Creating material properties for thermoset injection molding simulation process

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To simulate the injection molding process, it is necessary to set material data. The material data for an injection molding process must include a viscosity model and its fitted coefficients, heat capacity coefficients, thermal conductivity coefficients, a PVT model and its coefficients, a curing model and its coefficients (only for reactive injection molding). With thermoplastics injection molding simulation, the material data is generally available from simulation tools. Users could easily choose thermoplastics material data that was already embedded in the material data bank of simulation tools to simulate the entire phases of thermoplastics injection molding process. However, with thermosets injection molding simulation, the material data is found in limited sources and seldom available from data bank of simulation tools because of complication not only in rheological and thermal properties measurement but also in modeling rheological and cure kinetics mathematical models. Therefore, with thermoset injection molding compounds that its material data bank has not been found in data bank of simulation tools, before setting material data, it is necessary to create its own material data that simulation packages do not supply a tool. Therefore, to solve this problem, it requires an extensive knowledge base in measurements of material properties as well as optimization algorithm. In addition, to simulate exactly the thermosets injection molding compound process, it requires a profound knowledge in the mold filling characteristics of thermoset injection molding compounds. However, investigation of flow behavior of thermosets injection molding compounds inside the mold has not been adequately described. Up to now, there has not been any article that shows a complete way to create thermoset material data from measured experimental data (thermal data and rheological data) for the reactive injection molding simulation process. These problems are leading to the users ‘dependency on the material data bank of simulation tools, leading to restriction in application of computer simulation in the thermoset injection molding simulation and comparison between experimental and simulation results. Furthermore, there is still a big question related to whether there is or no slip phenomenon between thermosets melt and the wall surface during filling the cavity, for which has not yet been found an exact answer. Because of this the effect of wall slip on the cavity surface is still ignored during thermoset injection molding simulation process. This thesis focused on three key scientific goals. The first one is innovation of a new technical method to explain the mold filling behavior of thermoset injection molding compounds physically. The second key goal is developing numerical method to create thermoset material data sheet for simulation of mold filling characterizations of thermoset injection molding compounds. Finally, creating a simulation tool base on the physical technique and generated material data sheet.

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Ngoc Tu Tran

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