Computer Modeling for Injection 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.

“Overall, this book can be recommended for a reader interested in getting an overall idea of the contribution of computer science to injection molding, or to a researcher looking for an updated review of the latest applications of numerical techniques to this technology.”  (Materials Views, 22 October  2013)

• PREFACE xiiiCONTRIBUTORS xvPART I BACKGROUND 11 Introduction 3Huamin Zhou1.1 Introduction of Injection Molding, 31.2 Factors Influencing Quality, 51.3 Computer Modeling, 101.4 Objective of This Book, 172 Background 25Huamin Zhou2.1 Molding Materials, 252.2 Product Design, 312.3 Mold Design, 342.4 Molding Process, 372.5 Process Control, 43PART II SIMULATION 493 Mathematical Models for the Filling and Packing Simulation 51Huamin Zhou, Zixiang Hu, and Dequn Li3.1 Material Constitutive Relationships and Viscosity Models, 513.2 Thermodynamic Relationships, 563.3 Thermal Properties Model, 583.4 Governing Equations for Fluid Flow, 593.5 Boundary Conditions, 653.6 Model Simplifications, 674 Numerical Implementation for the Filling and Packing Simulation 71Huamin Zhou, Zixiang Hu, Yun Zhang, and Dequn Li4.1 Numerical Methods, 714.2 Tracking of Moving Melt Fronts, 1014.3 Methods for Solving Algebraic Equations, 1135 Cooling Simulation 129Yun Zhang and Huamin Zhou5.1 Introduction, 1295.2 Modeling, 1315.3 Numerical Implementation Based on Boundary Element Method, 1365.4 Acceleration Method, 1435.5 Simulation for Transient Mold Temperature Field, 1506 Residual Stress and Warpage Simulation 157Fen Liu, Lin Deng, and Huamin Zhou6.1 Residual Stress Analysis, 1576.2 Warpage Simulation, 1707 Microstructure and Morphology Simulation 195Huamin Zhou, Fen Liu, and Peng Zhao7.1 Types of Polymeric Systems, 1957.2 Crystallization, 1967.3 Phase Morphological Evolution in Polymer Blends, 2037.4 Orientation, 2147.5 Numerical Implementation, 2207.6 Microstructure-Property Relationships, 2247.7 Multiscale Modeling and Simulation, 2288 Development and Application of Simulation Software 237Zhigao Huang, Zixiang Hu, and Huamin Zhou8.1 Development History of Injection Molding Simulation Models, 2378.2 Development History of Injection Molding Simulation Software, 2408.3 The Process of Performing Simulation Software, 2438.4 Application of Simulation Results, 246PART III OPTIMIZATION 2559 Noniterative Optimization Methods 257Peng Zhao, Yuehua Gao, Huamin Zhou, and Lih-Sheng Turng9.1 Taguchi Method, 2589.2 Gray Relational Analysis, 2609.3 Expert Systems, 2619.4 Case-Based Reasoning, 2669.5 Fuzzy Systems, 2689.6 Injection Molding Applications, 27410 Intelligent Optimization Algorithms 283Yuehua Gao, Peng Zhao, Lih-Sheng Turng, and Huamin Zhou10.1 Genetic Algorithms, 28310.2 Simulated Annealing Algorithms, 28510.3 Particle Swarm Algorithms, 28710.4 Ant Colony Algorithms, 28910.5 Hill Climbing Algorithms, 29011 Optimization Methods Based on Surrogate Models 293Yuehua Gao, Lih-Sheng Turng, Peng Zhao, and Huamin Zhou11.1 Response Surface Method, 29411.2 Artificial Neural Network, 29611.3 Support Vector Regression, 29811.4 Kriging Model, 30111.5 Gaussian Process, 30411.6 Injection Molding Applications of Optimization Methods Based on Surrogate Models, 305PART IV PROCESS CONTROL 31312 Feedback Control 315Yi Yang and Furong Gao12.1 Traditional Feedback Control, 31512.2 Adaptive Control Strategy, 31612.3 Model Predictive Control Strategy, 31812.4 Optimal Control Strategy, 32212.5 Intelligent Control Strategy, 32912.6 Summary of Advanced Feedback Control, 33513 Learning Control 339Yi Yang and Furong Gao13.1 Learning Control, 33913.2 Two-Dimensional (2D) Control, 34513.3 Conclusions, 35014 Multivariate Statistical Process Control 355Yuan Yao and Furong Gao14.1 Statistical Process Control, 35514.2 Multivariate Statistical Process Control, 35614.3 MSPC for Batch Processes, 35814.4 MSPC for Injection Molding Process, 35914.5 Conclusions, 37315 Direct Quality Control 377Yi Yang and Furong Gao15.1 Review of Product Weight Control, 37715.2 Methods, 37815.3 Experimental Results and Discussion, 38015.4 Conclusions, 389References, 389INDEX 391