IKV.impulses The online event series on current plastics technology topics

The development of new injection moulds and the precise design of processes are often time-consuming and cost-intensive. Injection moulding simulations are used to speed up these processes and reduce iterations. These enable a detailed analysis of the sprue positions, the thermal conditions in the mold and the flow processes in the cavity. The quality of the simulation results depends heavily on the material data used. In the first impulse lecture of this online session, you will learn how optimised material cards are obtained in order to achieve realistic simulation results. The second presentation will show how injection moulding simulations can be used for process analysis in order to make even more precise predictions.

Research for realistic material data

The accuracy of simulations is significantly influenced by the material data that is determined in various processes. However, different boundary conditions often result in significant deviations between simulation and measurement. The aim of the research project presented here is to develop a workflow that determines material data directly under real process conditions. The dimensions of test specimens produced in the injection moulding process are precisely measured and compared with the simulation results. The prediction accuracy is continuously improved through iterative adjustments to the material data. The presentation will also highlight the sustainable adaptation of the material cards so that they can be used in the simulation independently of the component.

Cascade injection moulding: process analysis for greater precision

A further keynote lecture will then deal with simulative process analysis in cascade injection moulding. The aim is to learn more about the flow processes in the cavity and thus control the cavity pressure more precisely. To this end, the effect of individual movements of the hot runner sealing needles on the local pressure during the holding pressure phase is being investigated. On this basis, a control strategy is developed that stabilises the cavity pressure by means of variable opening strokes of the hot runner valve pins. The aim is to reduce process fluctuations and improve the consistency of the cascade injection molding process.

Find out in this session how simulations help to precisely analyze and optimise processes – for more efficient developments and reliable results in injection moulding technology.

Main topics:

• Optimisation of material data for injection moulding simulations
• Simulative process analysis in the injection molding process
• Process control in cascade injection molding

Moderation:

Dr.-Ing. Christoph Zimmermann, IKV

Lectures:

• Intelligent material card adaptation for precise deformation simulation of injection molded components
  (Sebastian Schwan, M.Sc., IKV)
• Process analysis of cascade injection molding for the development of cavity pressure control
  (Matthias Schöll, M.Sc., IKV)

Registration

Technical plastic components are usually exposed to high mechanical, thermal and chemical requirements. In the automotive industry, for example, these requirements include high temperature and media resistance. Thermosets are among the plastics that are able to meet these requirements due to their high cross-linking density. However, their high cross-linking density means that thermosets, unlike thermoplastics, cannot be joined by welding. Accordingly, the screw connection, in particular the direct screw connection, represents a promising possibility for realizing an economical and detachable connection of thermoset components. In contrast to thermoplastics, however, there are no guidelines for the design of a direct screw connection for thermosets. This knowledge gap is to be closed as part of the cooperation between the IKV and the KTP in the “Duroplast Direktverschraubung II” project. To this end, design guidelines for direct bolting are to be developed for both short and long-term stresses.

As part of the lecture, IKV will present the results already achieved in the field of short-term loading of thermoset direct screw connections. In addition, the intended investigations into the long-term dynamic loading of thermoset direct bolted joints are outlined and discussed.

Main topics:

• Thermoset injection molding
• Direct screwing of plastics
• Mechanical testing

Moderation:

Dr.-Ing. Christoph Zimmermann, IKV

Lectures:

• aiXtight – 100% detection of the head support for direct screw connections
  (Dr.-Ing. Rainer Peters, aiXtrusion GmbH)
• Derivation of design and application recommendations for the direct screwing of thermosets
  (Guilherme Labanca Bachiega, IKV)

Registration