposed method is effective.

  10. Optimization of a Permanent Step Mold Design for Mg Alloy Castings

    Science.gov (United States)

    Timelli, Giulio; Capuzzi, Stefano; Bonollo, Franco

    2015-02-01

    The design of a permanent Step mold for the evaluation of the mechanical properties of light alloys has been reviewed. An optimized Step die with a different runner and gating systems is proposed to minimize the amount of casting defects. Numerical simulations have been performed to study the filling and solidification behavior of an AM60B alloy to predict the turbulence of the melt and the microshrinkage formation. The results reveal how a correct design of the trap in the runners prevents the backwave of molten metal, which could eventually reverse out and enter the die cavity. The tapered runner in the optimized die configuration gently leads the molten metal to the ingate, avoiding turbulence and producing a balanced die cavity filling. The connection between the runner system and the die cavity by means of a fan ingate produces a laminar filling in contrast with a finger-type ingate. Solidification defects such as shrinkage-induced microporosity, numerically predicted through a dimensionless version of the Niyama criterion, are considerably reduced in the optimized permanent Step mold.

  11. Transferability of glass lens molding

    Science.gov (United States)

    Katsuki, Masahide

    2006-02-01

    Sphere lenses have been used for long time. But it is well known that sphere lenses theoretically have spherical aberration, coma and so on. And, aspheric lenses attract attention recently. Plastic lenses are molded easily with injection machines, and are relatively low cost. They are suitable for mass production. On the other hand, glass lenses have several excellent features such as high refractive index, heat resistance and so on. Many aspheric glass lenses came to be used for the latest digital camera and mobile phone camera module. It is very difficult to produce aspheric glass lenses by conventional process of curve generating and polishing. For the solution of this problem, Glass Molding Machine was developed and is spreading through the market. High precision mold is necessary to mold glass lenses with Glass Molding Machine. The mold core is ground or turned by high precision NC aspheric generator. To obtain higher transferability of the mold core, the function of the molding machine and the conditions of molding are very important. But because of high molding temperature, there are factors of thermal expansion and contraction of the mold and glass material. And it is hard to avoid the factors. In this session, I introduce following items. [1] Technology of glass molding and the machine is introduced. [2] The transferability of glass molding is analyzed with some data of glass lenses molded. [3] Compensation of molding shape error is discussed with examples.

  12. Based on database and asp.net technologies, a web platform of scientific data in the casting forces on the mold-fi lling behavior of titanium melts in vertically rotating molds

    Directory of Open Access Journals (Sweden)

    Xu Daming

    2008-11-01

    Full Text Available The vertical centrifugal-casting technique is widely used in the manufacture of various irregularlyshaped castings of advanced structural alloys with thin walls, complex shapes and/or large sizes. These castings are used in the increasing applications in aero-space/aviation industries, human teeth/bone repairs with nearnet shaped components, etc. In a vertically rotating casting system, the mold-filling processes of alloy melts, coupled with solidifi cation-heat transfer, may be much more complicated, because they are driven simultaneously by gravity, centrifugal and Coriolis forces. In the present work, an N-S/VOF-equations-based model, solved using a SOLA-VOF algorithm, under a rotating coordinate system was applied to numerically investigate the impacts of centrifugal and Coriolis forces on metallic melt mold-fi lling processes in different vertical centrifugal-casting configurations with different mold-rotation rates using an authors’ computer-codes system. The computational results show that the Coriolis force may cause remarkable variations in the fl ow patterns in the casting-part-cavities of a large horizontal-section area and directly connected to the sprue via a short ingate in a vertical centrifugalcasting process. A “turn-back” mold-filling technique, which only takes advantage of the centrifugal force in a transient rotating melt system, has been confi rmed to be a rational centrifugal-casting process in order to achieve smooth and layer-by-layer casting-cavities-fi lling control. The simulated mold-fi lling processes of Ti-6Al-4V alloy melt, in a vertical centrifugal-casting system with horizontally-connected plate-casting cavities, show reasonable agreement with experimental results from the literature.

  13. Numerical modeling of magnetic induction and heating in injection molding tools

    DEFF Research Database (Denmark)

    Guerrier, Patrick; Hattel, Jesper Henri

    2013-01-01

    Injection molding of parts with special requirements or features such as micro- or nanostructures on the surface, a good surface finish, or long and thin features results in the need of a specialized technique to ensure proper filling and acceptable cycle time. The aim of this study is to increase...... numerical modeling of the induction heating in the mold to investigate how the temperature in the mold will be distributed and how it is affected by different material properties....

  14. 散热片砂型铸造过程的数值模拟%Numerical Simulation of Sand Mold Casting Cooling Fin

    Institute of Scientific and Technical Information of China (English)

    王广太

    2013-01-01

    用真空负压方法生产铝合金散热片,根据奥赞公式计算散热片的阻流截面积,根据热节圆原理计算冒口尺寸.通过数值模拟,观察铸件充型、凝固过程,预测缺陷所在位置,进行工艺分析及改进.结果表明,通过升高静压头,加大冒口,将缺陷转移至冒口中,可有效地避免铸件中的缩孔、缩松.优化的最佳工艺参数:浇注时间为3 s,浇注温度为740℃时金属静压头高度为40 mm,9个直径为10 mm的冒口.此时充型平稳,无卷气与飞溅;由下至上顺序凝固,可以实现补缩,生产出结构完整的铸件.%Aluminum alloy cooling fin was produced by vacuum negative pressure technology, in which gating area of cooling fin was calculated by the Osann equation, and riser size was presented based on the hot spot circle. The numerical simulation was performed to visualize filling and solidification process to predict the potential position of casting defects, and process was optimized. The simulated results reveal that shrinkage porosity (hole) in the cooling fin can be eliminated effectively as a result of defects transferring into the riser by increasing height of static head and enlarging riser size. The optimized process parameters are as follows: pouring time of 3 s, pouring temperature of 740 ℃ , hydrostatic head height of 40mm and nine risers with Φ10 mm. With the optimized processing parameters, smooth filling with entrapment-gas free and splash free is conducted to realize the sequential solidification and feeding, producing successfully the qualified cooling fin.

  15. Optimization of Mold Yield in MultiCavity Sand Castings

    Science.gov (United States)

    Shinde, Vasudev D.; Joshi, Durgesh; Ravi, B.; Narasimhan, K.

    2013-06-01

    The productivity of ductile iron foundries engaging in mass production of castings for the automobile and other engineering sectors depends on the number of cavities per mold. A denser packing of cavities, however, results in slower heat transfer from adjacent cavities, leading to delayed solidification, possible shrinkage defects, and lower mechanical properties. In this article, we propose a methodology to optimize mold yield by selecting the correct combination of the mold box size and the number of cavities based on solidification time and mold temperature. Simulation studies were carried out by modeling solid and hollow cube castings with different values of cavity-wall gap and finding the minimum value of the gap beyond which there is no change in casting solidification time. Then double-cavity molds were modeled with different values of cavity-cavity gap, and simulated to find the minimum value of gap. The simulation results were verified by melting and pouring ductile iron in green sand molds instrumented with thermocouples, and recording the temperature in mold at predetermined locations. The proposed approach can be employed to generate a technological database of minimum gaps for various combinations of part geometry, metal and process, which will be very useful to optimize the mold cavity layouts.

  16. Dynamic of taking out molding parts at injection molding

    Directory of Open Access Journals (Sweden)

    E. Ragan

    2012-10-01

    Full Text Available Most plastic parts used in automobile production are manufactured by injection molding. Their quality depends also on taking out molding and on the manipulators for it. Task of this contribution is to theoretically describe a transport of molding at taking out after injection molding in relation on its regulation. The following quantities are derived at it: the transition characteristic of the taking out system, the blocking diagram of taking out molding regulation, the amplitude and phase characteristic and the transition characteristic of action quantity at taking out molding regulation.

  17. Injection molding of micro patterned PMMA plate

    Institute of Scientific and Technical Information of China (English)

    Yeong-Eun YOO; Tae-Hoon KIM; Tae-Jin JE; Doo-Sun CHOI; Chang-Wan KIM; Sun-Kyung KIM

    2011-01-01

    A plastic plate with surface micro features was injection molded to investigate the effect of pressure rise of melt on the replication of the micro structures. Prism pattern, which is used in many optical applications, was selected as a model pattern. The prism pattern is 50 μm in pitch and 108° in the vertical angle. The overall size of the plate was 335 mm×213 mm and the thickness of the plate varied linearly from 2.6 mm to 0.7 mm. The prism pattern was firstly machined on the nickel plated core block using micro diamond tool and this machined pattern core was installed in a mold for injection molding of prism patterned plate. Polymethyl methacrylate (PMMA) was used as a molding material. The pressure and temperature of the melt in the cavity were measured at different positions in the cavity and the replication of the pattern was also measured at the same positions. The results show that the pressure or temperature profile through the process depends on the shape and the size of the plate. The replication is affected by the temperature and pressure profiles at the early stage of filling, which is right after the melt reaches the position to be measured.

  18. Simulation of the X-Ray Beam Absorption by the ABS-Plastic Filled with Different Metallic Additives

    Science.gov (United States)

    Miloichikova, I. A.; Stuchebrov, S. G.; Verigin, D. A.; Krasnykh, A. A.; Danilova, I. B.

    2016-11-01

    This article is a part of the work on developing new materials for manufacturing filaments for fused deposition modeling (FDM). The computations of depth dose distributions for gamma-radiation in ABS plastic filled with lead and zinc additives of various concentration were performed via Monte Carlo technique and are represented in graphic form.

  19. Gully cut-and-fill cycles as related to agromanagement a historical curve number simulation in the Tigray Highlands

    NARCIS (Netherlands)

    Lanckriet, S.; Frankl, A.; Mesfin, G.; Descheemaeker, K.K.E.; Nyssen, J.

    2015-01-01

    Gully cut-and-fill dynamics are often thought to be driven by climate and/or deforestation related to population pressure. However, in this case-study of nine representative catchments in the Northern Ethiopian Highlands, we find that neither climate changes nor deforestation can explain gully

  20. 40 CFR 63.5714 - How do I demonstrate compliance if I use filled resins?

    Science.gov (United States)

    2010-07-01

    ... use filled resins? 63.5714 Section 63.5714 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY... Molding Resin and Gel Coat Operations § 63.5714 How do I demonstrate compliance if I use filled resins? (a) If you are using a filled production resin or filled tooling resin, you must demonstrate...

  1. Environmental impact estimation of mold making process

    Science.gov (United States)

    Kong, Daeyoung

    Increasing concern of environmental sustainability regarding depletion of natural resources and resulting negative environmental impact has triggered various movements to address these issues. Various regulations about product life cycle have been made and applied to industries. As a result, how to evaluate the environmental impact and how to improve current technologies has become an important issue to product developers. Molds and dies are very generally used manufacturing tools and indispensible parts to the production of many products. However, evaluating environmental impact in mold and die manufacturing is not well understood and not much accepted yet. The objective of this thesis is to provide an effective and straightforward way of environmental analysis for mold and die manufacturing practice. For this, current limitations of existing tools were identified. While conventional life cycle assessment tools provide a lot of life cycle inventories, reliable data is not sufficient for the mold and die manufacturer. Even with comprehensive data input, current LCA tools only provide another comprehensive result which is not directly applicable to problem solving. These issues are critical especially to the mold and die manufacturer with limited resource and time. This thesis addresses the issues based on understanding the needs of mold and die manufacturers. Computer aided manufacturing (CAM) is the most frequently used software tool and includes most manufacturing information including the process definition and sometimes geometric modeling. Another important usage of CAM software tools is problem identification by process simulation. Under the virtual environment, possible problems are detected and solved. Environmental impact can be handled in the same manner. To manufacture molds and dies with minimizing the associated environmental impact, possible environmental impact sources must be minimized before the execution in the virtual environment. Molds and dies

  2. Meer bekend over Black Mold

    NARCIS (Netherlands)

    Duyvesteijn, R.G.E.; Kohrman, E.

    2008-01-01

    In de vollegrondsrozenteelt zorgde Black Mold in 2007 voor een groot aantal mislukte oculaties. In 2008 waren er aanzienlijk minder problemen. Uit onderzoek is meer bekend over de oorzaak en bestrijding van Black Mold.

  3. Meer bekend over Black Mold

    NARCIS (Netherlands)

    Duyvesteijn, R.G.E.; Kohrman, E.

    2008-01-01

    In de vollegrondsrozenteelt zorgde Black Mold in 2007 voor een groot aantal mislukte oculaties. In 2008 waren er aanzienlijk minder problemen. Uit onderzoek is meer bekend over de oorzaak en bestrijding van Black Mold.

  4. EFFECT OF SEN DESIGN ON SURFACE FLUCTUATION AND SOLIDIFYING SHELL IN SLAB MOLD AND ITS OPTIMIZATION

    Institute of Scientific and Technical Information of China (English)

    D.F.Wu; S.S.Cheng

    2008-01-01

    Turbulent flow and heat transfer coupled with solidification in slab continuous casting mold was studied by numerical simulation method. Volume of fluid (VOF) model is used to solve steel-air two-phase flow problem and enthalpy-porosity scheme is introduced to solve the fluid flow problem involving solidification. Contributions of various nozzle port angles and port widths and heights on the free surface fluctuation and the thickness of solidifying shell in slab mold were particularly investigated, based on which the structure of submerged entry nozzle was optimized. Flow inside the common nozzle port cannot fill the entire ouaet area, having a recireulation in the upper portion of the port, which is enlarged for the nozzle port with both larger height and width. Results show that the flow in mold cavity is mainly controlled by the nozzle port angle. The increase of the angle of upper face of the port to shape a roughly streamlined inner-wall improves the effective area fraction of the nozzle, resulting in less jet impingement, weaker free surface turbulence and thicker solidifying steel shell.

  5. End moldings for cable dielectrics

    Energy Technology Data Exchange (ETDEWEB)

    Roose, L.D.

    1993-12-31

    End moldings for high-voltage cables are described wherein the dielectric insulator of the cable is heated and molded to conform to a desired shape. As a consequence, high quality substantially bubble- free cable connectors suitable for mating to premanufactured fittings are made. Disclosed are a method for making the cable connectors either in the field or in a factory, molds suitable for use with the method, and the molded cable connectors, themselves.

  6. Phase separation micro molding

    NARCIS (Netherlands)

    Vogelaar, Laura

    2005-01-01

    The research described in this thesis concerns the development of a new microfabrication method, Phase Separation Micro Molding (PSμM). While microfabrication is still best known from semiconductor industry, where it is used to integrate electrical components on a chip, the scope has immensely expan

  7. Numerical Simulation and Experimental Verification of Hollow and Foam-Filled Flax-Fabric-Reinforced Epoxy Tubular Energy Absorbers Subjected to Crashing

    Science.gov (United States)

    Sliseris, J.; Yan, L.; Kasal, B.

    2017-09-01

    Numerical methods for simulating hollow and foam-filled flax-fabric-reinforced epoxy tubular energy absorbers subjected to lateral crashing are presented. The crashing characteristics, such as the progressive failure, load-displacement response, absorbed energy, peak load, and failure modes, of the tubes were simulated and calculated numerically. A 3D nonlinear finite-element model that allows for the plasticity of materials using an isotropic hardening model with strain rate dependence and failure is proposed. An explicit finite-element solver is used to address the lateral crashing of the tubes considering large displacements and strains, plasticity, and damage. The experimental nonlinear crashing load vs. displacement data are successfully described by using the finite-element model proposed. The simulated peak loads and absorbed energy of the tubes are also in good agreement with experimental results.

  8. High Cost/High Risk Components to Chalcogenide Molded Lens Model: Molding Preforms and Mold Technology

    Energy Technology Data Exchange (ETDEWEB)

    Bernacki, Bruce E.

    2012-10-05

    This brief report contains a critique of two key components of FiveFocal's cost model for glass compression molding of chalcogenide lenses for infrared applications. Molding preforms and mold technology have the greatest influence on the ultimate cost of the product and help determine the volumes needed to select glass molding over conventional single-point diamond turning or grinding and polishing. This brief report highlights key areas of both technologies with recommendations for further study.

  9. Influence of mold surface temperature on polymer part warpage in rapid heat cycle molding

    Science.gov (United States)

    Berger, G. R.; Pacher, G. A.; Pichler, A.; Friesenbichler, W.; Gruber, D. P.

    2014-05-01

    Dynamic mold surface temperature control was examined for its influence on the warpage. A test mold, featuring two different rapid heat cycle molding (RHCM) technologies was used to manufacture complex plate-shaped parts having different ribs, varying thin-wall regions, and both, circular and rectangular cut-outs. The mold's nozzle side is equipped with the areal heating and cooling technology BFMOLD®, where the heating/cooling channels are replaced by a ball-filled slot near the cavity surface flooded through with hot and cold water sequentially. Two local electrical ceramic heating elements are installed into the mold's ejection side. Based on a 23 full-factorial design of experiments (DoE) plan, varying nozzle temperature (Tnozzle), rapid heat cycle molding temperature (TRHCM) and holding pressure (pn), specimens of POM were manufactured systematically. Five specimens were examined per DoE run. The resulting warpage was measured at 6 surface line scans per part using the non-contact confocal topography system FRT MicroProf®. Two warpage parameters were calculated, the curvature of a 2nd order approximation a, and the vertical deflection at the profile center d. Both, the influence strength and the acting direction of the process parameters and their interactions on a and d were calculated by statistical analysis. Linear mathematical process models were determined for a and d to predict the warpage as a function of the process parameter settings. Finally, an optimum process setting was predicted, based on the process models and Microsoft Excel GRG solver. Clear and significant influences of TRHCM, pn, Tnozzle, and the interaction of TRHCM and pn were determined. While TRHCM was dominant close to the gate, pn became more effective as the flow length increased.

  10. Numerical Simulation of P-Wave Propagation in Rock Mass with Granular Material-Filled Fractures Using Hybrid Continuum-Discrete Element Method

    Science.gov (United States)

    Gui, Y. L.; Zhao, Z. Y.; Zhou, H. Y.; Wu, W.

    2016-10-01

    In this paper, a cohesive fracture model is applied to model P-wave propagation through fractured rock mass using hybrid continuum-discrete element method, i.e. Universal Distinct Element Code (UDEC). First, a cohesive fracture model together with the background of UDEC is presented. The cohesive fracture model considers progressive failure of rock fracture rather than an abrupt damage through simultaneously taking into account the elastic, plastic and damage mechanisms as well as a modified failure function. Then, a series of laboratory tests from the literature on P-wave propagation through rock mass containing single fracture and two parallel fractures are introduced and the numerical models used to simulate these laboratory tests are described. After that, all the laboratory tests are simulated and presented. The results show that the proposed model, particularly the cohesive fracture model, can capture very well the wave propagation characteristics in rock mass with non-welded and welded fractures with and without filling materials. In the meantime, in order to identify the significance of fracture on wave propagation, filling materials with different particle sizes and the fracture thickness are discussed. Both factors are found to be crucial for wave attenuation. The simulations also show that the frequency of transmission wave is lowered after propagating through fractures. In addition, the developed numerical scheme is applied to two-dimensional wave propagation in the rock mass.

  11. 基于粘刚塑性模型非球面透镜三维模压成型模拟%Simulation of 3D molding of aspheric optical glass lens based on viscous-rigid model

    Institute of Scientific and Technical Information of China (English)

    张小兵

    2015-01-01

    The temperature dependence of flow stress model and glass material parameters at high temperature was analyzed and discussed. The three⁃dimensional finite element model of compression molding of aspheric lens at high temperature was established using viscous⁃rigid model based on DEFORM 3D. The whole process of optical glass spherical L⁃BAL42 preform being molded into aspheric lens was studied by numerical simulation. It is found that maximum stress is at lens edge and stresses increase rapidly when mold is closed,leading to the lens edge most easily being broken,the result is validated by experiments. Residual stress will increase with increasing compression rate and the cooling rate,and the rules of aspheric lens deviation were analyzed. Finally aspheric surface deviation was compensated during the mold design stage. It is found that the aspheric surface deviation will decrease,deviation changes from positive to negative.%分析与探讨了高温玻璃的应力流动模型及其材料参数的温度相关性。利用粘刚塑性力学模型,基于三维有限元软件DEFORM 3D建立非球面透镜高温模压有限元模型,对光学玻璃L-BAL42球形预制件模压成非球面透镜的整个过程进行了数值仿真,发现非球面透镜应力分布规律:透镜边缘处应力最大,在和模阶段应力快速增加,导致透镜边缘处最易破碎,结果得到实验的验证。采用较大的模压速度及冷却速度将导致残余应力增加,同时分析了透镜非球面偏差变化规律。最后在模具设计时将非球面偏差补偿进去,发现非球面透镜偏差减少,由正偏差变为负偏差。

  12. Analysis of accuracy of bladder volume by simulating water mold based on Computed Tomography and kilovoltage cone-beam computed tomography images%FBCT与CBCT水模体模拟膀胱体积的准确性研究

    Institute of Scientific and Technical Information of China (English)

    胡健; 徐利明; 李长虎; 张爱华; 徐细明; 戈伟; 彭宙峰; 杨仁杰

    2014-01-01

    Objective To study accuracy and stability of bladder mold volume using fan beam CT (FBCT) and kilovoltage cone-beam CT (CBCT).Methods The water bladder molds in 2 categories:hard and soft water wall molds (1 group and 3groups),scanned by FBCT and CBCT.FBCT was scanned by 2 rows of Hispeed dual and 64 rows of Lightspeed VCT spiral scan,then it was divided into two groups according to the pitch/speed of bed.CBCT was scanned by pelvis,pelvis spotlight and high quality head scan.Every scan repeated 5 times,then compared reconstruction volume with the real volume,analyzing stability and repetition by treatment planning system and the results of two phantoms by using independent sample t test.Results The deviation which compared the hard wall phantom with the real value was FBCT:-(1.5-0.2) %,CBCT:-(5.1-2.9) %.The deviation of soft wall molds,FBCT:-(4.2-0.1) %,CBCT:-(4.0-0.3)%.Reconstruction volume of FBCT decreases with the increase of motion speed and pitch of bed,the volume of Hispeed was greater than the Lightspeed (hard wall molds,P =0.010 and soft wall molds,P =0.004).Among CBCT modes,the pelvis one had the smallest reconstruction volume (hard wall molds:CBCTH vs.CBCTP,P =0.020,CBCTP vs.CBCTPS P =0.013 and soft wall molds:CBCTH vs.CBCTP,P =0.006,CBCTP vs.CBCTPS P =0.008.).Conclusions Reconstruction volume of FBCT and CBCT have no statistical difference,and both of them have a good repeatability.Slow scan mode is recommended when using FBCT for active organ (respiration,filling and so on).Pelvis spotlight and high quality head protocols are recommended when using CBCT scanning.%目的 基于FBCT、CBCT水模体模拟膀胱显示体积的准确性和稳定性.方法 用已知体积的硬壁水模体和软壁水模体模拟膀胱.FBCT由2排Hispeed dual CT、64排Lightspeed VCT螺旋CT扫描,各自据螺距或床速分别扫描.CBCT据曝光条件分别pelvis、pelvis spotlight、high quality head 扫描.每种扫描5次后于TPS重建分析体积差异并与

  13. Fiber Reinforcement in Injection Molded Nylon 6/6 Spur Gears

    Science.gov (United States)

    Senthilvelan, S.; Gnanamoorthy, R.

    2006-07-01

    Injection molded polymer composite gears are being used in many power and or motion transmission applications. In order to widen the utilization of reinforced polymers for precision motion transmission and noise less applications, the accuracy of molded gears should be increased. Since the injection molded gear accuracy is significantly influenced by the material shrinkage behaviour, there is a need to understand the influence of fiber orientation and gate location on part shrinkage behaviour and hence the gear accuracy. Unreinforced and 20% short glass fiber reinforced Nylon 6/6 spur gears were injection molded in the laboratory and computer aided simulations of gear manufacturing was also carried out. Results of the mold flow simulation of gear manufacturing were correlated with the actual fiber orientation and measured major geometrical parameters of the molded gears. Actual orientation of the fibers near the tooth profile, weld line region and injection points of molded gears were observed using optical microscope and correlated with predicted fiber orientation.

  14. 塑料刀叉气辅成型模具浇注系统设计%Runner System Design of the Gas-Assisted Injection Mold for Plastic Knife and Fork

    Institute of Scientific and Technical Information of China (English)

    牟一楠; 何建军

    2012-01-01

    Gas-assisted injection molding(GAIM) is a special injection molding process with less perfect design system on products and mold. Taking a plastic knife and fork as a example, this paper introduced the running gate system design in GAIM mold based on the simulation on filling flow of plastic melt and preservation of gas, the design is evaluated the design by the fill regions of melt and gas cores. Feasible process parameters were also recommended based on the simulation-design.%气体辅助注射成型是一种特殊注塑成型工艺,其模具设计尚未形成完善的体系.文章以塑料刀叉为例,基于塑料熔体的充填流动和气体保压模拟,通过熔体充填区域和气体充填区域来评价设计优劣,进行气辅成型模具浇注系统的设计,并推荐可行的工艺参数.

  15. Measuring mechanical stresses on inserts during injection molding

    Directory of Open Access Journals (Sweden)

    Martina Heinle

    2015-05-01

    Full Text Available Assembly molding presents an interesting approach to innovative product solutions. Here, individual components can be simultaneously positioned, affixed, and provided with a casing. However, while overmolding elements in the mold cavity with hot polymer melt, high mechanical loads occur on, in some cases, very sensitive components such as electronic devices. For the design of such systems, it is important to know these stresses, the influences on their quantities, and mathematical options for their prediction. In this article, a new measurement method for determining the forces acting on a small element in the cavity during the injection molding process in three dimensions is presented. Therefore, a new installation method for a force sensor was developed. The results in this article concentrate on force changes during one molding cycle. Our research shows that there are different mechanical load spectra in the different phases of the molding process. For example, the force component in flow direction on an element in the cavity is positive in the direction of the flow during filling. However, after the filling step, the force becomes negative due to the contraction of the injected material and results in a continuously increasing permanent force.

  16. Filling a Conical Cavity

    Science.gov (United States)

    Nye, Kyle; Eslam-Panah, Azar

    2016-11-01

    Root canal treatment involves the removal of infected tissue inside the tooth's canal system and filling the space with a dense sealing agent to prevent further infection. A good root canal treatment happens when the canals are filled homogeneously and tightly down to the root apex. Such a tooth is able to provide valuable service for an entire lifetime. However, there are some examples of poorly performed root canals where the anterior and posterior routes are not filled completely. Small packets of air can be trapped in narrow access cavities when restoring with resin composites. Such teeth can cause trouble even after many years and lead the conditions like acute bone infection or abscesses. In this study, the filling of dead-end conical cavities with various liquids is reported. The first case studies included conical cavity models with different angles and lengths to visualize the filling process. In this investigation, the rate and completeness at which a variety of liquids fill the cavity were observed to find ideal conditions for the process. Then, a 3D printed model of the scaled representation of a molar with prepared post spaces was used to simulate the root canal treatment. The results of this study can be used to gain a better understanding of the restoration for endodontically treated teeth.

  17. Injection-molded capsular device for oral pulsatile release: development of a novel mold.

    Science.gov (United States)

    Zema, Lucia; Loreti, Giulia; Macchi, Elena; Foppoli, Anastasia; Maroni, Alessandra; Gazzaniga, Andrea

    2013-02-01

    The development of a purposely devised mold and a newly set up injection molding (IM) manufacturing process was undertaken to prepare swellable/erodible hydroxypropyl cellulose-based capsular containers. When orally administered, such devices would be intended to achieve pulsatile and/or colonic time-dependent delivery of drugs. An in-depth evaluation of thermal, rheological, and mechanical characteristics of melt formulations/molded items made of the selected polymer (Klucel® LF) with increasing amounts of plasticizer (polyethylene glycol 1500, 5%-15% by weight) was preliminarily carried out. On the basis of the results obtained, a new mold was designed that allowed, through an automatic manufacturing cycle of 5 s duration, matching cap and body items to be prepared. These were subsequently filled and coupled to give a closed device of constant 600 μm thickness. As compared with previous IM systems having the same composition, such capsules showed improved closure mechanism, technological properties, especially in terms of reproducibility of the shell thickness, and release performance. Moreover, the ability of the capsular container to impart a constant lag phase before the liberation of the contents was demonstrated irrespective of the conveyed formulation.

  18. Research on the Forming Mechanism of Micro/Nano Features during the Cast Molding Pro cess

    Institute of Scientific and Technical Information of China (English)

    Xiangdong Ye; Yugang Duan; Yucheng Ding

    2011-01-01

    Cast molding process has provided a reliable, simple and cost-effective way to fabricate micro structures since decades ago. In order to obtain structures with fine, dense and deep nano-size features by cast molding, it is necessary to study the forming mechanism in the process. In this paper, based on major steps of cast molding, filling models of liquid are established and solved; and the forming mechanism of liquid is revealed. Moreover, the scale effect between the liquid and the cavity on the filling velocity of liquid is studied. It is also interesting to find out that the wettability of liquid on the cavity may be changed from wetting to dewetting depends on the pressure difference. Finally, we experimentally verify some of our modeling results on the flowing and filling state of the liquid during the cast molding process.

  19. Determining the effects of thermal conductivity on epoxy molds using profiled cooling channels with metal inserts

    Energy Technology Data Exchange (ETDEWEB)

    Altaf, Khurram; Rani, Abdul Ahmad Majdi; Ahmad, Faiz; Baharom, Masri [Mechanical Engineering Dept., Universiti Teknologi PETRONAS, Bandar Seri Iskandar, Perak (Malaysia); Raghavan, Vijay R. [OYL Manufacturing, Sungai Buloh (Malaysia)

    2016-11-15

    Polymer injection molds are generally manufactured with metallic materials, such as tool steel, which provide reliable working of molds and extended service life. The manufacture of injection molds with steel is a prolonged process because of the strength of steel. For a short prototype production run, one of the suitable choices could be the use of aluminum-filled epoxy material, which can produce a functional mold in a short time as compared with a conventionally machined tool. Aluminum-filled epoxy tooling is a good choice for short production runs for engineering applications, yet works best for relatively simple shapes. The advantages in relation to the fabrication of injection molds with epoxy-based materials include time saving in producing the mold, epoxy curing at ambient temperature, and ease of machining and post processing. Nevertheless, one major drawback of epoxy material is its poor thermal conductivity, which results in a relatively longer cooling time for epoxy injection molds. This study investigates some of the innovative ideas for enhancing the thermal conductivity for epoxy molds. The basic concept behind these ideas was to embed a highly thermally conductive metal insert within the mold between cavities with an innovative design of cooling channels called profiled cooling channels. This technique will increase the effective thermal conductivity of the epoxy mold, leading to the reduction in cooling time for the injection molded polymer part. Experimental analysis conducted in the current study also verified that the mold with profiled cooling channels and embedded metal insert has significantly reduced the cooling time.

  20. Fractal phenomena in powder injection molding process

    Institute of Scientific and Technical Information of China (English)

    郑洲顺; 曲选辉; 李云平; 雷长明; 段柏华

    2003-01-01

    The complicated characteristics of the powder were studied by fractal theory. It is illustrated that powder shape, binder structure, feedstock and mold-filling flow in powder injection molding process possess obvious fractal characteristics. Based on the result of SEM, the fractal dimensions of the projected boundary of carbonylic iron and carbonylic nickel particles were determined to be 1.074±0.006 and 1.230±0.005 respectively by box counting measurement. The results show that the fractal dimension of the projected boundary of carbonylic iron particles is close to smooth curve of one-dimension, while the fractal dimension of the projected boundary of carbonylic nickel particle is close to that of trisection Koch curve, indicating that the shape characteristics of carbonylic nickel particles can be described and analyzed by the characteristics of trisection Koch curve. It is also proposed that the fractal theory can be applied in the research of powder injection molding in four aspects.

  1. Assessment of Computer Simulation Software and Process Data for High Pressure Die Casting of Magnesium

    Energy Technology Data Exchange (ETDEWEB)

    Sabau, Adrian S [ORNL; Hatfield, Edward C [ORNL; Dinwiddie, Ralph Barton [ORNL; Kuwana, Kazunori [University of Kentucky; Viti, Valerio [University of Kentucky, Lexington; Hassan, Mohamed I [University of Kentucky, Lexington; Saito, Kozo [University of Kentucky

    2007-09-01

    Computer software for the numerical simulation of solidification and mold filling is an effective design tool for cast structural automotive magnesium components. A review of commercial software capabilities and their validation procedures was conducted. Aside form the software assessment, the program addressed five main areas: lubricant degradation, lubricant application, gate atomization, and heat transfer at metal mold interfaces. A test stand for lubricant application was designed. A sensor was used for the direct measurement of heat fluxes during lubricant application and casting solidification in graphite molds. Spray experiments were conducted using pure deionized water and commercial die lubricants. The results show that the sensor can be used with confidence for measuring heat fluxes under conditions specific to the die lube application. The data on heat flux was presented in forms suitable for use in HPDC simulation software. Severe jet breakup and atomization phenomena are likely to occur due to high gate velocities in HPDC. As a result of gate atomization, droplet flow affects the mold filling pattern, air entrapment, skin formation, and ensuing defects. Warm water analogue dies were designed for obtaining experimental data on mold filling phenomena. Data on break-up jet length, break-up pattern, velocities, and droplet size distribution were obtained experimentally and was used to develop correlations for jet break-up phenomena specific to die casting gate configurations.

  2. Capillary filling rules and displacement mechanisms for spontaneous imbibition of CO2 for carbon storage and EOR using micro-model experiments and pore scale simulation

    Science.gov (United States)

    Chapman, E.; Yang, J.; Crawshaw, J.; Boek, E. S.

    2012-04-01

    geometry of the pore body rather than the downstream pore throat sizes, contrary to the established capillary filling rules as used in current pore network models. Our experimental observations are confirmed by detailed lattice-Boltzmann pore scale computer simulations of fluid displacement in the same geometries. This suggests that capillary filling rules for imbibition as used in pore network models may need to be revised. [1] G. Lenormand, C. Zarcone and A. Sarr, J. Fluid Mech. 135 , 337-353 (1983).

  3. Foaming morphology control of microcellular injection molded parts with gas counter pressure and dynamic mold temperature control

    Science.gov (United States)

    Shiu, Tai-Yi; Huang, Chao-Tsai; Chang, Rong-Yu; Hwang, Shyh-Shin

    2014-05-01

    Microcellular injection molding process is a promising solution for products with special requirements such as weight reduction, extra thin wall, high dimensional stability, clamping force reduction, etc. Despite microcellular foaming application used in reciprocating screw injection molding machine was built more than a decade, some limitations, such as poor surface quality or poor foaming control, confine the usage of this technology. Earlier CAE simulation tool for microcellular injection molding was not successful due to insufficient physical and computational considerations, limited by complicated bubble growth mechanism; so that, an economic and efficient tool for examining foaming quality of injection foaming product was lack. In this study, a recent developed three-dimensional simulation tool is used to predict injection foaming process. Predictions are carried out with commodity polypropylene and polystyrene with nitrogen and carbon dioxide supercritical fluids (SCFs). Comparisons of simulations between microcellular injection molding with and without counter pressure are discussed to provide insights into the correlation of surface quality and cell size distribution near the surface of product. Furthermore, comparisons between simulation predictions and experimental results of molding process, which is featured with dynamic mold temperature and gas counter pressure, are given for understanding quality improvement by controlling foaming morphology, and benefit of industrial application.

  4. Simulation of electron beam formation and transport in a gas-filled electron-optical system with a plasma emitter

    Science.gov (United States)

    Grishkov, A. A.; Kornilov, S. Yu.; Rempe, N. G.; Shidlovskiy, S. V.; Shklyaev, V. A.

    2016-07-01

    The results of computer simulations of the electron-optical system of an electron gun with a plasma emitter are presented. The simulations are performed using the KOBRA3-INP, XOOPIC, and ANSYS codes. The results describe the electron beam formation and transport. The electron trajectories are analyzed. The mechanisms of gas influence on the energy inhomogeneity of the beam and its current in the regions of beam primary formation, acceleration, and transport are described. Recommendations for optimizing the electron-optical system with a plasma emitter are presented.

  5. Simulation of electron beam formation and transport in a gas-filled electron-optical system with a plasma emitter

    Energy Technology Data Exchange (ETDEWEB)

    Grishkov, A. A. [Russian Academy of Sciences, Institute of High Current Electronics, Siberian Branch (Russian Federation); Kornilov, S. Yu., E-mail: kornilovsy@gmail.com; Rempe, N. G. [Tomsk State University of Control Systems and Radioelectronics (Russian Federation); Shidlovskiy, S. V. [Tomsk State University (Russian Federation); Shklyaev, V. A. [Russian Academy of Sciences, Institute of High Current Electronics, Siberian Branch (Russian Federation)

    2016-07-15

    The results of computer simulations of the electron-optical system of an electron gun with a plasma emitter are presented. The simulations are performed using the KOBRA3-INP, XOOPIC, and ANSYS codes. The results describe the electron beam formation and transport. The electron trajectories are analyzed. The mechanisms of gas influence on the energy inhomogeneity of the beam and its current in the regions of beam primary formation, acceleration, and transport are described. Recommendations for optimizing the electron-optical system with a plasma emitter are presented.

  6. Manufacturing Science of Improved Molded Optics

    Science.gov (United States)

    2013-12-05

    a physical point shear thinning is an unlikely explanation. In a study of friction mechanisms in polymer extrusion , Joshi et al.27 present a...41 Appendix C2 – glass extrusion paper draft 61 Appendix C3 - ring compression test paper draft (Navier law) 97 D. Protective coatings...complex thermo-mechanical behavior of an optical glass during simulation of the lens molding, extrusion and other glass forming processes. This

  7. Numerical simulation of natural convection in a square enclosure filled with nanofluid using the two-phase Lattice Boltzmann method

    Science.gov (United States)

    2013-01-01

    Considering interaction forces (gravity and buoyancy force, drag force, interaction potential force, and Brownian force) between nanoparticles and a base fluid, a two-phase Lattice Boltzmann model for natural convection of nanofluid is developed in this work. It is applied to investigate the natural convection in a square enclosure (the left wall is kept at a high constant temperature (TH), and the top wall is kept at a low constant temperature (TC)) filled with Al2O3/H2O nanofluid. This model is validated by comparing numerical results with published results, and a satisfactory agreement is shown between them. The effects of different nanoparticle fractions and Rayleigh numbers on natural convection heat transfer of nanofluid are investigated. It is found that the average Nusselt number of the enclosure increases with increasing nanoparticle volume fraction and increases more rapidly at a high Rayleigh number. Also, the effects of forces on nanoparticle volume fraction distribution in the square enclosure are studied in this paper. It is found that the driving force of the temperature difference has the biggest effect on nanoparticle volume fraction distribution. In addition, the effects of interaction forces on flow and heat transfer are investigated. It is found that Brownian force, interaction potential force, and gravity-buoyancy force have positive effects on the enhancement of natural convective heat transfer, while drag force has a negative effect. PMID:23374509

  8. Analysis of the origin of periodic oscillatory flow in the continuous casting mold

    Science.gov (United States)

    Lee, Jun-young; Kim, Yong-tae; Yi, Kyung-woo

    2015-03-01

    It is very important to understand flow patterns within the continuous casting mold because they have a significant impact on product quality. Water model experiment and particle image velocimetry were conducted to identify the fluid flow pattern in the steel slab continuous casting mold. The fluid flow pattern in the mold is not steady but instead an oscillatory flow with a specific oscillation frequencies. Many studies have been reported about oscillatory flow within the mold. However, these studies do not provide a clear explanation of physical origin of oscillatory flow. We identified the physical origins of various specific oscillation frequencies, and confirmed through experimentation and simulation that each frequency is related to the cross flow and injection stream oscillation. Moreover, the degree of oscillation at each frequency appears differently depending on the location within the mold, and is shown to have a effect near the mold wall. These results provide a better understanding of complex oscillatory flow patterns within the mold.

  9. Effect of fast mold surface temperature evolution on iPP part morphology gradients

    Energy Technology Data Exchange (ETDEWEB)

    Liparoti, Sara [Department of Industrial Engineering, University of Salerno, via Giovanni Paolo II, 132, 84084 Fisciano (Italy); Sorrentino, Andrea [Institute for Polymers, Composites and Biomaterials (IPCB), National Research Council (CNR), P. Enrico Fermi 1, 80055 Portici (Italy); Guzman, Gustavo; Cakmak, Mukerrem; Titomanlio, Giuseppe, E-mail: gtitomanlio@unisa.it [Department of Polymer Engineering, The University of Akron, Akron, OH 44325 (United States)

    2016-03-09

    The control of mold surface temperature is an important factor that affects the sample surface morphology as well as the structural gradients (orientation crystal size, and type) as well as cooling stresses. The frozen layer thickness formed during the filling stage also has a very significant effect on the flow resistance and thus on the resulting pressure drop and flow length in thin wall parts. The possibility to have a hot mold during filling and a quick cooling soon afterward is a significant process enhancement particularly for specialized applications such as micro injection molding and for the reproduction of micro structured surfaces. Up to now, several methods (electromagnetic, infrared, hot vapor fleshing etc,) were tried to achieve fast temperature evolution of the mold. Unfortunately, all these methods require a complex balance between thermal and mechanical problems, equipment cost, energy consumption, safety, molding cycle time and part quality achievable. In this work, a thin electrical resistance was designed and used to generate a fast and confined temperature variation on mold surface (by joule effect). Since the whole temperature evolution can take place in a few seconds, one can couple the advantages of a high surface temperature during filling with the advantages of a low mold temperature, fast cooling and low heating dissipation. Some experiments were performed with a commercial iPP resin. The effects of the surface temperature and of the heating time (under constant electric power) on surface finishing and on the final morphology (thickness and structure of the different layers) are explored and discussed.

  10. Research in manufacturing of micro-structured injection molded polymer parts

    Science.gov (United States)

    Lucyshyn, Thomas; Struklec, Tobias; Burgsteiner, Martin; Graninger, Georg; Holzer, Clemens

    2015-12-01

    An overview of current research results is given for the topic of injection molding of micro-structured polymer parts regarding filling behavior and demolding process of micro-structures as well as the production of micro-structures on curved surfaces. In order to better understand how micro-structures are formed during the filling stage of injection molding, a study was performed on a test part with micro-channels placed parallely and perpendicularly to flow direction. Short shots with a highly fluent Polypropylene grade were injection molded with the melt front stopping in the structure fields. The melt and mold temperature, the injection rate as well as the use of a variotherm heating system were varied in a systematic Design of Experiments. The shape of the flow front was investigated with the optical measurement system Alicona InfiniteFocus. The data gained was analyzed with Matlab scripts and provided the needed distance to completely fill the structures as a reference value. The next topic covers the demolding step, which is a crucial process step in injection molding of micro-structured parts as the successfully replicated structures often get destroyed in the following demolding step. In order to evaluate the influence of the four aspects polymer, mold surface (coatings), structure (geometry and placement) and process settings on the demolding behavior, an injection mold with integrated measurement system was built, which makes it possible to measure the demolding force respectively a demolding energy under process conditions. These values can be used to quantitatively compare the impact of the above mentioned influencing factors on demolding. Finally, a concept to produce micro-structures on curved surfaces with injection molding is shown: A flat metal premaster structure is used to produce an elastomeric polymer (dimethylsiloxane) master in a casting process. This master is fixed in a conventional injection mold and a thermoplastic polymer is replicated

  11. Mathematical modeling of the in-mold coating process for injection-molded thermoplastic parts

    Science.gov (United States)

    Chen, Xu

    In-Mold Coating (IMC) has been successfully used for many years for exterior body panels made from compression molded Sheet Molding Compound (SMC). The coating material is a single component reactive fluid, designed to improve the surface quality of SMC moldings in terms of functional and cosmetic properties. When injected onto a cured SMC part, IMC cures and bonds to provide a pain-like surface. Because of its distinct advantages, IMC is being considered for application to injection molded thermoplastic parts. For a successful in mold coating operation, there are two key issues related to the flow of the coating. First, the injection nozzle should be located such that the thermoplastic substrate is totally covered and the potential for air trapping is minimized. The selected location should be cosmetically acceptable since it most likely will leave a mark on the coated surface. The nozzle location also needs to be accessible for easy of maintenance. Secondly, the hydraulic force generated by the coating injection pressure should not exceed the available clamping tonnage. If the clamping force is exceeded, coating leakage will occur. In this study, mathematical models for IMC flow on the compressible thermoplastic substrate have been developed. Finite Difference Method (FDM) is first used to solve the 1 dimensional (1D) IMC flow problem. In order to investigate the application of Control Volume based Finite Element Method (CV/FEM) to more complicated two dimensional IMC flow, that method is first evaluated by solving the 1D IMC flow problem. An analytical solution, which can be obtained when a linear relationship between the coating thickness and coating injection pressure is assumed, is used to verify the numerical results. The mathematical models for the 2 dimensional (2D) IMC flow are based on the generalized Hele-Shaw approximation. It has been found experimentally that the power law viscosity model adequately predicts the rheological behavior of the coating

  12. Thermomechanical Behavior in Continuous Bloom Casting with Different Mold Tapers

    Institute of Scientific and Technical Information of China (English)

    LUO Xin; CHEN Yong; SHEN Houfa

    2008-01-01

    A two-dimensional finite element model was used to analyze the thermal and mechanical behavior dunng solidification of the strand in a continuous bloom casting mold.The coupled heat transfer and defermation were analyzed to simulate the formation of the air gap between the mold and the strand.The model was used to investigate the influence of mold taper on the temperature and stress distributions in the strand.The results show that the air gap mainly forms around the strand corner,causing a hoRer and thinner solidifying shell in this region.The mold taper partially compensates for the strand shell shnnkage and reduces the infiuence of the air gap on the heat transfer.The mold taper compresses the shell and changes the stress state around the stmnd comer region.As the strand moves down into the mold,the mold constraint causes compressive stress beneath the comer surface.which reduces the hot tear that forms on the strand.

  13. Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites - FY 2014 Fourth Quarterly Report

    Energy Technology Data Exchange (ETDEWEB)

    Nguyen, Ba Nghiep [Pacific Northwest National Lab. (PNNL), Richland, WA (United States); Fifield, Leonard S. [Pacific Northwest National Lab. (PNNL), Richland, WA (United States); Mathur, Raj N. [PlastiComp, Inc., Winona, MN (United States); Kijewski, Seth A. [Purdue Univ., West Lafayette, IN (United States); Sangid, Michael D. [Purdue Univ., West Lafayette, IN (United States); Wang, Jin [Autodesk, Inc., Ithaca, NY (United States); Jin, Xiaoshi [Autodesk, Inc., Ithaca, NY (United States); Costa, Franco [Autodesk, Inc., Ithaca, NY (United States); Gandhi, Umesh N. [MAGNA Exteriors and Interiors Corp, Aurora, ON (Canada); Mori, Steven [Univ. of Illinois, Champaign, IL (United States); Tucker, III, Charles L.

    2014-09-30

    During the last quarter of FY 2014, the following technical progress has been made toward project milestones: 1) Autodesk, Inc. (Autodesk) has implemented a new fiber length distribution (FLD) model based on an unbreakable length assumption with Reduced Order Modeling (ROM) by the Proper Orthogonal Decomposition (POD) approach in the mid-plane, dual-domain and 3D solvers. 2) Autodesk improved the ASMI 3D solver for fiber orientation prediction using the anisotropic rotary diffusion (ARD) – reduced strain closure (RSC) model. 3) Autodesk received consultant services from Prof. C.L. Tucker at the University of Illinois on numerical simulation of fiber orientation and fiber length. 4) PlastiComp, Inc. (PlastiComp) suggested to Purdue University a procedure for fiber separation using an inert-gas atmosphere in the burn-off furnace. 5) Purdue University (Purdue) hosted a face-to-face project review meeting at Purdue University on August 6-7, 2014. 6) Purdue conducted fiber orientation measurements for 3 PlastiComp plaques: fast-fill 30wt% LCF/PP edged-gated, slow-fill 50wt% LCF/PP edge-gated, and slow-fill 50wt% LCF/PP center-gated plaques, and delivered the orientation data for these plaques at the selected locations (named A, B, and C) to PNNL. 7) PNNL conducted ASMI mid-plane analyses for the above PlastiComp plaques and compared the predicted fiber orientations with the measured data provided by Purdue at Locations A, B, and C on these plaques. 8) PNNL planned the project review meeting (August 6-7, 2014) with Purdue. 9) PNNL performed ASMI analyses for the Toyota complex parts with and without ribs, having different wall thicknesses, and using the PlastiComp 50wt% LCF/PP, 50wt% LCF/PA66, 30wt% LCF/PP, and 30wt% LCF/PA66 materials to provide guidance for tool design and modifications needed for molding these parts. 10) Magna Exteriors and Interiors Corp. (Magna) molded plaques from the 50% LCF/PP and 50% LCF/PA66 materials received from Plasticomp in order to

  14. Stress-strain behavior of block-copolymers and their nanocomposites filled with uniform or Janus nanoparticles under shear: a molecular dynamics simulation.

    Science.gov (United States)

    Wang, Lu; Liu, Hongji; Li, Fanzhu; Shen, Jianxiang; Zheng, Zijian; Gao, Yangyang; Liu, Jun; Wu, Youping; Zhang, Liqun

    2016-10-05

    Although numerous research studies have been focused on studying the self-assembled morphologies of block-copolymers (BCPs) and their nanocomposites, little attention has been directed to explore the relation between their ordered structures and the resulting mechanical properties. We adopt coarse-grained molecular dynamics simulation to study the influence of the morphologies on the stress-strain behavior of pure block copolymers and block copolymers filled with uniform or Janus nanoparticles (NPs). At first, we examine the effect of the arrangement (di-block, tri-block, alternating-block) and the components of the pure block copolymers, and by varying the component ratio between A and B blocks, spherical, cylindrical and lamellar phases are all formed, showing that spherical domains bring the largest reinforcing effect. Then by studying BCPs filled with NPs, the Janus NPs induce stronger bond orientation of polymer chains and greater mechanical properties than the uniform NPs, when these two kinds of NPs are both located in the interface region. Meanwhile, some other anisotropic Janus NPs, such as Janus rods and Janus sheets, are incorporated to examine the effect on the morphology and the stress-strain behavior. These findings deepen our understanding of the morphology-mechanics relation of BCPs and their nanocomposites, opening up a vast number of approaches such as designing the arrangement and components of BCPs, positioning uniform or Janus NPs with different shapes and shear flow to tailor their stress-strain performance.

  15. Nanofabrication with molds & stamps

    Directory of Open Access Journals (Sweden)

    Byron D. Gates

    2005-02-01

    Full Text Available A number of methods can be used to fabricate patterns with features having dimensions <100 nm. These techniques, however, can require specialized equipment and are often restricted to a cleanroom environment. Nanofabrication can be made accessible to multiple users by using elastomeric molds or stamps to transfer high-resolution patterns into other materials. These techniques are inexpensive and can transfer patterns into functional materials and onto a number of surfaces. This review describes recent advances in fabricating nanostructures using these techniques.

  16. Mold and Crucible Coatings

    Science.gov (United States)

    1986-04-28

    34;" -"""-"’" " " ""’’ "" "" ’"" ’ j * AD I. AT)-E 9 7 W CONTRACTOR REPORT ARCCD-CR-86007 MOLD AND CRUCIBLE COATINGS Sylvia J. Canino Arthur L. Geary Nuclear...IFnlRpr April 1984_-_December 198, .. AUTNORfo) S. CONTRACT on CRAM? # "I MWef(e)I Sylvia J. Canino and Arthur L. Geary DAAK1O-84-C-0056 PERFORMING

  17. Injection Compression Molding of Replica Molds for Nanoimprint Lithography

    Directory of Open Access Journals (Sweden)

    Keisuke Nagato

    2014-03-01

    Full Text Available As a breakthrough in the cost and durability of molds for nanoimprint lithography (NIL, replica molds are fabricated by injection compression molding (ICM. ICM is commonly used for optical disks such as DVDs or Blu-ray disks and is also a practical fabrication method for nanostructures. In this paper, I successfully demonstrated the fabrication of cycloolefin polymer replica molds with structures smaller than 60 nm by ICM. Furthermore, ultraviolet (UV-NIL using these replica molds was demonstrated. UV-cured resist was replicated over an area of 60 mm diameter. The degree of replication by UV-NIL in the first usage of each replica mold had good repeatability. Because ICM is a high-throughput, low-cost process, the replica mold can be disposed of after a certain time for UV-NIL. This method leads to a high-integrity UV-NIL process of patterned media because multiple large-area replica molds can be fabricated simultaneously.

  18. Effect of several thermoplastic canal filling techniques on surface temperature rise on roots with simulated internal resorption cavities: an infrared thermographic analysis.

    Science.gov (United States)

    Ulusoy, Ö I; Yılmazoğlu, M Z; Görgül, G

    2015-02-01

    To evaluate the surface temperature rise using an infrared thermal imaging camera on roots with and without simulated internal resorption cavities, during canal filling with injectable (Obtura II), carrier-based (Soft-Core) gutta-percha and continuous wave of condensation (System B) techniques. Root canals of 60 mandibular premolar teeth were instrumented to an apical size of 40. Circular artificial internal resorption cavities with a diameter of 2.40 mm were prepared on the root canal walls of 30 teeth. All teeth were divided into six groups of 10 specimen and root filled as follows: group 1 (teeth with internal resorption): thermoplasticized injectable gutta-percha (Obtura II), group 2 (teeth without internal resorption): thermoplasticized injectable gutta-percha (Obtura II), group 3 (teeth with internal resorption): carrier-based gutta-percha (Soft-Core), group 4 (teeth without internal resorption): carrier-based gutta-percha (Soft-Core), group 5 (teeth with internal resorption): continuous wave of condensation (System B) and group 6 (teeth without internal resorption): continuous wave of condensation (System B). The surface temperature changes during filling of canals were measured with an infrared thermal imaging camera. The thermograms were recorded at 2-s intervals over a period of 40 s to determine the maximum temperature rise at the apical, middle and cervical thirds of the root surface. The data were statistically analysed with one-way anova and Tukey HSD post hoc or Kruskal-Wallis and Bonferroni-adjusted Mann-Whitney U-tests if appropriate. The temperature rise on the surface of roots with artificial resorptive defects was significantly higher compared with the ones without defects in the Obtura II and System B groups (P internal resorption was associated with the maximum temperature rise in the apical (4.3 ± 2.1) and middle (19.5 ± 8.9) thirds amongst the groups (P internal resorptive cavities resulted in surface temperature rise over the critical

  19. Mold Materials For Permanent Molding of Aluminum Alloys

    Energy Technology Data Exchange (ETDEWEB)

    John F Wallace; David Schwam; Wen Hong dxs11@po.cwru.edu

    2001-09-14

    A test that involves immersion of the potential mod materials for permanent molds has been developed that provides a thermal cycle that is similar to the experienced during casting of aluminum in permanent molds. This test has been employed to determine the relative thermal fatigue resistance of several different types of mold materials. Four commercial mold coatings have been evaluated for their insulating ability, wear resistance and roughness. The results indicate that composition and structure of the mold materials have considerable effect on their thermal fatigue cracking behavior. Irons with a gray iron structure are the most prone to thermal fatigue cracking followed by compacted graphite irons with the least thermal fatigue cracking of the cast irons experienced by ductile iron. The composition of these various irons affects their behavior.

  20. Research and Application of 3D Simulation of Filling in Coal Mines%煤矿充填三维仿真系统的研究与应用

    Institute of Scientific and Technical Information of China (English)

    张新国; 刘冰; 江宁; 江兴元

    2013-01-01

    在介绍煤矿充填技术发展现状的基础上,运用虚拟现实技术对可实行的充填方案进行仿真模拟,探讨了三维实体建模、充填过程演示和充填效果比较等关键性技术.同时结合实例,阐述了煤矿通过充填三维仿真来进行充填方案的设计与选择的重要性和现实意义.在充填方案前期策划中,可视化三维仿真技术的应用突破了传统的可视化程度不高的缺点,使充填方案的设计更加直观形象、更容易理解,也为将来煤矿充填技术的推广应用提供了一个新方式.%On the basis of the introduction of development status of mine filling technology, simulation of feasible filling scheme was carried out with virtual reality technology, and the key technologies including 3D solid modeling, filling process demonstration and filling effect comparison were discussed. In the meantime, the importance and the realistic meaning of design and selection of filling scheme using 3D simulation of filling in coal mine were described. In the preplanning of filling scheme, application of visualized 3D simulation technology overcame the disadvantage of low visualization degree, which not only make the filling scheme design more intuitive and more pellucid, but also provide one new method for the spread and application of filling in the coal mine in the future.

  1. A Two-layer Model for the Simulation of the VARTM Process with Resin Distribution Layer

    Science.gov (United States)

    Young, Wen-Bin

    2013-12-01

    Vacuum assisted resin transfer molding (VARTM) is one of the important processes to fabricate high performance composites. In this process, resin is drawn into the mold to impregnate the fiber reinforcement to a form composite. A resin distribution layer with high permeability was often introduced on top of the fiber reinforcement to accelerate the filling speed. Due to the difference of the flow resistance in the resin distribution layer and the reinforcement as well as the resulting through thickness transverse flow, the filling flow field is intrinsically three-dimensional. This study developed a two-layer model with two-dimensional formulation to simulate the filling flow of the VARTM process with a resin distribution layer. Two-dimensional flow was considered in each layer and a transverse flow in the thickness direction was estimated between the two layers. Thermal analysis including the transverse convection was also performed to better simulate the temperature distribution.

  2. 塑料中央面板热流道注射模设计%Design of Hot Runner Injection Mold for Plastics Central Panel

    Institute of Scientific and Technical Information of China (English)

    陈鹏

    2012-01-01

    针对中央面板塑料件,利用Pro/Plastic Advisor进行充型模拟,确定最佳浇口数量与位置.基于UG/Moldwizerd和UG/Solid Modeling,应用手动与自动分模相结合的方法,进行整套模具结构的全三维设计.企业生产实践证明,用该模具生产的塑料件尺寸、形位公差符合要求.%Aiming at the plastics central panel, the whole filling process of plastics part was simulated by utilizing Pro/Plastic Advisor. Application of manual and automatic mold design method, the all three-dimensional design of injection mold structure was proceeded by UG / Moldwizerd and UG/Solid Modeling. The size and shape of plastic part conformed the request by production practice of proven.

  3. Theoretical simulation of the picosecond runaway-electron beam in coaxial diode filled with SF6 at atmospheric pressure

    Science.gov (United States)

    Kozyrev, Andrey; Kozhevnikov, Vasily; Lomaev, Mikhail; Sorokin, Dmitry; Semeniuk, Natalia; Tarasenko, Victor

    2016-05-01

    This paper presents detailed results of gas discharge theoretical simulation and the explanation of probabilistic mechanism of fast-electrons generation. Within the framework of a hybrid mathematical model, the hydrodynamic and the kinetic approaches are used simultaneously in order to describe the dynamics of different components of a low-temperature discharge plasma. The breakdown of a coaxial diode occurs in the form of a dense plasma region expanding from the cathode. On this background there is a formation of runaway electrons that are initiated by the ensemble of plasma electrons generated in the region of locally enhanced electric field within the front of the dense plasma. It is shown that the power spectrum of fast electrons in the discharge contains the group of electrons with the so-called “anomalous” energies. Comparison of the calculation results with the existent experimental data gives a good agreement for all major process parameters.

  4. Estudio experimental del llenado de moldes pulvimetalúrgicos

    Directory of Open Access Journals (Sweden)

    Istúriz, A.

    2005-12-01

    Full Text Available Die filling is the first step in the process of powder compaction. The density distribution depends of the powder characteristics and method of filling. In this work we present the first results obtained with different experimental methods of the filling. Results have been analyzed using a video system which permits the observation of the powder flow. The aim of the work is to determinate the effects of size, morphology and nature of the powder, as well as shoe speed, and die geometry on the apparent density distribution in industrial dies of complex geometry.

    En el proceso de conformado pulvimetalúrgico, la consolidación del polvo se inicia con el llenado del molde en el que se fabricará la preforma porosa, el cual está caracterizado por la distribución de densidades del polvo dentro del molde y depende tanto de las propiedades del mismo como del método de llenado utilizado. A continuación, presentamos los primeros resultados obtenidos mediante un montaje experimental que reproduce el llenado de moldes y que, empleando un sistema de video, permite analizar el flujo de las partículas durante el llenado. El objetivo es determinar el efecto del tamaño, naturaleza y morfología del polvo, así como el de la velocidad del cargador y la geometría del molde en la distribución de la densidad aparente en moldes industriales de geometría compleja.

  5. Thermophilic molds: Biology and applications.

    Science.gov (United States)

    Singh, Bijender; Poças-Fonseca, Marcio J; Johri, B N; Satyanarayana, Tulasi

    2016-11-01

    Thermophilic molds thrive in a variety of natural habitats including soils, composts, wood chip piles, nesting materials of birds and other animals, municipal refuse and others, and ubiquitous in their distribution. These molds grow in simple media containing carbon and nitrogen sources and mineral salts. Polyamines are synthesized in these molds and the composition of lipids varies considerably, predominantly containing palmitic, oleic and linoleic acids with low levels of lauric, palmiotoleic and stearic acids. Thermophilic molds are capable of efficiently degrading organic materials by secreting thermostable enzymes, which are useful in the bioremediation of industrial wastes and effluents that are rich in oil, heavy metals, anti-nutritional factors such as phytic acid and polysaccharides. Thermophilic molds synthesize several antimicrobial substances and biotechnologically useful miscellaneous enzymes. The analysis of genomes of thermophilic molds reveals high G:C contents, shorter introns and intergenic regions with lesser repetitive sequences, and further confirms their ability to degrade agro-residues efficiently. Genetic engineering has aided in ameliorating the characteristics of the enzymes of thermophilic molds. This review is aimed at focusing on the biology of thermophilic molds with emphasis on recent developments in the analysis of genomes, genetic engineering and potential applications.

  6. An in-mold packaging process for plastic fluidic devices.

    Science.gov (United States)

    Yoo, Y E; Lee, K H; Je, T J; Choi, D S; Kim, S K

    2011-01-01

    Micro or nanofluidic devices have many channel shapes to deliver chemical solutions, body fluids or any fluids. The channels in these devices should be covered to prevent the fluids from overflowing or leaking. A typical method to fabricate an enclosed channel is to bond or weld a cover plate to a channel plate. This solid-to-solid bonding process, however, takes a considerable amount of time for mass production. In this study, a new process for molding a cover layer that can enclose open micro or nanochannels without solid-to-solid bonding is proposed and its feasibility is estimated. First, based on the design of a model microchannel, a brass microchannel master core was machined and a plastic microchannel platform was injection-molded. Using this molded platform, a series of experiments was performed for four process or mold design parameters. Some feasible conditions were successfully found to enclosed channels without filling the microchannels for the injection molding of a cover layer over the plastic microchannel platform. In addition, the bond strength and seal performance were estimated in a comparison with those done by conventional bonding or welding processes.

  7. The application of fuzzy theory for the control of weld line positions in injection-molded part.

    Science.gov (United States)

    Chen, Mei-Yung; Tzeng, Huan-Wen; Chen, Yi-Cheng; Chen, Shia-Chung

    2008-01-01

    This research proposes the fuzzy theory for the control of weld lines in plastic injection molding. The weld line occurs as a result of geometrical changes in molded parts in the injection molding process. The weld line is one of the defects present in plastic injection-molded parts; the line affects the quality of parts as well as the strength of the products. In the present study, fuzzy theory was applied in the design of injection molding. First, expert experiences were transformed into IF approximately THEN approximately rules to establish the knowledge base for developing fuzzy inference rules. The rules were then used to adjust the molding parameters, which in turn were applied to control the weld line position in the injection molding process. The results indicate that fuzzy theory exhibited favorable applicability in the control of the weld line as well as decreased the simulation time, thereby accelerating the design process of injection molding.

  8. Permanent Mold Casting of JIS-AC4C Aluminum Alloy Using a Low-Temperature Mold

    Science.gov (United States)

    Yamagata, Hiroshi; Nikawa, Makoto

    2011-01-01

    Permanent mold casting using mold temperatures below 200° C was conducted to obtain a high-strength, thin-walled casting. Al-7.36 mass% Si -0.18 Cu- 0.27Mg-0.34Fe alloy JIS-AC4C was cast using a bottom pouring cast plan. The product had a rectangular tube shape (70 mm W x 68 mm D x 180 mm H) with wall thicknesses of 1, 3 and 5 mm. The effect of heat insulation at the melt path was compared when using a sand runner insert and when using a steel runner insert as well as a powder mold release agent. Fine microstructures were observed in the casting. The smaller the thickness, the higher the hardness with smaller secondary dendrite arm spacing (SDAS). However, the hardness and the SDAS were unaffected by the mold temperature. It was proposed that the avoidance of the formation of primary α dendrite at the melt path generates a higher strength casting with adequate mold filling.

  9. Predictive engineering tools for injection-molded long-carbon-fiber thermoplastic composites - FY 2015 third quarterly report

    Energy Technology Data Exchange (ETDEWEB)

    Nguyen, Ba Nghiep [Pacific Northwest National Lab. (PNNL), Richland, WA (United States); Fifield, Leonard S. [Pacific Northwest National Lab. (PNNL), Richland, WA (United States); Mori, Steven [MAGNA Exteriors and Interiors Corp. Aurora, ON (Canada); Gandhi, Umesh N. [Toyota Research Institute North America, Ann Arbor, MI (United States); Wang, Jin [Autodesk, Inc., Ithaca, NY (United States); Costa, Franco [Autodesk, Inc., Ithaca, NY (United States); Wollan, Eric J. [PlastiComp, Inc., Winona, MN (United States); Tucker, III, Charles L. [Univ. of Illinois at Urbana-Champaign, Urbana, IL (United States)

    2015-07-01

    During the third quarter of FY 2015, the following technical progress has been made toward project milestones: 1) Magna oversaw the tool build and prepared the molding plan for the complex part of Phase II. 2) PlastiComp hosted a visit by Magna and Toyota on April 23rd to finalize the molding scope and schedule. The plan for molding trials including selection of molding parameters for both LFT and D-LFT for the U-shape complex part was established. 3) Toyota shipped the U-shape complex part tool to Magna on May 28th, 2015. 4) Plasticomp provided 30wt% LCF/PP and 30wt% LCF/PA66 compounded pellets to Magna for molding the complex part. 5) Magna performed preliminary molding trials on June 2nd, 2015 to validate wall thickness, fill profile, tool temperature and shot size requirements for the complex part. 6) Magna performed the first complex part run on June 16th and 17th, 2015 at Magna’s Composite Centre of Excellence in Concord, ON, Canada. Dale Roland of Plasticomp, and Umesh Gandhi of Toyota also attended the molding. 7) Magna discussed and finalized the plan with PNNL and the team for cutting samples from molded parts at selected locations for fiber orientation and length measurements. 8) Magna provided the computer-aided design (CAD) files of the complex parts with and without ribs to PNNL and Autodesk to build the corresponding ASMI models for injection molding simulations. Magna also provided the actual parameters used. 9) Plasticomp’s provided knowledge and experience of molding LCF materials essential to the successful molding of the parts including optimization of fill speed, tool temperatures, and plasticizing conditions for the 30wt% LCF/PP and 30wt% LCF/PA66 materials in both rib and non-rib versions. 10) Magna molded additional parts for evaluation of mechanical property testing including torsional stiffness on June 29th and 30th, 2015 at Magna’s Composite Center of Excellence. 11) Toyota began preparation for the torsion test of the specimens

  10. In-mold sensor concept to calculate process-specific rheological properties

    Science.gov (United States)

    Pacher, G. A.; Berger, G. R.; Friesenbichler, W.; Gruber, D. P.; Macher, J.

    2014-05-01

    To gain extended knowledge on the flow behavior of polymer melts during filling phase of the injection molding process, an injection mold featuring complex sensor technology was developed. Three triple-combined FOS MTPS408 cavity sensors (FOS Messtechnik GmbH) are aligned along the flow path of a plate-shaped cavity. Each sensor features an infrared detector, a type K thermocouple, and a piezo-electric pressure detector. This configuration enables the local and transient recording of melt temperature, mold temperature and cavity pressure near gate, part center and end of part simultaneously. Averaged melt velocities are determined by evaluating the differing times of the rising edges of the infrared sensors. Local melt velocities and viscosities are calculated at each sensor position by evaluation of the gradients of temperature and pressure. Moreover, the used injection mold is equipped with RHCM technologies to additionally influence the mold surface temperature and hence the filling of the cavity. The specimens are plate-shaped parts having cut-outs and ribs similar to geometries found in numerous industrial applications such as cover panels. The application of this in-mold sensor concept provides novel possibilities for the systematic in-line analysis and evaluation of process-parameters in injection molding. Further studies will be carried out to connect the process-specific properties to the specimen morphology; aiming at controlling morphology by adjusting process parameters.

  11. FIBER ORIENTATION IN INJECTION MOLDED LONG CARBON FIBER THERMOPLASTIC COMPOSITES

    Energy Technology Data Exchange (ETDEWEB)

    Wang, Jin; Nguyen, Ba Nghiep; Mathur, Raj N.; Sharma, Bhisham; Sangid, Michael D.; Costa, Franco; Jin, Xiaoshi; Tucker III, Charles L.; Fifield, Leonard S.

    2015-03-23

    A set of edge-gated and center-gated plaques were injection molded with long carbon fiber-reinforced thermoplastic composites, and the fiber orientation was measured at different locations of the plaques. Autodesk Simulation Moldflow Insight (ASMI) software was used to simulate the injection molding of these plaques and to predict the fiber orientation, using the anisotropic rotary diffusion and the reduced strain closure models. The phenomenological parameters of the orientation models were carefully identified by fitting to the measured orientation data. The fiber orientation predictions show very good agreement with the experimental data.

  12. 洗衣机双缸的热流道注塑模设计%DESIGN OF WASHING MACHINE DUAL-TUB'S HOT RUNNER INJECTION MOLD

    Institute of Scientific and Technical Information of China (English)

    肖小峰; 宋琪; 薛琼

    2011-01-01

    Aiming at the thin-wall large-scale plastic part of dual-tub of washing machine,the whole filling process of plastic injection wsa simulated by utilizing Pro/Plastic Advisor.The quantity and location of gate were identified and runner size was computed according to theoretical model.The three-dimensional(3D)design of hot runner gating system was proceeded by Pro/E software and the splice of mold cavity of movable mold and fixed mold and insert design were proceeded according to the requirements of parting of plastic part and mold process,whold 3D assembly design of plastic injection mold was achieved by utilizing standard parts that EMX provided.The three links development of product design,mold design and mold manufacture were realizde smoothly by parametrical modeling technology of Pro/E.The size and shape of plastic part conformed the request when the mold was put into production.%针对洗衣机双缸薄壁大型塑料件,利用Pro/Plastic Advisor进行充型模拟,确定最佳进胶点数量与位置,按照理论模型进行了流道尺寸计算.基于Pro/E软件,进行三维热流道浇注系统设计,根据塑料件分型与模具加工工艺的要求,进行动、定模模腔的拼接、镶件设计,利用EMX提供的标准件完成模具全三维装配设计.通过Pro/E参数化建模技术,实现产品设计、模具设计和模具制造三个环节的开发.模具投产后,塑料件尺寸、形位符合要求.

  13. Optimization design of wide face water slots for medium-thick slab casting mold

    Directory of Open Access Journals (Sweden)

    Xue-lin Yin

    2016-09-01

    Full Text Available A three-dimensional finite-element model has been established to investigate the thermal behavior of the medium-thick slab copper casting mold with different cooling water slot designs. The mold wall temperatures measured using thermocouples buried in different positions of the mold with the original designed cooling system were analyzed to determine the corresponding heat flux profile. This profile was then used for simulation to predict the temperature distribution and the thermal stress distribution of the molds. The predicted temperatures during operation matched the plant measurements. The results showed that the maximum temperature, about 635 K in the wide hot surface, was found about 60 mm below the meniscus and 226 mm from the center of the mold. For the mold with the type I modified design, there was an insignificant decrease in temperature of about 5 K, and for the mold with the type II modified design, the maximum temperature was decreased by about 15 K and the temperature of the hot surface was distributed more uniformly along the length of the mold. The corresponding maximum thermal stress at the hot surface of the mold was reduced from 408 MPa to 386 MPa with the type II modified design. The results indicated that the modified design II is beneficial to the increase of mold life and the quality of casting slabs.

  14. Localized rapid heating process for precision chalcogenide glass molding

    Science.gov (United States)

    Li, Hui; He, Peng; Yu, Jianfeng; Lee, L. James; Yi, Allen Y.

    2015-10-01

    Precision glass molding is an important process for high volume optical fabrication. However, conventional glass molding is a bulk heating process that usually requires a long thermal cycle, where molding assembly and other mechanical parts are heated and cooled together. This often causes low efficiency and other heating and cooling related problems, such as large thermal expansion in both the molds and molded optics. To cope with this issue, we developed a localized rapid heating process to effectively heat only very small part of the glass. This localized rapid heating study utilized a fused silica wafer coated with a thin graphene layer to heat only the surface of the glass. The graphene coating functions as an electrical resistant heater when a power source was applied across the thin film coating, generating heat on and near the coating. The feasibility of this process was validated by both experiments and numerical simulation. To demonstrate the advantages of the localized rapid heating, both localized rapid heating process and bulk heating process were performed and carefully compared. The uniformity and quality of the molded sample by localized rapid heating process was also demonstrated. In summary, localized rapid heating process by using graphene coated fused silica wafer was characterized and can be readily implemented in replication of micro scale chalcogenide glasses. A fused silica wafer coated with a thin graphene layer was utilized for localized rapid heating only the surface of the glass. The graphene coating functions as an electrical resistant heater when a power source was applied across the thin film coating, generating high temperature on and near the coating. This process is fast and efficient since only interested areas are heated without affecting the entire glass substrate or the mold assembly. The uniformity and quality of the molded sample by localized rapid heating process was demonstrated by comparing both localized rapid heating

  15. Investigation of Heat Transfer at the Mold/Metal Interface in Permanent Mold Casting of Light Alloys

    Energy Technology Data Exchange (ETDEWEB)

    Robert D. Pehlke; John T. Berry

    2005-12-16

    Accurate modeling of the metal casting process prior to creating a mold design demands reliable knowledge of the interfacial heat transfer coefficient at the mold metal interface as a function of both time and location. The phenomena concerned with the gap forming between the mold and the solidifying metal are complex but need to be understood before any modeling is attempted. The presence of mold coatings further complicates the situation. A commercial casting was chosen and studied in a gravity permanent mold casting process. The metal/mold interfacial heat transfer coefficient (IHTC) was the focus of the research. A simple, direct method has been used to evaluate the IHTC. Both the simulation and experiments have shown that a reasonably good estimate of the heat transfer coefficient could be made in the case studied. It has been found that there is a good agreement between experiments and simulations in the temperature profiles during the solidification process, given that the primary mechanism of heat transfer across the gap in permanent mold casting of light alloys is by conduction across the gap. The procedure utilized to determine the interfacial heat transfer coefficient can be applied to other casting processes. A recently completed project involving The University of Michigan and Mississippi State University, together with several industrial partners, which was supported by the USDOE through the Cast Metals Coalition, examined a number of cases of thermal contact. In an investigation which gave special consideration to the techniques of measurement, several mold coatings were employed and results presented as a function of time. Realistic conditions of coating thickness and type together with an appropriate combination of mold preheat and metal pouring temperature were strictly maintained throughout the investigation. Temperature sensors, in particular thermocouples, play an important part in validating the predictions of solidification models. Cooling

  16. Injection Molding of High Aspect Ratio Nanostructures

    DEFF Research Database (Denmark)

    Matschuk, Maria; Larsen, Niels Bent

    We present a process for injection molding of 40 nm wide and >100 nm high pillars (pitch: 200 nm). We explored the effects of mold coatings and injection molding conditions on the replication quality of nanostructures in cyclic olefin copolymer. We found that optimization of molding parameters...

  17. Rapid control of mold temperature during injection molding process

    Energy Technology Data Exchange (ETDEWEB)

    Liparoti, Sara; Titomanlio, Giuseppe [Department of Industrial Engineering, University of Salerno Via Giovanni Paolo II, 132, 84084 Fisciano (Italy); Hunag, Tsang Min; Cakmak, Mukerrem [Department of Polymer Engineering, The University of Akron, Akron, OH 44325 (United States); Sorrentino, Andrea [Institute for Polymers, Composite and Biomaterials (IPCB) - CNR, P. Enrico Fermi 1, 80055 Portici (Italy)

    2015-05-22

    The control of mold surface temperature is an important factor that determines surface morphology and its dimension in thickness direction. It can also affect the frozen molecular orientation and the mold surface replicability in injection molded products. In this work, thin thermally active films were used to quickly control the mold surface temperature. In particular, an active high electrical conductivity carbon black loaded polyimide composites sandwiched between two insulating thin polymeric layers was used to condition the mold surface. By controlling the heating time, it was possible to control precisely the temporal variation of the mold temperature surface during the entire cycle. The surface heating rate was about 40°C/s and upon contact with the polymer the surface temperature decreased back to 40°C within about 5 s; the overall cycle time increased only slightly. The effect on cross section sample morphology of samples of iPP were analyzed and discussed on the basis of the recorded temperature evolution.

  18. Assessment Of Mold-Design Dependent Textures In CIM-Components By Polarized Light Optical Texture Analysis (PLOTA)

    Science.gov (United States)

    Kern, Frank; Rauch, Johannes; Gadow, Rainer

    2007-04-01

    By thermoplastic ceramic injection moulding (CIM) ceramic components of high complexity can be produced in a large number of items at low dimensional tolerances. The cost advantage by the high degree of automation leads to an economical mass-production. The structure of injection-moulded components is determined by the form filling behaviour and viscosity of the feedstock, the machine parameters, the design of the mold and the gate design. With an adapted mold- and gate-design CIM-components without textures are possible. The "Polarized Light Optical Texture analysis" (PLOTA) makes it possible to inspect the components and detect and quantify the textures produced by a new mold. Based on the work of R. Fischer (2004) the PLOTA procedure was improved by including the possibility to measure the inclination angle and thus describe the orientation of the grains in three dimensions. Sampled thin sections of ceramic components are analysed under the polarization microscope and are brought in diagonal position. Pictures are taken with a digital camera. The pictures are converted in the L*a*b*- colour space and the crystals color values a* and b* in the picture are measured. The color values are compared with the values of a quartz wedge, which serves as universal standard. From the received values the inclination angle can be calculated relative to the microscope axis. It is possible to use the received data quantitatively e.g. for the FEM supported simulation of texture-conditioned divergences of mechanical values. Thus the injection molding parameters can be optimized to obtain improved mechanical properties.

  19. 电磁搅拌条件下小方坯结晶器内钢液流动行为的数值模拟%Numerical Simulation of Flow Field in Mold for Small Billets Under Electromagnetic Stirring

    Institute of Scientific and Technical Information of China (English)

    胡国旭

    2012-01-01

    采用数模分析结合生产实践的方法,对小方坯连铸结晶器电磁搅拌过程及相关问题进行了理论与实践分析.结果表明,电流强度与频率对磁感应强度有直接影响;150 mm×150 mm断面的最佳搅拌频率为4Hz;当搅拌电流在250~400 A之间变化时,搅拌速度大小范围在0.71~ 1.06 m/s;该计算应用于生产实践取得了较好的生产实效.%The electromagnetic stirring process and related problems of the mold for small billets were theoretically and practically analyzed with the method of combining digital-to-analog analysis with production practice. The results show that the current strength and its frequency has a direct impact on the magnetic induction. The best stirring frequency is 4 Hz for 150 mm×l50 mm section; and when the mixing current changes in the range of 250~400 A, corresponding stirring speed is in the rage of 0.71~1.06 m/s. Applying the simulation results to practical production, a good production efficiency has been obtained.

  20. Investigation of the beryllia ceramics molding process by the hot casting method

    Science.gov (United States)

    Zhapbasbaev, U. K.; Ramazanova, G. I.; Sattinova, Z. K.

    2013-03-01

    Results of mathematical simulation of the ceramics molding process by the hot casting method are presented. The mathematical model describes the motion of beryllia liquid thermoplastic slurry in a form-building cavity subject to solidification. Velocity and temperature profiles providing homogeneous properties of the beryllia ceramics in the process of molding by the hot casting method are obtained.

  1. White mold of Jerusalem artichoke

    Science.gov (United States)

    Jerusalem artichoke (Helianthus tuberosus) is a Native American food plant closely related to the common sunflower (Helianthus annuus). Tubers of Jerusalem artichoke are increasingly available in retail grocery outlets. White mold (Sclerotinia stem rot), caused by the fungus, Sclerotinia sclerotioru...

  2. Prevention of Mold Contamination : Ozone Treatment

    OpenAIRE

    Nakarmi, Kanchan

    2016-01-01

    Mold is a common pest that can cause diseases and decay property. Moreover, certain mold can produce toxic chemicals which leads directly or indirectly to additional health impacts and economic losses. Therefore, prevention of mold growth is a major concern, and disinfection of mold has become a center of attention. The purpose of this thesis was to study about the effect of ozone in the disinfection of mold and the method of producing ozone. The usage of ozone for disinfection in in...

  3. Onychomycosis due to opportunistic molds*

    OpenAIRE

    Martínez-Herrera, Erick Obed; Arroyo-Camarena,Stefanie; Tejada-García, Diana Luz; Porras-López, Carlos Francisco; Arenas, Roberto

    2015-01-01

    Abstract BACKGROUND: Onychomycosis are caused by dermatophytes and Candida, but rarely by non- dermatophyte molds. These opportunistic agents are filamentous fungi found as soil and plant pathogens. OBJECTIVES: To determine the frequency of opportunistic molds in onychomycosis. METHODS: A retrospective analysis of 4,220 cases with onychomycosis, diagnosed in a 39-month period at the Institute of Dermatology and Skin surgery "Prof. Dr. Fernando A. Cordero C." in Guatemala City, and confirmed w...

  4. Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites - Fourth FY 2015 Quarterly Report

    Energy Technology Data Exchange (ETDEWEB)

    Nguyen, Ba Nghiep; Fifield, Leonard S.; Wollan, Eric J.; Roland, Dale; Gandhi, Umesh N.; Mori, Steven; Lambert, Gregory; Baird, Donald G.; Wang, Jin; Costa, Franco; Tucker III, Charles L.

    2015-11-13

    During the last quarter of FY 2015, the following technical progress has been made toward project milestones: 1) PlastiComp used the PlastiComp direct in-line (D-LFT) Pushtrusion system to injection mold 40 30wt% LCF/PP parts with ribs, 40 30wt% LCF/PP parts without ribs, 10 30wt% LCF/PA66 parts with ribs, and 35 30wt% LCF/PA66 parts without ribs. In addition, purge materials from the injection molding nozzle were obtained for fiber length analysis, and molding parameters were sent to PNNL for process modeling. 2) Magna cut samples at four selected locations (named A, B, C and D) from the non-ribbed Magna-molded parts based on a plan discussed with PNNL and the team and shipped these samples to Virginia Tech for fiber orientation and length measurements. 3) Virginia Tech started fiber orientation and length measurements for the samples taken from the complex parts using Virginia Tech’s established procedure. 4) PNNL and Autodesk built ASMI models for the complex parts with and without ribs, reviewed process datasheets and performed preliminary analyses of these complex parts using the actual molding parameters received from Magna and PlastiComp to compare predicted to experimental mold filling patterns. 5) Autodesk assisted PNNL in developing the workflow to use Moldflow fiber orientation and length results in ABAQUS® simulations. 6) Autodesk advised the team on the practicality and difficulty of material viscosity characterization from the D-LFT process. 7) PNNL developed a procedure to import fiber orientation and length results from a 3D ASMI analysis to a 3D ABAQUS® model for structural analyses of the complex part for later weight reduction study. 8) In discussion with PNNL and Magna, Toyota developed mechanical test setups and built fixtures for three-point bending and torsion tests of the complex parts. 9) Toyota built a finite element model for the complex parts subjected to torsion loading. 10) PNNL built the 3D ABAQUS® model of the complex ribbed

  5. Numerical Simulation of Internal Heat-curing Molding Process for Composite Gas Cylinder%复合材料气瓶内加热固化成型方法及数值模拟研究

    Institute of Scientific and Technical Information of China (English)

    陈海燕; 杨海; 于立英; 许家忠

    2014-01-01

    Internal heat-curing molding process of composite gas cylinder made of glass fiber reinforced epoxy resin and metal liner was studied with finite element method. The simulation program of the internal heat-curing molding process was developed on ANSYS software platform, which realized the numerical simulation research on the changing law of curing temperature and curing degree for the composite gas cylinder. The results indicate that the algorithm result based on the numerical simulation is accordance with the actual experimental data, so the algorithm is accurate and effective. During the curing process of the composite gas cylinder, the temperature is passed from the inner layer of the composite to its outer layer and the peak temperature in the curing process becomes higher from the inner layer to outer layer,the gas cylinder is cured step by step,and curing time becomes shorter gradually from the inner layer to outer layer. The influences of the metal liner materials,environment temperature and the composite thickness on the changing law of curing temperature and curing degree were also analyzed according to the simulation result. The results show when the environment temperature is higher,the time of reaching the curing peak temperature becomes early and the peak temperature is lower,the time of starting curing becomes early. When the composite gets thicker,the time of reaching the curing peak temperature gets later and the peak temperature is higher,the time of starting curing becomes later. The influences of the metal liner materials on this composite cylinder with thin wall liner are small.%采用有限元方法对由玻璃纤维增强环氧树脂复合材料和金属内衬组成的复合材料气瓶内固化成型工艺进行研究,利用ANSYS仿真软件开发了复合材料气瓶内固化过程的仿真程序,实现复合气瓶固化过程温度和固化度变化规律的数值模拟研究。结果表明,数值模拟与实际实验数据较吻合

  6. Hydrogen silsesquioxane mold coatings for improved replication of nanopatterns by injection molding

    DEFF Research Database (Denmark)

    Hobæk, Thor Christian; Matschuk, Maria; Kafka, Jan;

    2015-01-01

    We demonstrate the replication of nanosized pillars in polymer (cyclic olefin copolymer) by injection molding using nanostructured thermally cured hydrogen silsesquioxane (HSQ) ceramic coatings on stainless steel mold inserts with mold nanostructures produced by a simple embossing process...

  7. Hot-leakage fault simulation and analysis of filter in liquid hydrogen filling system%液氢加注系统中过滤器漏热故障仿真与分析

    Institute of Scientific and Technical Information of China (English)

    马昕晖; 栾骁; 陈景鹏; 孙克

    2012-01-01

    液氢管道输送需要在极低温度下进行,需要较高的保温措施,而且出现漏热故障的时候将十分危险.发生漏热后的液氢会迅速产生气液两相流,其对加注系统中的器件造成很大的冲击与危害,造成加注系统损坏等事故.因此,对液氢加注系统进行仿真研究有着重要的作用.而过滤器漏热的影响大约是管道漏热的三倍,所以研究过滤器漏热更具有防范风险的指导意义.本文依据AMEsim工程仿真软件,对液氢加注系统进行建模与仿真,并置入过滤器故障仿真进行对比与分析.%Hydrogen Pipeline needs to run at very low temperatures, requiring a higher insulation measures. When the heat leakage occurs the failure it will be very dangerous. Leaking heat of liquid hydrogen occurs and rapidly produces gas - liquid two - phase flow, its filling system components will cause great impact and harm, the filling system will be damaged. Therefore, the simulation of liquid hydrogen filling system plays an important role. The heat - leakage of the filter is about three times than the pipe heat leakage, so to study the heat leak of the filter to prevent the risk is more significance. In this article using AMEsim engineering simulation software, A liquid - hydrogen filling system was modelled and simulated. The comparison and analysis of the filling system simulation with the filter fault simulation were made.

  8. Route 20, Autobahn 7, and Slime Mold: Approximating the Longest Roads in USA and Germany With Slime Mold on 3-D Terrains.

    Science.gov (United States)

    Adamatzky, Andrew I

    2014-01-01

    A cellular slime mould Physarum polycephalum is a monstrously large single cell visible by an unaided eye. The slime mold explores space in parallel, is guided by gradients of chemoattractants, and propagates toward sources of nutrients along nearly shortest paths. The slime mold is a living prototype of amorphous biological computers and robotic devices capable of solving a range of tasks of graph optimization and computational geometry. When presented with a distribution of nutrients, the slime mold spans the sources of nutrients with a network of protoplasmic tubes. This protoplasmic network matches a network of major transport routes of a country when configuration of major urban areas is represented by nutrients. A transport route connecting two cities should ideally be a shortest path, and this is usually the case in computer simulations and laboratory experiments with flat substrates. What searching strategies does the slime mold adopt when exploring 3-D terrains? How are optimal and transport routes approximated by protoplasmic tubes? Do the routes built by the slime mold on 3-D terrain match real-world transport routes? To answer these questions, we conducted pioneer laboratory experiments with Nylon terrains of USA and Germany. We used the slime mold to approximate route 20, the longest road in USA, and autobahn 7, the longest national motorway in Europe. We found that slime mold builds longer transport routes on 3-D terrains, compared to flat substrates yet sufficiently approximates man-made transport routes studied. We demonstrate that nutrients placed in destination sites affect performance of slime mold, and show how the mold navigates around elevations. In cellular automaton models of the slime mold, we have shown variability of the protoplasmic routes might depends on physiological states of the slime mold. Results presented will contribute toward development of novel algorithms for sensorial fusion, information processing, and decision making, and

  9. About Dental Amalgam Fillings

    Science.gov (United States)

    ... and Medical Procedures Dental Devices Dental Amalgam About Dental Amalgam Fillings Share Tweet Linkedin Pin it More ... should I have my fillings removed? What is dental amalgam? Dental amalgam is a dental filling material ...

  10. Performance of powder-filled evacuated panel insulation in a manufactured home roof cavity: Tests in the Large Scale Climate Simulator

    Energy Technology Data Exchange (ETDEWEB)

    Petrie, T.W.; Kosny, J.; Childs, P.W.

    1996-03-01

    A full-scale section of half the top of a single-wide manufactured home has been studied in the Large Scale Climate Simulator (LSCS) at the Oak Ridge National Laboratory. A small roof cavity with little room for insulation at the eaves is often the case with single-wide units and limits practical ways to improve thermal performance. The purpose of the current tests was to obtain steady-state performance data for the roof cavity of the manufactured home test section when the roof cavity was insulated with fiberglass batts, blown-in rock wool insulation or combinations of these insulations and powder-filled evacuated panel (PEP) insulation. Four insulation configurations were tested: (A) a configuration with two layers of nominal R{sub US}-7 h {center_dot} ft{sup 2} {center_dot} F/BTU (R{sub SI}-1.2 m{sup 2} {center_dot} K/W) fiberglass batts; (B) a layer of PEPs and one layer of the fiberglass batts; (C) four layers of the fiberglass batts; and (D) an average 4.1 in. (10.4 cm) thick layer of blown-in rock wool at an average density of 2.4 lb/ft{sup 3} (38 kg/m{sup 3}). Effects of additional sheathing were determined for Configurations B and C. With Configuration D over the ceiling, two layers of expanded polystyrene (EPS) boards, each about the same thickness as the PEPs, were installed over the trusses instead of the roof. Aluminum foils facing the attic and over the top layer of EPS were added. The top layer of EPS was then replaced by PEPs.

  11. Functional nanostructures on injection molded plastic

    DEFF Research Database (Denmark)

    Johansson, Alicia Charlotte; Søgaard, Emil; Andersen, Nis Korsgaard

    Nanotechnology can be used to make inexpensive plastic parts with functional surfaces. The plastic parts can be molded using a standard injection molding process. The nanostructures are directly transferred from the surface of the molding tool to the surface of the molded plastic part during...... the molding process. The main advantage with this method is that surface treatments and chemical additives are avoided, which minimizes health risks and simplifies recycling. Another advantage is that the unique technology enables nanostructuring of free form molded parts. The functional surfaces can have...

  12. Gas-Assisted Heating Technology for High Aspect Ratio Microstructure Injection Molding

    Directory of Open Access Journals (Sweden)

    Shia-Chung Chen

    2013-01-01

    Full Text Available A hot gas is used for heating the cavity surface of a mold. Different mold gap sizes were designed. The mold surface temperature was heated to above the glass transition temperature of the plastic material, and the mold then closed for melt filling. The cavity surface can be heated to 130°C to assist the melt filling of the microfeatures. Results show that hot gas heating can improve the filling process and achieve 91% of the high aspect ratio microgrooves (about 640.38 μm of the maximum of 700 μm. The mold gap size strongly affects the heating speed and heating uniformity. Without surface preheating, the center rib is the highest. When the heating target temperature is 90°C or 100°C, the three microribs have a good uniformity of height. However, when the target temperature exceeds 100°C, the left side rib is higher than the other ribs.

  13. OPTIMIZATION OF INJECTION MOLDING PROCESS BASED ON NUMERICAL SIMULATIONAND BP NEURAL NETWORKS

    Institute of Scientific and Technical Information of China (English)

    王玉; 邢渊; 阮雪榆

    2001-01-01

    Plastic injection molding is a very complex process and its process planning has a direct influence on product quality and production efficiency. This paper studied the optimization of injection molding process by combining the numerical simulation with back-propagation(BP) networks. The BP networks are trained by the results of numerical simulation. The trained BP networks may:(1) shorten time for process planning;(2) optimize process parameters;(3) be employed in on-line quality control;(4) be integrated with knowledge-based system(KBS) and case-based reasoning(CBR) to make intelligent process planning of injection molding.

  14. Numerical Simulation for Filling Process of Aluminum Alloy in Semi-Solid Diecasting and Liquid Diecasting%铝合金半固态压铸与液态压铸充型过程的模拟

    Institute of Scientific and Technical Information of China (English)

    史立峰; 赵大志; 王平; 崔建忠

    2012-01-01

    利用AnyCasting软件模拟了ZL201合金半固态压铸和液态压铸充型的流动过程,并进行了试验验证.模拟及试验结果显示:合理的控制速度转换位置,能够保证半固态浆料以层流方式充填型腔,获得平缓的充型过程,有利于避免卷气、氧化夹杂等缺陷的产生.在相同的速度条件下进行液态压铸,金属液以湍流方式充填型腔,容易形成喷溅和卷气的现象.模拟结果与试验相符合.%The flow characteristics of semi-solid filling and liquid filling were compared and analyzed by using the AnyCasting software. The experiment was conducted to validate the simulated results. The results indicate that if speed switch section is reasonable, the semi-solid slurry fill the cavity by way of laminar flow which can reduce the foundry defects such as gas cavity and oxide inclusion. However, under the same speed conditions, the liquid filling is characteristic of turbulent flow, and air entrapment and sputtering easily occur. The simulation results are well in agreement with experimental ones.

  15. Solidification process and infrared image characteristics of permanent mold castings

    Science.gov (United States)

    Viets, Roman; Breuer, Markus; Haferkamp, Heinz; Kruessel, Thomas; Niemeyer, Matthias

    1999-03-01

    Interdependence between the development of temperature gradients at the solid-liquid interface during solidification of metals and the formation of local defects demands for thermal investigation. In foundry practice thermocouples are used to control the die's overall cooling-rate, but fluctuations in product quality still occur. Capturing FIR- thermograms after opening the die visualizes the state, when most thermal throughput has already flattened the temperature gradients in the mold. Rapid dissipation of heat from liquid metal to the mold during solidification forces further approach of the process investigation by slowing down the heat flux or the use of transparent mold material. Aluminum gravity casting experiments under technical vacuum conditions lead to decelerated solidification by suppression of convection and image sequences containing explicit characteristics that could be assigned to local shrinkage of the casting. Hence relevant clusters are extracted and thermal profiles are drawn from image series, pointing out correlations between feeding performance from the sink heads and the appearance of local defects. Tracing thermal processes in vacuum casting can scarcely be transferred to image data in foundry practice, since only little analogies exist between atmospheric and vacuum casting. The diagnosis of the casting process requires detection of the still closed mold using a transparent silica- aerogel sheet as part of the die. Hereby thermograms of the initial heat input are recorded by adapting a NIR-camera in addition to the FIR-unit. Thus the entire thermal compensation at the joint face for each casting is visualized. This experimental set-up is used for image sequence analysis related to the intermediate casting phases of mold filling, body formation and solidification shrinkage.

  16. Silane based coating of aluminium mold

    DEFF Research Database (Denmark)

    2013-01-01

    having at least one closed cavity is provided, at least one surface of the at least one cavity being an aluminium surface coated with a silane based coating layer. The silane based anti-stiction coating improves the anti-stiction properties of the mold which may allow for molding and demolding...... of structures which would otherwise be difficult to mold. The resistance of the coated aluminium mold is significantly improved by applying a silane-based coating layer....

  17. Effects of glass fibers on the properties of micro molded plastic parts

    DEFF Research Database (Denmark)

    Islam, Aminul; Hansen, Hans Nørgaard; Gasparin, Stefania

    2011-01-01

    of polymeric thin ribs. It investigates the effect of feature size and gate location on distribution of glass fibers inside the molded parts. The results from this work indicate that glass filled plastic materials have poor replication quality and nonhomogeneous mechanical properties due to the nonuniform...

  18. Simplified Algebraic Stress Model for Numerical Simulation of Mold Filling%简化代数应力模型在型腔充填数值模拟中的应用

    Institute of Scientific and Technical Information of China (English)

    麻向军; 杨秉俭; 苏俊义

    1999-01-01

    针对型腔充填过程中的紊流流动,将计及紊流各向异性的简化代数应力模型引入PHOE-NICS软件中,并通过对确定自由表面界面流率的van Leer格式进行修正,完成了恒温流体充填过程三维时均速度场和自由表面的数值模拟.与实验结果的对比表明,基于PHOENICS软件开发的充填模拟能够对复杂型腔的充填过程进行数值计算.

  19. Calculation Method for Mold Filling Flow Simulation Based on Body-fitted Coordinate (BFC)%适体坐标系下充型流动模拟的计算方法

    Institute of Scientific and Technical Information of China (English)

    戴挺; 赵建新; 梁英业; 朱鸣芳; 吴炳尧

    2006-01-01

    介绍了一种基于适体坐标系(BFC)的充型过程模拟方法.在网格剖分、控制方程转换、控制方程离散和自由表面处理等方面进行了介绍和讨论.通过算例比较了BFC方法与基于笛卡尔正交网格方法的各自特点.通过对模拟结果进行比较,表明在相同网格密度下,BFC方法可以获得更高的计算精度,并在网格系统、计算时间和内存消耗综合水平上均比传统的基于笛卡尔正交网格的模拟方法优越.

  20. Surface microstructure replication in injection molding

    DEFF Research Database (Denmark)

    Theilade, Uffe Arlø; Hansen, Hans Nørgaard

    2006-01-01

    In recent years, polymer components with surface microstructures have been in rising demand for applications such as lab-on-a-chip and optical components. Injection molding has proven to be a feasible and efficient way to manufacture such components. In injection molding, the mold surface topogra...

  1. Injection Molding of Plastics from Agricultural Materials

    Energy Technology Data Exchange (ETDEWEB)

    Bhattacharya, M.; Ruan, R.

    2001-02-22

    The objective of this research was to conduct a systematic study to relate injection molding parameters to properties of blends of starch and synthetic polymer. From this study, we wished to develop a thorough understanding of the injection molding process and gain significant insight into designing molds and aiding in developing products cheaply and efficiently.

  2. Planning an Injection Mold Design Training Program.

    Science.gov (United States)

    Allyn, Edward P.

    With the increased use of plastics worldwide the shortage of trained personnel in moldmaking and design for plastic injection molds is becoming critical. Local schools and community colleges should provide courses in mold design and mold making, since most workers presently learn while working under experienced designers on the job. Following this…

  3. Tool application CAD / CAM for design and construction of a prototype of plastic injection mold

    Directory of Open Access Journals (Sweden)

    Albert Miyer Suárez Castrillón

    2015-11-01

    Full Text Available The study, development and production of injection molds comes with the implementation of CAD and CAM tools available on the market; using these tools, a prototype injection mold for thermoplastic materials was designed and built, based on a mold is injection in the laboratory of the University of Pamplona, in which a couple of modifications were made in order to experiment with its design. The prototype was manufactured through a 3D scan of the original mold to provide the CAD / CAM files with the simulated 3D printing technique for performing an experimental study with the prototype for adjusting temperature and pressure sensors and for coatings metallic materials for use in the injection molding process.

  4. Is Mold the New Asbestos?

    Science.gov (United States)

    Colgan, Craig

    2003-01-01

    Mold and indoor air quality (IAQ) are matters of major concern to architects and their educational clients. The Environmental Protection Agency's Indoor Air Quality Tools for Schools program offers help to districts seeking to tackle IAQ issues. Strengthening community relations is one way to be ready in case of a bad environmental or IAQ report.…

  5. Is Mold the New Asbestos?

    Science.gov (United States)

    Colgan, Craig

    2003-01-01

    Mold and indoor air quality (IAQ) are matters of major concern to architects and their educational clients. The Environmental Protection Agency's Indoor Air Quality Tools for Schools program offers help to districts seeking to tackle IAQ issues. Strengthening community relations is one way to be ready in case of a bad environmental or IAQ report.…

  6. Molded Concrete Center Mine Wall

    Science.gov (United States)

    Lewis, E. V.

    1987-01-01

    Proposed semiautomatic system forms concrete-foam wall along middle of coal-mine passage. Wall helps support roof and divides passage into two conduits needed for ventilation of coal face. Mobile mold and concrete-foam generator form sections of wall in place.

  7. Nonisothermal glass molding for the cost-efficient production of precision freeform optics

    Science.gov (United States)

    Vu, Anh-Tuan; Kreilkamp, Holger; Dambon, Olaf; Klocke, Fritz

    2016-07-01

    Glass molding has become a key replication-based technology to satisfy intensively growing demands of complex precision optics in the today's photonic market. However, the state-of-the-art replicative technologies are still limited, mainly due to their insufficiency to meet the requirements of mass production. This paper introduces a newly developed nonisothermal glass molding in which a complex-shaped optic is produced in a very short process cycle. The innovative molding technology promises a cost-efficient production because of increased mold lifetime, less energy consumption, and high throughput from a fast process chain. At the early stage of the process development, the research focuses on an integration of finite element simulation into the process chain to reduce time and labor-intensive cost. By virtue of numerical modeling, defects including chill ripples and glass sticking in the nonisothermal molding process can be predicted and the consequent effects are avoided. In addition, the influences of process parameters and glass preforms on the surface quality, form accuracy, and residual stress are discussed. A series of experiments was carried out to validate the simulation results. The successful modeling, therefore, provides a systematic strategy for glass preform design, mold compensation, and optimization of the process parameters. In conclusion, the integration of simulation into the entire nonisothermal glass molding process chain will significantly increase the manufacturing efficiency as well as reduce the time-to-market for the mass production of complex precision yet low-cost glass optics.

  8. Hydrogen silsesquioxane mold coatings for improved replication of nanopatterns by injection molding

    OpenAIRE

    Hobæk, Thor Christian; Matschuk, Maria; Kafka, Jan; Pranov, Henrik J.; Larsen, Niels Bent

    2015-01-01

    We demonstrate the replication of nanosized pillars in polymer (cyclic olefin copolymer) by injection molding using nanostructured thermally cured hydrogen silsesquioxane (HSQ) ceramic coatings on stainless steel mold inserts with mold nanostructures produced by a simple embossing process. At isothermal mold conditions, the average pillar height increases by up to 100% and a more uniform height distribution is observed compared to a traditional metal mold insert. Thermal heat transfer simulat...

  9. Modeling of the flow continuum and optimal design of control-oriented injection systems in liquid composite molding processes

    Science.gov (United States)

    Gokce, Ali

    Several methodologies are presented in this dissertation that aim to ensure successful filling of the mold cavity consistently, during the mold filling stage of Liquid Composite Molding (LCM) processes such as Resin Transfer Molding (RTM), Vacuum Assisted Resin Transfer Molding (VARTM) and Seemann Composites Resin Infusion Molding (SCRIMP). Key parameters that affect the resin flow in the mold cavity can be divided into two main groups as continuum-related parameters and injection-related parameters. Flow continuum, which consists of all the spaces resin can reach in the mold cavity, has two major components: the porous medium, which is made up of the fiber reinforcements, and the flow channels that are introduced into the flow continuum unintentionally and offer an easy flow path to the resin. The properties that characterize the porous medium and the unintentional flow channels are continuum-related parameters. The injection-related parameters include resin injection locations (gates), resin injection conditions and air drainage locations (vents). Modeling the flow continuum is crucial in predicting the resin flow in the mold cavity. In this study, permeability, the key property of the porous medium, is predicted using the Method of Cells, a proven method to predict macroscopic properties of heterogeneous materials. Unintentional flow channels, which are also called racetracking channels, are modeled using a probabilistic approach. Injection-related parameters are the key tools to influence the resin flow in the mold cavity. In this study, Branch and Bound Search is modified for single gate optimization. Due to its pertinence to injection system design, the parameters that govern gate effectiveness in steering the resin advance are studied. A combinatorial search algorithm is proposed for vent optimization. Vent optimization and gate optimization algorithms are integrated for simultaneous gate and vent optimization. Overall, these methodologies reduce the cycle

  10. Thermal modeling of wafer-based precision glass molding process

    Science.gov (United States)

    Hu, Yang; Shen, Lianguan; Zhou, Jian; Li, Mujun

    2016-10-01

    Wafer based precision glass optics manufacturing has been an innovative approach for combining high accuracy with mass production. However, due to the small ratio of thickness and diameter of the glass wafer, deformation and residual stress would be induced for the nonuniform temperature distribution in the glass wafer after molding. Therefore, thermal modelling of the heating system in the wafer based precision glass molding (PGM) process is of great importance in optimizing the heating system and the technique of the process. The current paper deals with a transient thermal modelling of a self-developed heating system for wafer based PGM process. First, in order to investigate the effect of radiation from the surface and interior of the glass wafer, the thermal modeling is simulated with a discrete ordinates radiation model in the CFD software FLUENT. Temperature distribution of the glass wafer obtained from the simulations is then used to evaluate the performance of heating system and investigate some importance parameters in the model, such as interior and surface radiation in glass wafer, thermal contact conductance between glass wafer and molds, thickness to diameter ratio of glass wafer. Finally, structure modification in the molding chamber is raised to decrease the temperature gradient in the glass wafer and the effect is significant.

  11. Investigations on Void Formation in Composite Molding Processes and Structural Damping in Fiber-Reinforced Composites with Nanoscale Reinforcements

    Science.gov (United States)

    DeValve, Caleb Joshua

    Fiber-reinforced composites (FRCs) offer a stronger and lighter weight alternative to traditional materials used in engineering components such as wind turbine blades and rotorcraft structures. Composites for these applications are often fabricated using liquid molding techniques, such as injection molding or resin transfer molding. One significant issue during these processing methods is void formation due to incomplete wet-out of the resin within the fiber preform, resulting in discontinuous material properties and localized failure zones in the material. A fundamental understanding of the resin evolution during processing is essential to designing processing conditions for void-free filling, which is the first objective of the dissertation. Secondly, FRCs used in rotorcraft experience severe vibrational loads during service, and improved damping characteristics of the composite structure are desirable. To this end, a second goal is to explore the use of matrix-embedded nanoscale reinforcements to augment the inherent damping capabilities in FRCs. The first objective is addressed through a computational modeling and simulation of the infiltrating dual-scale resin flow through the micro-architectures of woven fibrous preforms, accounting for the capillary effects within the fiber bundles. An analytical model is developed for the longitudinal permeability of flow through fibrous bundles and applied to simulations which provide detailed predictions of local air entrapment locations as the resin permeates the preform. Generalized design plots are presented for predicting the void content and processing time in terms of the Capillary and Reynolds Numbers governing the molding process. The second portion of the research investigates the damping enhancement provided to FRCs in static and rotational configurations by different types and weight fractions of matrix-embedded carbon nanotubes (CNTs) in high fiber volume fraction composites. The damping is measured using

  12. Precision injection molding of freeform optics

    Science.gov (United States)

    Fang, Fengzhou; Zhang, Nan; Zhang, Xiaodong

    2016-08-01

    Precision injection molding is the most efficient mass production technology for manufacturing plastic optics. Applications of plastic optics in field of imaging, illumination, and concentration demonstrate a variety of complex surface forms, developing from conventional plano and spherical surfaces to aspheric and freeform surfaces. It requires high optical quality with high form accuracy and lower residual stresses, which challenges both optical tool inserts machining and precision injection molding process. The present paper reviews recent progress in mold tool machining and precision injection molding, with more emphasis on precision injection molding. The challenges and future development trend are also discussed.

  13. Getting a prescription filled

    Science.gov (United States)

    ... are located inside of a grocery or large "chain" store. It is best to fill all prescriptions ... be used for long-term medicines and medical supplies. The website should have clear directions for filling ...

  14. Micro-extrusion using a Graphit-ic coating mold and its numerical simulation%Graphit-ic涂层模具微挤压成形及数值模拟

    Institute of Scientific and Technical Information of China (English)

    李仕成; 王东峰; 郑捷; 陈泽中

    2014-01-01

    运用闭合场非平衡磁控溅射方法(CFUBMSIP)在微型杯状零件挤压模具成形部位的表面镀上一层约2μm厚度的石墨微晶结构的低摩擦系数、高耐磨性的固体自润滑Graphit‐ic涂层,挤压成形出材质为CuZn33铜合金圆柱形微型杯,其壁厚0.45 mm ,外部直径为2.9 mm ,内部直径为2 mm。通过DEFORM软件模拟零件的成形过程,分析成形过程中的金属流动规律。研究发现,所镀涂层能起到良好的自润滑效果,可减小由于成形零件的微型化带来的摩擦效应,为微挤压成形的研究提供了一种新的润滑思路。%By a closed‐field unbalanced magnetron sputter ion plating technique ,a low‐friction and highly wear‐resistant Graphit‐ic coating with the thickness of 2μm was applied on the forming section of a micro‐extrusion mold .A micro‐cup of CuZn33 brass al‐loy was then extruded ,with wall thickness of 0.45mm ,outside diameter of 2.9mm ,and internal diameter of 2mm .Also ,based on DEFORM software ,the micro‐extrusion process was simulated and the metal flow rules were analyzed .The results show that the self‐lubrication effect can be obtained by this coating ,and the friction effect along with the miniaturization of product was re‐duced .The study provides a new method for the study of micro‐extrusion lubrication .

  15. Silane based coating of aluminium mold

    DEFF Research Database (Denmark)

    2013-01-01

    comprising a chemically bonded monolayer of silane compounds on the at least one surface wherein the silane is a halogenated silane. The at least one surface coated with the anti-stiction coating may be configured to withstand an injection molding process at a pressure above 100 MPa. Furthermore, a mold......A method of preparing an aluminum mold for injection molding is provided, the method comprises the steps of providing an aluminum mold having a least one surface, subjecting the at least one surface to a gas or liquid phase silane to thereby form an anti-stiction coating, the anti-stiction coating...... having at least one closed cavity is provided, at least one surface of the at least one cavity being an aluminium surface coated with a silane based coating layer. The silane based anti-stiction coating improves the anti-stiction properties of the mold which may allow for molding and demolding...

  16. 贵阳机场岩溶洼地填筑体变形与稳定性数值模拟%Numerical Simulation on Fill Deformation and Stability of Karst Depression at Guiyang Airport

    Institute of Scientific and Technical Information of China (English)

    石波; 高奋飞

    2012-01-01

    以贵阳龙洞堡国际机场试验段工程为例对岩溶洼地填筑体变形及稳定性进行数值模拟研究。研究结果表明:强夯对岩溶洼地地基土处理具有较好的效果,能有效降低填筑体的沉降量及边坡位移量;填筑体沉降量随着填筑体厚度减小而减小。%Taking the engineering in the test section of Longd example, the fill deformation and stability of karst depression result shows that dynamic compaction is good way to treat the ongbao International Airport in Guiyang as the is studied through numerical simulation. The foundation soil in karst depression and could reduce the fill settlement and the slope displacement effectively, while the fill settlement is decreased with the decreased fill thickness.

  17. 基于 CAE 早餐杯密封盖模具的开发%Development of Breakfast Cup Sealing Cover Mold Based on the CAE

    Institute of Scientific and Technical Information of China (English)

    王明哲

    2014-01-01

    By analyzing the structural characteristics of breakfast cup sealing cover , designed 4 × 8 stacked injection mould .The pressure drop ,temperature and CAE simulation molding process of the drop and the filling time , determine the size of molding and casting system of multi cavity mold; mold structure with multilayer combined movable core and cavity ,pushing plate forced demolding mechanism ,reasonable set of die structure,reliable action,products be moulding successfully ,production which is high precision plastic parts meets customer requirements fully ,have a reference value to similar shape plastic parts .%通过对早餐杯密封盖的结构、材料、成型等特征的分析,自主开发4(层)×8(腔)注射模具。运用了CAE对模具的成型性能分析,优化模具的成型工艺性能,预测塑件的成型质量;模具结构采用多层叠组合活动型芯和型腔,定距开模,推件板强制脱模机构,整套模具结构合理,动作可靠,制品脱模顺利,生产的塑件精度高,产品完全达到客户要求,对同类形状塑件具有一定的参考价值。

  18. Applications of thin carbon coatings and films in injection molding

    Science.gov (United States)

    Cabrera, Eusebio Duarte

    In this research, the technical feasibility of two novel applications of thin carbon coatings is demonstrated. The first application consists of using thin carbon coatings on molds for molding ultra-thin plastic parts (coated nanoparticle thin films or nanopapers to create a conductive top layer. During this research, the technical feasibility of a new approach was proven which provides injection molding of ultra-thin parts at lower pressures, without the need of fast heating/fast cooling or other expensive mold modification. An in-house developed procedure by other members of our group, was employed for coating the mold surface using chemical vapor deposition (CVD) resulting in a graphene coating with carbide bonding to the mold surface. The coating resulted in a significant decrease of surface friction and consequently easiness of flow when compared to their uncoated counterparts. Thermoplastic polymers and their composites are a very attractive alternative but are hindered by the non-conductive nature of polymers. There are two general approaches used to date to achieve EMI shielding for plastic products. One is to spray a conductive metal coating onto the plastic surface forming a layer that must maintain its shielding effectiveness (SE), and its adhesion to the plastic throughout the expected life of the product. However, metal coatings add undesirable weight and tend to corrode over time. Furthermore, scratching the coating may create shielding failure; therefore, a protective topcoat may be required. The other approach is to use polymer composites filled with conductive fillers such as carbon black (CB), carbon nanofiber (CNF), and carbon nanotube (CNT). While conductive fillers may increase the electrical conductivity of polymer composites, the loading of such fillers often cannot reach a high level (coated nanoparticle thin films or nanopapers to create a conductive top layer. For many years, in-mold coating (IMC) has been commercially applied to Sheet

  19. Compression molding of aerogel microspheres

    Energy Technology Data Exchange (ETDEWEB)

    Pekala, Richard W. (Pleasant Hill, CA); Hrubesh, Lawrence W. (Pleasanton, CA)

    1998-03-24

    An aerogel composite material produced by compression molding of aerogel microspheres (powders) mixed together with a small percentage of polymer binder to form monolithic shapes in a cost-effective manner. The aerogel composites are formed by mixing aerogel microspheres with a polymer binder, placing the mixture in a mold and heating under pressure, which results in a composite with a density of 50-800 kg/m.sup.3 (0.05-0.80 g/cc). The thermal conductivity of the thus formed aerogel composite is below that of air, but higher than the thermal conductivity of monolithic aerogels. The resulting aerogel composites are attractive for applications such as thermal insulation since fabrication thereof does not require large and expensive processing equipment. In addition to thermal insulation, the aerogel composites may be utilized for filtration, ICF target, double layer capacitors, and capacitive deionization.

  20. Compression molding of aerogel microspheres

    Energy Technology Data Exchange (ETDEWEB)

    Pekala, R.W.; Hrubesh, L.W.

    1998-03-24

    An aerogel composite material produced by compression molding of aerogel microspheres (powders) mixed together with a small percentage of polymer binder to form monolithic shapes in a cost-effective manner is disclosed. The aerogel composites are formed by mixing aerogel microspheres with a polymer binder, placing the mixture in a mold and heating under pressure, which results in a composite with a density of 50--800 kg/m{sup 3} (0.05--0.80 g/cc). The thermal conductivity of the thus formed aerogel composite is below that of air, but higher than the thermal conductivity of monolithic aerogels. The resulting aerogel composites are attractive for applications such as thermal insulation since fabrication thereof does not require large and expensive processing equipment. In addition to thermal insulation, the aerogel composites may be utilized for filtration, ICF target, double layer capacitors, and capacitive deionization. 4 figs.

  1. Diamond turning of high-precision roll-to-roll imprinting molds for fabricating subwavelength gratings

    Science.gov (United States)

    Liu, Chun-Wei; Yan, Jiwang; Lin, Shih-Chieh

    2016-06-01

    Diamond turning of high-precision molds is a vital process for the roll-to-roll-based ultraviolet resin imprinting process in fabricating subwavelength gratings. The effects of the grating shape and grating period on diffraction efficiencies and diffraction angles were simulated. Experiments were then conducted to examine the effects of shape design, grating period, and cutting speed on machinability of the mold. According to the optical measurement results, the performance of the subwavelength gratings matched the design well at various incident angles. The results confirm that diamond turning of high-precision molds is a feasible approach for ensuring the continual mass production of subwavelength gratings.

  2. Onychomycosis due to opportunistic molds*

    Science.gov (United States)

    Martínez-Herrera, Erick Obed; Arroyo-Camarena, Stefanie; Tejada-García, Diana Luz; Porras-López, Carlos Francisco; Arenas, Roberto

    2015-01-01

    BACKGROUND: Onychomycosis are caused by dermatophytes and Candida, but rarely by non- dermatophyte molds. These opportunistic agents are filamentous fungi found as soil and plant pathogens. OBJECTIVES: To determine the frequency of opportunistic molds in onychomycosis. METHODS: A retrospective analysis of 4,220 cases with onychomycosis, diagnosed in a 39-month period at the Institute of Dermatology and Skin surgery "Prof. Dr. Fernando A. Cordero C." in Guatemala City, and confirmed with a positive KOH test and culture. RESULTS: 32 cases (0.76%) of onychomycosis caused by opportunistic molds were confirmed. The most affected age group ranged from 41 to 65 years (15 patients, 46.9%) and females were more commonly affected (21 cases, 65.6%) than males. Lateral and distal subungual onychomycosis (OSD-L) was detected in 20 cases (62.5%). The microscopic examination with KOH showed filaments in 19 cases (59.4%), dermatophytoma in 9 cases (28.1%), spores in 2 cases (6.25%), and filaments and spores in 2 cases (6.25%). Etiologic agents: Aspergillus sp., 11 cases (34.4%); Scopulariopsis brevicaulis, 8 cases (25.0%); Cladosporium sp., 3 cases (9.4%); Acremonium sp., 2 cases (6.25%); Paecilomyces sp., 2 cases (6.25%); Tritirachium oryzae, 2 cases (6.25%); Fusarium sp., Phialophora sp., Rhizopus sp. and Alternaria alternate, 1 case (3.1%) each. CONCLUSIONS: We found onychomycosis by opportunistic molds in 0.76% of the cases and DLSO was present in 62.5%. The most frequent isolated etiological agents were: Aspergillus sp. and Scopulariopsis brevicaulis. PMID:26131862

  3. SEMICONDUCTOR TECHNOLOGY Dummy fill effect on CMP planarity

    Science.gov (United States)

    Junxiong, Zhou; Lan, Chen; Wenbiao, Ruan; Zhigang, Li; Weixiang, Shen; Tianchun, Ye

    2010-10-01

    With the use of a chemical-mechanical polishing (CMP) simulator verified by testing data from a foundry, the effect of dummy fill characteristics, such as fill size, fill density and fill shape, on CMP planarity is analyzed. The results indicate that dummy density has a significant impact on oxide erosion, and copper dishing is in proportion to dummy size. We also demonstrate that cross shape dummy fill can have the best dishing performance at the same density.

  4. Numerical simulation of coherent visible-to-near-infrared supercontinuum generation in the CHCl3-filled photonic crystal fiber with 1.06 μm pump pulses

    Science.gov (United States)

    Wang, Chun-can; Li, Wei-min; Li, Na; Wang, Wen-quan

    2017-02-01

    The hollow-core photonic crystal fiber (PCF) is filled by highly nonlinear liquid chloroform (CHCl3) in the center core. The CHCl3-filled PCF with an appropriate geometric parameters exhibits a normal dispersion profile in the visible-to-near-infrared (NIR) region, where the values of group velocity dispersion (GVD) in the vicinity of 1060-nm pump wavelength can be tuned in the range from -20 to -50 ps/nm/km. Furthermore, the nonlinear parameters at wavelengths power), the generated supercontinuum (SC) spectra with high degree of coherence can cover near 2 octaves spanning from 340 to 1360 nm at -20 dB level. The spectral variations are < 5 dB in the wavelength range of 365-1315 nm.

  5. Study the Formation Process of Cuboid Microprotrusion by Glass Molding Process †

    Directory of Open Access Journals (Sweden)

    Tao Wang

    2017-02-01

    Full Text Available This paper investigates the formation process of a typical microstructure in the glass microfluidic chip, i.e., cuboid microprotrusion, by the soda-lime glass molding process (GMP. The finite element models on the platform Abaqus/Standard were established for simulating the glass molding process. The glass viscoelasticity at pressing temperature was described by the General Maxwell model. The influence of the temperature, aspect ratio and side wall angle on the replication ratio was investigated, and the corresponding predicted molded profiles were demonstrated as well. The established simulation model was verified by experimental results eventually. It could provide a fundamental experience for optimizing glass molding parameters to fabricate microstructures on glass chips.

  6. A Recurrent Neural Network for Warpage Prediction in Injection Molding

    Directory of Open Access Journals (Sweden)

    A. Alvarado-Iniesta

    2012-11-01

    Full Text Available Injection molding is classified as one of the most flexible and economical manufacturing processes with high volumeof plastic molded parts. Causes of variations in the process are related to the vast number of factors acting during aregular production run, which directly impacts the quality of final products. A common quality trouble in finishedproducts is the presence of warpage. Thus, this study aimed to design a system based on recurrent neural networksto predict warpage defects in products manufactured through injection molding. Five process parameters areemployed for being considered to be critical and have a great impact on the warpage of plastic components. Thisstudy used the finite element analysis software Moldflow to simulate the injection molding process to collect data inorder to train and test the recurrent neural network. Recurrent neural networks were used to understand the dynamicsof the process and due to their memorization ability, warpage values might be predicted accurately. Results show thedesigned network works well in prediction tasks, overcoming those predictions generated by feedforward neuralnetworks.

  7. Application of 3-D numerical simulation software SRIFCAST to produce ductile iron castings

    Institute of Scientific and Technical Information of China (English)

    2005-01-01

    Based on a method using numerical simulation equations and their solution schemes for liquid metal flows and heat transfer during mold filling and the solidification process of casting, 3-D numerical simulation software SRIFCAST was created. This includes enmeshment of casting; velocity and temperature fields calculation; displaying iso-temperature lines;velocity vectors and 3-D temperature fields on a Windows 9x operating system. SRIFCAST was applied to produce sound castings of automobile and diesel engines, and also to connect with microstructure simulation for ductile iron castings.

  8. Effect of Functional Nano Channel Structures Different Widths on Injection Molding and Compression Molding Replication Capabilities

    DEFF Research Database (Denmark)

    Calaon, M.; Tosello, G.; Garnaes, J.

    The present study investigates the capabilities of the two employed processes, injection molding (IM) and injection compression molding (ICM) on replicating different channel cross sections. Statistical design of experiment was adopted to optimize replication quality of produced polymer parts wit...

  9. Fabrication of long-focal-length plano-convex microlens array by combining the micro-milling and injection molding processes.

    Science.gov (United States)

    Chen, Lei; Kirchberg, Stefan; Jiang, Bing-Yan; Xie, Lei; Jia, Yun-Long; Sun, Lei-Lei

    2014-11-01

    A uniform plano-convex spherical microlens array with a long focal length was fabricated by combining the micromilling and injection molding processes in this work. This paper presents a quantitative study of the injection molding process parameters on the uniformity of the height of the microlenses. The variation of the injection process parameters, i.e., barrel temperature, mold temperature, injection speed, and packing pressure, was found to have a significant effect on the uniformity of the height of the microlenses, especially the barrel temperature. The filling-to-packing switchover point is also critical to the uniformity of the height of the microlenses. The optimal uniformity was achieved when the polymer melts completely filled the mold cavity, or even a little excessively filled the cavity, during the filling stage. In addition, due to the filling resistance, the practical filling-to-packing switchover point can vary with the change of the filling processing conditions and lead to a non-negligible effect on the uniformity of the height of the microlenses. Furthermore, the effect of injection speed on the uniformity of the height of the microlenses was analyzed in detail. The results indicated that the effect of injection speed on the uniformity of the height of the microlenses is mainly attributed to the two functions of injection speed: transferring the filling-to-packing switchover point and affecting the distribution of residual flow stress in the polymer melt.

  10. Model and Simulation of a Tunable Birefringent Fiber Using Capillaries Filled with Liquid Ethanol for Magnetic Quasiphase Matching In-Fiber Isolator

    Directory of Open Access Journals (Sweden)

    Clint Zeringue

    2010-01-01

    Full Text Available A technique to tune a magnetic quasi-phase matching in-fiber isolator through the application of stress induced by two mutually orthogonal capillary tubes filled with liquid ethanol is investigated numerically. The results show that it is possible to “tune” the birefringence in these fibers over a limited range depending on the temperature at which the ethanol is loaded into the capillaries. Over this tuning range, the thermal sensitivity of the birefringence is an order-of-magnitude lower than conventional fibers, making this technique well suited for magnetic quasi-phase matching.

  11. Psychrophilic and Mesophilic Fungi in Fruit-Filled Pastries

    Science.gov (United States)

    Kuehn, Harold H.; Gunderson, Millard F.

    1962-01-01

    Surveys of the mold flora of frozen blueberry and cherry pastries were undertaken. Molds were enumerated by preparing pour plates of the blended product and incubating the plates at 0, 5, 10, and 20 C. In this manner, the total fungal content of the product could be ascertained from the 10 and 20 C plates, and the psychrophilic fungal population was represented by those fungi which grew at 0 and 5 C. The pastry portion, or crust, of the blueberry material was sampled separately from the filling portion. Certain differences in fungal flora were apparent. Aureobasidium pullulans was the dominant fungus in crust at all temperatures of isolation. However, Penicillium thomii proved to be the most common mesophilic fungus in the filling portion, and A. pullulans was the most common psychrophile in the filling. Aspergilli were quite common in the crust, but, in general, were absent from the fruit filling. Cherry pastries had a much smaller total fungal flora than did the blueberry product. However, A. pullulans again was the most prevalent fungus in cherry pastries at all temperatures of isolation. Certain differences in fungal flora were apparent in the two fruit products. Phoma spp. were almost completely absent in blueberries, but represented the second most common fungus in cherry pastries. Blueberry filling had 440 psychrophilic fungi per gram of sample (at 0 C), blueberry crust had 65 per gram, and cherry pastries had 77 per gram. Images FIG. 1 PMID:14460237

  12. Porous media heat transfer for injection molding

    Energy Technology Data Exchange (ETDEWEB)

    Beer, Neil Reginald

    2016-05-31

    The cooling of injection molded plastic is targeted. Coolant flows into a porous medium disposed within an injection molding component via a porous medium inlet. The porous medium is thermally coupled to a mold cavity configured to receive injected liquid plastic. The porous medium beneficially allows for an increased rate of heat transfer from the injected liquid plastic to the coolant and provides additional structural support over a hollow cooling well. When the temperature of the injected liquid plastic falls below a solidifying temperature threshold, the molded component is ejected and collected.

  13. 微孔塑料连续挤出成型快速降压口模的数值模拟%Numerical Simulation of Microcellular Plastic in Rapid Decompressive Die of Continuous Extrusion Molding

    Institute of Scientific and Technical Information of China (English)

    陈昕; 柳和生; 黄兴元

    2013-01-01

    利用Polyflow有限元软件对聚苯乙烯(PS)/CO2均相体系在连续挤出成型圆形快速降压口模中的流动进行数值模拟,考察快速降压口模入口角、长径比及口模温度对PS微孔塑料熔体沿轴线方向的压力降速率和剪切速率的影响.结果表明,当入口角大于30°时,改变入口角对压力降速率和剪切速率无明显影响,即对微孔塑料的气泡成核影响微小,但当入口角为0°时,与其它各入口角相比,其熔体压力降速率最大,气泡成核时间最早;在毛细管段口模直径不变的情况下,改变其长径比对熔体气泡成核亦无明显影响,但压力降随口模长度缩短而变小;口模温度对剪切速率影响不大,但降低口模温度,压力降速率明显提高,从而有利于微孔塑料的气泡成核.%Numerical simulation of polystyrene (PS)/CO2 homogeneous phase system flowing in circular rapid decompressive die of continuous extrusion molding was done through finite element analysis software Polyflow,moreover,effects of inlet angle and aspect ratio (L/D) of the rapid decompressive die and die temperature on pressure drop rate and shearing rate of the PS microcellular plastic melt along the direction of axis were analyzed.The results show that when the inlet angle is more than 30°,changing inlet angle has no obvious effect on the pressure drop rate and shearing rate,in other words,it has little influence on bubble nucleation of microcellular plastic,but when the inlet angle is 0°,the pressure drop rate is highest and the bubble nucleation time is earliest comparing with other inlet angles.Changing L/D has also no obvious influence on bubble nucleation of microcellular plastic under the conditions of die diameter in capillary section being constant,but pressure drop decreases with the die length shortening.The effect of die temperature on shearing rate is slight,but the die temperature decreases,the pressure drop rate increases obviously,which is

  14. The effect of interface heat transfer on solidification, microstructure evolution, and mold wear in permanent mold casting of titanium-aluminum-vanadium

    Science.gov (United States)

    Kobryn, Pamela Astra

    Recently, a permanent mold casting approach for titanium alloys (Ti PMC) was developed. This process generated a lot of interest in the titanium casting industry due to its potential to decrease cost and improve mechanical properties. However, little research has been conducted in this area. Hence, the research described in this dissertation was performed to augment and complement prior work on Ti PMC. The current research dealt with the development of computer simulation capabilities for predicting characteristics of solidification, microstructure evolution, and mold wear for Ti PMC. It focused on the effect of interface heat transfer on ProCASTTM simulation results. A combination of physical and numerical experiments were used to determine interface heat transfer coefficients for Ti PMC, the sensitivity of FEM results to input parameters, and the validity of using the chosen modeling approach and input parameters to simulate various casting geometries. Laboratory and in-plant casting trials were conducted to obtain casting data. Thermocouple data were compared to simulation results to determine interface heat transfer coefficients for "shrink off" and "shrink on" geometries. Both a conventional thermocouple technique and a novel microstructure-based mold temperature signature analysis technique were used to determine mold temperatures for model validation. The validated models were used as a starting point for the application of two microstructure prediction techniques (solidification mapping and the parabolic grain growth law) and the study of mold wear causes and mechanisms. The importance of properly accounting for the casting-mold interface contact condition was stressed throughout. The results demonstrated the importance of considering the casting-mold interface geometry when selecting interface heat transfer coefficients for casting simulations, as the coefficient varied from an initial value of 2000 W/m2-K to less than 50 W/m2-K in the "shrink off" case

  15. Experimental Investigation into Suitable Process Conditions for Plastic Injection Molding of Thin-Sheet Parts

    Directory of Open Access Journals (Sweden)

    Dyi-Cheng Chen

    2014-04-01

    Full Text Available This study performs an experimental investigation into the effects of the process parameters on the surface quality of injection molded thin-sheet thermoplastic components. The investigations focus specifically on the shape, number and position of the mold gates, the injection pressure and the injection rate. It can be seen that the gravity force entering point improved filling of the cavity for the same forming time and injection pressure. Moreover, it shows the same injection pressure and packing time, the taper-shape gate yields a better surface appearance than the sheet-shape gate. The experimental results provide a useful source of reference in suitable the process conditions for the injection molding of thin-sheet plastic components.

  16. Semi-solid thixo casting structure of aluminum alloy and relevant assistant analysis with the help of computer simulation

    Institute of Scientific and Technical Information of China (English)

    Yi-tao YANG; Jian-fu WANG; Meng CHEN; Heng-hua ZHANG; Guang-jie SHAO

    2008-01-01

    The relationship between structure morphology of semi-solid aluminum alloy die-casting sample and filling condition was studied. By systematical structure analysis and computer simulation of the filling process, the quant-itative relationship between microscopic morphology (such as solid fraction, grain size and shape) and formation state was studied. The results showed that the billet microstruc-ture must have fine and round grains for the die-casting of complex shapes. It is necessary to optimize injection speeds to escape the non-uniform distribution of the solid fraction in complex and changeable mold cavity.

  17. Water-filled telescopes

    CERN Document Server

    Antonello, E

    2014-01-01

    In this short note we discuss the case of the thought experiments on water-filled telescopes and their realizations during 18th and 19th century. The story of those instruments shows that the scientific progress occurs in a curious way, since there was no stringent reason for the construction of a water-filled telescope.

  18. Minimization of sink mark defects in injection molding process ...

    African Journals Online (AJOL)

    Minimization of sink mark defects in injection molding process – Taguchi approach. ... plays a very important role in controlling the quality of the injection molded products. ... of injection molding variables on sink marks using Taguchi approach.

  19. Mold

    Science.gov (United States)

    ... all, may produce toxins or poisonous substances called mycotoxins that may cause effects in humans. Although there are many types of mycotoxins, aflatoxins are probably the best known and most ...

  20. Mechanical Properties of Injection Molded and Compression Molded Samples from Nature-Butadiene Rubber

    Directory of Open Access Journals (Sweden)

    Skrobak Adam

    2016-01-01

    Full Text Available The aim of this paper is to show what extent there is an impact on the mechanical properties (tensile strength and tear strength of a standardized testing sample made of rubber compound based on nature rubber and butadiene rubber produced by injection molding in comparison with a sample produced by classic preparation (cutting out a compression molded plate according to the standard ISO 23529. For realization of this study it was necessary to design and produce an injection mold for all types testing samples. Subsequently, mechanical properties such as the tensile stress-strain and tear strenght of compression molded samples and injection molded samples were studied, compared and discussed.

  1. THREE-DIMENSIONAL CHARACTERISTICS AND HOMOGENIZATION OF ELECTROMAGNETIC FIELD IN SOFT-CONTACT CONTINUOUS CASTING MOLD

    Institute of Scientific and Technical Information of China (English)

    A.Y. Deng; G.L. Jia; J.C. He

    2001-01-01

    The three-dimensional electromagnetic characteristics and non-uniform distribution of electromagnetic field in soft-contact mold have been analyzed by numerical simulation. The results show that the maximum electromagnetic flux density is found in front of slit; the electromagnetic flux density becomes large as coil current and slit number increase. In a certain frequency range, the electromagnetic flux density increases with increasing frequency; and the frequency range is different with changing of azimuthal position along inner wall of mold. The uniformity of electromagnetic field is effected mainly by frequency and mold structure parameters. Increasing slit number and adjusting slit arrangement position can improve the electromagnetic flux density and the uniformity of electromagnetic field. For a soft-contact mold with 16 slits, when frequency is 20kHz, the optimal slit arrangement parameter is a: b = 1: 2.c=0.

  2. 大孔道油藏注冻胶调剖数值模拟研究%Dissecting numerical simulation study of filling jelly in reservoirs of large pore path

    Institute of Scientific and Technical Information of China (English)

    李宗阳

    2015-01-01

    On the basis of reservoirs of large pore path in Dongxin oilfiled, dissecting numerical simulation was studied by filling biradical crosslinked jelly polymer with numerical simulation of reservoirs.The key parameters of injection-to producing were optimized so as to improve the effect of water precipitation and oil increases in the reservoirs in high water cut stage.%本文以东辛油田大孔道油藏条件为基础,应用油藏数值模拟手段,通过注入高分子聚合物双基团交联冻胶体系,对大孔道油藏进行封堵调剖数值模拟研究,对关键注采参数进行优化分析,提高胜利油区特高含水期油藏降水增油效果。

  3. Experimental and numerical analysis of the temperature distribution of injection molded products using protruding microprobes.

    Science.gov (United States)

    Liu, Shih-Jung; Ho, Chia-Wei

    2011-05-01

    Injection molding has been one of the most important polymer processing methods for manufacturing plastic parts. In the process, the temperature is an important parameter that influences process features such as cycle times, crystallization rates, degree of crystallinity, melt flow properties, and molded product qualities. This study aims to, experimentally and numerically, examine the three-dimensional temperature distribution along the melt flow path of injection molded parts. A special experimental set-up, which includes an injection mold equipped with protruding microprobes for guiding embedded thermocouples, was designed and built to measure the temperature field along the flow path, i.e., inside the runner and the cavity, of injection molded products. The experimental results suggested that the disturbance induced by the probes remained negligible and precise temperature profiles could be measured at various positions inside the cavity. A significant increase of melt temperature was found to result from the viscous dissipation of the polymeric materials in the runner. Additionally, a commercially available code was employed to simulate and predict the temperature variation in injection molded parts. It was shown that the numerical simulation predicted better the temperature distributions inside the cavity than those along the runner.

  4. Mold Remediation in Schools and Commercial Buildings.

    Science.gov (United States)

    Environmental Protection Agency, Washington, DC. Office of Radiation and Indoor Air.

    This document describes how to investigate and evaluate moisture and mold problems in educational facilities, and presents the key steps for implementing a remediation plan. A checklist is provided for conducting mold remediation efforts along with a resource list of helpful organizations and governmental agencies. Appendices contain a glossary,…

  5. Nanostructuring steel for injection molding tools

    DEFF Research Database (Denmark)

    Al-Azawi, A.; Smistrup, Kristian; Kristensen, Anders

    2014-01-01

    and ion beam etching are combined to nanostructure the planar surface of a steel wafer. Injection molded plastic parts with enhanced surface properties, like anti-reflective, superhydrophobic and structural colors can be achieved by micro-and nanostructuring the surface of the steel molds. We investigate...

  6. The Thermal Distortion of a Funnel Mold

    Science.gov (United States)

    Hibbeler, Lance C.; Thomas, Brian G.; Schimmel, Ronald C.; Abbel, Gert

    2012-10-01

    This article investigates the thermal distortion of a funnel mold for continuous casting of thin slabs and explores the implications on taper and solidification of the steel shell. The three-dimensional mold temperatures are calculated using shell-mold heat flux and cooling water profiles that were calibrated with plant measurements. The thermal stresses and distorted shape of the mold are calculated with a detailed finite-element model of a symmetric fourth of the entire mold and waterbox assembly, and they are validated with plant thermocouple data and measurements of the wear of the narrow-face copper mold plates. The narrow-face mold distorts into the typical parabolic arc, and the wide face distorts into a "W" shape owing to the large variation in bolt stiffnesses. The thermal expansion of the wide face works against the applied narrow-face taper and funnel effects, so the effect of thermal distortion must be considered to accurately predict the ideal mold taper.

  7. Simulating thermo-mechanical interaction between a xenon gas-filled chamber and tungsten first-wall armor for the LIFE reactor design using the BUCKY 1-D radiation hydrodynamics code

    Energy Technology Data Exchange (ETDEWEB)

    Heltemes, T A; Prochaska, A E; Moses, G A, E-mail: taheltemes@wisc.ed [Fusion Technology Institute, University of Wisconsin - Madison, 1500 Engineering Dr., Madison WI 53706 (United States)

    2010-08-01

    The BUCKY 1-D radiation hydrodynamics code has been used to simulate the dynamic thermo-mechanical interaction between a xenon gas-filled chamber and tungsten first-wall armor with an indirect-drive laser fusion target for the LIFE reactor design. Two classes of simulations were performed: (1) short-time (0-2 ms) simulations to fully capture the hydrodynamic effects of the introduction of the LIFE indirect-drive target x-ray and ion threat spectra and (2) long-time (2-70 ms) simulations starting with quiescent chamber conditions characteristic of those at 2 ms to estimate xenon plasma cooling between target implosions at 13 Hz. The short-time simulation results reported are: (1) the plasma hydrodynamics of the xenon in the chamber, (2) dynamic overpressure on the tungsten armor, and (3) time-dependent temperatures in the tungsten armor. The ramifications of local thermodynamic equilibrium (LTE) vs. non-LTE opacity models are also addressed.

  8. Characteristics of shell thickness in a slab continuous casting mold

    Institute of Scientific and Technical Information of China (English)

    Di-feng Wu; Shu-sen Cheng; Zi-jian Cheng

    2009-01-01

    The key to reduce shell breakout in the continuous casting process is to control shell thickness in the mold.A numerical simulation on the turbulent flow and heat transfer coupled with solidification in the slab mold using the volume of fluid (VOF) model and the enthalpy-porosity scheme was conducted and the emphasis was put upon the flow effect on the shell thickness profiles in longitudinal and transverse directions.The results show that the jet acts a stronger impingement on the shell of narrow face,which causes a zero-increase of shell thickness in a certain range near the impingement point.The thinnest shell on the slab cross-section locates primarily in the center of the narrow face,and secondly near the comer of the wide face.Nozzle optimization can obviously increase the shell thickness and make it more uniform.

  9. The use of IR thermography to show the mold and part temperature evolution in injection molding

    Science.gov (United States)

    Bula, Karol; Różański, Leszek; Marciniak-Podsadna, Lidia; Wróbel, Dawid

    2016-12-01

    This study concerns the application of infrared camera for injection molding analysis by measuring temperatures of both injection molded parts and injection mold cavities in a function of injection cycles. The mold with two cavities, differing in thickness (1 and 3 mm), and a cold direct runner was used. Isotactic polypropylene homopolymer was utilized to produce parts. Mold temperature was set at 22°C and controlled by a water chiller. Five measuring points were determined: SP1, SP2 (placed in the 3 mm cavity), SP3, SP4 (located in the 1 mm cavity) and SP5 around an injection molding gate. Our investigations showed that the highest temperature is localized around SP2 point and the lowest at SP4. Also, it was proved that even after 62 injection molding cycles, temperatures of cavities were not stable, revealing their further increase with each cycle.

  10. The use of IR thermography to show the mold and part temperature evolution in injection molding

    Directory of Open Access Journals (Sweden)

    Bula Karol

    2016-12-01

    Full Text Available This study concerns the application of infrared camera for injection molding analysis by measuring temperatures of both injection molded parts and injection mold cavities in a function of injection cycles. The mold with two cavities, differing in thickness (1 and 3 mm, and a cold direct runner was used. Isotactic polypropylene homopolymer was utilized to produce parts. Mold temperature was set at 22°C and controlled by a water chiller. Five measuring points were determined: SP1, SP2 (placed in the 3 mm cavity, SP3, SP4 (located in the 1 mm cavity and SP5 around an injection molding gate. Our investigations showed that the highest temperature is localized around SP2 point and the lowest at SP4. Also, it was proved that even after 62 injection molding cycles, temperatures of cavities were not stable, revealing their further increase with each cycle.

  11. Immune Response among Patients Exposed to Molds

    Directory of Open Access Journals (Sweden)

    Jordan N. Fink

    2009-12-01

    Full Text Available Macrocyclic trichothecenes, mycotoxins produced by Stachybotrys chartarum, have been implicated in adverse reactions in individuals exposed to mold-contaminated environments. Cellular and humoral immune responses and the presence of trichothecenes were evaluated in patients with mold-related health complaints. Patients underwent history, physical examination, skin prick/puncture tests with mold extracts, immunological evaluations and their sera were analyzed for trichothecenes. T-cell proliferation, macrocyclic trichothecenes, and mold specific IgG and IgA levels were not significantly different than controls; however 70% of the patients had positive skin tests to molds. Thus, IgE mediated or other non-immune mechanisms could be the cause of their symptoms.

  12. Final Report: Grant DE-FG02-05ER15682. Simulation of Complex Microphase Formation in Pure and Nanoparticle-filled Diblock Copolymers

    Energy Technology Data Exchange (ETDEWEB)

    Fernando A. Escobedo

    2009-11-18

    The goal of this project was to use molecular simulation to quantify the impact of additives on the onset and structure of bicontinuous phases in linear diblock copolymers (DBC). The focus was on understanding how additives with selective affinity for a given block will distribute and perturb the structure of complex bicontinuous phases (like gyroid, double diamond, and plumbers nightmare whose minority component block forms two interweaving 3D networks) in DBCs; it was hypothesized that a suitable choice of additive type, size, affinity, and concentration may suppress or stabilize a particular bicontinuous phase. The ultimate goal in this line of investigation is to elucidate the rational design of the optimal additive for which the composition range of stability of a particular bicontinuous phase is maximized. Ours are the first published simulation studies to report on the formation of the gyroid phase in DBC melts and of other bicontinuous phases in DBC-modified by homopolymer. The following tasks were carried out: (i) simulation of bicontinuous phases of pure DBCs via both on-lattice Monte Carlo simulations and continuum-space Monte Carlo and molecular dynamics simulations, (ii) determination of the effect of selective additives (homopolymer) of different sizes on such bicontinuous phases, and (iii) development of novel Monte Carlo methods to map out reliable phase diagrams and improve ergodic sampling; in particular, optimized expanded-ensemble techniques for measuring free-energies and for chemical potential equilibration.

  13. Rapid fabrication method of a microneedle mold with controllable needle height and width.

    Science.gov (United States)

    Lin, Yen-Heng; Lee, I-Chi; Hsu, Wei-Chieh; Hsu, Ching-Hong; Chang, Kai-Ping; Gao, Shao-Syuan

    2016-10-01

    The main issue of transdermal drug delivery is that macromolecular drugs cannot diffuse through the stratum corneum of skin. Many studies have pursued micro-sized needles encapsulated with drugs to overcome this problem, as these needles can pierce the stratum corneum and allow drugs to enter the circulatory system of the human body. However, most microneedle fabrication processes are time-consuming and require expensive equipment. In this study, we demonstrate a rapid method for fabricating a microneedle mold using drawing lithography and a UV-cured resin. The mold was filled with a water-soluble material, polyvinylpyrrolidone (PVP), which was then demolded to produce a water-soluble microneedle array. The results of an in vitro skin insertion test using PVP microneedles and pig ear skin demonstrated the feasibility of the microneedle mold. In addition, by controlling the viscosity of the UV-cured resin through various heat treatments, microneedles with different heights and aspect ratios were produced. Compared with other methods, this technology significantly simplifies and accelerates the mold fabrication process. In addition, the required equipment is relatively simple and inexpensive. Through this technology, we can rapidly fabricate microneedle molds with controllable dimensions for various applications.

  14. An apparatus for in situ x-ray scattering measurements during polymer injection molding.

    Science.gov (United States)

    Rendon, Stanley; Fang, Jun; Burghardt, Wesley R; Bubeck, Robert A

    2009-04-01

    We report a novel instrument for synchrotron-based in situ x-ray scattering measurements during injection molding processing. It allows direct, real-time monitoring of molecular-scale structural evolution in polymer materials undergoing a complex processing operation. The instrument is based on a laboratory-scale injection molding machine, and employs customized mold tools designed to allow x-ray access during mold filling and subsequent solidification, while providing sufficient robustness to withstand high injection pressures. The use of high energy, high flux synchrotron radiation, and a fast detector allows sufficiently rapid data acquisition to resolve time-dependent orientation dynamics in this transient process. Simultaneous monitoring of temperature and pressure signals allows transient scattering data to be referenced to various stages of the injection molding cycle. Representative data on a commercial liquid crystalline polymer, Vectra(R) B950, are presented to demonstrate the features of this apparatus; however, it may find application in a wide range of polymeric materials such as nanocomposites, semicrystalline polymers and fiber-reinforced thermoplastics.

  15. Comparing suppository mold variability which can lead to dosage errors for suppositories prepared with the same or different molds.

    Science.gov (United States)

    Alexander, Kenneth S; Baki, Gabriella; Hart, Christine; Hejduk, Courtney; Chillas, Stephanie

    2013-01-01

    Suppository molds must be properly calibrated to ensure accurate dosing. There are often slight differences between molds and even in the cavities within a mold. A method is presented for the calibration of standard aluminum 6-, 12-, 50-, or 100-well suppository molds. Ten different molds were tested using water for volume calibration, and cocoa butter for standardization involving establishing the density factor. This method is shown to be straightforward and appropriate for calibrating suppository molds.

  16. Tribology of Graphite-Filled Polystyrene

    Directory of Open Access Journals (Sweden)

    Raffaele Gilardi

    2016-06-01

    Full Text Available Self-lubricating polymer compounds are currently used for a wide range of applications such as bearings, gears, and water meters. Under severe conditions such as high pressure, high velocity, and/or high temperatures, the material fails (PV limit. In this study, we investigated the effect of graphite on the tribological properties of polystyrene (PS with “ball-on-three-plates” tests. Graphite-filled PS plates were produced via an internal mixer and compression molding. Unhardened steel (1.4401 and nylon (PA66 balls were used for the tribological tests. Our results indicate that graphite loading, graphite type, and particle size have a big influence on the friction coefficient, the wear resistance, and the PV limit of PS both against steel and PA66. In particular, primary synthetic graphite performs better than secondary synthetic graphite due to the higher degree of crystallinity.

  17. Simulated water-level and water-quality changes in the bolson-fill aquifer, Post Headquarters area, White Sands Missile Range, New Mexico

    Science.gov (United States)

    Risser, D.W.

    1988-01-01

    The quantity of freshwater available in the Post Headquarters well field, White Sand Missile Range, New Mexico, is limited and its quality is threatened by saltwater enroachment. A three-dimensional, finite-difference, groundwater flow model and a cross-sectional, density-dependent solute-transport model were constructed to simulate possible future water level declines and water quality changes in the Post Headquarters well field. A six-layer flow model was constructed using hydraulic-conductivity values in the upper 600 ft of saturated aquifer ranging from 0.1 to 10 ft/day, specific yield of 0.15, and average recharge of about 1,590 acre-ft/yr. Water levels simulated by the model closely matched measured water levels for 1948-82. Possible future water level changes for 1983-2017 were simulated using rates of groundwater withdrawal of 1,033 and 2 ,066 acre-ft/year and wastewater return flow of 0 or 30% of the groundwater withdrawal rate. The cross-sectional solute-transport model indicated that the freshwater zone is about 1,500 to 2,000 ft thick beneath the well field. Transient simulations show that solutes probably will move laterally toward the well field rather than from beneath the well field. (USGS)

  18. Filling and solidification of TiAl melt in centrifugal field

    Institute of Scientific and Technical Information of China (English)

    SHENG Wen-bin

    2006-01-01

    A model was established based on the combination of the equation of continuity,the equation of conservation of momentum and the equation of general energy to describe the filling and solidification of TiAl melt by permanent mold centrifugal casting. The model was solved numerically and the filling and solidification processes in the centrifugal field were discussed. The results indicate that the centrifugal field essentially influences the filling and solidification processes of TiAl melt. The melt will first fill the cavity along the back boundary until it reaches the end. After the end is fully filled,the whole cavity will be filled gradually by the way that free surface of the melt moves towards the entrance,hence the entrance is the last part to be filled. Furthermore,the mechanism by which internal defects can be formed in centrifugally cast TiAl components were interpreted.

  19. Optimization of Resin Infusion Processing for Composite Pipe Key-Part and K/T Type Joints Using Vacuum-Assisted Resin Transfer Molding

    Science.gov (United States)

    Wang, Changchun; Bai, Guanghui; Yue, Guangquan; Wang, Zhuxi; Li, Jin; Zhang, Boming

    2016-10-01

    In present study, the optimization injection processes for manufacturing the composite pipe key-part and K/T type joints in vacuum-assisted resin transfer molding (VARTM) were determined by estimating the filling time and flow front shape of four kinds of injection methods. Validity of the determined process was proved with the results of a scaling-down composite pipe key-part containing of the carbon fiber four axial fabrics and a steel core with a complex surface. In addition, an expanded-size composite pipe part was also produced to further estimate the effective of the determined injection process. Moreover, the resin injection method for producing the K/T type joints via VARTM was also optimized with the simulation method, and then manufactured on a special integrated mould by the determined injection process. The flow front pattern and filling time of the experiments show good agreement with that from simulation. Cross-section images of the cured composite pipe and K/T type joints parts prove the validity of the optimized injection process, which verify the efficiency of simulation method in obtaining a suitable injection process of VARTM.

  20. Medical diagnostics for indoor mold exposure.

    Science.gov (United States)

    Hurraß, Julia; Heinzow, Birger; Aurbach, Ute; Bergmann, Karl-Christian; Bufe, Albrecht; Buzina, Walter; Cornely, Oliver A; Engelhart, Steffen; Fischer, Guido; Gabrio, Thomas; Heinz, Werner; Herr, Caroline E W; Kleine-Tebbe, Jörg; Klimek, Ludger; Köberle, Martin; Lichtnecker, Herbert; Lob-Corzilius, Thomas; Merget, Rolf; Mülleneisen, Norbert; Nowak, Dennis; Rabe, Uta; Raulf, Monika; Seidl, Hans Peter; Steiß, Jens-Oliver; Szewszyk, Regine; Thomas, Peter; Valtanen, Kerttu; Wiesmüller, Gerhard A

    2017-04-01

    In April 2016, the German Society of Hygiene, Environmental Medicine and Preventative Medicine (Gesellschaft für Hygiene, Umweltmedizin und Präventivmedizin (GHUP)) together with other scientific medical societies, German and Austrian medical societies, physician unions and experts has provided an AWMF (Association of the Scientific Medical Societies) guideline 'Medical diagnostics for indoor mold exposure'. This guideline shall help physicians to advise and treat patients exposed indoors to mold. Indoor mold growth is a potential health risk, even without a quantitative and/or causal association between the occurrence of individual mold species and health effects. Apart from the allergic bronchopulmonary aspergillosis (ABPA) and the mycoses caused by mold, there is only sufficient evidence for the following associations between moisture/mold damages and different health effects: Allergic respiratory diseases, asthma (manifestation, progression, exacerbation), allergic rhinitis, exogenous allergic alveolitis and respiratory tract infections/bronchitis. In comparison to other environmental allergens, the sensitizing potential of molds is estimated to be low. Recent studies show a prevalence of sensitization of 3-10% in the total population of Europe. The evidence for associations to mucous membrane irritation and atopic eczema (manifestation, progression, exacerbation) is classified as limited or suspected. Inadequate or insufficient evidence for an association is given for COPD, acute idiopathic pulmonary hemorrhage in children, rheumatism/arthritis, sarcoidosis, and cancer. The risk of infections from indoor molds is low for healthy individuals. Only molds that are capable to form toxins can cause intoxications. The environmental and growth conditions and especially the substrate determine whether toxin formation occurs, but indoor air concentrations are always very low. In the case of indoor moisture/mold damages, everyone can be affected by odor effects and

  1. Fluid Flow in Continuous Casting Mold with a Configured Nozzle

    Institute of Scientific and Technical Information of China (English)

    王镭; 沈厚发; 柳百成

    2004-01-01

    The influence of a configured nozzle on the turbulent fluid flow in a continuous casting mold was investigated using the simulation program Visual Cast, which used the finite difference method and the SIMPLER algorithm. CAD software was used to construct the complicated nozzle in the calculational region. The simulation accuracy was validated by comparison with the classic driven cavity flow problem. The simulation results agree well with water modeling experiments. The simulations show that the velocity distribution at the nozzle port is uneven and the jet faces downward more than the nozzle outlet. Simulations with a configured nozzle and the inlet velocity at the nozzle entrance give precise results and overcome the traditional difficulty in determining the nozzle outlet velocity.

  2. Thermoplastic blow molding of metals

    Directory of Open Access Journals (Sweden)

    Jan Schroers

    2011-01-01

    Full Text Available While plastics have revolutionized industrial design due to their versatile processability, their relatively low strength has hampered their use in structural components. On the other hand, while metals are the basis for strong structural components, the geometries into which they can be processed are rather limited. The “ideal” material would offer a desirable combination of superior structural properties and the ability to be precision (net shaped into complex geometries. Here we show that bulk metallic glasses (BMGs, which have superior mechanical properties, can be blow molded like plastics. The key to the enhanced processability of BMG formers is their amenability to thermoplastic forming. This allows complex BMG structures, some of which cannot be produced using any other metal process, to be net shaped precisely.

  3. The Sink Term to Different Kinds of Fibrous Mat During the Unsaturated Filling Process

    Science.gov (United States)

    Lee, Yongjing; Yan, Shilin; Lee, Dequan; Yan, Fei

    2016-06-01

    The fibrous pre-form of resin transfer molding is a dual-scale porous medium with two distinct scales of pores, i.e., pores in intra- and inter-tow, which produce an unsaturated infiltration phenomenon during filling. A sink term representing the delayed flow rate from the inter-tow gap into the intra-tow one is introduced to establish governing equations. This study mainly analyzes the sink term by tow saturation during the microscopic flow. First, fiber-tow permeability is calculated by FLOTRAN of ANSYS, Second, periodic unit cells are built according to different structures, and the concrete expression of the sink term is indirectly obtained through the numerical simulation and date fitting of tow saturation under different pressure and viscosity conditions. Results indicate that: the FLOTRAN module can be used to calculate the permeability of fiber tow in two directions; Moreover, the filling time and infiltration process for diverse unit cells with the same volume fraction are different; under the same injection condition, different unit cells have different parameters for the sink term.

  4. Challenges in mold manufacturing for high precision molded diffractive optical elements

    Science.gov (United States)

    Pongs, Guido; Bresseler, Bernd; Schweizer, Klaus; Bergs, Thomas

    2016-09-01

    Isothermal precision glass molding of imaging optics is the key technology for mass production of precise optical elements. Especially for numerous consumer applications (e.g. digital cameras, smart phones, …), high precision glass molding is applied for the manufacturing of aspherical lenses. The usage of diffractive optical elements (DOEs) can help to further reduce the number of lenses in the optical systems which will lead to a reduced weight of hand-held optical devices. But today the application of molded glass DOEs is limited due to the technological challenges in structuring the mold surfaces. Depending on the application submicrometer structures are required on the mold surface. Furthermore these structures have to be replicated very precisely to the glass lens surface. Especially the micro structuring of hard and brittle mold materials such as Tungsten Carbide is very difficult and not established. Thus a multitude of innovative approaches using diffractive optical elements cannot be realized. Aixtooling has investigated in different mold materials and different suitable machining technologies for the micro- and sub-micrometer structuring of mold surfaces. The focus of the work lays on ultra-precision grinding to generate the diffractive pattern on the mold surfaces. This paper presents the latest achievements in diffractive structuring of Tungsten Carbide mold surfaces by ultra-precision grinding.

  5. Study of a Compression-Molding Process for Ultraviolet Light-Emitting Diode Exposure Systems via Finite-Element Analysis.

    Science.gov (United States)

    Wu, Kuo-Tsai; Hwang, Sheng-Jye; Lee, Huei-Huang

    2017-06-15

    Although wafer-level camera lenses are a very promising technology, problems such as warpage with time and non-uniform thickness of products still exist. In this study, finite element simulation was performed to simulate the compression molding process for acquiring the pressure distribution on the product on completion of the process and predicting the deformation with respect to the pressure distribution. Results show that the single-gate compression molding process significantly increases the pressure at the center of the product, whereas the multi-gate compressing molding process can effectively distribute the pressure. This study evaluated the non-uniform thickness of product and changes in the process parameters through computer simulations, which could help to improve the compression molding process.

  6. Using Raman spectroscopic imaging for non-destructive analysis of filler distribution in chalk filled polypropylene

    DEFF Research Database (Denmark)

    Boros, Evelin; Porse, Peter Bak; Nielsen, Inga

    2016-01-01

    A feasibility study on using Raman spectral imaging for visualization and analysis of filler distribution in chalk filled poly-propylene samples has been carried out. The spectral images were acquired using a Raman spectrometer with 785 nm light source.Eight injection-molded samples...

  7. Simulations of the new cryogenic gas filled stopping cell for the low energy branch of the Super-FRS at FAIR

    Energy Technology Data Exchange (ETDEWEB)

    Reiter, Moritz Pascal; Schaefer, Daniel [Justus-Liebig-Universitaet Giessen (Germany); Dickel, Timo; Plass, Wolfgang; Geissel, Hans; Scheidenberger, Christoph [Justus-Liebig-Universitaet Giessen (Germany); GSI, Darmstadt (Germany); Collaboration: FRS Ion Catcher-Collaboration

    2012-07-01

    At the low energy branch of the Super-FRS at FAIR exotic nuclei will be produced at relativistic energies, slowed down, thermalized and provided as a low energy beam to high precision experiments. The ions are stopped in a cryogenic stopping cell in high density helium gas. In order to guide the development of the new cryogenic stopping cell and to study the performance of the new techniques used, numerical simulations of the stopping cell have been performed. A parameter study of the RF carpet has been done and optimized working parameters for the stopping cell have been found. The simulation results show good agreement with the first offline and online experiments of the cryogenic stopping cell obtained at the FRS Ion Catcher at GSI. For the first time cryogenic operation of a stopping cell with a radio frequency carpet and hitherto unreached helium densities have been demonstrated.

  8. Simulation of the Resin Film Infusion Process Based on the Finite Element Method

    Institute of Scientific and Technical Information of China (English)

    YANG Mei; YAN Shilin; TAN Hua

    2006-01-01

    A physically accurate and computationally effective pure finite element method (FEM) was developed to simulate the isothermal resin infusing process. The FEM was based on conservation of resin mass at any instant of time and was objective of resin film infusion (RFI) fiber impregnation and mold filling. The developed computer code was able to simulate the resin infusing visually. A numerical example presented here demonstrated that compared with traditional finite element/ control-volume (FE/CV), and FEM was physically accurate and computationally efficient.

  9. The fluidity and molding ability of glass-forming Zr-based alloy melt

    Institute of Scientific and Technical Information of China (English)

    2008-01-01

    The fluidity and filling ability of glass-forming Zr-based alloy melt in copper mould were investigated both theoretically and experimentally. The major factors which affected the flowing behavior of the metallic melt in the mold were determined,which provides the foundation for overcoming the contradiction between the filling and formation of amorphous alloy during the rapid cooling process of the metallic melts. The casting factors to prepare a metallic ring were discussed and selected. As a result,a Zr-based bulk metallic glass ring was prepared successfully.

  10. Influence of the Mold Current on the Electroslag Remelting Process

    Science.gov (United States)

    Hugo, Mathilde; Dussoubs, Bernard; Jardy, Alain; Escaffre, Jessica; Poisson, Henri

    2016-08-01

    The electroslag remelting process is widely used to produce high value-added alloys. The use of numerical simulation has proven to be a valuable way to improve its understanding. In collaboration with Aubert & Duval, the Institute Jean Lamour has developed a numerical transient model of the process. The consumable electrode is remelted within a mold assumed to be electrically insulated by the solidified slag skin. However, this assumption has been challenged by some recent studies: the solidified slag skin may actually allow a part of the melting current to reach the mold. In this paper, the evolution of our model, in order to take into account this possibility, is presented and discussed. Numerical results are compared with experimental data, while several sensitivity studies show the influence of some slag properties and operating parameters on the quality of the ingot. Even, a weakly conductive solidified slag skin at the inner surface of the mold may be responsible for a non-negligible amount of current circulating between the slag and crucible, which in turn modifies the fluid flow and heat transfer in the slag and ingot liquid pool. The fraction of current concerned depends mainly on the electrical conductivities of both the liquid and solidified slag.

  11. Novel Approach for Modeling of Nonuniform Slag Layers and Air Gap in Continuous Casting Mold

    Science.gov (United States)

    Wang, Xudong; Kong, Lingwei; Yao, Man; Zhang, Xiaobing

    2017-02-01

    Various kinds of surface defects on the continuous casting slab usually originate from nonuniform heat transfer and mechanical behavior, especially during the initial solidification inside the mold. In this article, a model-coupled inverse heat transfer problem incorporating the effect of slag layers and air gap is developed to study the nonuniform distribution of liquid slag, solid slag, and air gap layers. The model considers not only the formation and evolution of slag layers and air gap but also the temperatures in the mold copper as measured by thermocouples. The simulation results from the model and the measured temperatures from experiments are shown to be in good agreement with each other. At the casting speed of 0.65 m/min, the liquid slag film disappears and transforms into solid slag entirely at about 400 mm away from meniscus, and an air gap begins to form. Until the mold exit, the maximum thickness of the solid slag layer and air gap gradually increases to 1.34 and 0.056 mm, respectively. The results illustrate that the magnitude and nonuniform distribution of the slag layers and air gap along the cross direction, correlating with heat flux between the shell and mold, eventually determine the temperature profiles of the mold hot face and slab surface. The proposed model may provide a convenient approach for analyzing nonuniform heat transfer and mechanical behaviors between the mold and slab in the real casting process.

  12. Effect of mold designs on molten metal behaviour in high-pressure die casting

    Science.gov (United States)

    Ibrahim, M. D.; Rahman, M. R. A.; Khan, A. A.; Mohamad, M. R.; Suffian, M. S. Z. M.; Yunos, Y. S.; Wong, L. K.; Mohtar, M. Z.

    2017-04-01

    This paper presents a research study conducted in a local automotive component manufacturer that produces aluminium alloy steering housing local and global markets. This study is to investigate the effect of design modification of mold in die casting as to improve the production rate. Design modification is carried out on the casting shot of the mold. Computer flow simulation was carried out to study the flow of molten metal in the mold with respect to the mold design modification. The design parameters of injection speed, die temperature and clamping force has been included in the study. The result of the simulation showed that modifications of casting shot give significant impact towards the molten flow behaviour in casting process. The capabilities and limitations of die casting process simulation to conduct defect analysis had been optimized. This research will enhance the efficiency of the mass production of the industry of die casting with the understanding of defect analysis, which lies on the modification of the mold design, a way early in its stages of production.

  13. L Tube Gravity Feed Simulation Test Based on Coarse Tailings Cemented Filling%基于粗尾砂胶结充填的L管自流输送模拟试验

    Institute of Scientific and Technical Information of China (English)

    郭江龙; 白金

    2015-01-01

    Through simulation test of the gravity feed resistance of the L tube cemented filled with coarse tailings, it is proved that to add some MSP into the filling slurry can greatly improve its suspension property and liquidity, thus reducing the wear to the tube, and effectively solving the layering, separation and riffling phenomenon. So it has good popularization prospect in mine industry.%通过对某铁矿粗尾砂胶结充填的L管自流输送阻力模拟试验研究,证明了在充填料浆中添加适量的悬浮剂(简称MSP),可使其具有良好的悬浮性、流动性,减少了料浆对管道的磨损,可有效解决充填料浆在自流输送中的分层、离析、沉砂等现象,在矿山行业有较好推广前景。

  14. Simulation of Grain-filling of Spring Maize(Zhengdan 958) in Northeast China%东北春玉米郑单958籽粒灌浆过程的模拟∗

    Institute of Scientific and Technical Information of China (English)

    郭春明; 任景全; 曲思邈; 李忠辉

    2015-01-01

    利用白城国家一级农试站2011-2013年春玉米田间试验观测数据,基于 Richards 方程建立和验证东北春玉米籽粒灌浆模型,并进行籽粒灌浆特性分析。结果表明:分别以相对开花后天数、相对活动积温和相对≥10℃有效积温为自变量,相对百粒重为因变量建立的籽粒灌浆过程普适模型(模型 I、模型 II 和模型 III)均通过了0.01水平的显著性检验(R2>0.98)。模型回代后模拟值与实测值的评价指标 NSE(Nash ̄Sutcliffe 指数)和RSR(均方根误差与标准差的比值)值均表现为“很好”的效果。模拟值与实测值散点均在1︰1线±10%范围内。模型 I 显示,东北春玉米籽粒灌浆活跃期为46d,整个灌浆过程平均速率为0.84g.d -1;籽粒灌浆速率在开花后32d 达到最大,为1.23g.d -1,此时玉米百粒重为15.17g;灌浆中期对百粒重的贡献率最大,为65.60%,前期和后期贡献率分别为10.50%和23.90%。模型 II 和模型 III 显示,籽粒灌浆活跃期活动积温和≥10℃有效积温分别为1043.5℃.d 和679.1℃.d;灌浆速率在开花后活动积温和≥10℃有效积温分别为782.8℃.d 和473.3℃.d 时达到最大值;中期灌浆贡献率为67.68%。3个模型均显示,中期灌浆贡献率较大,前期和后期相对较小,说明春玉米籽粒干物质积累主要在灌浆中期完成。%The grain ̄filling model of spring maize was established by richards equation with the experiement data of Baicheng from 2011 to 2013. The grain ̄filling characteristic was analyzed based on the confirm and calibration of the model. The results showed that universal grain ̄filling model passed the 0. 01 level of significance test which the days after flowering(model I), active accumulated temperature(model II), effective accumulated temperature above 10℃(model III) were independent variable and the dry weight of 100 ̄grain was dependent variable. Measured and simulated value scattered

  15. A Combined Experimental and Computational Approach for the Design of Mold Topography that Leads to Desired Ingot Surface and Microstructure in Aluminum Casting.

    Energy Technology Data Exchange (ETDEWEB)

    Dr. Zabaras, N.; Tan, L.

    2005-07-12

    A thermomechanical study of the effects of mold topography on the solidification of Aluminum alloys at early times is provided. The various coupling mechanisms between the solid-shell and mold deformation and heat transfer at the mold/solid-shell interface during the early stages of Aluminum solidification on molds with uneven topographies are investigated. The air-gap nucleation time, the stress evolution and the solid-shell growth pattern are examined for different mold topographies to illustrate the potential control of Aluminum cast surface morphologies during the early stages of solidification using proper design of mold topographies. The unstable shell growth pattern in the early solidification stages results mainly from the unevenness of the heat flux between the solid-shell and the mold surface. This heat flux is determined by the size of the air-gaps formed between the solidifying shell and mold surface or from the value of the contact pressure. Simulation results show that a sinusoidal mold surface with a smaller wavelength leads to nucleation of air-gaps at earlier times. In addition, the unevenness in the solid-shell growth pattern decreases faster for a smaller wavelength. Such studies can be used to tune mold surfaces for the control of cast surface morphologies.

  16. Evaluation of stability for monolayer injection molding tools coating

    DEFF Research Database (Denmark)

    Cech, Jiri; Taboryski, Rafael J.

    2012-01-01

    We tested and characterized molecular coating of Aluminium and Nickel prototype molds and mold inserts for polymer replication via injection molding (IM). X-Ray photoelectron spectroscopy (XPS) data, sessile drop contact angles with multiple fluids, surface energy and roughness data have been...... and especially suitable for rapid prototyping and mold geometry testing....

  17. Mechanical Properties of Injection Molded and Compression Molded Samples from Nature-Butadiene Rubber

    OpenAIRE

    Skrobak Adam; Janoštík Václav; Stanek Michal; Manas David; Ovsik Martin; Senkerik Vojtech; Reznicek Martin

    2016-01-01

    The aim of this paper is to show what extent there is an impact on the mechanical properties (tensile strength and tear strength) of a standardized testing sample made of rubber compound based on nature rubber and butadiene rubber produced by injection molding in comparison with a sample produced by classic preparation (cutting out a compression molded plate) according to the standard ISO 23529. For realization of this study it was necessary to design and produce an injection mold for all typ...

  18. Solving depressions formed during production of plastic molding

    Directory of Open Access Journals (Sweden)

    J. Dobránsky

    2015-07-01

    Full Text Available This article deals with improvement of design properties of molded plastic parts. It can be achieved by modifying construction of metal injection mold and optimization of parameters in injection process. The subject of our examination was depressions formed on molded plastic parts which are inacceptable in the process of approval. The problem which has arisen was solved in two phases. The first phase consisted in alteration of injection mold design – enlargement of injection molding gate. In the second phase, we have changed the location of injection molding gate. After performing constructional modifications, new molded plastic parts were manufactured and assessed.

  19. Numerical Simulation of Filling and Solidification of Magnesium Alloy Bottom-shell Body for Automobile%镁合金汽车下壳体充型和凝固过程数值模拟

    Institute of Scientific and Technical Information of China (English)

    李力; 王翠芳

    2011-01-01

    对镁合金汽车下壳体铸件在液态和半固态条件下的充型凝固过程进行了数值模拟,并对两种状态下的零件在铸造过程中可能出现缺陷的位置进行了预测.结果表明,半固态合金熔体的充填有利于平稳充填型腔、型腔的气体能及时排出,减少了铸件的内部缺陷.同时,铸件的整体温度场相对均匀,有利于铸件内部的补缩和残余气体的排放,从而提高了铸件质量.%With the help of numerical simulation method, filling and solidification process of magnesium alloy bottom-shell body for automobile in liquid state and in semi-solid state were simulated, and potential position of defects in the parts in two different states was predicted. The results show that semi-solid magnesium melt is beneficial for smoothly filling cavity and exhaustion of gas in the cavity in time to eliminate the internal defects in the parts. Meanwhile, the whole temperature field of the parts is relatively homogeneous, which is helpful for the internal feeding and exhaustion of residual gas in the cavity, improving the quality of the magnesium alloy parts.

  20. Assessment of mold concentrations in Singapore shopping centers using mold-specific quantitative PCR (MSQPCR) analysis.

    Science.gov (United States)

    Yap, Jennifer; Toh, Zhen Ann; Goh, Vivien; Ng, Lee Chen; Vesper, Stephen

    2009-09-01

    Molds can pose a human health threat and may amplify in buildings in humid climates. The objective of this study was to evaluate the mold growth in Singapore shopping centers based on the collection of 40 dust samples from 15 shopping centers, including one with a history of water damage. The dust was analyzed by a DNA-based technology called mold-specific quantitative PCR (MSQPCR). In a water-damaged shopping center, most of the 26 water-damage indicator species were detected at some concentration and many were much more abundant than the average in the shopping centers. MSQPCR is a useful method for quantifying indoor molds in tropical climates.

  1. A new insight into foaming mechanisms in injection molding via a novel visualization mold

    Directory of Open Access Journals (Sweden)

    V. Shaayegan

    2016-06-01

    Full Text Available The complex mechanisms of bubble nucleation and dynamics in foam injection molding have not been uncovered despite many previous efforts due to the non-steady stop-and-flow nature of injection molding and the non-uniform temperature and pressure distributions in the mold. To this end, a new visualization mold was designed and manufactured for the direct observation of bubble nucleation and growth/collapse in foam injection molding. A reflective prism was incorporated into the stationary part of the injection mold with which the nucleation and growth behaviors of bubbles were successfully observed. The mechanisms of bubble nucleation in low- and high-pressure foam injection molding, with and without the application of gas-counter pressure, was investigated. We identified how the inherently non-uniform cell structure is developed in low-pressure foam injection molding with gate-nucleated bubbles, and when and how cell nucleation occurs in high-pressure foam injection molding with a more uniform pressure drop.

  2. The effect of mold surface topography on plastic parat in-process shrinkage in injection molding

    DEFF Research Database (Denmark)

    Arlø, Uffe Rolf; Hansen, Hans Nørgaard; Kjær, Erik Michael

    2003-01-01

    An experimental study of the effect of mold surface roughness on in-process in-flow linear part shrinkage in injection molding has been carried out. The investigation is based on an experimental two-cavity tool, where the cavities have different surface topographies, but are otherwise identical....... The study has been carried out for typical commercial polystyrene and polypropylene grades. The relationship between mold surface topography and linear shrinkage has been investigated with an experimental two-cavity mold producing simple rectangular parts with the nominal dimensions 1 x 25 x 50 mm (see...

  3. Molds on Food: Are They Dangerous?

    Science.gov (United States)

    ... food was stored. Check nearby items the moldy food might have touched. Mold spreads quickly in fruits and vegetables. See the attached chart "Moldy Food: When to Use, When to Discard." FOOD HANDLING ...

  4. Injection molded optical backplane for broadcast architecture

    Science.gov (United States)

    Rosenberg, Paul; Mathai, Sagi; Sorin, Wayne V.; McLaren, Moray; Straznicky, Joseph; Panotopoulos, Georgios; Warren, David; Morris, Terry; Tan, Michael R. T.

    2012-01-01

    A low cost, blind mate, injection molded optical backplane is presented. The optical backplane is comprised of 12 channel optical broadcast buses, operating at 10Gbps/channel with six blindmate optical output ports spaced 1U apart.

  5. Three-Dimensional Pneumatic Molding of Veneers

    Directory of Open Access Journals (Sweden)

    Milan Gaff

    2014-07-01

    Full Text Available The goal of this paper is to introduce a new testing method suitable for the evaluation of the three-dimensional (3-D moldability of veneers and to use this method to test the impact of specific factors on the 3-D pneumatic molding process. The tested factors included veneer moisture content, wood species, shape of test piece, and fixing method on the maximum wood deflection. Veneers were molded using compressed air on equipment designed by our group for the sole purpose of this experiment. The results indicated that the monitored factors had an effect on deflection during the 3-D molding process. The results of this investigation extend the state-of-the-art knowledge regarding this technology and indicate the possibility of utilizing this innovative testing method for 3-D molded veneers.

  6. Secondary metabolites of slime molds (myxomycetes).

    Science.gov (United States)

    Dembitsky, Valery M; Rezanka, Tomás; Spízek, Jaroslav; Hanus, Lumír O

    2005-04-01

    The compounds reported from the slime molds (myxomycetes) species are described. Almost 100 natural compounds including their chemical structures and biological activities are described in this review article. Only metabolites with a well-defined structure are included.

  7. Rozen : steeds meer bekend over Black Mold

    NARCIS (Netherlands)

    Smits, A.P.; Kohrman, E.

    2009-01-01

    Onderzoek naar Black Mold heeft al veel informatie opgeleverd over de verspreiding, bestrijding en ontwikkeling van de oculatieschimmel. In dit artikel de nieuwste resultaten van PPO en Cultus Agro Advies

  8. Facts about Stachybotrys chartarum and Other Molds

    Science.gov (United States)

    ... Organization issued additional guidance, the WHO Guidelines for Indoor Air Quality: Dampness and Mould [PDF - 2.52 MB] . Other ... reliable sampling for mold can be expensive, and standards for judging what is and what is not ...

  9. Custom molded thermal MRg-FUS phantom

    Science.gov (United States)

    Eames, Matthew D. C.; Snell, John W.; Hananel, Arik; Kassell, Neal F.

    2012-11-01

    This article describes a method for creating custom-molded thermal phantoms for use with MR-guided focused ultrasound systems. The method is defined here for intracranial applications, though it may be modified for other anatomical targets.

  10. Additive Manufacturing of Wind Turbine Molds

    Energy Technology Data Exchange (ETDEWEB)

    Post, Brian [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Richardson, Bradley [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Lloyd, Peter [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Love, Lonnie [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Nolet, Stephen [TPI Composites, Scottsdale, AZ (United States); Hannan, James [TPI Composites, Scottsdale, AZ (United States)

    2017-07-01

    The objective of this project was to explore the utility of Big Area Additive Manufacturing (BAAM) for low cost manufacturing of wind turbine molds. Engineers at Oak Ridge National Laboratory (ORNL) and TPI Composites (TPI) collaborated to design and manufacture a printed mold that can be used for resin infusion of wind turbine components. Specific focus was on required material properties (operating temperatures and pressures, coefficient of thermal expansion (CTE), thermal conductivity), surface finish (accuracy and coatings) and system integration (integrated vacuum ports, and heating element). The project began with a simple proof of principle components, targeting surface coatings and material properties for printing a small section (approximately 4’ x 4’ x 2’) of a mold. Next, the second phase scaled up and integrated with the objective of capturing all of the necessary components (integrated heating to accelerate cure time, and vacuum, sealing) for resin infusion on a mold of significant size (8’ x 20’ x 6’).

  11. National Allergy Bureau Pollen and Mold Report

    Science.gov (United States)

    ... the Expert Search Search AAAAI National Allergy Bureau Pollen and Mold Report Date: April 11, 2017 Location: ... 11, 2017 Click Here to View Most Recent Pollen and Spore Levels (04/10/2017) If you ...

  12. Polymerization shrinkage and depth of cure of bulk-fill resin composites and highly filled flowable resin.

    Science.gov (United States)

    Jang, J-H; Park, S-H; Hwang, I-N

    2015-01-01

    The aim of this study was to evaluate the polymerization behavior and depth of cure (DOC) of recently introduced resin composites for posterior use: highly filled flowable composite and composites for bulk fill. A highly filled flowable (G-aenial Universal Flo [GUF]), two bulk-fill flowables (Surefil SDR Flow [SDR] and Venus Bulk fill [VBF]), and a bulk-fill nonflowable composite (Tetric N-Ceram Bulk fill [TBF]) were compared with two conventional composites (Tetric Flow [TF], Filtek Supreme Ultra [FS]). Linear polymerization shrinkage and polymerization shrinkage stress were each measured with custom-made devices. To evaluate DOC, the composite specimen was prepared using a mold with a hole of 4 mm depth and 4 mm internal diameter. The hole was bulk filled with each of the six composites and light cured for 20 seconds, followed by 24 hours of water storage. The surface hardness was measured on the top and the bottom using a Vickers microhardness (HV) indenter. The linear polymerization shrinkage of the composite specimens after photo-initiation decreased in the following order: TF and GUF > VBF > SDR > FS and TBF (pcomposite groups decreased in the following order: GUF > TF and VBF > SDR > FS and TBF (pflowable (GUF) revealed limitations in polymerization shrinkage and DOC. Bulk-fill flowables (SDR and VBF) were properly cured in 4-mm bulk, but they shrank more than the conventional nonflowable composite. A bulk-fill nonflowable (TBF) showed comparable shrinkage to the conventional nonflowable composite, but it was not sufficiently cured in the 4-mm bulk.

  13. 21 CFR 133.184 - Roquefort cheese, sheep's milk blue-mold, and blue-mold cheese from sheep's milk.

    Science.gov (United States)

    2010-04-01

    ... 21 Food and Drugs 2 2010-04-01 2010-04-01 false Roquefort cheese, sheep's milk blue-mold, and blue-mold cheese from sheep's milk. 133.184 Section 133.184 Food and Drugs FOOD AND DRUG ADMINISTRATION..., sheep's milk blue-mold, and blue-mold cheese from sheep's milk. (a) Description. (1) Roquefort...

  14. Model predictive control of servo motor driven constant pump hydraulic system in injection molding process based on neurodynamic optimization

    Institute of Scientific and Technical Information of China (English)

    Yong-gang PENG; Jun WANG; Wei WEI

    2014-01-01

    In view of the high energy consumption and low response speed of the traditional hydraulic system for an injection molding machine, a servo motor driven constant pump hydraulic system is designed for a precision injection molding process, which uses a servo motor, a constant pump, and a pressure sensor, instead of a common motor, a constant pump, a pressure pro-portion valve, and a flow proportion valve. A model predictive control strategy based on neurodynamic optimization is proposed to control this new hydraulic system in the injection molding process. Simulation results showed that this control method has good control precision and quick response.

  15. Post-cure depth of cure of bulk fill dental resin-composites.

    Science.gov (United States)

    Alrahlah, A; Silikas, N; Watts, D C

    2014-02-01

    To determine the post-cure depth of cure of bulk fill resin composites through using Vickers hardness profiles (VHN). Five bulk fill composite materials were examined: Tetric EvoCeram(®) Bulk Fill, X-tra base, Venus(®) Bulk Fill, Filtek™ Bulk Fill, SonicFill™. Three specimens of each material type were prepared in stainless steel molds which contained a slot of dimensions (15 mm × 4 mm × 2 mm), and a top plate. The molds were irradiated from one end. All specimens were stored at 37°C for 24h, before measurement. The Vickers hardness was measured as a function of depth of material, at 0.3mm intervals. Data were analysed by one-way ANOVA using Tukey post hoc tests (α=0.05). The maximum VHN ranged from 37.8 to 77.4, whilst the VHN at 80% of max.VHN ranged from 30.4 to 61.9. The depth corresponding to 80% of max.VHN, ranged from 4.14 to 5.03 mm. One-way ANOVA showed statistically significant differences between materials for all parameters tested. SonicFill exhibited the highest VHN (presin composites can be cured to an acceptable post-cure depth, according to the manufacturers' claims. SonicFill and Tetric EvoCeram Bulk Fill had the greatest depth of cure among the composites examined. Copyright © 2013 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

  16. Die Casting Mold Design for Aluminum Alloy Shell of Instrument

    Directory of Open Access Journals (Sweden)

    Li Yuanyuan

    2015-01-01

    Full Text Available This paper is about die casting mold design for aluminum alloy shell of instrument. Three-dimensional model of the casting and mold are designed by using Pro/Engineer and AutoCad which can analyze forming quality. Digital design and theoretical calculation can greatly shorten product development cycle and mold design cycle, improve the accuracy of product design and mold design, and reduce the cost of mold design.

  17. Simulation study on three casting processes for a marine propeller hub body

    Directory of Open Access Journals (Sweden)

    Wang Tongmin

    2013-11-01

    Full Text Available The mold filling and solidification process of a marine propeller hub were simulated using ProCAST? Three casting processes ?gravity casting, centrifugal casting and low pressure casting ?were compared in order to get the best process. The heat transfer coefficient of the casting/mold interface was determined using a reverse method. The simulated results of velocity, temperature and shrinkage porosity distribution were discussed in detail for the three casting processes. A smooth filling was found in all three casting processes, especially the low pressure casting exhibiting a better filling performance than the other two, but the solidification processes were different. The casting did not experience the sequential solidification, and the feeding paths were blocked, leading to shrinkage porosity defects in the riser and the bottom of the casting in gravity casting and in the upper zone of the casting in low pressure casting. While, the sequential solidification was well controlled in the solidification process of centrifugal casting, and majority of the shrinkage porosity defects can only be observed in the riser. It could be concluded that the centrifugal casting process is the most suitable casting process for the production of propeller hub body. The casting experiments verified the simulation results, and a defect-free propeller hub was obtained by centrifugal casting with a rotational speed of 150 r.in-1.

  18. Numerical Simulation on Heat Transfer Characteristics of Plate Heat Exchanger Filled with Iron-Nickel Foam%铁镍泡沫填充板式换热器传热特性数值模拟

    Institute of Scientific and Technical Information of China (English)

    晁攸明; 程聪; 张铱鈖

    2012-01-01

    The complex three-dimensional network structure of open-cell foam metal can enhance the nonlinear flow effect of fluid through foam. Large specific surface area and large coefficient of thermal conductivity of the matrix material can improve the heat transfer efficiency. Based on the above features of open-cell foam, a new type of compact plate heat exchanger filled with iron-nickel foam was developed. The characteristics of air-air heat transfer in the plate heat exchanger were numerically simulated. All computations were performed using CFD of the commercially available finite element code FLUENT. Under the same operating conditions, the simulation results agreed well with the experimental results. The simulation results show that filling with iron-nickel foam in plate heat exchanger could improve the extent of turbulence of cold and hot air in plate heat exchanger. Compared with the heat exchanger without fillers, the plate heat exchanger filled with iron-nickel foam was obviously improved in heat transter efficiency. Iron-nickel foam fillers increased flow resistance of the hot and cold air, but the resulting loss of pressure was of little effect on heat exchanger performance. While filling with the same porosity iron-nickel foam, the influence of pore density change on heat exchanger efficiency was relatively small. The research results can be reference for structure optimization design and performance a-nalysis of heat transfer equipment.%利用开孔泡沫金属比表面积大、基体金属材料导热系数大和其复杂的三维立体网状结构能提高流体非线性效果的特点,研制了一种新型紧凑式镍铁泡沫填充板式换热器.并用CFD商用有限元软件FLUENT对空气空气在该换热器中的传热特性进行数值模拟.在相同的操作条件下,模拟结果与实验结果吻合较好.研究结果表明:在板式换热器中填充开孔铁镍泡沫材料,冷热空气在换热器中的湍流程度有所增强,板式换热

  19. EFFECTIVENESS OF CELLULAR INJECTION MOLDING PROCESS

    Directory of Open Access Journals (Sweden)

    Tomasz Garbacz

    2013-06-01

    Full Text Available In a study of cellular injection, molding process uses polyvinylchloride PVC. Polymers modified with introducing blowing agents into them in the Laboratory of the Department of Technologies and Materiase of Technical University of Kosice. For technological reasons, blowing agents have a form of granules. In the experiment, the content of the blowing agent (0–2,0 % by mass fed into the processed polymer was adopted as a variable factor. In the studies presented in the article, the chemical blowing agents occurring in the granulated form with a diameter of 1.2 to 1.4 mm were used. The view of the technological line for cellular injection molding and injection mold cavity with injection moldings are shown in Figure 1. The results of the determination of selected properties of injection molded parts for various polymeric materials, obtained with different content of blowing agents, are shown in Figures 4-7. Microscopic examination of cross-sectional structure of the moldings were obtained using the author's position image analysis of porous structure. Based on analysis of photographs taken (Figures 7, 8, 9 it was found that the coating containing 1.0% of blowing agents is a clearly visible solid outer layer and uniform distribution of pores and their sizes are similar.

  20. Numerical simulation of the flow field in a wide slab continuous casting mold%宽板坯连铸结晶器流场的数值模拟

    Institute of Scientific and Technical Information of China (English)

    姜平国; 赖朝斌

    2016-01-01

    针对某钢厂150 mm×1503 mm宽板坯连铸结晶器生产中出现的表面波动及卷渣情况,利用FLUENT软件对其进行了三维稳态数学计算.计算以流体表面流速为主要衡量指标,研究了出水口的倾斜角度、倒角形状对该水口作用下结晶器内流场的影响.计算结果表明,原型结晶器浸入式水口作用下,流场内的表面流速大,射流冲击深度小,液面波动大,卷渣严重.改变出水口的倾斜角度,结晶器内表面流速依旧较大,依然有较严重的卷渣现象发生.改用方案3出水口倒角形状改为相切后,表面流速由原型最大的0.6 m/s减小到0.2 m/s,冲击深度增加,流场改善,卷渣问题得到解决.%The surface fluctuation and slag entrapment involved in the wide slab continuous casting mold of 150 mmí1503 mm in a steel plant was caculated by FLUENT software. Surface velocity was set as the main measure to study about port angle and guide an-gular shape of the nozzle influence on flow field. The calculation results show that under the condition of original nozzle, the surface velocity was large, but the impact depth was small and the fluctuation was severe. Entrapment of slag was serious. After changed the angle of the outlet, the mold surface velocity remained large and severe entrapment of slag. When scheme 3 ( outlet lead angle changed shape to tangent) was applied, surface velocity reduced from 0. 6 m/s to 0. 2 m/s, impact depth improved, flow field character became better, and problem of slag entrapment was resolved.

  1. Finite Element Modeling of Reheat Stretch Blow Molding of PET

    Science.gov (United States)

    Krishnan, Dwarak; Dupaix, Rebecca B.

    2004-06-01

    Poly (ethylene terephthalate) or PET is a polymer used as a packaging material for consumer products such as beverages, food or other liquids, and in other applications including drawn fibers and stretched films. Key features that make it widely used are its transparency, dimensional stability, gas impermeability, impact resistance, and high stiffness and strength in certain preferential directions. These commercially useful properties arise from the fact that PET crystallizes upon deformation above the glass transition temperature. Additionally, this strain-induced crystallization causes the deformation behavior of PET to be highly sensitive to processing conditions. It is thus crucial for engineers to be able to predict its performance at various process temperatures, strain rates and strain states so as to optimize the manufacturing process. In addressing these issues; a finite element analysis of the reheat blow molding process with PET has been carried out using ABAQUS. The simulation employed a constitutive model for PET developed by Dupaix and Boyce et al.. The model includes the combined effects of molecular orientation and strain-induced crystallization on strain hardening when the material is deformed above the glass transition temperature. The simulated bottles were also compared with actual blow molded bottles to evaluate the validity of the simulation.

  2. METHODS FOR STRENGTHENING OF ADHESION BONDS BETWEEN SURFACE OF USED MOLDING SAND AND ORGANIC BINDER WHILE OBTAINING ACTIVATED MINERAL POWDERS

    Directory of Open Access Journals (Sweden)

    Ya. N. Kovalev

    2016-01-01

    Full Text Available Value of adhesion bond between mineral surface of acid quartz materials and organic binder (bitumen has a great significance while forming structure of asphalt concrete strengthening. It has been established theoretically and experimentally that that the bond is insignificant and it causes premature destruction of structure for asphalt-binding substance and finally asphalt concrete. In this connection the relevant objective of the paper is a search for efficient methods for strengthening of adhesion bonds between the indicated structural components. A development for obtaining mineral powders from used molding sand activated by various hydrofobisation methods plays rather important role in that matter. The development of several methods for obtainment of activated mineral powders from used molding sand and also know-how pertaining to behavior of asphalt concrete formed on their basis have made it possible to create rational technologies which are applicable under operational conditions of the specified asphalt concrete plants in any region. The executed investigations on hydrofobisation of particles surface for the used molding sand with the help of sodium alkyl siliconates have established the basis for development of new efficient method for obtaining activated mineral powders from the used molding sand. The method presupposes treatment of the used molding sand in the process of mill flow in a ball drum while using sodium ethyl siliconate (0.3–0.7 % as compared with the mass of mineral raw material. Juvenile particle surface of fresh milled powder from the used molding sand has a maximum activity among the known filling compounds in relation to althin and this phenomenon can be explained by additional structure-forming impact of chemically active organic foundry binding agents which are contained in the used molding sand. That particular property allows to use widely powder from the used molding sand which contains uncured althin as a

  3. Fast Mold Temperature Evolution on Micro Features Replication Quality during Injection Molding

    DEFF Research Database (Denmark)

    Liparoti, S.; Calaon, Matteo; Speranza, V.;

    2016-01-01

    lithography and subsequent nickel electroplating. The mold temperature was controlled by a thin heating device (composed by polyimide as insulating layer and polyimide carbon black loaded aselectrical conductive layer) able to increase the temperature on mold surface in a few seconds (40°C/s) by Joule effect...

  4. Development of sheet molding compound solar collectors with molded-in silvered glass reflective surfaces

    Energy Technology Data Exchange (ETDEWEB)

    Champion, R. L.; Allred, R. E.

    1980-12-01

    The reflecting concentrator of a parabolic trough solar collector system comprises approximately 40% of initial system cost. The parabolic concentrator structure is also the most influential component in determining overall system efficiency. Parabolic test moldings have been fabricated from a general purpose sheet molding compound with flat chemically strengthened glass, flat annealed glass, and thermally formed glass. The test panel configuration was a 1.22 m x 0.61 m, 45/sup 0/ rim angle (0.762 m focal length) parabola. Attempts to mold with annealed sheet glass (1 mm thick) and thermally formed glass (1.25 mm thick) were unsuccessful; only the chemically strengthened glass (1.25 mm thick) was strong enough to survive molding pressures. Because of the mismatch in thermal expansion between glass and sheet molding compound, the as-molded panels contained a sizeable residual stress. The results are given of dimensional changes taking place in the panels under accelerated thermal cycling and outdoor aging conditions; these results are compared to an analytical model of the laminate. In addition, the sheet molding compound has been examined for thermomechanical properties and flow behavior in the rib sections. Results indicated that lowering the thermal expansion coefficient of the sheet molding compound through material modifications would produce a more stable structure.

  5. Finite Element Analysis of Reciprocating Screw for Injection Molding Machine

    Directory of Open Access Journals (Sweden)

    Nagsen B. Nagrale

    2011-06-01

    Full Text Available This paper deals with, the solution of problem occurred for reciprocating screw of Injection molding machine. It identifies and solves the problem by using the modeling and simulation techniques. The problem occurred in the reciprocating screw of machine which was wearing of threads due to affect of temperature of mold materials(flow materials i.e. Nylon, low density polypropylene, polystyrene, PVC etc., The main work was to model the components of machine with dimensions, assemble those components and then simulate the whole assembly for rotation of the screw. The modeling software used is PRO-E wildfire 4.0 for modeling the machine components like body, movable platen, fixed platen, barrel, screw, nozzle, etc. The analysis software ANSYS is used to analyze the reciprocating screws. The objectives involved are:- • To model all the components using modeling software Pro-E 4.0 • To assemble all the components of the machine in the software. • To make the assembly run in Pro-E software.• Analysis of screw of machine using Ansys 11.0 software. • To identify the wearing of threads and to provide the possible solutions.This problem is major for all industrial injection molding machines which the industries are facing and they need the permanent solution, so if the better solution is achieved then the industries will think for implementing it. The industries are having temporary solution but it will affect the life of the screw, because the stresses will be more in machined screw on lathe machine as compared to normal screw. Also if the screw will fail after some years of operation, the new screw available in the market will have the same problem. Also the cost associated with new screw and its mounting is much more as it is the main component of machine.

  6. Ultrasonic torsional guided wave sensor for flow front monitoring inside molds.

    Science.gov (United States)

    Visvanathan, Karthik; Balasubramaniam, Krishnan

    2007-01-01

    Measuring the extent of flow of viscous fluids inside opaque molds has been a very important parameter in determining the quality of products in the manufacturing process such as injection molding and resin transfer molding. Hence, in this article, an ultrasonic torsional guided wave sensor has been discussed for monitoring the movement of flow front during filling of resins in opaque molds. A pair of piezoelectric normal shear transducers were used for generating and receiving the fundamental ultrasonic torsional guided wave mode in thin copper wires. The torsional mode was excited at one end of the wire, while the flowing viscous fluid progressively wet the other free end of the wire. The time of flight of the transient reflections of this fundamental mode from the air-fluid interface, where the wire enters the resin, was used to measure the position of the fluid flow front. Experiments were conducted on four fluids with different viscosity values. Two postprocessing algorithms were developed for enhancing the transient reflected signal and for suppressing the unwanted stationary signals. The algorithms were tested for cases where the reflected signals showed a poor signal to noise ratio.

  7. Monitoring of resin transfer in CFRP molding using 3D-DIC technique

    Science.gov (United States)

    Chen, Dingding; Arakawa, Kazuo; Uchino, Masakazu

    2014-06-01

    Vacuum-assisted resin transfer molding (VARTM) is a manufacturing process that is used to make large and complex composite structures. While promising, VARTM still suffers from relatively low fiber volume fractions and high void content in the final products. The infusion step of VARTM is very important, because the quality of the final product is usually decided by this process. Consequently, a comprehensive understanding of the infusion process is essential. In this study, a three-dimensional digital image correlation (3D-DIC) testing system was set up to research the entire infusion process through the monitor of the thickness change of the laminates in this process. Two distinct VARTM processes, with and without a rigid cover mold, were designed to be studied. The 3D-DIC technique proved to be a valid method that not only can monitor the thickness evolution of isolated points but also can give a full-field distribution of the thickness change of the laminate. The results showed that, without the use of a rigid cover mold, the stack of reinforcements initially shrank and then expanded as the resin filled the cavities before closing the inlet, while when using a rigid cover mold there was an additional expansion period before the shrinkage occurred. Such an expansion stage could promote the flow of the resin, shortening the infusion time.

  8. Effects of mold geometry on fiber orientation of powder injection molded metal matrix composites

    Energy Technology Data Exchange (ETDEWEB)

    Ahmad, Faiz, E-mail: faizahmad@petronas.com.my; Aslam, Muhammad, E-mail: klaira73@gmail.com; Altaf, Khurram, E-mail: khurram.altaf@petronas.com.my; Shirazi, Irfan, E-mail: irfanshirazi@hotmail.com [Mechanical Engineering Universiti Teknologi PETRONAS Malaysia (Malaysia)

    2015-07-22

    Fiber orientations in metal matrix composites have significant effect on improving tensile properties. Control of fiber orientations in metal injection molded metal composites is a difficult task. In this study, two mold cavities of dimensions 6x6x90 mm and 10x20x180 mm were used for comparison of fiber orientation in injection molded metal composites test parts. In both mold cavities, convergent and divergent flows were developed by modifying the sprue dimensions. Scanning electron microscope (SEM) was used to examine the fiber orientations within the test samples. The results showed highly aligned fiber in injection molded test bars developed from the convergent melt flow. Random orientation of fibers was noted in the composites test bars produced from divergent melt flow.

  9. Transient Asymmetric Flow and Bubble Transport Inside a Slab Continuous-Casting Mold

    Science.gov (United States)

    Liu, Zhongqiu; Li, Baokuan; Jiang, Maofa

    2014-04-01

    A one third scale water model experiment was conducted to observe the asymmetric flow and vortexing flow inside a slab continuous-casting mold. Dye-injection experiment was used to show the evolution of the transient flow pattern in the liquid pool without and with gas injection. The spread of the dye was not symmetric about the central plane. The flow pattern inside the mold was not stationary. The black sesames were injected into water to visualize the vortexing flow pattern on the top surface. The changes of shape and location of single vortex and two vortices with time had been observed during experiments. Plant ultrasonic testing (UT) of slabs was used to analyze the slab defects distribution, which indicated that the defects are intermittent and asymmetric. A mathematical model has been developed to analyze the time-dependent flow using the realistic geometries, which includes the submerged entry nozzle (SEN), actual mold, and part of the secondary cooling zone. The transient turbulent flow of molten steel inside the mold has been simulated using the large eddy simulation computational approach. Simulation results agree acceptably well with the water model experimentally observed and plant UT results. The oscillating motions of jet and the turbulence naturally promote the asymmetric flow even without the effects of slide gate nozzle or the existence of clogs inside the SEN. The periodic behavior of transient fluid flow in the mold is identified and characterized. The vortexing flow is resulted from asymmetric flow in the liquid pool. The vortices are located at the low-velocity side adjacent to the SEN, and the positions and sizes are different. Finally, the model is applied to investigate the influence of bubble size and casting speed on the time-dependent bubble distribution and removal fraction from the top surface inside the mold.

  10. Microstructure Filled Hohlraums

    Energy Technology Data Exchange (ETDEWEB)

    Moore, A. S. [Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States); Thomas, C. A. [Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States); Reese, T. M. [Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

    2017-02-24

    We propose replacing the gas fill in a hohlraum with a low average density, variable uniformity 3D printed structure. This creates a bimodal hohlraum which acts like a vacuum hohlraum initially during the picket, but could protect the capsule from glint or direct illumination, and then once expanded, homogenizes to behave like a variable z gas-fill during peak portion of the drive. This is motivated by a two main aims: 1) reduction of the Au bubble velocity to improve inner beam propagation, and 2) the introduction of a low density, high-Z, x-ray converter to improve x-ray production in the hohlraum and uniformity of the radiation field seen by the capsule.

  11. Mold appearance and modeling on selected corn stover components during moisture sorption.

    Science.gov (United States)

    Igathinathane, C; Womac, A R; Pordesimo, L O; Sokhansanj, S

    2008-09-01

    Occurrence of mold was visually monitored for 26days on samples of major anatomical components of corn stover maintained at several storage temperatures (T) and water activities (a(w)). Glass desiccators with saturated salt solutions placed in temperature controlled chambers provided simulated storage conditions with temperatures ranging from 10 degrees C to 40 degrees C and water activities ranging from 0.11 to 0.98. Mold affected leaf, stalk skin, and stalk pith equally at water activity greater than 0.9. As expected, a combination of increased water activity greater than 0.9 and temperatures greater than 30 degrees C was conducive to mold growth. Based on material moisture content during the initial mold growth, it was postulated that among the corn stover components the stalk pith was the least resistant to mold growth followed by stalk skin and leaf for the studied range of temperature and water activity. Mold growth models fitted well with the observation. A linear mold-free days predictions using a three-parameter regression model (T, a(w), and T x a(w)) was superior (R(2)=0.99) to other models considered. The exponential spoilage model using two parameter T and a(w) also gave comparable performance (R(2)=0.95). Among the independent factors, T x a(w) product was the most significant (p=0.0069) followed by T (p=0.0114), and a(w) (p=0.3140) in explaining the experimental data. The developed models can be applied to predict the safe storage period of corn stover components exposed to various temperature and moisture environmental conditions.

  12. Monitoring metal-fill in a lost foam casting process.

    Science.gov (United States)

    Abdelrahman, Mohamed; Arulanantham, Jeanison Pradeep; Dinwiddie, Ralph; Walford, Graham; Vondra, Fred

    2006-10-01

    The lost foam casting (LFC) process is emerging as a reliable casting method. The metal-fill profile in LFC plays an important role among several factors that affect casting quality. The metal-fill profile is in turn affected by several factors. Several casting defects may result due to an improper metal-fill process. Hence, it becomes essential to characterize and control, if possible, the metal-fill process in LFC. This research presents instrumentation and a technique to monitor and characterize the metal-fill process. The characterization included the determination of the position of the metal front and the profile in which the metal fills up the foam pattern. The instrumentation included capacitive sensors. Each sensor is comprised of two electrodes whose capacitive coupling changes as the metal fills the foam pattern. Foundry tests were conducted to obtain the sensors' responses to the metal fill. Two such sensors were used in the foundry tests. Data representing the responses of these sensors during the metal-fill process were collected using a data acquisition system. A number of finite element electrostatic simulations were carried out to study the metal-fill process under conditions similar to those experienced in foundry tests. An artificial neural network was trained using the simulation data as inputs and the corresponding metal-fill profiles as outputs. The neural network was then used to infer the profile of the metal-fill during foundry tests. The results were verified by comparing the metal-fill profile inferred from the neural network to the actual metal-fill profile captured by an infrared camera used during the foundry tests. The match up between the inferred profiles and the infrared camera measurements was satisfactory, indicating that the developed technique provides a reliable and cost effective method to monitor the metal-fill profile in LFC.

  13. Complications of Dermal Filling

    Directory of Open Access Journals (Sweden)

    Sajad Ahmad Salati

    2011-11-01

    Full Text Available Dermal fillers have globally become sought after drugs due to the desire of aging population to regain the youthful looks without any surgical operations. But like other procedures, dermal filling can become complicated. Besides the profitability have introduced the factor of malpractice which can bring in misery rather than beauty and youthful body contours. This article briefly reviews the common adverse effects of dermal fillers.

  14. An axisymmetrical non-linear finite element model for induction heating in injection molding tools

    DEFF Research Database (Denmark)

    Guerrier, Patrick; Nielsen, Kaspar Kirstein; Menotti, Stefano;

    2016-01-01

    To analyze the heating and cooling phase of an induction heated injection molding tool accurately, the temperature dependent magnetic properties, namely the non-linear B-H curves, need to be accounted for in an induction heating simulation. Hence, a finite element model has been developed...... in to the injection molding tool. The model shows very good agreement with the experimental temperature measurements. It is also shown that the non-linearity can be used without the temperature dependency in some cases, and a proposed method is presented of how to estimate an effective linear permeability to use...

  15. Injection molding of high aspect ratio sub-100 nm nanostructures

    DEFF Research Database (Denmark)

    Matschuk, Maria; Larsen, Niels B

    2013-01-01

    with FDTS. Reduced adhesion forces are consistent with lowered friction that reduces the risk of fracturing the nanoscopic pillars during demolding. Optimized mold surface chemistry and associated injection molding conditions permitted the fabrication of square arrays of 40 nm wide and 107 nm high (aspect......We have explored the use of mold coatings and optimized processing conditions to injection mold high aspect ratio nanostructures (height-to-width >1) in cyclic olefin copolymer (COC). Optimizing the molding parameters on uncoated nickel molds resulted in slight improvements in replication quality...

  16. Development of a plastic injection molding training system using Petri nets and virtual reality

    Institute of Scientific and Technical Information of China (English)

    2006-01-01

    In this study, Virtual Reality (VR)-based plastic injection molding training system (VPIMTS), which can be modeled as an integrated system with a task planning module, an intelligent instruction module, a simulation module, and virtual environment (VE) module, was developed. Presented in this paper are an architecture of VPIMTS, a practical knowledge modelling approach for modelling the training scenarios of the system by using Petri nets formalism and key techniques (FEM, injection molding procedure modelling) which have been developed independently. The utilization of the Petri net model realized the environment where the trainee can behave freely, and also made it possible to equip the system with the function of showing the next action of the trainee whenever he wants. The overall system is a powerful approach for highly improving the trainee's comprehension and injection molding study-efficiency by building digital, intelligent, knowledgeable, and visual aids.

  17. Fatigue stipulation of bulk-fill composites: An in vitro appraisal.

    Science.gov (United States)

    Vidhawan, Shruti A; Yap, Adrian U; Ornaghi, Barbara P; Banas, Agnieszka; Banas, Krzysztof; Neo, Jennifer C; Pfeifer, Carmem S; Rosa, Vinicius

    2015-09-01

    The aim of this study was to determine the Weibull and slow crack growth (SCG) parameters of bulk-fill resin based composites. The strength degradation over time of the materials was also assessed by strength-probability-time (SPT) analysis. Three bulk-fill [Tetric EvoCeram Bulk Fill (TBF); X-tra fil (XTR); Filtek Bulk-fill flowable (BFL)] and a conventional one [Filtek Z250 (Z250)] were studied. Seventy five disk-shaped specimens (12mm in diameter and 1mm thick) were prepared by inserting the uncured composites in a stainless steel split mold followed by photoactivation (1200mW/cm(2)/20s) and storage in distilled water (37°C/24h). Degree of conversion was evaluated in five specimens by analysis of FT-IR spectra obtained in the mid-IR region. The SCG parameters n (stress corrosion susceptibility coefficient) and σf0 (scaling parameter) were obtained by testing ten specimens in each of the five stress rates: 10(-2), 10(-1), 10(0), 10(1) and 10(2)MPa/s using a piston-on-three-balls device. Weibull parameter m (Weibull modulus) and σf0 (characteristic strength) were obtained by testing additional 20 specimens at 1MPa/s. Strength-probability-time (SPT) diagrams were constructed by merging SCG and Weibull parameters. BFL and TBF presented higher n values, respectively (40.1 and 25.5). Z250 showed the highest (157.02MPa) and TBF the lowest (110.90MPa) σf0 value. Weibull analysis showed m (Weibull modulus) of 9.7, 8.6, 9.7 and 8.9 for TBF, BFL, XTR and Z250, respectively. SPT diagram for 5% probability of failure showed strength decrease of 18% for BFL, 25% for TBF, 32% for XTR and 36% for Z250, respectively, after 5 years as compared to 1 year. The reliability and decadence of strength over time for bulk-fill resin composites studied are, at least, comparable to conventional composites. BFL shows the highest fatigue resistance under all simulations followed by TBF, while XTR was at par with Z250. Copyright © 2015 Academy of Dental Materials. Published by Elsevier

  18. 基于CAE注射成型工艺参数的优化%Optimization of Injection Molding Technology Parameters Based on CAE

    Institute of Scientific and Technical Information of China (English)

    黄颖

    2012-01-01

    UG software is used for storage box with three-dimensional graphics,MoldFlow software is applied for instance grid,adopted orthogonal test analysis in the process of injection molding filling,packing and warping deformation of such key factors and get reasonable injection process parameters and optimal design of mold structure,reduce product development cycles and improve product quality of injection%采用UG软件对储物盒进行三维造型,应用CAE软件MoldFlow对实例进行网格划分,采用正交试验分析注射成型过程中充填、保压及翘曲变形等关键因素,得到合理的注射工艺参数,从而优化模具结构,缩短产品开发周期,提高注射产品质量。

  19. Future Specialist’s Professional Position Molding

    Directory of Open Access Journals (Sweden)

    Irina A. Levitskaya

    2013-01-01

    Full Text Available The search of conditions for future specialist’s professional position molding is crucial nowadays. This article discloses the features of “position” notion essence in the context of professional self-determination, analyses the problems of future specialist’s professional development in terms of topical social and professional objectives solution, considers debatable issues of professional development as an integral continuous process of future specialist’s personality formation. The stages of personality professional molding are elaborated. The author determines the relation of professional position with different types of positions (social, personal, role-based. It is mentioned that professional position is determined by professional attitudes and characterizes person’s system of stable value relations towards future professional activities. The relation between the professional position molding and the professional orientation, determining person’s peculiarly experienced selective attitude towards reality, influencing his/her activity is emphasized

  20. Modelling and monitoring in injection molding

    DEFF Research Database (Denmark)

    Thyregod, Peter

    2001-01-01

    -conforning unit is only expected very rarely during sampling, a moving sum chart and a CUSUM chart are equivalent. Finally, the correlation structure of 21 process variables has been studied prior to monitoring the process. Is is illustrated how the process can be analysed with multivariate techniques......This thesis is concerned with the application of statistical methods in quality improvement of injection molded parts. The methods described are illustrated with data from the manufacturing of parts for a medical device. The emphasis has been on the variation between cavities in multi-cavity molds...... taken within the same machine set-point did not cause great variation compared to the two preceding sources of variation. A simple graphical approach is suggested for finding patterns in the cavity differences. Applying this method to data from a 16 cavity mold, a clear connection was found between...

  1. High rate fabrication of compression molded components

    Energy Technology Data Exchange (ETDEWEB)

    Matsen, Marc R.; Negley, Mark A.; Dykstra, William C.; Smith, Glen L.; Miller, Robert J.

    2016-04-19

    A method for fabricating a thermoplastic composite component comprises inductively heating a thermoplastic pre-form with a first induction coil by inducing current to flow in susceptor wires disposed throughout the pre-form, inductively heating smart susceptors in a molding tool to a leveling temperature with a second induction coil by applying a high-strength magnetic field having a magnetic flux that passes through surfaces of the smart susceptors, shaping the magnetic flux that passes through surfaces of the smart susceptors to flow substantially parallel to a molding surface of the smart susceptors, placing the heated pre-form between the heated smart susceptors; and applying molding pressure to the pre-form to form the composite component.

  2. Injection molded self-cleaning surfaces

    DEFF Research Database (Denmark)

    Søgaard, Emil

    This PhD thesis concerns the development of superhydrophobic surfaces fabricated by injection molding. Today, injection molding is the prevalent production method for consumer plastic products. However, concerns regarding the environmental impact of a plastic production are increasing, especially...... that are superhydrophobic based on topography rather than chemical compounds. Therefore, a novel method for fabricating superhydrophobic polymer surfaces with excellent water-repellant properties is developed. The method is based on microstructure fabrication and superposed nanostructures on silicon wafers. The nano......° for structured surfaces with a drop roll-off angle of less than 2°. Thereby, it is shown that an extremely water repellant surface can be injection molded directly with clear perspectives for more environmental and healthier plastic consumer products....

  3. Neonatal Ear Molding: Timing and Technique.

    Science.gov (United States)

    Anstadt, Erin Elizabeth; Johns, Dana Nicole; Kwok, Alvin Chi-Ming; Siddiqi, Faizi; Gociman, Barbu

    2016-03-01

    The incidence of auricular deformities is believed to be ∼11.5 per 10,000 births, excluding children with microtia. Although not life-threatening, auricular deformities can cause undue distress for patients and their families. Although surgical procedures have traditionally been used to reconstruct congenital auricular deformities, ear molding has been gaining acceptance as an efficacious, noninvasive alternative for the treatment of newborns with ear deformations. We present the successful correction of bilateral Stahl's ear deformity in a newborn through a straightforward, nonsurgical method implemented on the first day of life. The aim of this report is to make pediatric practitioners aware of an effective and simple molding technique appropriate for correction of congenital auricular anomalies. In addition, it stresses the importance of very early initiation of ear cartilage molding for achieving the desired outcome.

  4. Ultrasonically-assisted Polymer Molding: An Evaluation

    Science.gov (United States)

    Moles, Matthew; Roy, Anish; Silberschmidt, Vadim

    Energy reduction in extrusion and injection molding processes can be achieved by the introduction of ultrasonic energy. Polymer flow can be enhanced on application of ultrasonic vibration, which can reduce the thermal and pressure input requirements to produce the same molding; higher productivity may also be achieved. In this paper, a design of an ultrasound-assisted injection mold machine is explored. An extrusion-die design was augmented with a commercial 1.5 kW ultrasonic transducer and sonotrode designed to resonate close to 20 kHz with up to 100 μm vibration amplitude. The design was evaluated with modal and thermal analysis using finite-element analysis software. The use of numerical techniques, including computational fluid dynamics, fluid-structure interaction and coupled Lagrangian-Eulerian method, to predict the effect of ultrasound on polymer flow was considered. A sonotrode design utilizing ceramic to enhance thermal isolation was also explored.

  5. Arrays of spherical micromirrors and molded microlenses fabricated with bulk Si micromachining

    Science.gov (United States)

    Vdovin, Gleb V.; Akhzar-Mehr, Ourang; Sarro, Pasqualina M.; De Lima Monteiro, Davies W.; Loktev, Mikhail Y.

    2003-03-01

    We have extended the technology of fabrication of optical spherical mirrors by using single-mask bulk micromachining to fabricate highly-uniform spherical arrays of micro-mirrors and to mold polymer-on-glass microlenses. The arrays fabricated feature 100% optical fill factor and very high field uniformity of optical characteristics of individual micro-mirrors (lenses). The technology is specially suitable for the fabrication of uniform arrays of spherical mirrors with small numerical apertures for use in Hartmann-Shack wavefront sensors. Optical tests with the hexagonal array of molded microlenses with pitch of 300μm and focal length of ~30mm demonstrated that the contribution of microlens imperfections into the wavefront reconstruction error does not exceed λ/50 rms.

  6. Monolithic multilayer microfluidics via sacrificial molding of 3D-printed isomalt†

    Science.gov (United States)

    Gelber, Matthew K.

    2015-01-01

    Here we demonstrate a method for creating multilayer or 3D microfluidics by casting a curable resin around a water-soluble, freestanding sacrificial mold. We use a purpose-built 3D printer to pattern self-supporting filaments of the sugar alcohol isomalt, which we then back-fill with a transparent epoxy resin. Dissolving the sacrificial mold leaves a network of cylindrical channels as well as input and output ports. We use this technique to fabricate a combinatorial mixer capable of producing 8 combinations of two fluids in ratios ranging from 1 : 100 to 100 : 1. This approach allows rapid iteration on microfluidic chip design and enables the use of geometry and materials not accessible using conventional soft lithography. The ability to precisely pattern round channels in all three dimensions in hard and soft media may prove enabling for many organ-on-chip systems. PMID:25671493

  7. Monolithic multilayer microfluidics via sacrificial molding of 3D-printed isomalt.

    Science.gov (United States)

    Gelber, Matthew K; Bhargava, Rohit

    2015-04-07

    Here we demonstrate a method for creating multilayer or 3D microfluidics by casting a curable resin around a water-soluble, freestanding sacrificial mold. We use a purpose-built 3D printer to pattern self-supporting filaments of the sugar alcohol isomalt, which we then back-fill with a transparent epoxy resin. Dissolving the sacrificial mold leaves a network of cylindrical channels as well as input and output ports. We use this technique to fabricate a combinatorial mixer capable of producing 8 combinations of two fluids in ratios ranging from 1 : 100 to 100 : 1. This approach allows rapid iteration on microfluidic chip design and enables the use of geometry and materials not accessible using conventional soft lithography. The ability to precisely pattern round channels in all three dimensions in hard and soft media may prove enabling for many organ-on-chip systems.

  8. Replicative manufacturing of complex lighting optics by non-isothermal glass molding

    Science.gov (United States)

    Kreilkamp, Holger; Vu, Anh Tuan; Dambon, Olaf; Klocke, Fritz

    2016-09-01

    The advantages of LED lighting, especially its energy efficiency and the long service life have led to a wide distribution of LED technology in the world. However, in order to make fully use of the great potential that LED lighting offers, complex optics are required to distribute the emitted light from the LED efficiently. Nowadays, many applications use polymer optics which can be manufactured at low costs. However, due to ever increasing luminous power, polymer optics reach their technological limits. Due to its outstanding properties, especially its temperature resistance, resistance against UV radiation and its long term stability, glass is the alternative material of choice for the use in LED optics. This research is introducing a new replicative glass manufacturing approach, namely non-isothermal glass molding (NGM) which is able to manufacture complex lighting optics in high volumes at competitive prices. The integration of FEM simulation at the early stage of the process development is presented and helps to guarantee a fast development cycle. A coupled thermo-mechanical model is used to define the geometry of the glass preform as well as to define the mold surface geometry. Furthermore, simulation is used to predict main process outcomes, especially in terms of resulting form accuracy of the molded optics. Experiments conducted on a commercially available molding machine are presented to validate the developed simulation model. Finally, the influence of distinct parameters on important process outcomes like form accuracy, surface roughness, birefringence, etc. is discussed.

  9. Powder injection molding of pure titanium

    Institute of Scientific and Technical Information of China (English)

    GUO Shibo; DUAN Bohua; HE Xinbo; QU Xuanhui

    2009-01-01

    An improved wax-based binder was developed for powder injection molding of pure titanium. A critical powder loading of 69 vol.% and a pseudo-plastic flow behavior were obtained by the feedstock based on the binder. The injection molding, debinding, and sintering process were studied. An ideal control of carbon and oxygen contents was achieved by thermal debinding in vacuum atmosphere (10-3 Pa). The mechanical properties of as-sintered specimens were less than those of titanium made by the conventional press-sintering process. Good shape retention and ±0.04 mm dimension deviation were achieved.

  10. Natural latex (Hevea brasiliensis) mold for neovaginoplasty

    OpenAIRE

    2008-01-01

    OBJETIVO: avaliar a utilização do molde de látex natural (Hevea brasiliensis) como modificação à neovaginoplastia de McIndoe e Bannister em pacientes portadoras da síndrome de Mayer-Rokitansky-Küster-Hauser (MRKH). MÉTODOS: análise retrospectiva de nove pacientes com o diagnóstico de síndrome de MRKH, submetidas à neovaginoplastia pela técnica de McIndoe e Bannister com molde de látex natural. Foram avaliadas epitelização, amplitude e profundidade das neovaginas, ocorrência de coitos bem como...

  11. Chemotaxis in the Plasmodial Slime Mold, Physarum polycephalum.

    Science.gov (United States)

    Bozzone, Donna M.; Martin, Denise A.

    1998-01-01

    Describes a biology unit designed so that students pose their own questions and perform experiments to answer these questions. Plasmodial slime mold is employed as the focus of the study with background information about the mold provided. (DDR)

  12. EPA Scientists Develop Research Methods for Studying Mold Fact Sheet

    Science.gov (United States)

    In 2002, U.S. Environmental Protection Agency researchers developed a DNA-based Mold Specific Quantitative Polymerase Chain Reaction method (MSQPCR) for identifying and quantifying over 100 common molds and fungi.

  13. Brief Guide to Mold, Moisture, and Your Home

    Science.gov (United States)

    ... plastic or rubber and have removable cartridges that trap most of the mold spores from entering. In ... thank Paul Ellringer, PE, CIH, for providing the photo of Mold growing on the back side of ...

  14. Affordable, Precision Reflector Mold Technology (PDRT08-029) Project

    Data.gov (United States)

    National Aeronautics and Space Administration — Advances in replication mold technology that reduce material costs, grinding time, and polishing time would enable fabrication of large, precision molds and possibly...

  15. Tool steel quality and surface finishing of plastic molds

    Directory of Open Access Journals (Sweden)

    Rafael Agnelli Mesquita

    2010-01-01

    Full Text Available Plastic industry is today in a constant growth, demanding several products from other segments, which includes the plastic molds, mainly used in the injection molding process. Considering all the requirements of plastic molds, the surface finishing is of special interest, as the injected plastic part is able to reproduce any details (and also defects from the mold surface. Therefore, several aspects on mold finishing are important, mainly related to manufacturing conditions - machining, grinding, polishing and texturing, and also related to the tool steel quality, in relation to microstructure homogeneity and non-metallic inclusions (cleanliness. The present paper is then focused on this interrelationship between steel quality and manufacturing process, which are both related to the final quality of plastic mold surfaces. Examples are discussed in terms of surface finishing of plastic molds and the properties or the microstructure of mold steels.

  16. Exploring the problem of mold growth and the efficacy of various mold inhibitor methods during moisture sorption isotherm measurements.

    Science.gov (United States)

    Yu, X; Martin, S E; Schmidt, S J

    2008-03-01

    Mold growth is a common problem during the equilibration of food materials at high relative humidity values using the standard saturated salt slurry method. Exposing samples to toluene vapor and mixing samples with mold inhibitor chemicals are suggested methods for preventing mold growth while obtaining isotherms. However, no published research was found that examined the effect of mold growth on isotherm performance or the efficacy of various mold inhibitor methods, including their possible effect on the physicochemical properties of food materials. Therefore, the objectives of this study were to (1) explore the effect of mold growth on isotherm performance in a range of food materials, (2) investigate the effectiveness of 4 mold inhibitor methods, irradiation, 2 chemical inhibitors (potassium sorbate and sodium acetate), and toluene vapor, on mold growth on dent corn starch inoculated with A. niger, and (3) examine the effect of mold inhibitor methods on the physicochemical properties of dent corn starch, including isotherm performance, pasting properties, gelatinization temperature, and enthalpy. Mold growth was found to affect starch isotherm performance by contributing to weight changes during sample equilibration. Among the 4 mold inhibitor methods tested, irradiation and toluene vapor were found to be the most effective for inhibiting growth of A. niger on dent cornstarch. However, both methods exhibited a significant impact on the starches' physiochemical properties, suggesting the need to probe the efficacy of other mold inhibitor methods and explore the use of new rapid isotherm instruments, which hamper mold growth by significantly decreasing measurement time.

  17. Fabrication of large area gratings with sub-micron pitch using mold micromachining

    Energy Technology Data Exchange (ETDEWEB)

    Fleming, J.G.; Barron, C.C.; Stallard, B.; Kaushik, S.

    1997-03-01

    In this work, the authors have applied mold micromachining and standard photolithographic techniques to the fabrication of parts integrated with 0.4 micron pitch diffraction gratings. In principle, the approach should be scaleable to considerably finer pitches. They have achieved this by relying on the thickness of deposited or grown films, instead of photolithography, to determine the grating pitch. The gratings can be made to extend over large areas and the entire process is compatible with batch processing. Literally thousands of parts can be batch fabricated from a single lot of six inch wafers. In the first stage of the process they fabricate a planarized silicon dioxide pad over which the silicon nitride wave guide runs. The grating is formed by first patterning and etching single crystalline silicon to form a series of trenches with well defined pitch. The silicon bounding the trenches is then thinned by thermal oxidation followed by stripping of the silicon dioxide. The trenches are filled by a combination of polysilicon depositions and thermal oxidations. Chemical mechanical polishing (CMP) is used to polish back these structures resulting in a series of alternating 2000 {angstrom} wide lines of silicon and silicon dioxide. The thickness of the lines is determined by the oxidation time and the polysilicon deposition thickness. The silicon lines are selectively recessed by anisotropic reactive ion etching, thus forming the mold for the grating. The mold is filled with low stress silicon nitride deposited by chemical vapor deposition. A wave guide is then patterned into the silicon nitride and the mold is locally removed by a combination of deep silicon trench etching and wet KOH etching. This results in a suspended diffraction grating/membrane over the KOH generated pit.

  18. 等离子体填充金属光子晶体Cherenkov辐射源模拟研究∗%Simulation of cherenkov radiation source in a plasma-filled metallic photonic crystal

    Institute of Scientific and Technical Information of China (English)

    傅涛; 欧阳征标

    2016-01-01

    Plasma filling can significantly improve the efficiency and power of a vacuum device. In this paper, we first analyze the dispersion properties of a plasma-filled metal-photonic-crystal slow-wave structure (SWS), and then investigate the interaction procedure between a relativistic electron beam and the Cherenkov radiation in the plasma-filled metallic-photonic-crystal by the particle in cell method. We pay our attention to the influences of plasma density, cathode voltage, and guiding magnetic field on output frequency and power. The results show that the electric field strength in the SWS increases obviously at a fixed plasma density of 50 mTorr (1 mTorr = 0.133 Pa). The device works at a stable single TM01 mode due to the good mode properties of the metal photonic crystal even if plasma is filled in it. The maximum value of Ez field along the z axis of the device increases from 46.34 MV/m without plasma to 79 MV/m with plasma. The value along the x axis increases from 136 MV/m without plasma to 185 MV/m with plasma. The working frequency (35.5 GHz) of the device, obtained from simulation, is consistent with the theoretical estimation (35.4 GHz). The power increases with the cathode voltage between 500 kV and 600 kV while the frequency increases only a little. When the magnetic field B increases, the output power first increases and then decreases. But the frequency is not affected due to the dispersion property. The output power of the device increases 20% when the air pressure increases from 0 to 100 mTorr. However, there is a pretty distribution of the field Ez along the angular direction only in an appropriate plasma density around 50 mTorr. According to the theory and simulation, the output power and efficiency can be improved in an appropriate range of plasma density. These results provide a basis for developing the plasma-filled vacuum devices.%等离子体填充能够明显提高真空电子器件的效率和功率,研究等离子体填充器件具有

  19. 240 Mold Sensitization in Chronic Rhinosinusitis Patients

    OpenAIRE

    2012-01-01

    Background It is estimated that about 10% of the population have IgE antibodies to common inhalant molds. Exposure to fungal allergens could be linked to the presence and persistence of asthma, rhinitis and atopic dermatitis. Mold sensitization is a risk factor for development and deterioration of upper airway allergy, especially chronic rhinosinusitis. We addressed the incidence of mold allergy measured as specific IgE to molds and skin prick tests in chronic sinusitis patients. We assessed ...

  20. COMPUTER AIDED THREE DIMENSIONAL DESIGN OF MOLD COMPONENTS

    Directory of Open Access Journals (Sweden)

    Kerim ÇETİNKAYA

    2000-02-01

    Full Text Available Sheet metal molding design with classical methods is formed in very long times calculates and drafts. At the molding design, selection and drafting of most of the components requires very long time because of similar repetative processes. In this study, a molding design program has been developed by using AutoLISP which has been adapted AutoCAD packet program. With this study, design of sheet metal molding, dimensioning, assemly drafting has been realized.

  1. Application of Numerical Simulation Technique to Casting Process of Valve Block

    Institute of Scientific and Technical Information of China (English)

    MI Guo-fa; LIU Xiang-yu; WANG Kuang-fei; FU Heng-zhi

    2009-01-01

    The numerical simulation technique was applied to the casting process of a valve-type part. The mold-filling and solidification stages of the casting were numerically analyzed. The filling behavior, solidification sequence,and thermal stress distribution were reproduced and the possible defects, such as cold shut and shrinkage, were predicted. Based on the simulation result, the double-gating system was replaced by a single-gating system. Meanwhile,the chills were used to regulate the solidification sequence of casting. To eliminate the cracks in the casting, the sand core was converted into a canulate one. By modifying the original process, the defects were eliminated and the casting with good quality was obtained.

  2. Hydrogen Filling Station

    Energy Technology Data Exchange (ETDEWEB)

    Boehm, Robert F; Sabacky, Bruce; Anderson II, Everett B; Haberman, David; Al-Hassin, Mowafak; He, Xiaoming; Morriseau, Brian

    2010-02-24

    future. Project partners also conducted a workshop on hydrogen safety and permitting. This provided an opportunity for the various permitting agencies and end users to gather to share experiences and knowledge. As a result of this workshop, the permitting process for the hydrogen filling station on the Las Vegas Valley Water District’s land was done more efficiently and those who would be responsible for the operation were better educated on the safety and reliability of hydrogen production and storage. The lessons learned in permitting the filling station and conducting this workshop provided a basis for future hydrogen projects in the region. Continuing efforts to increase the working pressure of electrolysis and efficiency have been pursued. Research was also performed on improving the cost, efficiency and durability of Proton Exchange Membrane (PEM) hydrogen technology. Research elements focused upon PEM membranes, electrodes/catalysts, membrane-electrode assemblies, seals, bipolar plates, utilization of renewable power, reliability issues, scale, and advanced conversion topics. Additionally, direct solar-to-hydrogen conversion research to demonstrate stable and efficient photoelectrochemistry (PEC) hydrogen production systems based on a number of optional concepts was performed. Candidate PEC concepts included technical obstacles such as inefficient photocatalysis, inadequate photocurrent due to non-optimal material band gap energies, rapid electron-hole recombination, reduced hole mobility and diminished operational lifetimes of surface materials exposed to electrolytes. Project Objective 1: Design, build, operate hydrogen filling station Project Objective 2: Perform research and development for utilizing solar technologies on the hydrogen filling station and convert two utility vehicles for use by the station operators Project Objective 3: Increase capacity of hydrogen filling station; add additional vehicle; conduct safety workshop; develop a roadmap for

  3. Hydrogen Filling Station

    Energy Technology Data Exchange (ETDEWEB)

    Boehm, Robert F; Sabacky, Bruce; Anderson II, Everett B; Haberman, David; Al-Hassin, Mowafak; He, Xiaoming; Morriseau, Brian

    2010-02-24

    future. Project partners also conducted a workshop on hydrogen safety and permitting. This provided an opportunity for the various permitting agencies and end users to gather to share experiences and knowledge. As a result of this workshop, the permitting process for the hydrogen filling station on the Las Vegas Valley Water District’s land was done more efficiently and those who would be responsible for the operation were better educated on the safety and reliability of hydrogen production and storage. The lessons learned in permitting the filling station and conducting this workshop provided a basis for future hydrogen projects in the region. Continuing efforts to increase the working pressure of electrolysis and efficiency have been pursued. Research was also performed on improving the cost, efficiency and durability of Proton Exchange Membrane (PEM) hydrogen technology. Research elements focused upon PEM membranes, electrodes/catalysts, membrane-electrode assemblies, seals, bipolar plates, utilization of renewable power, reliability issues, scale, and advanced conversion topics. Additionally, direct solar-to-hydrogen conversion research to demonstrate stable and efficient photoelectrochemistry (PEC) hydrogen production systems based on a number of optional concepts was performed. Candidate PEC concepts included technical obstacles such as inefficient photocatalysis, inadequate photocurrent due to non-optimal material band gap energies, rapid electron-hole recombination, reduced hole mobility and diminished operational lifetimes of surface materials exposed to electrolytes. Project Objective 1: Design, build, operate hydrogen filling station Project Objective 2: Perform research and development for utilizing solar technologies on the hydrogen filling station and convert two utility vehicles for use by the station operators Project Objective 3: Increase capacity of hydrogen filling station; add additional vehicle; conduct safety workshop; develop a roadmap for

  4. Modeling and verification of the nonlinear system of oscillation platform of continuous casting mold driven by servo motor

    Directory of Open Access Journals (Sweden)

    Le Liu

    2016-06-01

    Full Text Available The driving mode by servo motor is a new driving mode and can realize oscillations of continuous casting mold as expected. The oscillation system of continuous casting mold driven by servo motor is a complicated nonlinear system. Therefore, it is necessary to establish an accurate model for the system before performing simulation experiments. Based on the oscillation platform system of continuous casting mold driven by servo motor in the laboratory, the nonlinear models of servo motor speed system and mechanical transmission parts were respectively established and the viscous friction coefficient, moment of inertia, and load torque were identified. Then, the nonlinear mathematical model of the whole oscillation platform of continuous casting mold driven by servo motor was obtained. The comparison results between the simulated output curves of established model and the measured output curves of actual system under the same input signals indicated that the simulated curves were almost in accord with the measured curves. Therefore, the proposed model can reflect the capabilities of practical system and lay a good foundation for subsequent research on simulation experiments and accurate control of continuous casting mold oscillation driven by servo motor.

  5. Modelling die filling with charged particles using DEM/CFD

    Institute of Scientific and Technical Information of China (English)

    Emmanuel Nkem Nwose; Chunlei Pei; Chuan-Yu Wu

    2012-01-01

    The effects of electrostatic charge on powder flow behaviour during die filling in a vacuum and in air were analysed using a coupled discrete element method and computational fluid dynamics (DEM/CFD) code,in which long range electrostatic interactions were implemented.The present 2D simulations revealed that both electrostatic charge and the presence of air can affect the powder flow behaviour during die filling.It was found that the electrostatic charge inhibited the flow of powders into the die and induced a loose packing structure.At the same filling speed,increasing the electrostatic charge led to a decrease in the fill ratio which quantifies the volumetric occupancy of powder in the die.In addition,increasing the shoe speed caused a further decrease in the fill ratio,which was characterised using the concept of critical filling speed.When the electrostatic charge was low,the air/particle interaction was strong so that a lower critical filling speed was obtained for die filling in air than in a vacuum.With high electrostatic charge,the electrostatic interactions became dominant.Consequently,similar fill ratio and critical filling speed were obtained for die filling in air and in a vacuum.

  6. Acoustic Emission Detection of Macro-Cracks on Engraving Tool Steel Inserts during the Injection Molding Cycle Using PZT Sensors

    Directory of Open Access Journals (Sweden)

    Aleš Hančič

    2013-05-01

    Full Text Available This paper presents an improved monitoring system for the failure detection of engraving tool steel inserts during the injection molding cycle. This system uses acoustic emission PZT sensors mounted through acoustic waveguides on the engraving insert. We were thus able to clearly distinguish the defect through measured AE signals. Two engraving tool steel inserts were tested during the production of standard test specimens, each under the same processing conditions. By closely comparing the captured AE signals on both engraving inserts during the filling and packing stages, we were able to detect the presence of macro-cracks on one engraving insert. Gabor wavelet analysis was used for closer examination of the captured AE signals’ peak amplitudes during the filling and packing stages. The obtained results revealed that such a system could be used successfully as an improved tool for monitoring the integrity of an injection molding process.

  7. 21 CFR 874.3430 - Middle ear mold.

    Science.gov (United States)

    2010-04-01

    ... 21 Food and Drugs 8 2010-04-01 2010-04-01 false Middle ear mold. 874.3430 Section 874.3430 Food... DEVICES EAR, NOSE, AND THROAT DEVICES Prosthetic Devices § 874.3430 Middle ear mold. (a) Identification. A middle ear mold is a preformed device that is intended to be implanted to reconstruct the middle...

  8. Comparison of two setups for induction heating in injection molding

    DEFF Research Database (Denmark)

    Menotti, Stefano; Hansen, Hans Nørgaard; Bissacco, Giuliano

    2015-01-01

    To eliminate defects and improve the quality of molded parts, increasing the mold temperature is one of the applicable solutions. A high mold temperature can increase the path flow of the polymer inside the cavity allowing reduction of the number of injection points, reduction of part thickness, ...

  9. Compaction Behavior and Part Thickness Variation in Vacuum Infusion Molding Process

    Science.gov (United States)

    Yang, Jinshui; Xiao, Jiayu; Zeng, Jingcheng; Jiang, Dazhi; Peng, Chaoyi

    2012-06-01

    In vacuum infusion molding process (VIMP), it is difficult to manufacture a composite part with small dimensional tolerance, since the upper mold for the process is flexible. In this study, the static and cyclic compaction responses of five kinds of fabrics were experimentally studied under real VIMP conditions, with the effects of compaction pressure, compaction time, compaction cycle and number of the fabric layers. The static and cyclic compaction responses of the all fabrics follow different power law models and the resulting fiber volume fraction and relaxation factor increase with the number of layers. Although the resulting fiber volume fraction increases with the layer numbers, change of the fiber volume fraction of the composite parts with 10 layers to 100 layers of the all fabrics is less than 2.5%. The thickness of the composite part was monitored and measured using micrometer gauges, and the effects of processing parameters on the final thickness of part was investigated. The part thickness varies as a function of spatial coordinates and time during pre-filling, filling and post-filling stages in VIMP. The variation and the final value of the part thickness would be significantly affected by the processing parameters. Statistical results show that the final part thickness is equivalent to the thickness of the dry preform under the 0.08 MPa vacuum compaction pressure in VIMP. The difference between the fiber volume fraction of the final part and that of the dry preform is 2% ~ 5.7%.

  10. Fabrication of silicon molds for polymer optics

    DEFF Research Database (Denmark)

    Nilsson, Daniel; Jensen, Søren; Menon, Aric Kumaran

    2003-01-01

    A silicon mold used for structuring polymer microcavities for optical applications is fabricated, using a combination of DRIE (deep reactive ion etching) and anisotropic chemical wet etching with KOH + IPA. For polymer optical microcavities, low surface roughness and vertical sidewalls are often...

  11. Onychomycosis by molds. Report of 78 cases.

    Science.gov (United States)

    Bonifaz, Alexandro; Cruz-Aguilar, Pamela; Ponce, Rosa María

    2007-01-01

    A retrospective study of onychomycohosis by molds was carried out during a 14-year period (1992-2005). All cases were clinically and mycologically proven (repetitive KOH and culture) and then each of the molds was identified. A total of 5,221 cases of onychomycosis were evaluated, 78 of which were molds (1.49%). Mean patient age was 44.1 years. 75/78 cases occurred in toenails. Associated factors were detected in 39/78 (50.0%) cases, with the major ones being: peripheral vascular disease, contact with soil, and trauma. The most frequent clinical presentation was distal and lateral subungual onychomycosis (DLSO), in 54/78 cases (69%). The most frequent causative agents were: Scopulariopsis brevicaulis in 34/78 cases and Aspergillus niger in 13/78 cases. Onychomycoses by molds are infrequent; in this study they accounted for 1.49% of cases. The clinical features are virtually similar to those caused by dermatophytes, which makes the clinicomycological tests necessary.

  12. Flexible Interior-Impression-Molding Tray

    Science.gov (United States)

    Anders, Jeffrey E.

    1991-01-01

    Device used inside combustion chamber of complicated shape for nondestructive evaluation of qualities of welds, including such features as offset, warping, misalignment of parts, and dropthrough. Includes flexible polypropylene tray trimmed to fit desired interior surface contour. Two neodymium boron magnets and inflatable bladder attached to tray. Tray and putty inserted in cavity to make mold of interior surface.

  13. Molding cork sheets to complex shapes

    Science.gov (United States)

    Sharpe, M. H.; Simpson, W. G.; Walker, H. M.

    1977-01-01

    Partially cured cork sheet is easily formed to complex shapes and then final-cured. Temperature and pressure levels required for process depend upon resin system used and final density and strength desired. Sheet can be bonded to surface during final cure, or can be first-formed in mold and bonded to surface in separate step.

  14. Epidemics of mold poisoning past and present.

    Science.gov (United States)

    Meggs, William J

    2009-01-01

    Molds are ubiquitous throughout the biosphere of planet earth and cause infectious, allergic, and toxic diseases. Toxic diseases arise from exposure to mycotoxins produced by molds. Throughout history, there have been a number of toxic epidemics associated with exposure to mycotoxins. Acute epidemics of ergotism are caused by consumption of grain infested by fungi of the genus Claviceps, which produce the bioactive amine ergotamine that mimics the neurotransmitters norepinephrine, serotonin, and dopamine. Acute aflatoxin outbreaks have occurred from ingestion of corn stored in damp conditions that potentiate growth of the molds of the species Aspergillus. Contemporary construction methods that use cellulose substrates such as fiber board and indoor moisture have caused an outbreak of contaminated buildings with Stachybotrys chartarum, with the extent of health effects still a subject of debate and ongoing research. This article reviews several of the more prominent epidemics and discusses the nature of the toxins. Two diseases that were leading causes of childhood mortality in England in the 1970s and vanished with changing dietary habits, putrid malignant fever, and slow nervous fever were most likely toxic mold epidemics.

  15. Introducing the slime mold graph repository

    Science.gov (United States)

    Dirnberger, M.; Mehlhorn, K.; Mehlhorn, T.

    2017-07-01

    We introduce the slime mold graph repository or SMGR, a novel data collection promoting the visibility, accessibility and reuse of experimental data revolving around network-forming slime molds. By making data readily available to researchers across multiple disciplines, the SMGR promotes novel research as well as the reproduction of original results. While SMGR data may take various forms, we stress the importance of graph representations of slime mold networks due to their ease of handling and their large potential for reuse. Data added to the SMGR stands to gain impact beyond initial publications or even beyond its domain of origin. We initiate the SMGR with the comprehensive Kist Europe data set focusing on the slime mold Physarum polycephalum, which we obtained in the course of our original research. It contains sequences of images documenting growth and network formation of the organism under constant conditions. Suitable image sequences depicting the typical P. polycephalum network structures are used to compute sequences of graphs faithfully capturing them. Given such sequences, node identities are computed, tracking the development of nodes over time. Based on this information we demonstrate two out of many possible ways to begin exploring the data. The entire data set is well-documented, self-contained and ready for inspection at http://smgr.mpi-inf.mpg.de.

  16. Residual thermal stresses in injection molded products

    NARCIS (Netherlands)

    Zoetelief, W.F.; Douven, L.F.A.; Ingen Housz, A.J.

    1996-01-01

    Nonisothermal flow of a polymer melt in a cold mold cavity introduces stresses that are partly frozen-in during solidification. Flow-induced stresses cause anisotropy of mechanical, thermal, and optical properties, while the residual thermal stresses induce warpage and stress-cracking. In this study

  17. Mold Die Making. 439-322/324.

    Science.gov (United States)

    Yunke, P.; And Others

    Each unit in this curriculum guide on mold die making contains an introduction, objectives, materials required, lessons, space for notes, figures, and diagrams. There are 10 units in this guide: (1) introduction to Electrical Discharge Machining (EDM); (2) EDM principles; (3) the single pulse; (4) EDM safety; (5) electrode material; (6) electrode…

  18. A REVOLUTION IN MOLD IDENTIFICATION AND ENUMERATION

    Science.gov (United States)

    More than 100 assay were developed to identify and quantify indoor molds using quantitiative PCR (QPCR) assays. This technology incorporates fluorigenic 5' nuclease (TaqMan�) chemistry directed at the nuclear ribosomal RNA operon internal transcribed spacer regions (ITS1 or ITS2...

  19. Progress in Titanium Metal Powder Injection Molding

    Directory of Open Access Journals (Sweden)

    Randall M. German

    2013-08-01

    Full Text Available Metal powder injection molding is a shaping technology that has achieved solid scientific underpinnings. It is from this science base that recent progress has occurred in titanium powder injection molding. Much of the progress awaited development of the required particles with specific characteristics of particle size, particle shape, and purity. The production of titanium components by injection molding is stabilized by a good understanding of how each process variable impacts density and impurity level. As summarized here, recent research has isolated the four critical success factors in titanium metal powder injection molding (Ti-MIM that must be simultaneously satisfied—density, purity, alloying, and microstructure. The critical role of density and impurities, and the inability to remove impurities with sintering, compels attention to starting Ti-MIM with high quality alloy powders. This article addresses the four critical success factors to rationalize Ti-MIM processing conditions to the requirements for demanding applications in aerospace and medical fields. Based on extensive research, a baseline process is identified and reported here with attention to linking mechanical properties to the four critical success factors.

  20. Residual stresses in injection molded products

    NARCIS (Netherlands)

    Jansen, K.M.B.

    2015-01-01

    During the molding process residual stresses are formed due to thermal contraction during cooling as well as the local pressure history during solidification. In this paper a simple analytical model is reviewed which relates residual stresses, product shrinkage as well as warpage to the temperature