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The purpose of this book is to introduce the reader to some topics relevant to the modeling of the injection molding process. Injection molding processing links to various scientific and engineering disciplines such as rheology, mechanical and chemical engineering, polymer science and computational methods. While it is impossible to address every aspect of such a broad range of issues, this book is intended to address the up-to-date status of fundamental understanding and sim-ulation technologies, without losing sight of still useful classical approaches.23990
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The book is organized as follows. In Chap. 1, a general overview of the
injection molding stages, material classification, rheological characterization of
polymers, and the development of numerical simulation methods is presented as an
introduction. In Chap. 2, fundamentals of rheology are described, focused on
constitutive models useful in practice. Chapter 3 describes assumptions and
mathematical models for filling and packing phases of the injection molding
process. Chapter 4 is devoted to flow-induced crystallization and the processing–
morphology–properties relationship. This is a very active field, which has attracted
great attention in recent years. Chapter 5 discusses the modeling of flow-induced
orientation distribution in injection molded fiber-reinforced polymers, highlighting
the efforts to simulate particle–particle interactions. The application of the mul-
tilevel micro–macro approach to fiber suspensions is also demonstrated. Chapter 6
presents methods to predict shrinkage and warpage. Micromechanics for
mechanical property predictions is also included in this chapter. Finally, Chap. 7
deals with the application of boundary integral equations to the mold cooling
analysis. Chapter 8 provides a guide to some computational techniques used in
simulations of melt flow in mold filling and packing, deformation of the solid
parts, and mold cooling. Cartesian tensors are used in this book for conciseness.
The authors wish to acknowledge with deep appreciation our many colleagues
and research collaborators: Nhan Phan-Thien, Peter Kennedy, Graham Edward,
Pengwei Zhu, Ahmad Jabbarzadeh, Chitiur Hadinata, Shaocong Dai, Huashu Dou
and Duane Lee Wo, who have contributed to the research outcomes which the
book is based on. We also wish to thank Charles Tucker, Jay Schieber, Gilles
Regnier, Rene Fulchiron, Didier Delaunay, Vito Leo, Gerhard Eder, Gerrit Peters,Zhilaing Fan, Huagang Yu, Clinton Kietzman, Xiaoshi Jin, Zhongshuang Yuan,
Franco Costa and Edwin Klompen for many fruitful interactions and discussions.
Thanks also due to the Australian Research Council (ARC), the Cooperative
Research Centre for Polymers (CRC-P) and Moldflow Pty Ltd (now, Autodesk
Australia) for the financial support to the authors’ research during the past years.
Finally, our personal thanks are extended to our families for the love, support
and encouragement.We acknowledge with gratitude the assistance of the following organizations and
inpiduals.
American Chemical Society
Figure 4.10 is reproduced with permission from the article by A. Jabbarzadeh
and R.I. Tanner, Macromol 43: 8136–8142. Copyright 2010.
American Institute of Physics for the Society of Rheology
Figure 4.3 is reproduced with permission from the article by R. Zheng and
P.K. Kennedy, J Rheol 48: 823–842. Copyright 2004.
Elsevier Science Publishers B.V.
Experimental data in Fig. 4.4 is reproduced with permission from the article by
R. Mendoza, G. Régnier, W. Seiler, and J.L. Lebrun, J Mater Sci 30: 5002–5012.
Copyright 2003.
Figures 5.2, 6.4 and 6.6 are reproduced with permission from the article by
R. Zheng, P.K. Kennedy, N. Phan-Thien and X.-J. Fan, J Non-Newtonian Fluid