Experimental investigation of key parameters on the effects of cavity surface roughness in microinjection molding

For microinjection molding, it is envisaged that cavity surface roughness plays an important role in the cavity filling of polymer melt. This article presents an experimental investigation into the surface roughness effects on the flow area of a microthickness disk through injection molding. Three c...

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Bibliographic Details
Published in:Polymer engineering and science 2008-03, Vol.48 (3), p.490-495
Main Authors: Zhang, H.L., Ong, N.S., Lam, Y.C.
Format: Article
Language:English
Subjects:
Applied sciences
Biotechnology
Evaluation
Exact sciences and technology
Experiments
Injection molding
Machinery and processing
Methods
Molds & molding
Moulding compound preparation. Mixing
Plastics
Polymer industry, paints, wood
Surface roughness
Technology of polymers
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Summary:For microinjection molding, it is envisaged that cavity surface roughness plays an important role in the cavity filling of polymer melt. This article presents an experimental investigation into the surface roughness effects on the flow area of a microthickness disk through injection molding. Three core inserts, each of which has different surface roughness on its two semicircular halves but with the same roughness mean lines, were machined and formed the mold cavity. The difference in flow area (or volume) between these two semicircular halves of the molded part was investigated by varying the mold and melt temperatures. Regressive analysis of the significance of mold and melt temperatures and cavity thickness on the surface roughness effects was carried out. Experimental results obtained indicated that the flow area on the smoother half is larger than that on the rougher half during cavity filling. For the same surface roughness, its effect on cavity filling is a function of mold temperature, melt temperature, and cavity thickness. An increase in mold temperature or melt temperature will result in smaller surface roughness effect on the flow area. When cavity thickness is reduced, the surface roughness effect will become more significant. Moreover, a larger difference in the surface roughness between the two semicircular halves of the insert will result in a larger difference in the flow area between the two halves of the molded part. POLYM. ENG. SCI., 2008. © 2008 Society of Plastics Engineers.
ISSN:0032-3888
1548-2634
DOI:10.1002/pen.20981