Yes / An ultrasound sensor system has been applied to the mould of both the water and gas assisted injection moulding processes. The mould has a cavity wall mounted pressure sensor and instrumentation to monitor the injection moulding machine. Two ultrasound sensors are used to monitor the arrival of the fluid (gas or water) bubble tip through the detection of reflected ultrasound energy from the fluid polymer boundary and the fluid bubble tip velocity through the polymer melt is estimated. The polymer contact with the cavity wall is observed through the reflected ultrasound energy from that boundary. A theoretically based estimation of the residual wall thickness is made using the ultrasound reflection from the fluid (gas or water) polymer boundary whilst the samples are still inside the mould and a good correlation with a physical measurement is observed.

Yes / An approximation to the Phan-Thien Tanner (PTT) constitutive model is developed with the aim of giving low-cost simulation of Gas Assisted Injection Moulding (GAIM) while incorporating important viscoelastic characteristics. It is shown that the developed model gives a response typical of full viscoelastic models in transient and steady state uniaxial and constant shear rate deformations. The model is incorporated into a 3D finite element GAIM simulation which uses the ‘pseudo-concentration’ method to predict residual polymer, and applied to published experimental results for a Boger fluid and a shear-thinning polystyrene melt. It is shown that the simulation gives a very good match to published results for the Boger fluid which show increasing Residual Wall Thickness (RWT) with increasing Deborah number. Against the shear-thinning polymer, the quality of match depends upon which of two ‘plausible’ relaxation times is chosen; qualitatively different results arise from two different means of estimating a single relaxation time. A ‘multi-mode’ approach is developed to avoid this uncertainty. It is shown that the multi-mode approach gives decreasing RWT with increasing Deborah number in agreement with the published experimental results, and avoids the issues that arise from estimating a single relaxation time for a molten polymer.

The gas assisted injection moulding process is an important extension to conventional injection moulding. Gas assist can be applied in a number of ways, but here the penetration of a gas bubble through the polymer melt is of interest. A 3D fi nite element implementation of a pseudo concentration method is employed to simulate the primary penetration of the gas bubble. The wall thickness prediction is an important result since the extent of bubble penetration is sensitive to the remaining melt fraction. A number of methods for experimental measurement are developed to measure characteristics of the gas assisted injection moulding process dynamics and product. Key process variables, on an industrial gas-assist machine, were measured and analysed, leading to an empirical model for wall thickness prediction. Gas delay time and injection velocity are shown to be most influential in controlling residual wall thickness. Simulation results are evaluated against the empirical model. The trends observed, for simulation and experiment, in wall thickness after changes in process variable settings are found to agree qualitatively. The wall thickness prediction is found to be within 10% of the experimentally obtained measurements.

The gas assisted injection moulding process is an important extension to conventional injection moulding. Gas assist can be applied in a number of ways, but here the penetration of a gas bubble through the polymer melt is of interest. A 3D fi nite element implementation of a pseudo concentration method is employed to simulate the primary penetration of the gas bubble. The wall thickness prediction is an important result since the extent of bubble penetration is sensitive to the remaining melt fraction. A number of methods for experimental measurement are developed to measure characteristics of the gas assisted injection moulding process dynamics and product. Key process variables, on an industrial gas-assist machine, were measured and analysed, leading to an empirical model for wall thickness prediction. Gas delay time and injection velocity are shown to be most influential in controlling residual wall thickness. Simulation results are evaluated against the empirical model. The trends observed, for simulation and experiment, in wall thickness after changes in process variable settings are found to agree qualitatively. The wall thickness prediction is found to be within 10% of the experimentally obtained measurements. / EPSRC