Modeling the effect of cooling system on the shrinkage and temperature of the polymer by injection molding

Injection molding is one of the most exploited industrial processes in the production of plastic parts. Shrinkage behavior of a molded plastic part plays an important role in determining final dimensions of the part. In this paper, the effect of the cooling system on the shrinkage rate of a polystyrene product during injection molding is carried out. A compressible fluid model for the physical system is presented. A finite volume numerical solution is used for the solution of the physical model. A validation of the numerical model in case of square cavity filled with polymer material is presented. The compressibility behavior of polymer material observed by the pressure, volume, and temperature for the state equation (P-v-T equation) is represented by Tait's equation. A Cross type rheological model depending on the temperature and pressure is assumed for the polymer material. The studied configurations consist of a mold having T-shaped plastic part and four cooling channels. Different cooling channels' positions are assumed and the effect of their positions on the cooling process is studied. The results indicate a good agreement between the numerical solution and those of the literatures. They also, show that the position of the cooling channels has a great effect on final product temperature and the shrinkage rate distribution throughout the product. (C) 2010 Elsevier Ltd. All rights reserved.