Journal articles: 'Hybrid Injection Molding'

1

TOMARI, Kiyotaka. "Hybrid Injection Molding Process." Kobunshi 47, no. 9 (1998): 665–68. http://dx.doi.org/10.1295/kobunshi.47.665.

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Asanuma, Nobuyuki. "Applying Direct Injection Molding Process and Hybrid Molding System to CFRP Molding." Seikei-Kakou 27, no. 3 (February 20, 2015): 89–93. http://dx.doi.org/10.4325/seikeikakou.27.89.

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Chen, Wei, Xian Hong Han, Xiong Hui Zhou, and Xue Wei Ge. "Hybrid Optimization Approach for Gas-Assisted Injection Molding Based on Metamodeling and Particle Swarm Algorithm." Advanced Materials Research 97-101 (March 2010): 3353–56. http://dx.doi.org/10.4028/www.scientific.net/amr.97-101.3353.

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As a new plastic process technique, Gas-assisted injection molding has many advantages comparing to the traditional injection molding. Meanwhile, Optimization of Gas-assisted injection molding is more complex since many additional parameters have been introduced to the process. In this paper, a hybrid optimization approach based on metamodeling and particle swarm optimization algorithm is proposed and applied for Gas-assisted injection molding. Moreover, the validation of the approach will be illustrated through the optimization process of a real panel.

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Frick, Achim, and Marcel Spadaro. "Injection Molded Aluminum-Polymer-Composites - Integral Lightweight Structures with Potential." Key Engineering Materials 742 (July 2017): 381–88. http://dx.doi.org/10.4028/www.scientific.net/kem.742.381.

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Innovative lightweight structures realized by employing assembly injection molding bears high potential. Using assembly injection molding, complex shaped hybrid structures can be manufactured in a precise and fast processing step. Though, especially the interface quality of a hybrid joint is a crucial factor, which determines the overall quality of such lightweight structures. High bonding strength values were achieved between aluminum and multiple polymeric materials with double-lap joints manufactured by employing assembly injection molding. Thereby, the influence of aluminum surface pre-treatments as well as intrinsic adhesion modifications of the polymeric materials were investigated.

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Hirsch, Patrick, Marianne John, Daniel Leipold, André Henkel, Sylvia Gipser, Ralf Schlimper, and Matthias Zscheyge. "Numerical Simulation and Experimental Validation of Hybrid Injection Molded Short and Continuous Fiber-Reinforced Thermoplastic Composites." Polymers 13, no. 21 (November 7, 2021): 3846. http://dx.doi.org/10.3390/polym13213846.

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In-situ thermoforming and overmolding of continuous fiber-reinforced thermoplastic composites by hybrid injection molding enables the mass production of thermoplastic lightweight structures with a complex geometry. In this study, the anisotropic mechanical behavior of such hybrid injection molded short and continuous fiber-reinforced thermoplastics and the numerical simulation of the resulting mechanical properties under flexural loading were investigated. For this, the influence of the volume flow rate between 25 and 100 cm3/s during injection molding of a PP/GF30 short fiber-reinforced overmolding material was studied and showed a strong effect on the fiber orientation but not on the fiber length, as investigated by computer tomography and fiber length analysis. Thus, the resulting anisotropies of the stiffness and strength as well as the strain hardening investigated by tensile testing were considered when the mechanical behavior of a hybrid test structure of short and continuous fiber-reinforced thermoplastic composites was predicted by numerical simulations. For this, a PP/GF60 and PP/GF30 hybrid injection molded test structure was investigated by a numerical workflow with implemented injection molding simulation data. In result, the prediction of the mechanical behavior of the hybrid test structure under flexural loading by numerical simulation was significantly improved, leading to a reduction of the deviation of the numerically predicted and experimentally measured flexural strength from 21% to 9% in comparison to the isotropic material model without the implementation of the injection molding data.

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Ling, Wei. "PID Control of Hybrid Injection Molding Machine Temperature." Advanced Materials Research 753-755 (August 2013): 2607–11. http://dx.doi.org/10.4028/www.scientific.net/amr.753-755.2607.

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This article analyzing the importance of PID in the design of the temperature process controller for hybrid injection mould machine. The injection mould machine is a basic requirement of plastic. Its process to mould the items through adjustment of proper temperatures realized desired shapes. And it is very indispensable to maintain these desired temperatures. PID controller is used as an industrial process controller. It may not get satisfying results when used as a temperature process controller. The temperature process has the characteristics of non-linearity, large inertia and time variations. To solve these problems, this article put forward an effective controller design by introducing PID in the designing of temperature process controller. The paper drafted the performance analysis of PID controller versus based controller designs.

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Liao, Xiao Ping, Ting Ruan, Wei Xia, Jun Yan Ma, and Liu Lin Li. "Multi-Objective Optimization by Gaussian Genetic Algorithm and its Application in Injection Modeling." Advanced Materials Research 399-401 (November 2011): 1672–76. http://dx.doi.org/10.4028/www.scientific.net/amr.399-401.1672.

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A method of combining Gaussian Process (GP) Surrogate model and Gaussian genetic algorithm is discussed to optimize the injection molding process. GP surrogate model is constructed to map the complex non-linear relationship between process conditions and quality indexes of the injection molding parts. While the surrogate model is established, a Gaussian genetic algorithm (GGA) combined with Gaussian mutation and hybrid genetic algorithm is employed to evaluate the model to search the global optimal solutions. The example presented shows that the GGA is more effective for the process optimization of injection molding.

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Nishiyabu, Kazuaki, Kenichi Kakishita, and Shigeo Tanaka. "Micro Metal Injection Molding Using Hybrid Micro/Nano Powders." Materials Science Forum 534-536 (January 2007): 381–84. http://dx.doi.org/10.4028/www.scientific.net/msf.534-536.381.

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This study aims to investigate the effects of hybrid micro/nano powders in a micro metal injection molding (μ-MIM) process. A novel type of mixing-injection molding machine was used to produce tiny specimens (<1mm in size) with high trial efficiency using a small amount of feedstock (<0.05cm3 in volume). Small dumbbell specimens were produced using various feedstocks prepared by changing binder content and fraction of nano-scale Cu powder (130nm in particle size). The effects of adding the fraction of nano-scale Cu powder on the melt viscosity of the feedstock, microstructure, density and tensile strength of sintered parts were discussed.

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Tomioka, Masao, Takeshi Ishikawa, Akira Inoue, and Tatsuya Tanaka. "Influence of Molding Conditions in Hybrid Injection Molding on Interfacial Adhesion between Inserted and Injection-molded Materials." Seikei-Kakou 30, no. 4 (March 20, 2018): 170–77. http://dx.doi.org/10.4325/seikeikakou.30.170.

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Petrova, Tatiana, and David Kazmer. "Hybrid neural models for pressure control in injection molding." Advances in Polymer Technology 18, no. 1 (1999): 19–31. http://dx.doi.org/10.1002/(sici)1098-2329(199921)18:1<19::aid-adv3>3.0.co;2-u.

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Burmeister, Frank, Jan Hagen, Joern Denter, Marco Wirth, Alexander Fromm, and Guenter Kleer. "Hybrid Inorganic-Organic Functional Coatings for Injection Molding Applications." Plasma Processes and Polymers 6, S1 (June 2009): S1—S5. http://dx.doi.org/10.1002/ppap.200930102.

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Kirchheim, Andreas, Yogeshkumar Katrodiya, Livia Zumofen, Frank Ehrig, and Curdin Wick. "Dynamic conformal cooling improves injection molding." International Journal of Advanced Manufacturing Technology 114, no. 1-2 (March 8, 2021): 107–16. http://dx.doi.org/10.1007/s00170-021-06794-0.

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AbstractTo achieve a certain visual quality or acceptable surface appearance in injection-molded components, a higher mold surface temperature is needed. In order to achieve this, injection molds can be dynamically tempered by integrating an active heating and cooling process inside the mold halves. This heating and cooling of the mold halves becomes more efficient when the temperature change occurs closer to the mold surface. Complex channels that carry cold or hot liquids can be manufactured close to the mold surface by using the layer by layer principle of additive manufacturing. Laser powder bed fusion (L-PBF), as an additive manufacturing process, has special advantages; in particular, so-called hybrid tools can be manufactured. For example, complex tool inserts with conformal cooling channels can be additively built on simple, machined baseplates. This paper outlines the thermal simulation carried out to optimize the injection molding process by use of dynamic conformal cooling. Based on the results of this simulation, a mold with conformal cooling channels was designed and additively manufactured in maraging steel (1.2709) and then experimentally tested.

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Sönmez, D., and A. A. Eker. "Numerical Simulation and Process Optimization of a 3D Thin-Walled Polymeric Part Using Injection Compression Molding." International Polymer Processing 36, no. 4 (September 1, 2021): 459–67. http://dx.doi.org/10.1515/ipp-2020-4075.

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Abstract Injection compression molding (ICM) is a hybrid injection molding process for manufacturing polymer products with high precision and surface accuracy. In this study, a 3D flow simulation was employed for ICM and injection molding (IM) processes. Initially, the process parameters of IM and ICM were discussed based on the numerical simulations. The IM and ICM processes were compared via numerical simulation by using CAE tools of Moldflow software. The effect of process parameters of mold surface temperature, melting temperature, compression force and injection time on clamping force and pressure at the injection location of molded 3D BJ998MO Polypropylene (MFI 100) part was investigated by Taguchi analysis. In conclusion, it was found that the ICM has a relatively lower filling pressure than ICM, which results in reduced clamping force for producing a 3D thin-walled polymeric part.

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Llewelyn, Rees, Griffiths, and Jacobi. "A Novel Hybrid Foaming Method for Low-Pressure Microcellular Foam Production of Unfilled and Talc-Filled Copolymer Polypropylenes." Polymers 11, no. 11 (November 17, 2019): 1896. http://dx.doi.org/10.3390/polym11111896.

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Unfilled and talc-filled Copolymer Polypropylene (PP) samples were produced through low-pressure foam-injection molding (FIM). The foaming stage of the process has been facilitated through a chemical blowing agent (C6H7NaO7 and CaCO3 mixture), a physical blowing agent (supercritical N2) and a novel hybrid foaming (combination of said chemical and physical foaming agents). Three weight-saving levels were produced with the varying foaming methods and compared to conventional injection molding. The unfilled PP foams produced through chemical blowing agent exhibited the strongest mechanical characteristics due to larger skin wall thicknesses, while the weakest were that of the talc-filled PP through the hybrid foaming technique. However, the hybrid foaming produced superior microcellular foams for both PPs due to calcium carbonate (CaCO3) enhancing the nucleation phase.

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Chen, Tianran, Dana Kazerooni, Lin Ju, David A. Okonski, and Donald G. Baird. "Development of Recyclable and High-Performance In Situ Hybrid TLCP/Glass Fiber Composites." Journal of Composites Science 4, no. 3 (August 24, 2020): 125. http://dx.doi.org/10.3390/jcs4030125.

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By combining the concepts of in situ thermotropic liquid crystalline polymer (TLCP) composites and conventional fiber composites, a recyclable and high-performance in situ hybrid polypropylene-based composite was successfully developed. The recycled hybrid composite was prepared by injection molding and grinding processes. Rheological and thermal analyses were utilized to optimize the processing temperature of the injection molding process to reduce the melt viscosity and minimize the degradation of polypropylene. The ideal temperature for blending the hybrid composite was found to be 305 °C. The influence of mechanical recycling on the different combinations of TLCP and glass fiber composites was analyzed. When the weight fraction ratio of TLCP to glass fiber was 2 to 1, the hybrid composite exhibited better processability, improved tensile performance, lower mechanical anisotropy, and greater recyclability compared to the polypropylene reinforced by either glass fiber or TLCP alone.

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Furusawa, Tsuyoshi. "Eco-Friendly Injection Molding Machine (Hybrid Type) FVX-III series." Seikei-Kakou 26, no. 12 (November 20, 2014): 572. http://dx.doi.org/10.4325/seikeikakou.26.572.

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Turng, L. S., and H. Kharbas. "Development of a Hybrid Solid-Microcellular Co-injection Molding Process." International Polymer Processing 19, no. 1 (March 2004): 77–86. http://dx.doi.org/10.3139/217.1806.

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KAKISHITA, Kenichi, Kazuaki NISHIYABU, and Shigeo TANAKA. "2722 Micro Metal Injection Molding Using Hybrid Micro/Nano Powder." Proceedings of the JSME annual meeting 2006.1 (2006): 173–74. http://dx.doi.org/10.1299/jsmemecjo.2006.1.0_173.

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19

Liu, Z. Y., D. Kent, and G. B. Schaffer. "Powder Injection Molding of Al-(Steel and Magnet) Hybrid Components." Metallurgical and Materials Transactions A 40, no. 12 (October 10, 2009): 2785–88. http://dx.doi.org/10.1007/s11661-009-0012-1.

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20

Ganesh, G. Dongre, S. Chaitanya Sarang, and M. Jonnalagadda Sai. "Design, Optimization and Validation of Conformal Cooling Technique for Additively Manufactured Mold Insert." Journal of Physics: Conference Series 2070, no. 1 (November 1, 2021): 012225. http://dx.doi.org/10.1088/1742-6596/2070/1/012225.

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Abstract Injection molding is a cyclic process comprising of cooling phase as the largest part of this cycle. Providing efficient cooling in lesser cycle times is of significant importance in the molding industry. Conformal cooling is a proven technique for reduction in cycle times for injection molding. In this study, we have replaced a conventional cooling circuit with an optimized conformal cooling circuit in an injection molding tool (mold). The required heat transfer rate, coolant flow rate and diameter of channel was analytically calculated. Hybrid Laser powder bed fusion technique was used to manufacture this mold tool with conformal channels. The material used for manufacturing mold was maraging steel (M300). Thermal efficiency of the conformal channels was experimentally calculated using thermal imaging. Autodesk MoldFlow software was used to simulate and predict the cooling time required using conformal cooling channels. The results showed a decrease in cooling time and increase in cooling efficiency with the help of conformal cooling in additively manufactured mold insert.

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Zhao, Zhongguo, Xin Zhang, Qi Yang, Taotao Ai, Shikui Jia, and Shengtai Zhou. "Crystallization and Microstructure Evolution of Microinjection Molded Isotactic Polypropylene with the Assistance of Poly(Ethylene Terephthalate)." Polymers 12, no. 1 (January 16, 2020): 219. http://dx.doi.org/10.3390/polym12010219.

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In this work, a series of isotactic polypropylene/poly(ethylene terephthalate) (iPP/PET) samples were prepared by microinjection molding (μIM) and mini-injection molding (IM). The properties of the samples were investigated in detail by differential scanning calorimetry (DSC), Wide-Angle X-ray Diffraction (WAXD), Polarized light microscope (PLM) and scanning electron microscopy (SEM). Results showed that the difference in thermomechanical history between both processing methods leads to the formation of different microstructures in corresponding iPP/PET moldings. For example, the dispersed spherical PET phase deforms and emerges into continuous in-situ microfibrils due to the intensive shearing flow field and temperature field in μIM. Additionally, the incorporation of PET facilitates both the laminar branching and the reservation of oriented molecular chains, thereby leading to forming a typical hybrid structure (i.e., fan-shaped β-crystals and transcrystalline). Furthermore, more compact and higher degrees of oriented structure can be obtained via increasing the content of PET. Such hybrid structure leads to a remarkable enhancement of mechanical property in terms of μIM samples.

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Gebauer, J., M. Fischer, A. F. Lasagni, I. Kühnert, and A. Klotzbach. "Laser structured surfaces for metal-plastic hybrid joined by injection molding." Journal of Laser Applications 30, no. 3 (August 2018): 032021. http://dx.doi.org/10.2351/1.5036803.

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Schift, Helmut, Prabitha Urwyler, and Per Magnus Kristiansen. "Surface-patterned micromechanical elements by polymer injection molding with hybrid molds." Journal of Vacuum Science & Technology B, Nanotechnology and Microelectronics: Materials, Processing, Measurement, and Phenomena 31, no. 6 (November 2013): 06FD01. http://dx.doi.org/10.1116/1.4821649.

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Serban, Daniiel, Giuseppe Lamanna, and Constantin Gheorghe Opran. "Mixing, Conveying and Injection Molding Hybrid System for Conductive Polymer Composites." Procedia CIRP 81 (2019): 677–82. http://dx.doi.org/10.1016/j.procir.2019.03.175.

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Ren, Zhigang, Yaodong Li, Zongze Wu, and Shengli Xie. "Deep Learning-Based Predictive Control of Injection Velocity in Injection Molding Machines." Advances in Polymer Technology 2022 (November 15, 2022): 1–14. http://dx.doi.org/10.1155/2022/7662264.

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Rapid and reliable optimal control of injection molding machines (IMMs) is critical for the effective production of injection-molded goods, especially in the situation of restricted computer resources of embedded equipment in IMMs. In this paper, an optimal tracking injection velocity control problem arising in a typical IMM is studied. An effective hybrid intelligent control approach with less computing resources for real-time implementation based on the deep learning (DL) method to mimic the classical model predictive control rule is developed to deal with the tracking control of the injection speed. The proposed method utilizes the gated recurrent unit neural network to learn and predict the optimal time series control process data produced by the traditional model predictive controller. The benefits of this approach over the conventional optimization method are illustrated through simulation results, which show that the convergent DL-based controller can effectively avoid the complex calculation in the control process of IMMs and meet the requirements of more robustness and resist environmental uncertainty to a certain level and can be potentially implemented in embedded hardware much more efficiently and conveniently with a smaller memory footprint and faster computation time.

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Budiyantoro, Cahyo, Heru S. B. Rochardjo, and Gesang Nugroho. "Overmolding of Hybrid Long and Short Carbon Fiber Polypropylene Composite: Optimizing Processing Parameters." Journal of Manufacturing and Materials Processing 5, no. 4 (December 8, 2021): 132. http://dx.doi.org/10.3390/jmmp5040132.

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Injection overmolding was used to produce hybrid unidirectional continuous-short carbon fiber reinforced polypropylene. Polypropylene pellets containing short carbon fibers were melted and overmolded on unidirectional carbon fibers, which act as the core of the composite structure. Four factors were varied in this study: fiber pretension applied to unidirectional fibers, injection pressure, melting temperature, and backpressure used for melting and injecting the composite pellet. This study aimed to evaluate the effect of these factors on fiber volume fraction, flexural strength, and impact strength of the hybrid composite. The relationship between factors and responses was analyzed using Box–Behnken Response Surface Methodology (RSM) and analysis of variance (ANOVA). Each aspect was divided into three levels. There were 27 experimental runs carried out, with three replicated center points. The results showed that the injection molding process parameters had no significant effect on the fiber’s volume fraction. On the other hand, melting temperature and fiber pretension significantly affected impact strength and flexural strength.

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Fernandez, Ellen, Mariya Edeleva, Rudinei Fiorio, Ludwig Cardon, and Dagmar R. D’hooge. "Increasing the Sustainability of the Hybrid Mold Technique through Combined Insert Polymeric Material and Additive Manufacturing Method Design." Sustainability 14, no. 2 (January 13, 2022): 877. http://dx.doi.org/10.3390/su14020877.

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To reduce plastic waste generation from failed product batches during industrial injection molding, the sustainable production of representative prototypes is essential. Interesting is the more recent hybrid injection molding (HM) technique, in which a polymeric mold core and cavity are produced via additive manufacturing (AM) and are both placed in an overall metal housing for the final polymeric part production. HM requires less material waste and energy compared to conventional subtractive injection molding, at least if its process parameters are properly tuned. In the present work, several options of AM insert production are compared with full metal/steel mold inserts, selecting isotactic polypropylene as the injected polymer. These options are defined by both the AM method and the material considered and are evaluated with respect to the insert mechanical and conductive properties, also considering Moldex3D simulations. These simulations are conducted with inputted measured temperature-dependent AM material properties to identify in silico indicators for wear and to perform cooling cycle time minimization. It is shown that PolyJetted Digital acrylonitrile-butadiene-styrene (ABS) polymer and Multi jet fusioned (MJF) polyamide 11 (PA11) are the most promising. The former option has the best durability for thinner injection molded parts, and the latter option the best cooling cycle times at any thickness, highlighting the need to further develop AM options.

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Tanaka, Kazuto, Akihiro Hirata, and Tsutao Katayama. "Effect of Press Condition on the Mechanical Properties of GFRTP Molded by the Melted Thermoplastic-Resin Transfer Molding." Key Engineering Materials 774 (August 2018): 367–72. http://dx.doi.org/10.4028/www.scientific.net/kem.774.367.

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The application of Fiber Reinforced Thermoplastics (FRTP) is expected to reduce the weight of automobiles. The press and injection hybrid molding method was developed to mold FRTP with high strength and high stiffness by giving complicated shapes such as ribs and bosses to the outer shell structure of FRTP with continuous fiber. However, as this method uses high-cost FRTP laminated sheets, it is necessary to develop a low-cost FRTP manufacturing process. In this study, we aim at the development of Melted Thermoplastic-Resin Transfer Molding (MT-RTM) to mold FRTP with complicated shape at low cost by injecting melted short fiber reinforced thermoplastics into dry fabric. The effects of press condition on the mechanical properties of GFRTP molded by MT-RTM were clarified by bending tests. GFRTP molded at high mold temperature and high closing speed showed high mechanical properties because of good impregnation of injection resin into continuous fabric in the outer shell structure.

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Thodsaratpreeyakul, Wiranphat, Putinun Uawongsuwan, Akio Kataoka, Takanori Negoro, and Hiroyuki Hamada. "Mechanical properties and fiber characteristics of glass fiber/carbon fiber reinforced polyethylene terephthalate hybrid composites fabricated by direct fiber feeding injection molding." Journal of Polymer Engineering 38, no. 6 (July 26, 2018): 513–23. http://dx.doi.org/10.1515/polyeng-2017-0193.

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Abstract Improving the applicability of polyethylene terephthalate (PET) by carbon fiber/glass fiber reinforcement is of great interest. Glass fiber (GF)/carbon fiber (CF)/PET hybrid composites were fabricated by direct fiber feeding injection molding (DFFIM) process. The aim of DFFIM is to obtain longer fibers in composites in order to improve their mechanical properties. In this study, the mechanical properties of GF/PET composites fabricated by conventional injection molding and hybrid GF/CF/PET composites fabricated by DFFIM process were investigated. The influence of GF and CF volume fractions on fiber distribution, fiber orientation, and fiber length is discussed. Fiber distribution status was quantitatively measured by the fiber distribution index. Fiber agglomeration problem was observed by scanning electron microscopy. The results indicate that incorporating CF in GF/CF/PET hybrid composites by the DFFIM process greatly enhances mechanical performance even when only a small amount of CF is added. Too high GF content leads to less effective CF hybridization because it causes poor fiber distribution and poor fiber orientation and intensifies fiber attrition. The ideal volume fractions of GF and CF for fabricating GF/CF/PET hybrid composites by using DFFIM are provided.

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Lu, Yanjun, Wang Luo, Xiaoyu Wu, Bin Xu, Chunjin Wang, Jiajun Li, and Liejun Li. "Fabrication of Micro-Structured LED Diffusion Plate Using Efficient Micro Injection Molding and Micro-Ground Mold Core." Polymers 12, no. 6 (June 8, 2020): 1307. http://dx.doi.org/10.3390/polym12061307.

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In this paper, a new style of micro-structured LED (light-emitting diode) diffusion plate was developed using a highly efficient and precise hybrid processing method combined with micro injection molding and micro-grinding technology to realize mass production and low-cost manufacturing of LED lamps with excellent lighting performance. Firstly, the micro-structured mold core with controllable shape accuracy and surface quality was machined by the precision trued V-tip grinding wheel. Then, the micro-structured LED diffusion plate was rapidly fabricated by the micro injection molding technology. Finally, the influences of micro injection molding process parameters on the illumination of the micro-structured diffusion plate were investigated. The simulated optical results show that the illumination of the micro-structured diffusion plate can achieve a maximum value when the V-groove depth and V-groove angle are designed to be 300 μm and 60°, respectively. The experimental results indicate that the developed micro-structured diffusion plate may improve the illumination by about 40.82% compared with the traditional diffusion plate. The prediction accuracy of the designed light efficiency simulation method was about 90.33%.

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Fernandez, Angel, and Manuel Muniesa. "Influence of Packing Phase Parameters in the Optimization of Mechanical, Weight Reduction and Dimensional Properties of Microcellular Foaming Injection Molding of Polypropilene." Advanced Materials Research 445 (January 2012): 319–24. http://dx.doi.org/10.4028/www.scientific.net/amr.445.319.

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Microcellular foaming of injected plastics offers the possibility to manufacture parts with reductions in costs and weight if compared with conventional injection molding. For this reason there is an increasing interest in challenging applications such as HEV (hybrid and electrical vehicles) and lightweight material applications in general. Complexity of microcellular injection molding is very high because the final properties of the material obtained depend largely on the processing conditions and these in turn unalterable factors such as mold design and manufacturing. The shrinkage of the molded part must be applied as an oversize of the mold cavity in the design phase. Shrinkage of a microcellular foam depends on the reduction of foam density. Moreover, the piece is designed to get a mechanical performance and meet the dimensional tolerances. Knowing that the reduction of foam density implies a reduction of the mechanical properties and influences the final piece dimensions the conclusion is that the microcellular injection process has a very small process window to fit all these factors. This research focuses on two objectives. First is the variation of post-molding shrinkage in terms of reduction of weight to determine the process window. Second is the determination of mechanical properties which do not show a proportional reduction but exponentially with weight reduction components. The results obtained with a 750 Tons. injection moulding machine equipped with a MuCell plastication unit and a large spiral mold have shown small variations in the dimensions for a predetermined process window and smaller reduction of mechanical properties with weight reductions for 20% talc filled polypropylene. The goal of this applied research is that all experiments have been developed with scaled-industry tools (large injection molding machine, Mucell unit and mold and test parts) comparing with conventional injection molding.

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Chen, Shia-Chung, Hai-Mei Li, Shyh-Shin Hwang, and Ho-Hsiang Wang. "Passive mold temperature control by a hybrid filming-microcellular injection molding processing." International Communications in Heat and Mass Transfer 35, no. 7 (August 2008): 822–27. http://dx.doi.org/10.1016/j.icheatmasstransfer.2008.03.013.

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Yu, Jingxian, and Qiyuan Zhang. "Limited Rolling Time Domain-Based Hybrid Tracking Control for Injection Molding Process." IEEE Access 7 (2019): 67446–55. http://dx.doi.org/10.1109/access.2019.2918020.

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Bakshi, Payal, Asokan Pappu, Ravi Patidar, Manoj Kumar Gupta, and Vijay Kumar Thakur. "Transforming Marble Waste into High-Performance, Water-Resistant, and Thermally Insulative Hybrid Polymer Composites for Environmental Sustainability." Polymers 12, no. 8 (August 9, 2020): 1781. http://dx.doi.org/10.3390/polym12081781.

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Marble waste is generated by marble processing units in large quantities and dumped onto open land areas. This creates environmental problems by contaminating soil, water, and air with adverse health effects on all the living organisms. In this work, we report on understanding the use of calcium-rich marble waste particulates (MPs) as economic reinforcement in recyclable polypropylene (PP) to prepare sustainable composites via the injection molding method. The process was optimized to make lightweight and high-strength thermally insulated sustainable composites. Physicochemical, mineralogical, and microscopic characterization of the processed marble waste particulates were carried out in detail. Composite samples were subsequently prepared via the injection molding technique with different filler concentrations (0%, 20%, 40%, 60%, and 80%) on weight fraction at temperatures of 160, 180, and 200 °C. Detailed analysis of the mechanical and thermal properties of the fabricated composites was carried out. The composites showed a density varying from 0.96 to 1.27 g/cm3, while the water absorption capacity was very low at 0.006%–0.034%. Marble waste particulates were found to considerably increase the tensile, as well as flexural, strength of the sustainable composites, which varied from 22.06 to 30.65 MPa and 43.27 to 58.11MPa, respectively, for the molding temperature of 160 °C. The impact strength of the sustainable composites was found to surge with the increment in filler concentration, and the maximum impact strength was recorded as 1.66 kJ/m2with 20% particulates reinforcement at a molding temperature of 200 °C. The thermal conductivity of the particulates-reinforced sustainable composites was as low as 0.23 Wm−1K−1 at a 200 °C molding temperature with 20% and 40% filler concentrations, and the maximum thermal conductivity was 0.48 Wm−1K−1 at a 160 °C molding temperature with 80% filler concentration. Our findings have shown a technically feasible option for manufacturing a lightweight composite with better mechanical and thermal properties using marble waste particulates as a potential civil infrastructural material.

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Hummel, Sabine, Katharina Obermeier, Katja Zier, Sandra Krommes, Michael Schemme, and Peter Karlinger. "Analysis of Mechanical Properties Related to Fiber Length of Closed-Loop-Recycled Offcuts of a Thermoplastic Fiber Composites (Organo Sheets)." Materials 15, no. 11 (May 29, 2022): 3872. http://dx.doi.org/10.3390/ma15113872.

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Increasing demand for energy-efficient means of transport has steadily intensified the trend towards lightweight components. Thermoplastic glass fiber composites (organo sheets) play a major role in the production of functional automotive components. Organo sheets are cut, shaped and functionalized by injection molding to produce hybrid components, such as those used in car door modules. The cutting process produces a considerable amount of production waste, which has thus far been thermally recycled. This study develops a closed mechanical recycling process and analyzes the different steps of the process. The offcuts were shredded using two shredding methods and implemented directly in the injection-molding process. Using tensile tests and impact bending tests, the material properties of the recycled materials were compared with the virgin material. In addition, fiber length degradation via the injection-molding process and the influence of the waterjet-cutting process on the mechanical properties are investigated. Recycled offcuts are both comparable to new material in terms of mechanical properties and usability, and are also economically and ecologically advantageous. Recycling polypropylene waste with glass fiber reinforcement in a closed loop is an effective way to reduce industrial waste in a sustainable and economical production process.

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Almeida, Fátima de, Vitor F. C. Sousa, Francisco J. G. Silva, Raúl D. S. G. Campilho, and Luís P. Ferreira. "Development of a Novel Design Strategy for Moving Mechanisms Used in Multi-Material Plastic Injection Molds." Applied Sciences 11, no. 24 (December 12, 2021): 11805. http://dx.doi.org/10.3390/app112411805.

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Plastics injection molding is a sector that is becoming increasingly competitive due to the environmental issues it entails, pressuring consumers to reduce its use. Thus, plastics processing companies attempt to minimize costs, with the aim of increasing competitiveness. This pressure is transmitted to the mold manufacturers, as the mold conditions the equipment that it is used for, which may have significantly different amortization costs. The present work aimed to design a novel mechanism able to deal with the necessary movements in 2K injection molding in a more compact way. A novel hybrid mechanical and hydraulic movement was developed. More compact movements lead to smaller molds, which can be used on smaller injection machines, leading to reduced costs. This methodology consists of multiplying a disproportionate movement to the mold through several movements, which results in a slightly more complex, but much more compact, system for molds devoted to multi-material injected parts.

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Tóth, Csenge, and Norbert Krisztián Kovács. "Development of a Novel Hybrid Manufacturing Technology For Continuous Fiber-Reinforced Thermo-Plastic Composites." Acta Materialia Transylvanica 5, no. 1 (April 1, 2022): 39–44. http://dx.doi.org/10.33924/amt-2022-01-09.

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Abstract In this study, we present a novel approach for the production of continuous fiber-reinforced thermoplastic composites by combining injection molding and additive manufacturing. After exploring the design requirements, we manufactured inserts via continuous fiber-reinforced 3D printing, then we used them as reinforcement for injection-molded samples. Improper fiber placement can cause warpage as the continuous fibers prevent shrinking; however, warpage can be compensated with the insert geometry. The reinforcement resulted in an increase of about 30% in the properties tested.

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Moritzer, Elmar, and Christopher Budde. "Influence of Material Properties on the Bond Strength of a Hybrid Part Consisting of Composite Sheet and Short-Fiber Thermoplastic." Materials Science Forum 825-826 (July 2015): 409–16. http://dx.doi.org/10.4028/www.scientific.net/msf.825-826.409.

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A significant advantage of continuous-fiber-reinforced thermoplastics (composite sheets) compared with sheet steel or aluminum is that the forming process can be integrated directly into the injection molding process. To do so, the composite sheet is heated by contact or infrared heating to a suitable temperature, then formed with the closing stroke of the injection molding tool, and subsequently back molded. In this way it is possible to achieve a high level of functional integration, because functional elements such as snap hooks and clips can be directly integrated as part of the molded component without the need for any additional process steps after finishing the part.This study investigates the influence of key material properties on the strength of the bond between such a composite sheet and the back-molded thermoplastic component, determined with a peel test.

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Deringer, Tim, and Dietmar Drummer. "The influence of mold temperature on thermoset in-mold forming." Journal of Polymer Engineering 40, no. 3 (February 25, 2020): 256–66. http://dx.doi.org/10.1515/polyeng-2019-0322.

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AbstractA new process, called thermoset in-mold forming, for combining thermoset master forming and thermoset forming in one mold is in development. A pre-impregnated continuous-fiber reinforced sheet based on epoxy (prepreg) is formed in the injection molding machine, followed by instantaneous overmolding of a short-fiber reinforced epoxy compound in one step. Compared with conventional processes in which thermoset injection molding, prepreg compression molding, and hence curing of the materials are separated, the new process allows for the combination in one step and simultaneous curing of both components. The result is a hybrid component, which features a continuous-fiber reinforced part for higher mechanical performance and a short-fiber reinforced part with high design freedom for integration of additional functions. For a successful combination of both materials in one process, it is essential to investigate the bond strength between them in relation to the processing parameters and their influence on the degree of cure. This paper analyzes the influence of the mold temperature in this process on curing degree, bond strength, and the processing viscosity.

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NISHIMUKAI, Koji, Daiki TANABE, and Kazuaki Daiki. "J0450105 Fabrication of Thermoplastic CFRP Shock Absorber by Hot Pressing-Injection Hybrid Molding." Proceedings of Mechanical Engineering Congress, Japan 2015 (2015): _J0450105——_J0450105—. http://dx.doi.org/10.1299/jsmemecj.2015._j0450105-.

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Guo, Gangjian, Joseph C. Chen, and Guan Gong. "Injection molding of polypropylene hybrid composites reinforced with carbon fiber and wood fiber." Polymer Composites 39, no. 9 (March 24, 2017): 3329–35. http://dx.doi.org/10.1002/pc.24350.

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Chen, Wen Jong, and Jia Ru Lin. "Design of Optimization Parameters with Hybrid Genetic Algorithm Method in Multi-Cavity Injection Molding Process." Advanced Materials Research 463-464 (February 2012): 587–91. http://dx.doi.org/10.4028/www.scientific.net/amr.463-464.587.

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This paper combines an artificial neural network (ANN) with a traditional genetic algorithm (GA) method, called hybrid genetic algorithm (HGA), to analyze the warpage of multi-cavity plastic injection molding parts. Simulation results indicate that the minimum and the maximum warpage of the hybrid genetic algorithm (HGA) method were lower than that of the traditional GA method and CAE simulation. These results reveal that, when HGA is applied to multi-cavity plastic warpage analysis, the optimal process conditions are significantly better than those using the traditional GA method or CAE simulation.

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Machado, Ricardo, Waldyr Ristow, P. R. Alba, Aloísio Nelmo Klein, Paulo A. P. Wendhausen, and D. Fusão. "Plasma Assisted Debinding and Sintering (PADS) – Metal Injection Molding Application." Materials Science Forum 530-531 (November 2006): 224–29. http://dx.doi.org/10.4028/www.scientific.net/msf.530-531.224.

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this paper describes the PADS process and equipment, which has been developed to produce PIM components. The use of a hybrid system of plasma discharge and Mo heating elements makes debinding and sintering PIM components in the same heating cycle possible. The use of an abnormal discharge between a cathode and anode under low-pressure provides reactive specimens that break the polymeric chains of the binder of the molded parts. By the combination of these features it was possible to use heating rates of 2,0º C/min during the debinding step. The hydrocarbons, resulted from debinding, are pumped out through vacuum pumps, without traps. The clean environment makes possible to sinter the parts in the same cycle, as well as execute a surface treatment during cooling. The results present short process times as 6 hours to Fe2Ni0,6C low alloy steel and 7 hours to 316-L stainless steel. Characteristics as density, carbon content and mechanical properties are similar to traditional PIM process. The reduction of energy and gas consumption and shorter lead-times are economic advantages of PADS system. The clean environment of PADS is also an ecological advantage.

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Mehner, Andreas, Ju An Dong, Timo Hoja, Torsten Prenzel, Yildirim Mutlugünes, Ekkard Brinksmeier, Don Lucca, and Fritz Klaiber. "Diamond Machinable Sol-Gel Silica Based Hybrid Coatings for High Precision Optical Molds." Key Engineering Materials 438 (May 2010): 65–72. http://dx.doi.org/10.4028/www.scientific.net/kem.438.65.

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The demand for high precision optical elements as micro lens arrays for displays increases continually. Economic mass production of such optical elements is done by replication with high precision optical molds. A new approach for manufacturing such molds was realized by diamond machinable and wear resistant sol-gel coatings. Crack free silica based hybrid coatings from base catalyzed sols from tetraethylorthosilicate (TEOS: Si(OC2H5)4) and methyltriethoxysilane (MTES: Si(CH3)(OC2H5)3) precursors were deposited onto pre-machined steel molds by spin coating process followed by a heat treatment at temperatures up to 800°C. Crack-free multilayer coatings with a total thickness of up to 18 µm were achieved. Micro-machining of these coatings was accomplished by high precision fly cutting with diamond tools. Molds with micro-structured coatings were successfully tested for injection molding of PMMA optical components. The wear resistance of the coatings was successfully tested by injection molding of 1000 PMMA lenses. Hardness and elastic modulus of the coatings were measured by nano indentation. The chemical composition was measured by X-ray photo electron spectroscopy (XPS) as a function of the sol-gel processing parameters.

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Himasekhar, K., J. Lottey, and K. K. Wang. "CAE of Mold Cooling in Injection Molding Using a Three-Dimensional Numerical Simulation." Journal of Engineering for Industry 114, no. 2 (May 1, 1992): 213–21. http://dx.doi.org/10.1115/1.2899774.

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In recent years, increased attention has been paid to the design of cooling systems in injection molding, as it became clear that cooling affects both productivity and part quality. In order to systematically improve the performance of a cooling system in terms of rapid, uniform, and even cooling, the designer needs a CAE analysis tool. For this, a computer simulation has been developed for three-dimensional mold heat transfer during the cooling stage of an injection molding process. In this simulation, mold heat transfer is considered as cyclic-steady, three-dimensional conduction; heat transfer within the melt region is treated as transient, one-dimensional conduction; heat exchange between the cooling channel surfaces and coolant is treated as steady, as is heat exchange with the ambient air and mold exterior surfaces. Numerical implementation includes the application of a hybrid scheme consisting of a modified three-dimensional, boundary-element method for the mold region and a finite-difference method with a variable mesh for the melt region. These two analyses are iteratively coupled so as to match the temperature and heat flux at the mold-melt interface. Using an example, the usefulness of the simulation developed here in the design of a cooling system for an injection molding process is amply demonstrated.

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MATSUMOTO, Fumiya, Daiki TANABE, and Kazuaki NISHIYABU. "Evaluation method for tensile shear strength of woven CF/PA66 hybrid specimen manufactured by hybrid injection molding." Proceedings of Mechanical Engineering Congress, Japan 2019 (2019): J04410P. http://dx.doi.org/10.1299/jsmemecj.2019.j04410p.

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Sobhanie, M., and A. I. Isayev. "Viscoelastic Simulation of Flow of Rubber Compounds." Rubber Chemistry and Technology 62, no. 5 (November 1, 1989): 939–56. http://dx.doi.org/10.5254/1.3536285.

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Abstract A hybrid scheme has been developed for numerical simulation of a nonisothermal viscoelastic flow in an arbitrary planar geometry of uniform thickness during extrusion and injection molding. This formulation is based on the control-volume finite-element method for solution of the continuity and momentum equations and finite difference method for solution of the energy equation. Application of this numerical technique for simulation of an extrusion and injection molding process was performed in a slit die and a quarter of a circular disk cavity, respectively. Development of pressures, shear and normal stresses, velocities, and temperature fields were calculated during nonisothermal flow of the rubber compound. Furthermore, the relaxation of stresses was calculated after cessation of the flow. The location of the meltfront was predicted during the cavity filling process. The contribution of normal stresses was studied by comparing results following from the viscoelastic and inelastic simulations.

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Loaldi, Dario, Leonardo Piccolo, Eric Brown, Guido Tosello, Corey Shemelya, and Davide Masato. "Hybrid Process Chain for the Integration of Direct Ink Writing and Polymer Injection Molding." Micromachines 11, no. 5 (May 18, 2020): 509. http://dx.doi.org/10.3390/mi11050509.

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The integration of additive manufacturing direct-writing technologies with injection molding provides a novel method to combine functional features into plastic products, and could enable mass-manufacturing of custom-molded plastic parts. In this work, direct-write technology is used to deposit conductive ink traces on the surface of an injection mold. After curing on the mold surface, the printed trace is transferred into the plastic part by exploiting the high temperature and pressure of a thermoplastic polymer melt flow. The transfer of the traces is controlled by interlocking with the polymer system, which creates strong plastic/ink interfacial bonding. The hybrid process chain uses designed mold/ink surface interactions to manufacture stable ink/polymer interfaces. Here, the process chain is proposed and validated through systematic interfacial analysis including feature fidelity, mechanical properties, adhesion, mold topography, surface energy, and hot polymer contact angle.

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Hisakura, Yuuki, Keinichi Kitahara, Makoto Sugihara, Akihiko Imajo, and Hiroyuki Hamada. "Mechanical Properties of GF/CF Hybrid ABS Composite by DFFIM." Key Engineering Materials 728 (January 2017): 240–45. http://dx.doi.org/10.4028/www.scientific.net/kem.728.240.

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The direct fiber feeding injection molding (DFFIM) process is the new fabrication technique. This technique is able to eliminate the compounding process. In this study, the composite consisting of glass fiber/carbon fiber/ABS (GF/CF/ABS) were fabricated. Tensile, bending and Izod impact test were conducted to compare mechanical properties between glass fiber and glass fiber/carbon fiber hybrid composites. The additional of carbon fiber improved tensile, bending and impact properties of the hybrid composites. SEM photographs indicated that carbon fiber tended to agglomerate during DFFIM process. It can be noted that the low content of carbon fiber was suitable for enhanced mechanical performances of GF/CF/ABS hybrid composites.

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Kang, Ji-Heon, Jae-Wook Lee, Jae-Hong Kim, Tae-Min Ahn, and Dae-Cheol Ko. "Design of Center Pillar with Composite Reinforcements Using Hybrid Molding Method." Materials 14, no. 8 (April 20, 2021): 2047. http://dx.doi.org/10.3390/ma14082047.

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Recently, with the increase in awareness about a clean environment worldwide, fuel efficiency standards are being strengthened in accordance with exhaust gas regulations. In the automotive industry, various studies are ongoing on vehicle body weight reduction to improve fuel efficiency. This study aims to reduce vehicle weight by replacing the existing steel reinforcements in an automobile center pillar with a composite reinforcement. Composite materials are suitable for weight reduction because of their higher specific strength and stiffness compared to existing steel materials; however, one of the disadvantages is their high material cost. Therefore, a hybrid molding method that simultaneously performs compression and injection was proposed to reduce both process time and production cost. To replace existing steel reinforcements with composite materials, various reinforcement shapes were designed using a carbon fiber-reinforced plastic patch and glass fiber-reinforced plastic ribs. Structural analyses confirmed that, using these composite reinforcements, the same or a higher specific stiffness was achieved compared to the that of an existing center pillar using steel reinforcements. The composite reinforcements resulted in a 67.37% weight reduction compared to the steel reinforcements. In addition, a hybrid mold was designed and manufactured to implement the hybrid process.

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Journal articles on the topic 'Hybrid Injection Molding'

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