Modeling and Experimental Studies on Polymer Melting and Flow in Injection Molding

Injection molding, in addition to extrusion, is the most important technology in the polymer processing industry. When modeling injection molding, the global approach is necessary to take into account the solid polymer transport, polymer melting and the polymer melt flow. The model of polymer melting is fundamental for the development of such a global injection molding model. In the paper, the state-of-the-art of modeling and experimentation of the flow and melting in injection molding machines has been presented and discussed. It has been concluded that the existing mathematical models have no strong experimental basis. Therefore, experimentation of the polymer flow and melting in the injection molding machine has been performed, and the effect of processing conditions: the screw speed, the plasticating stroke and the back pressure on the process course has been investigated. Starving in the beginning sections of the screw has been observed, which was not presented in the literature so far. The novel concepts of injection molding modeling have been discussed.