Instructor

Room No. 105

Email

Course Basics
Credit Hours 4 (2 Theory + 2 Laboratory)
Contact Hours 8 (2 Theory + 6 Laboratory)

Course Description
- Simulation of polymer processing operations and data on material properties
- Computer aided simulations and analysis in design work
- Use of commercial simulation software
- Interpretation of output data from design packages
- Modeling of selected components of manufacturing machines

Grading Breakup
Theory Part

Quizzes: 20 %
Midterm: 30 %
Final Examination: 50 %

An attendance of 75% is mandatory to sit in the final
examination.
Laboratory Part

Class Tutorials: 20 %
Class Assignments: 45 %
Poster: 15 %
Terminal Viva-Voce: 20 %


Examination Detail
Midterm Duration: 60 Minutes
Exam Specifications: Closed books/Closed notes
Final Examination Duration: 90 Minutes
Exam Specifications: Closed books/Closed notes
Final exam will include 20-30 % course from pre-midterm lectures.


Course Overview
Week Topics Recommended Reading
1
Introduction to Injection Molding Simulation using SolidWorks
Plastics
- Drawing basic 3D objects using SolidWorks
- Tutorial on the use of Plastics add-in to simulate the
injection molding of thermoplastics
Nil
2
The Future of Polymer Processing
- Approaches to Polymer Process Simulation
- Material Data
- The Edges of Polymer Processing
- Processes for Special Materials
- Bioplastics
Clemens Holzer, The Future of Polymer
Processing pp. 124-129
3
Polymer Flow Behavior in Injection Molds
- Phases of Injection Molding
- Development of Frozen Layer in Injection Molding
- Flow Shear Stress
- Details of Pressurization Phase
- Details of Compensation Phase: Temperature Variations
- Details of Compensation Phase: Natural Instability
- Details of Compensation Phase: Optimum Part Quality
Jay Shoemaker, Moldflow Design Guide:
A Resource for Plastics Engineers, pp. 1-4
4
Polymer Flow Behavior in Injection Molds
- Flow How Do Plastics Flow?
- Material Behavior
- Deformation Types
- Viscoelastic Behavior
- Melt Shear Viscosity
- Newtonian Fluid vs. Non-Newtonian Fluid
- Shear-thinning Behavior
- Shear Rate Distribution
- Effects of Temperature and Pressure
Jay Shoemaker, Moldflow Design Guide:
A Resource for Plastics Engineers, pp. 7-
12
5
Polymer Flow Behavior in Injection Molds
- Pressure-driven Flow
- Pressure Gradient and Injection Times
- Melt Flow Length
- Injection Pressure vs. Fill Time
- Flow Instability
Jay Shoemaker, Moldflow Design Guide:
A Resource for Plastics Engineers, pp. 12-
15
6
Molding Conditions and Injection Pressure
- Injection-pressure Overview
- Factors Influencing Injection-pressure Requirements
- Useful Equations
- Circular Channel Flow
- Strip Channel Flow
- Effect of Molding Conditions
- Evaluation of Part Quality
- Effects of Melt Temperature
- Effects of Mold Temperatures
Jay Shoemaker, Moldflow Design Guide:
A Resource for Plastics Engineers, pp. 17-
22
7
Molding Conditions and Injection Pressure
- Effects of Mold Temperatures
- Fill Time
- Packing Pressure and Time
- Back Flow
- Using Moldflow to Determine Optimum Molding Conditions
Jay Shoemaker, Moldflow Design Guide:
A Resource for Plastics Engineers, pp. 22-
31
8
Filling Pattern
- Filling Pattern Overview
- Flow in Complex Molds
Jay Shoemaker, Moldflow Design Guide:
A Resource for Plastics Engineers, pp. 33-
41
9 MIDTERM
10
Filling Pattern
- Flow-front Velocity and Flow-front Area
- Using Moldflow to Determine the Filling Pattern
- Using Moldflow to Achieve Constant FFV

Moldflow Design Principles
- Product Design and Moldflow
Sequence of Analysis
Jay Shoemaker, Moldflow Design Guide:
A Resource for Plastics Engineers, pp. 41-
47
11
Moldflow Design Principles
- Sequence of Analysis
o Part Filling Optimization
o Molding Conditions
o Runner Design
o Cooling, Packing and Warpage Optimization
- Moldflow Flow Concepts
o Unidirectional and Controlled Flow Pattern
o Flow Balancing
o Constant Pressure Gradient
Jay Shoemaker, Moldflow Design Guide:
A Resource for Plastics Engineers, pp. 48-
52
12
Moldflow Design Principles
- Moldflow Flow Concepts
o Maximum Shear Stress
o Uniform Cooling
o Positioning Weld and Meld Lines
o Avoiding Hesitation Effects
o Avoiding Underflow
o Balancing with Flow Leaders and Flow Deflectors
o Controlled Frictional Heat
o Thermal Shutoff of Runners
o Acceptable Runner/Cavity Ratio
Jay Shoemaker, Moldflow Design Guide:
A Resource for Plastics Engineers, pp. 53-
59
13
Defects in injection molded products: Causes and Solutions
- Knit lines
- Excessive shrinkage
- Sink marks
- Warpage
Website: ThePlasticTroubleshooter
14
QUIZ 1 (From Lecture 10)

Gate Design
- Gate Design Overview
- Gate Types: Manually Trimmed
- Gate Types: Automatically Trimmed
Jay Shoemaker, Moldflow Design Guide:
A Resource for Plastics Engineers, pp.
103-113
15
Gate Design
- Determining the Number of Gates
- Flow Patterns
- Gate Position
- Avoiding Common Problems
Jay Shoemaker, Moldflow Design Guide:
A Resource for Plastics Engineers, pp.
113-126
16
QUIZ 2 (From Lecture 8 and 9)

Shrinkage and Warpage
- What Are Shrinkage and Warpage?
- Shrinkage and Machine Settings
- Mold Filling and Packing
- How Pressure and Time Affect Shrinkage
Jay Shoemaker, Moldflow Design Guide:
A Resource for Plastics Engineers, pp.
173-180
17
Shrinkage and Warpage
- Causes of Shrinkage
- Causes of Warpage
- Orientation Effects
- Area Shrinkage
- Differential Cooling
- Relating Orientation and Area Shrinkage to Warpage
Jay Shoemaker, Moldflow Design Guide:
A Resource for Plastics Engineers, pp.
181-183
18 FINAL EXAMINATION