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Student paper

Optimization of the flow front speed in cascade injection moulding

Bachelor’s thesis or master’s thesis

The aim of the work is the simulative investigation of factors influencing the flow front speed in cascade injection molding.
Stuwi-Optimierung der Fließfrontgeschwindigkeit im Kaskadenspritzgießen© Oerlikon HRSflow
Hot runner system for cascade injection moulding of a spoiler

Topic of the work:

Injection molding is a cyclical manufacturing process in which plasticized plastic is injected under high pressure into a shaping tool cavity. Cascade injection molding is used in this process to produce large components with long flow paths. This is used in the automotive sector in particular for the production of exterior components such as bumpers and interior components such as instrument panels. Against the background of rising quality requirements and the increased use of recycled materials, the question arises as to how the injection phase influences the resulting component quality.

The work is related to this research project:

You are writing the thesis as part of the “OptiKas” research project, which deals with the injection phase in cascade injection molding. The project aims to develop a routine for achieving a constant flow front speed. Strong local delays and accelerations of the flow front should be avoided, as these have a negative effect on component quality. This should reduce the amount of waste produced and increase productivity through an efficient set-up process.

Objective:

The aim of the work is to identify and analyze factors influencing the flow front speed in cascade injection molding using injection molding simulation. To this end, an injection molding simulation for an existing cascade mold will first be set up, which will then be used to investigate the influence of various parameters on the flow front speed. For example, the focus could be on the influence of geometry or the movement of the hot runner needle.

Your task:

Familiarization with the basics of cascade injection moulding Familiarization with the basics of cascade injection moulding
Development of a simulation model to investigate the flow front velocity in cascade injection molding Development of a simulation model to investigate the flow front velocity in cascade injection molding
Carrying out injection molding simulations to investigate the influence of the hot runner valve gate needle on the volume flows through the individual hot runner nozzles Identification of input and output variables
Execution and analysis of injection molding simulations in the form of a parameter study

Your profile:

  • Technical or scientific studies (mechanical engineering, industrial engineering, automation technology, computational engineering science (CES), simulation sciences)
  • Previous knowledge of plastics processing or injection molding simulation is an advantage, but not essential, as you will learn the necessary skills as part of your work.
  • Interest in simulative work
  • Structured, independent and autonomous way of working

Your benefits:

  • Work in a young, motivated team
  • Independent work with intensive support
  • Co-design of current research projects
  • Individual coordination of tasks and time frame

If you are interested in writing your thesis at IKV and in this task, please get in touch with me. We agree on the exact scope of content and schedule individually.