Reducing residual stresses in molded parts

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<jats:title>Abstract</jats:title><jats:p>Means of reducing the flow‐induced residual stresses in injection molded parts through optimization of the thermal history of the process are presented. An approach through the use of a passive insulation layer with low thermal inertia on the cavity surface was investigated. The passive insulation layer prevents the polymer melt from freezing during mold filling and allows the flow‐induced stresses to relax after the filling. The criteria for the optimal thermal properties and the required thickness of the layer are presented. A numerical simulation model of non‐isothermal filling and cooling of viscoelastic materials was also used to understand the molding process and to evaluate this approach. This model predicts the stress development and relaxation in the molding cycle. Both simulation and experimental results show that the final stresses in the molded parts can be reduced significantly with the use of an insulation layer. This technique can also be applied to other molding or forming processes in order to decouple the material flow and cooling process for minimum residual stresses in the molded parts.</jats:p>

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