Injection molding shrinkage of PP: Experimental progress

Injection molding shrinkage deals with dimensional differences between a molded part and the cavity. By adding an array of orthogonal marks into a mold, local shrinkage values may be obtained by comparing dimensions of this array with dimensions of the array replicated on the surface of the parts. A profilograph is employed to obtain dimensional measurements, in the parallel to flow direction and in the cross flow direction. A sensitivity analysis is conducted to determine aspects of shrinkage evaluation causing uncertainty on the results. Prominent sources of uncertainty found are mark straightness defect and part warpage. Uncertainty on shrinkage is evaluated to 0.00025 mm/mm for a distance between the marks of 6.350 mm. Shrinkages have been evaluated locally for molded plates. Different distribution forms were observed for parallel to flow and cross flow shrinkage. Important anisotropy is also observed. The effects of holding pressure and injection velocity on shrinkages have been evaluated using a 23 factorial design of experiment for three locations on the plates. Finally, shrinkages for three mold geometries have been compared: constant thickness plate, variable in thickness symmetrical plate, and variable in thickness asymmetrical plate. Variable in thickness plates showed the importance of solidification dynamics on final shrinkages.