Computer Modeling for Injection Molding Simulation, Optimization, and Control

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  • Edition: 1st
  • Format: eBook
  • Copyright: 2013-03-29
  • Publisher: Wiley

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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.

Author Biography

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.

Table of Contents



Part I Background

1 Introduction
Huamin Zhou

1.1 Introduction of injection molding

1.2 Factors influencing quality

1.3 Computer modeling

1.4 Objective of this book


2 Background
Huamin Zhou

2.1 Molding materials

2.2 Product design

2.3 Mold design

2.4 Molding process

2.5 Process control


Part II Simulation

3 Mathematical Models for the Filling and Packing Simulation
Huamin Zhou, and Zixiang Hu

3.1 Material constitutive relationships and viscosity models

3.4 Governing equations for fluid flow

3.5 Boundary conditions

3.6 Model simplifications


4 Numerical Implementation for the Filling and Packing Simulation
Huamin Zhou, Zixiang Hu, and Yun Zhang

4.1 Numerical methods

4.2 Tracking of moving melt fronts

4.3 Methods for solving algebraic equations


5 Cooling Simulation
Yun Zhang, and Huamin Zhou

5.1 Introduction

5.2 Modeling

5.3 Numerical implementation based on boundary element method

5.4 Acceleration method

5.5 Simulation for transient mold temperature field


6 Residual Stress and Warpage Simulation

Fen Liu, Lin Deng, and Huamin Zhou
6.1 Residual stress analysis

6.2 Warpage simulation


7 Microstructure and Morphology Simulation
Huamin Zhou, Fen Liu, and Peng Zhao

7.1 Types of polymeric systems

7.2 Crystallization

7.3 Phase morphological evolution in polymer blends

7.4 Orientation

7.5 Numerical implementation

7.6 Microstructure-property relationships

7.7 Multiscale modeling and simulation


8 Development and Application of Simulation Software
Zhigao Huang, Zixiang Hu, and Huamin Zhou

8.1 Development history of injection molding simulation models

8.2 Development history of injection molding simulation software

8.3 The process of performing simulation software

8. 4 The application of simulation results


Part III Optimization

9 Non-iterative optimization methods
Peng Zhao, Yuehua Gao, Huamin Zhou, and Lih-Sheng Turng

9.1 Taguchi method

9.2 Grey relational analysis

9.3 Expert systems

9.4 Case-based reasoning

9.5 Fuzzy systems

9.6 Injection molding applications


10 Intelligent Optimization Algorithms
Yuehua Gao, Peng Zhao, Lih-Sheng Turng, and Huamin Zhou

10.1 Genetic algorithms

10.2 Simulated annealing algorithms

10.3 Particle swarm algorithms

10.4 Ant colony algorithms

10.5 Hill climbing algorithms


11 Optimization Methods Based on Surrogate Models
Yuehua Gao, Lih-Sheng Turng, Peng Zhao, and Huamin Zhou

11.1 Response surface method

11.2 Artificial neural network

11.3 Support vector regression

11.4 Kriging model

11.5 Gaussian process

11.6 Injection molding applications of optimization methods based on surrogate models


Part IV  Process Control

12 Feedback Control
Yi Yang, and Furong Gao

12.1 Traditional feedback control

12.2 Adaptive control strategy

12.3 Model predictive control strategy

12.4 Optimal control strategy

12.5 Intelligent control strategy

12.6 Summary of advanced feedback control


13 Learning Control
Yi Yang, and Furong Gao

13.1 Learning control

13.2 Two-dimensional (2D) control

13.3 Conclusions


14 Multivariate Statistical Process Control
Yuan Yao, and Furong Gao

14.1 Statistical process control

14.2 Multivariate statistical process control

14.3 MSPC for batch processes

14.4 MSPC for injection molding process

14.5 Conclusions


15 Direct Quality Control
Yi Yang, and Furong Gao

15.1 Review of product weight control

15.2 Methods

15.3 Experimental results and discussion

15.4 Conclusions



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