A Study on Thin Cooling Layers Between the Cooling Channel and Cavity in the Injection Molding Process for Mold Temperature Control to Enhance Weld Line Flexural Strength in Plastic Products
Tran-Phu Nguyen, Pham Thi Mai Khanh, Pham Son Minh, Tran Minh The Uyen, Bui Chan Thanh
TL;DR
This study improves the strength of weld lines in plastic products by optimizing mold temperature control and injection parameters.
Contribution
A novel mold with a cooling layer and Taguchi optimization is introduced to enhance weld line strength in injection molding.
Findings
A maximum weld line stress of 121.88 MPa was achieved under optimal conditions.
Part thickness had the greatest impact on weld line strength, followed by injection pressure.
Cavity temperature control combined with parameter optimization effectively strengthens weld lines.
Abstract
Weld lines in injection-molded plastics often act as structural weak points that reduce mechanical performance. Enhancing weld line strength is therefore essential to improve product reliability and service life. This study aims to develop and validate an injection mold system capable of localized cavity temperature control to strengthen weld line regions. A specialized mold with an integrated cooling layer was designed to enable rapid thermal response during molding. The Taguchi method was applied to optimize three key parameters—part thickness, melt temperature, and injection pressure—to maximize weld line flexural strength. Experiments based on an L25 orthogonal array revealed that weld line stress varied significantly across parameter combinations, with a maximum of 109.23 MPa. A subsequent validation test conducted under the optimal conditions (250 °C melt temperature, 1.5 mm part…
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Taxonomy
TopicsInjection Molding Process and Properties · Engineering Applied Research · Manufacturing Process and Optimization