Experimental analysis of gas-assisted co-injection molding for complex polymer multilayer circular tubular components

IF 2.8 3区化学 Q3 POLYMER SCIENCE

Iranian Polymer Journal Pub Date : 2025-02-12 DOI:10.1007/s13726-025-01461-7

Shuhui Huang, Zhuyu Zhao, Tao Zhang, Jun Lin, Haikun Du, Wei Zhang, Bin Xiao

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Abstract

Based on the self-built gas-assisted co-injection experimental platform, the gas-assisted co-injection molding experiments were conducted on the cylindrical pipe fittings with cavity sectional diameters of 20 and 30 mm. A UDF model was constructed using CFD software for numerical simulation. The study investigated the influence of melt injection sequence, melt filling methods, and cavity tube diameters on the rheological behavior of inner layer melt penetrating the outer layer melt and the penetration behavior of gas through the inner layer melts. The evolution mechanism was analyzed in conjunction with the flow field effects. The findings revealed that when a higher viscosity melt penetrates a lower viscosity melt, i.e., the injection sequence of PP-HDPE, HDPE tends to squeeze more PP towards the mold wall; and the N₂ with the same injection pressure was subjected to increased resistance when the melt with higher viscosity penetrates, intensifying the interface instability between the inner and outer layer melt. The variability and fluctuation in the total residual wall thickness and the residual wall thickness of the outer melt in GACIM samples increased. When the melt-filling method and injection sequence were the same, an increase in the cavity tube diameter decreased the instability of the gas–melt and inner-outer layer melt interfaces. These insights provide technical guidance and references for the sectional design and process parameter adjustment of gas-assisted co-injection molding products.

Graphical abstract

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复杂聚合物多层圆管件气体辅助共注射成型实验分析

基于自建气体辅助共注射实验平台，对型腔截面直径为20和30 mm的圆柱形管件进行了气体辅助共注射成型实验。利用CFD软件建立UDF模型进行数值模拟。研究了熔体注入顺序、熔体填充方式和空腔管径对内层熔体穿透外层熔体流变行为和气体穿透内层熔体行为的影响。结合流场效应分析了其演化机理。结果表明：当高粘度熔体穿透低粘度熔体时，即PP-HDPE的注射顺序，HDPE倾向于向模壁挤压更多的PP；当黏度较高的熔体渗透时，相同注入压力下的N2受到的阻力增大，加剧了内外层熔体界面的不稳定性。GACIM样品总残余壁厚和外熔体残余壁厚的变异性和波动性增大。在填充方式和注射顺序相同的情况下，增大腔管直径降低了气-熔体和内外层熔体界面的不稳定性。这些见解为气辅共注射成型产品的截面设计和工艺参数调整提供了技术指导和参考。图形抽象

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来源期刊

Iranian Polymer Journal 化学-高分子科学

CiteScore

4.90

自引率

9.70%

发文量

107

审稿时长

2.8 months

期刊介绍： Iranian Polymer Journal, a monthly peer-reviewed international journal, provides a continuous forum for the dissemination of the original research and latest advances made in science and technology of polymers, covering diverse areas of polymer synthesis, characterization, polymer physics, rubber, plastics and composites, processing and engineering, biopolymers, drug delivery systems and natural polymers to meet specific applications. Also contributions from nano-related fields are regarded especially important for its versatility in modern scientific development.