This book covers a wide range of applications and uses of simulation and modeling techniques in polymer injection molding, filling a noticeable gap in the literature of design, manufacturing, and the use of plastics injection molding. The authors help readers solve problems in the advanced control, simulation, monitoring, and optimization of injection molding processes. The book provides a tool for researchers and engineers to calculate the mold filling, optimization of processing control, and quality estimation before prototype molding.
This book covers a wide range of applications and uses of simulation and modeling techniques in polymer injection molding, filling a noticeable gap in the literature of design, manufacturing, and the use of plastics injection molding. The authors help readers solve problems in the advanced control, simulation, monitoring, and optimization of injection molding processes. The book provides a tool for researchers and engineers to calculate the mold filling, optimization of processing control, and quality estimation before prototype molding.
HUAMIN ZHOU, PhD, is Vice Dean of the School of Materials Science and Engineering and Vice Director of the State Key Laboratory of Materials Processing and Die & Mould Technology at the Huazhong University of Science and Technology, Wuhan, China. Dr. Zhou has published more than 200 peer-reviewed papers. His research examines polymer processing, numerical simulation, and process optimization and control.
Inhaltsangabe
PREFACE xiii CONTRIBUTORS xv PART I BACKGROUND 1 1 Introduction 3 Huamin Zhou 1.1 Introduction of Injection Molding 3 1.2 Factors Influencing Quality 5 1.3 Computer Modeling 10 1.4 Objective of This Book 17 2 Background 25 Huamin Zhou 2.1 Molding Materials 25 2.2 Product Design 31 2.3 Mold Design 34 2.4 Molding Process 37 2.5 Process Control 43 PART II SIMULATION 49 3 Mathematical Models for the Filling and Packing Simulation 51 Huamin Zhou Zixiang Hu and Dequn Li 3.1 Material Constitutive Relationships and Viscosity Models 51 3.2 Thermodynamic Relationships 56 3.3 Thermal Properties Model 58 3.4 Governing Equations for Fluid Flow 59 3.5 Boundary Conditions 65 3.6 Model Simplifications 67 4 Numerical Implementation for the Filling and Packing Simulation 71 Huamin Zhou Zixiang Hu Yun Zhang and Dequn Li 4.1 Numerical Methods 71 4.2 Tracking of Moving Melt Fronts 101 4.3 Methods for Solving Algebraic Equations 113 5 Cooling Simulation 129 Yun Zhang and Huamin Zhou 5.1 Introduction 129 5.2 Modeling 131 5.3 Numerical Implementation Based on Boundary Element Method 136 5.4 Acceleration Method 143 5.5 Simulation for Transient Mold Temperature Field 150 6 Residual Stress and Warpage Simulation 157 Fen Liu Lin Deng and Huamin Zhou 6.1 Residual Stress Analysis 157 6.2 Warpage Simulation 170 7 Microstructure and Morphology Simulation 195 Huamin Zhou Fen Liu and Peng Zhao 7.1 Types of Polymeric Systems 195 7.2 Crystallization 196 7.3 Phase Morphological Evolution in Polymer Blends 203 7.4 Orientation 214 7.5 Numerical Implementation 220 7.6 Microstructure-Property Relationships 224 7.7 Multiscale Modeling and Simulation 228 8 Development and Application of Simulation Software 237 Zhigao Huang Zixiang Hu and Huamin Zhou 8.1 Development History of Injection Molding Simulation Models 237 8.2 Development History of Injection Molding Simulation Software 240 8.3 The Process of Performing Simulation Software 243 8.4 Application of Simulation Results 246 PART III OPTIMIZATION 255 9 Noniterative Optimization Methods 257 Peng Zhao Yuehua Gao Huamin Zhou and Lih-Sheng Turng 9.1 Taguchi Method 258 9.2 Gray Relational Analysis 260 9.3 Expert Systems 261 9.4 Case-Based Reasoning 266 9.5 Fuzzy Systems 268 9.6 Injection Molding Applications 274 10 Intelligent Optimization Algorithms 283 Yuehua Gao Peng Zhao Lih-Sheng Turng and Huamin Zhou 10.1 Genetic Algorithms 283 10.2 Simulated Annealing Algorithms 285 10.3 Particle Swarm Algorithms 287 10.4 Ant Colony Algorithms 289 10.5 Hill Climbing Algorithms 290 11 Optimization Methods Based on Surrogate Models 293 Yuehua Gao Lih-Sheng Turng Peng Zhao and Huamin Zhou 11.1 Response Surface Method 294 11.2 Artificial Neural Network 296 11.3 Support Vector Regression 298 11.4 Kriging Model 301 11.5 Gaussian Process 304 11.6 Injection Molding Applications of Optimization Methods Based on Surrogate Models 305 PART IV PROCESS CONTROL 313 12 Feedback Control 315 Yi Yang and Furong Gao 12.1 Traditional Feedback Control 315 12.2 Adaptive Control Strategy 316 12.3 Model Predictive Control Strategy 318 12.4 Optimal Control Strategy 322 12.5 Intelligent Control Strategy 329 12.6 Summary of Advanced Feedback Control 335 13 Learning Control 339 Yi Yang and Furong Gao 13.1 Learning Control 339 13.2 Two-Dimensional (2D) Control 345 13.3 Conclusions 350 14 Multivariate Statistical Process Control 355 Yuan Yao and Furong Gao 14.1 Statistical Process Control 355 14.2 Multivariate Statistical Process Control 356 14.3 MSPC for Batch Processes 358 14.4 MSPC for Injection Molding Process 359 14.5 Conclusions 373 15 Direct Quality Control 377 Yi Yang and Furong Gao 15.1 Review of Product Weight Control 377 15.2 Methods 378 15.3 Experimental Results and Discussion 380 15.4 Conclusions 389 References 389 INDEX 391
PREFACE xiii CONTRIBUTORS xv PART I BACKGROUND 1 1 Introduction 3 Huamin Zhou 1.1 Introduction of Injection Molding 3 1.2 Factors Influencing Quality 5 1.3 Computer Modeling 10 1.4 Objective of This Book 17 2 Background 25 Huamin Zhou 2.1 Molding Materials 25 2.2 Product Design 31 2.3 Mold Design 34 2.4 Molding Process 37 2.5 Process Control 43 PART II SIMULATION 49 3 Mathematical Models for the Filling and Packing Simulation 51 Huamin Zhou Zixiang Hu and Dequn Li 3.1 Material Constitutive Relationships and Viscosity Models 51 3.2 Thermodynamic Relationships 56 3.3 Thermal Properties Model 58 3.4 Governing Equations for Fluid Flow 59 3.5 Boundary Conditions 65 3.6 Model Simplifications 67 4 Numerical Implementation for the Filling and Packing Simulation 71 Huamin Zhou Zixiang Hu Yun Zhang and Dequn Li 4.1 Numerical Methods 71 4.2 Tracking of Moving Melt Fronts 101 4.3 Methods for Solving Algebraic Equations 113 5 Cooling Simulation 129 Yun Zhang and Huamin Zhou 5.1 Introduction 129 5.2 Modeling 131 5.3 Numerical Implementation Based on Boundary Element Method 136 5.4 Acceleration Method 143 5.5 Simulation for Transient Mold Temperature Field 150 6 Residual Stress and Warpage Simulation 157 Fen Liu Lin Deng and Huamin Zhou 6.1 Residual Stress Analysis 157 6.2 Warpage Simulation 170 7 Microstructure and Morphology Simulation 195 Huamin Zhou Fen Liu and Peng Zhao 7.1 Types of Polymeric Systems 195 7.2 Crystallization 196 7.3 Phase Morphological Evolution in Polymer Blends 203 7.4 Orientation 214 7.5 Numerical Implementation 220 7.6 Microstructure-Property Relationships 224 7.7 Multiscale Modeling and Simulation 228 8 Development and Application of Simulation Software 237 Zhigao Huang Zixiang Hu and Huamin Zhou 8.1 Development History of Injection Molding Simulation Models 237 8.2 Development History of Injection Molding Simulation Software 240 8.3 The Process of Performing Simulation Software 243 8.4 Application of Simulation Results 246 PART III OPTIMIZATION 255 9 Noniterative Optimization Methods 257 Peng Zhao Yuehua Gao Huamin Zhou and Lih-Sheng Turng 9.1 Taguchi Method 258 9.2 Gray Relational Analysis 260 9.3 Expert Systems 261 9.4 Case-Based Reasoning 266 9.5 Fuzzy Systems 268 9.6 Injection Molding Applications 274 10 Intelligent Optimization Algorithms 283 Yuehua Gao Peng Zhao Lih-Sheng Turng and Huamin Zhou 10.1 Genetic Algorithms 283 10.2 Simulated Annealing Algorithms 285 10.3 Particle Swarm Algorithms 287 10.4 Ant Colony Algorithms 289 10.5 Hill Climbing Algorithms 290 11 Optimization Methods Based on Surrogate Models 293 Yuehua Gao Lih-Sheng Turng Peng Zhao and Huamin Zhou 11.1 Response Surface Method 294 11.2 Artificial Neural Network 296 11.3 Support Vector Regression 298 11.4 Kriging Model 301 11.5 Gaussian Process 304 11.6 Injection Molding Applications of Optimization Methods Based on Surrogate Models 305 PART IV PROCESS CONTROL 313 12 Feedback Control 315 Yi Yang and Furong Gao 12.1 Traditional Feedback Control 315 12.2 Adaptive Control Strategy 316 12.3 Model Predictive Control Strategy 318 12.4 Optimal Control Strategy 322 12.5 Intelligent Control Strategy 329 12.6 Summary of Advanced Feedback Control 335 13 Learning Control 339 Yi Yang and Furong Gao 13.1 Learning Control 339 13.2 Two-Dimensional (2D) Control 345 13.3 Conclusions 350 14 Multivariate Statistical Process Control 355 Yuan Yao and Furong Gao 14.1 Statistical Process Control 355 14.2 Multivariate Statistical Process Control 356 14.3 MSPC for Batch Processes 358 14.4 MSPC for Injection Molding Process 359 14.5 Conclusions 373 15 Direct Quality Control 377 Yi Yang and Furong Gao 15.1 Review of Product Weight Control 377 15.2 Methods 378 15.3 Experimental Results and Discussion 380 15.4 Conclusions 389 References 389 INDEX 391
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