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Research Papers

Multi-Objective Optimization of the Heating Rods Layout for Rapid Electrical Heating Cycle Injection Mold

[+] Author and Article Information
Guoqun Zhao1

Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan 250061, PR Chinazhaogq@sdu.edu.cn

Xiping Li

Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan 250061, PR Chinaxpl2005@163.com

Yanjin Guan

Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan 250061, PR China; State Key Laboratory of Material Processing and Die and Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, PR Chinaguan_yanjin@sdu.edu.cn

1

Corresponding author.

J. Mech. Des 132(6), 061001 (May 20, 2010) (8 pages) doi:10.1115/1.4001529 History: Received June 23, 2009; Revised March 04, 2010; Published May 20, 2010; Online May 20, 2010

Rapid electrical heating cycle injection molding (ERHCM) technology is a promising green manufacturing technology for plastic parts. By using this technology, the defects that usually appear on the surface of conventionally injected parts, such as weld and flow marks, can be avoided effectively. This paper studies rapid electrical heating cycle injection molding technology and its mold structure design techniques. Temperature distribution uniformity and heating efficiency on the mold cavity surface are considered as the major influencing factors on product quality and production efficiency. A multi-objective optimization model for the heating rods layout in the mold cavity plate is formulated to optimize temperature distribution uniformity and heating efficiency with respect to the heating rods layout. An application to a liquid crystal display TV panel is implemented successfully using a genetic algorithm.

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Copyright © 2010 by American Society of Mechanical Engineers
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Figures

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Figure 1

Surface morphologies of the ERHCM and the conventional injection mold cavity: (a) surface of the ERHCM mold cavity and (b) surface of the conventional mold cavity

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Figure 2

Comparison of products for different injection methods: (a) ERHCM molding and (b) conventional injection molding

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Figure 3

Schematic illustration of the TV panel and the ERHCM mold: (a) panel shape of the LCD TV and (b) one-quarter of the ERHCM mold for the panel

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Figure 4

Geometric model for heat transfer analysis: (a) electrical heating rods, (b) cavity surface, (c) temperature tracking points along cavity surface, and (d) cross section of the cavity plate

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Figure 5

Pareto optimal solutions of the design variables

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Figure 8

Injected LCD TV panel products using the ERHCM mold designed in this paper

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Figure 7

Temperatures of the tracking points on the cavity surface: (a) the initial mold design and (b) the optimal mold design

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Figure 6

Temperature distributions for the initial and optimal designs: (a) temperature distributions for the initial mold design and (b) temperature distributions for the optimal mold design

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