Korea-Australia Rheology Journal

The Korean Society of Rheology (한국유변학회)
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Residual stresses and viscoelastic deformation of an injection molded automotive part

  • Kim, Sung-Ho (Department of Materials Science and Engineering, Seoul National University) ;
  • Kim, Chae-Hwan (Department of Materials Science and Engineering, Seoul National University) ;
  • Oh, Hwa-Jin (Department of Materials Science and Engineering, Seoul National University) ;
  • Choi, Chi-Hoon (Department of Materials Science and Engineering, Seoul National University) ;
  • Kim, Byoung-Yoon (Advanced Technology Center, Hyundai-Kia Motors) ;
  • Youn, Jae-Ryoun (Department of Materials Science and Engineering, Seoul National University)
  • Published : 2007.12.31
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Abstract

Injection molding is one of the most common operations in polymer processing. Good quality products are usually obtained and major post-processing treatment is not required. However, residual stresses which exist in plastic parts affect the final shape and mechanical properties after ejection. Residual stresses are caused by polymer melt flow, pressure distribution, non-uniform temperature field, and density distribution. Residual stresses are predicted in this study by numerical methods using commercially available softwares, $Hypermesh^{TM},\;Moldflow^{TM}\;and\;ABAQUS^{TM}$. Cavity filling, packing, and cooling stages are simulated to predict residual stress field right after ejection by assuming an isotropic elastic solid. Thermo-viscoelastic stress analysis is carried out to predict deformation and residual stress distribution after annealing of the part. Residual stresses are measured by the hole drilling method because the automotive part selected in this study has a complex shape. Residual stress distribution predicted by the thermal stress analysis is compared with the measurement results obtained by the hole drilling method. The molded specimen has residual stress distribution in tension, compression, and tension from the surface to the center of the part. Viscoelastic deformation of the part is predicted during annealing and the deformed geometry is compared with that measured by a three dimensional scanner. The viscoelastic stress analysis with a thermal cycle will enable us to predict long term behavior of the injection molded polymeric parts.

Keywords

References

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