Robust injection moulding of automotive components with low environmental impact
| Reference number | |
| Coordinator | Volvo Personvagnar AB - Avd 93644 PV3C2 |
| Funding from Vinnova | SEK 3 183 179 |
| Project duration | November 2018 - May 2021 |
| Status | Completed |
| Venture | FFI - Sustainable Production |
| End-of-project report | 2018-02689sv.pdf(pdf, 1565 kB) (In Swedish) |
Purpose and goal
Injection molding offers fantastic opportunities to manufacture innovative and environmentally friendly products. However, injection molding of products with the intended appearance can be difficult. The objective of the project was, therefore, to increase knowledge about robust injection molding. Based on the results obtained, it is clear that it is important to consider everything from the product´s design and choice of material to the machine settings. Parameters of particular importance are e.g. melt viscosity, tool temperature, injection rate and pressure.
Expected results and effects
Most of the project´s work has focused on simulation of texture replication and extensive mold filling simulations have shown that the pressure when the surface layer solidifies is probably the parameter that best correlates with the gloss of the finished product. In addition to extensive simulations, five experimental investigations have been carried out and a large number of different parameters have been analyzed. The experimental investigations have led to increased knowledge about texture replication, but also generated a lot of input data for the simulations.
Planned approach and implementation
To improve the knowledge of robust injection molding of textured products, 5 experimental studies have been performed. Each study has been performed as a Design of Experiment (DoE) and has been prepared and evaluated very carefully using extensive flow simulations. A large variety of materials and process parameters have been tested e.g. melting temperature, tool temperature, injection rate, back pressure and back pressure. And the gloss, color, surface topography, and scratch resistance of the manufactured test objects have been analysed.