Computer Modeling for Injection Molding Simulation, Optimization, and Control

HUAMIN ZHOU, PhD, is Vice Dean of the School of Materials Science and Engineering and Vice Director of the State Key Laboratory of Materials Processing and Die & Mould Technology at the Huazhong University of Science and Technology, Wuhan, China. Dr. Zhou has published more than 200 peer-reviewed papers. His research examines polymer processing, numerical simulation, and process optimization and control.

Preface

Contributors

Part I Background

1 Introduction
Huamin Zhou

1.1 Introduction of injection molding

1.2 Factors influencing quality

1.3 Computer modeling

1.4 Objective of this book

References

2 Background
Huamin Zhou

2.1 Molding materials

2.2 Product design

2.3 Mold design

2.4 Molding process

2.5 Process control

References

Part II Simulation

3 Mathematical Models for the Filling and Packing Simulation
Huamin Zhou, and Zixiang Hu

3.1 Material constitutive relationships and viscosity models

3.4 Governing equations for fluid flow

3.5 Boundary conditions

3.6 Model simplifications

References

4 Numerical Implementation for the Filling and Packing Simulation
Huamin Zhou, Zixiang Hu, and Yun Zhang

4.1 Numerical methods

4.2 Tracking of moving melt fronts

4.3 Methods for solving algebraic equations

References

5 Cooling Simulation
Yun Zhang, and Huamin Zhou

5.1 Introduction

5.2 Modeling

5.3 Numerical implementation based on boundary element method

5.4 Acceleration method

5.5 Simulation for transient mold temperature field

References

6 Residual Stress and Warpage Simulation

Fen Liu, Lin Deng, and Huamin Zhou
6.1 Residual stress analysis

6.2 Warpage simulation

Reference

7 Microstructure and Morphology Simulation
Huamin Zhou, Fen Liu, and Peng Zhao

7.1 Types of polymeric systems

7.2 Crystallization

7.3 Phase morphological evolution in polymer blends

7.4 Orientation

7.5 Numerical implementation

7.6 Microstructure-property relationships

7.7 Multiscale modeling and simulation

Reference

8 Development and Application of Simulation Software
Zhigao Huang, Zixiang Hu, and Huamin Zhou

8.1 Development history of injection molding simulation models

8.2 Development history of injection molding simulation software

8.3 The process of performing simulation software

8. 4 The application of simulation results

References

Part III Optimization

9 Non-iterative optimization methods
Peng Zhao, Yuehua Gao, Huamin Zhou, and Lih-Sheng Turng

9.1 Taguchi method

9.2 Grey relational analysis

9.3 Expert systems

9.4 Case-based reasoning

9.5 Fuzzy systems

9.6 Injection molding applications

References

10 Intelligent Optimization Algorithms
Yuehua Gao, Peng Zhao, Lih-Sheng Turng, and Huamin Zhou

10.1 Genetic algorithms

10.2 Simulated annealing algorithms

10.3 Particle swarm algorithms

10.4 Ant colony algorithms

10.5 Hill climbing algorithms

References

11 Optimization Methods Based on Surrogate Models
Yuehua Gao, Lih-Sheng Turng, Peng Zhao, and Huamin Zhou

11.1 Response surface method

11.2 Artificial neural network

11.3 Support vector regression

11.4 Kriging model

11.5 Gaussian process

11.6 Injection molding applications of optimization methods based on surrogate models

References

Part IV  Process Control

12 Feedback Control
Yi Yang, and Furong Gao

12.1 Traditional feedback control

12.2 Adaptive control strategy

12.3 Model predictive control strategy

12.4 Optimal control strategy

12.5 Intelligent control strategy

12.6 Summary of advanced feedback control

References

13 Learning Control
Yi Yang, and Furong Gao

13.1 Learning control

13.2 Two-dimensional (2D) control

13.3 Conclusions

References

14 Multivariate Statistical Process Control
Yuan Yao, and Furong Gao

14.1 Statistical process control

14.2 Multivariate statistical process control

14.3 MSPC for batch processes

14.4 MSPC for injection molding process

14.5 Conclusions

References

15 Direct Quality Control
Yi Yang, and Furong Gao

15.1 Review of product weight control

15.2 Methods

15.3 Experimental results and discussion

15.4 Conclusions

References

Index

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