Abstract
The purpose of this study is to present a simulation-based approach capable of predicting the fatigue life of a mold core with the help of CAE technology based on injection molding simulation, core stress analysis and fatigue life prediction. Injection molding simulation is performed in order to obtain the non-uniform pressure acting on a mold core due to the polymer melt flow during injection molding process. Subsequently, the melt pressure profile is used as loading condition for core stress analysis via one-way coupling technique. The lifetime of a mold core is then predicted by fatigue analysis with stress-life approach. For verification of simulation-based approach to the fatigue life prediction, tests were also performed.
Similar content being viewed by others
References
Ahn, D. G., Kim, D. W. and Yoon, Y. U. (2010). Optimal injection molding conditions considering the core shift for a plastic battery case with thin and deep walls. J. Mech. Sci. Tech. 24,1, 145–148.
Bannantine, J. A., Comer, J. J. and Handbrock, J. L. (1990). Fundamentals of Metal Fatigue Analysis. Prentice-Hall. Englewood Cliffs. New Jersey.
Carpenter, B., Patil, S., Hoffman, R. and Lilly, B. (2006). Effect of machine compliance on mold deflection during injection and packing of thermoplastic parts. Polymer Engineering & Science 46,7, 844–852.
Chen, Y. C., Liao, Y. J., Tseng, S. C. and Giacomin, A. J. (2011). Core deflection in plastics injection molding: Direct measurement, flow visualization and 3D simulation. Polymer-Plastics Technology & Engineering 50,9, 863–872.
Fukaura, K., Yokoyama, Y., Yokoi, D., Tsujii, N. and Ono, K. (2004). Fatigue of cold-work tool steels: Effect of heat treatment and carbide morphology on fatigue crack formation, life, and fracture surface observations. Metallurgical and Materials Trans. A, 35A, 1289–1300.
Giacomin, A. J., Hade, A. J., Johnson, L. M., Mix, A. W., Chen, Y. C., Liao, H. C. and Tseng, S. C. (2011). Core deflection in injection molding. J. Non-Newtonian Fluid Mechanics 166,16, 908–914.
Hashemi, S. (2010). Effect of temperature on weldline integrity of injection moulded short glass fibre and glass bead filled ABS hybrids. Polymer Testing, 29, 327–336.
Juvinall, R. C. and Marshek, K. M. (1991). Fundamentals of Machine Component Design. 2nd edn. John Wiley & Sons. Somerset. New Jersey.
Kim, S. H., Kim, C. W., Oh, H. J. and Youn, J. R. (2007). Residual stresses and viscoelastic deformation of an injection molded automotive part throgh 3D analysis. Sping Conf. Proc. Korean Sociery of Automotive Engineers, 1782–1787.
Krug, S., Evans, J. R. G. and Maat, J. H. H. (2000). Residual stresses and cracking in large ceramic injection mouldings subjected to different solidification schedules. J. European Ceramic Society 20,14–15, 2535–2541.
Lee, Y. L., Pan, J., Hathaway, R. and Barkey, M. (2005). Fatigue Testing and Analysis: Theory and Practice. 1st edn. Elsevier. Boston.
Loewenthal, S. H. (1986). Factors that affect the fatigue strength of power transmission shafting and their impact on design. ASME Trans. J. Mechanisms, Transmission and Automation in Design 108,1, 106–118.
Lutz, W., Herrmann, J., Korckelmann, M., Hoosseini, H. S., Jackel, A. and Schmauder, S. (2009). Damage development in short-fiber reinforced injection molded composites. Computational Material Science 45,3, 698–708.
Wang, G., Zhao, G., Guan, Y. and Li, H. (2009). Threedimensional thermal response and thermo-mechanical fatigue analysis for a large LCD TV frame mould in steam-assisted rapid heat cycle moulding. Fatigue Fract. Engng. Mater. Sturct. 34,2, 108–122.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Kim, J.K., Lee, C.S. Fatigue life estimation of injection mold core using simulation-based approach. Int.J Automot. Technol. 14, 723–729 (2013). https://doi.org/10.1007/s12239-013-0079-y
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12239-013-0079-y