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Numerical simulation analysis of the in-cavity residual stress distribution of lignocellulosic (wood) polymer composites used in shallow thin-walled parts formed by the injection moulding process


Citation

Md Deros, Mohd Azaman and Salit, Mohd Sapuan and Sulaiman, Shamsuddin and Zainudin, Edi Syams and Abdan, Khalina (2014) Numerical simulation analysis of the in-cavity residual stress distribution of lignocellulosic (wood) polymer composites used in shallow thin-walled parts formed by the injection moulding process. Materials and Design, 55. pp. 381-386. ISSN 0264-1275; ESSN: 1873-4197

Abstract

In this paper, a numerical analysis of in-cavity residual stress formation in the thin-walled parts of injection-moulded parts is presented by considering the residual stresses produced during the post-filling stage. Injection moulding of shallow thin-walled parts with a thickness of 0.7 mm was performed using lignocellulosic polymer composites (PP + 50 wt% wood), and the parts have been systematically investigated using simulation results from Autodesk MoldFlow Insight® software. In-cavity residual stresses constitute the primary stage for analysis because of the need to control the quality of moulded parts to prevent problems with shrinkage and warpage. The analysis showed that the cooling times and packing times had a less significant effect; nevertheless, the optimal levels that are required to be used in the moulding process for thin-walled parts yielded better results. The in-cavity residual stress results show that the stress variation across the thickness exhibits a high tensile stress at the part surface, which changes to a low tensile stress peak value close to the surface, with the core region experiencing a parabolic tensile stress peak. The optimum parameter ranges for obtaining the minimum in-cavity residual stresses are as follows: a mould temperature of 40–45 °C, a cooling time of 20–30 s, a packing pressure of 0.85Pinject, and a packing time of 15–20 s.


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Additional Metadata

Item Type: Article
Divisions: Faculty of Engineering
Institute of Tropical Forestry and Forest Products
DOI Number: https://doi.org/10.1016/j.matdes.2013.09.041
Publisher: Elsevier
Keywords: Numerical simulation analysis; In-cavity residual stress; Lignocellulosic; Wood; Polymer composites; Injection moulding process
Depositing User: Nurul Ainie Mokhtar
Date Deposited: 18 Dec 2015 01:35
Last Modified: 04 Nov 2016 08:59
Altmetrics: http://www.altmetric.com/details.php?domain=psasir.upm.edu.my&doi=10.1016/j.matdes.2013.09.041
URI: http://psasir.upm.edu.my/id/eprint/34681
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