Residual stress and viscoelastic deformation of film insert molded automotive parts

• Published in: Journal of applied polymer science Vol. 118; no. 5; pp. 2530 - 2540
• Main Authors: Kim, Seong Yun, Kim, Sung Ho, Oh, Hwa Jin, Lee, Seung Hwan, Youn, Jae Ryoun
• Format: Journal Article
• Language: English
• Published: Hoboken Wiley Subscription Services, Inc., A Wiley Company 05.12.2010; Wiley
• Subjects: Annealing; Application fields; Applied sciences; Automotive components; Deformation; Exact sciences and technology; injection molding; Inserts; Polymer industry, paints, wood; Residual stress; Stress analysis; Technology of polymers; viscoelastic behavior; Viscoelasticity; Warpage; Non isothermal flow; Insert molding; Viscoelasticity; Stress analysis; Motor car; Annealing; Experimental test; Warping; viscoelastic behavior; Theoretical study; Methyl methacrylate polymer; Vehicle element; Modeling; Finite element method; warpage; ABS; Manufacturing defect; Three dimensional flow; Injection molding; Numerical simulation; Mold filling; Residual stress; Temperature time superposition; Rheological properties
• ISSN: 0021-8995; 1097-4628; 1097-4628
• DOI: 10.1002/app.32371

Complex automotive parts were produced by film insert molding and the ejected parts were annealed to investigate the viscoelastic deformation. Warpage of the part was predicted by numerical simulation of mold filling, packing, and cooling stages with non-isothermal three-dimensional flow analysis. The flow analysis results were transported to a finite element stress analysis program and the stress analysis was performed by using time-temperature superposition principle to investigate viscoelastic deformation. Predicted residual stresses, viscoelastic deformation, and warpage showed good agreement with experimental results. Thermal shrinkage of the inserted film and relaxation of the residual stress affected the viscoelastic deformation of the part significantly during annealing.