Optimisation of the filling phase in foam injection moulding through geometry-optimised injection
Topic of the work
In order to save material and energy, lightweight construction technologies are coming to the fore in the automotive industry, for example. At the same time, the demands on the quality of moulded plastic parts are increasing. Foam injection moulding offers various advantages over conventional injection moulding. Moulded parts can be produced with greater dimensional accuracy while using less material, enabling more energy-efficient production with shorter cycle times. However, the blowing agent load in the plastic melt results in only moderate surface qualities. Silver streaks and melt eruptions inhibit the use of the special process for moulded parts in visible applications.
The typical surface defects originate from the flow front that spreads during the filling of the cavity. By adapting the profile of the injection volume flow to the geometry of the moulded part produced, more homogeneous surface qualities can be achieved. Injection moulding simulation is an effective mould for optimizing processes virtually and efficiently. Models for conventional injection moulding already exist for profiling the injection volume flow on the basis of filling simulations, which are to be transferred to foam injection moulding.
© IKVThe work is written in this working group:
In the thermoplastic foam injection moulding working group, we deal with various aspects of the innovative lightweight construction technology of foam injection moulding. The main areas of research include design guidelines for lightweight structural construction, process optimization for foamed moulded parts to be welded and the improvement of surface qualities for use in automobiles or white goods.
Objective:
The aim of your work is to investigate the extent to which the existing process models of conventional injection moulding are also suitable for profiling the injection volume flow and achieving homogeneous flow front speeds in foam injection moulding. The first step is to adapt an existing process model for conventional injection moulding to an injection moulding machine suitable for foam injection moulding. Subsequently, the influence of the expanding blowing agent on the resulting flow front velocities during mould filling will be investigated and the optimization potential for the process model identified.
Your task for a bachelor thesis:
- Production of test specimens on a modern injection moulding machine using the special foam injection moulding process and conventional injection moulding
- Evaluation of machine and mould sensor data to analyze the resulting flow front velocities during mould filling
- Identification and implementation of necessary adjustments to the model in MatLab
Your profile
Preferred study programs:
- Mechanical engineering / industrial engineering, specialising in mechanical engineering
- General mechanical engineering
- Materials science
- Industrial engineering, specialising in materials and process engineering
That also sets you apart:
- Enthusiasm for practical work on the machine
- Communicative and a team player
- Motivation and commitment