Simulation of polymer melt during injection molding: Influence of undercooling rates

The influence of undercooling rates on the behaviour of polymer melts during
injection molding process was studied using simulation from computer. The study
involves the usage of injection molding simulation software, SimpoeWorks. The
polymer product under investigation is insulated piercing connector (!PC). !PC is
used for branches of service entry cable of low voltage electricity distribution line.
Material used in producing this product is Polyamide (Nylon) 6 with 30% glass fibre
reinforcement (Akulon® K224-G6). There are two plug-in modules that was used in
SimpoeWorks; FILL module for filling phase simulation and COOL module for
cooling phase simulation. For filling simulation, polymer melt movement inside the
mold cavity was observed. In cooling simulation, the effect of different cooling times
with the product dimension was studied. Calculation of the percentage of shrinkage
was also done between product drawing and actual injection molding product. The
purpose of polymer flow simulation is to predict the behaviour of polymer melt
inside mold cavity and avoid defects on the molded product prior to actual injection
molding process. Polymer flow simulation can saves time and effort for development
of new polymer product. It can also reduce the manufacturing cost of a polymer
product by replacing trial and error method.
iv