PERTANIKA JOURNAL OF SOCIAL SCIENCES AND HUMANITIES

This study describes the results of a mold filling simulation analysis of a medical syringe performed during the thermoplastic injection molding process, which was performed using a computational Fluid Dynamic Simulation (CFD) with the Volume of Fluid Method (VOF). ANSYS Fluent was used for analysis and data collection. Medical grade polypropylene (PP) is considered in this study. The studies consider physical parameters (such as inlet position and syringe thickness) of the injection molding process. The outlet vent must be placed as far away from the inlet as possible to root out entrapped air and allow the molten PP to occupy the mold cavity. The findings revealed that syringe thicknesses ranging from 0.75 mm to 1.00 mm resulted in increased flow velocity, shorter filling time, and faster flow front advancement.

• Cao, W., Shen, Y., Wang, P., Yang, H., Zhao, S., & Shen, C. (2019). Viscoelastic modeling and simulation for polymer melt flow in injection/compression molding. Journal of Non-Newtonian Fluid Mechanics, 274, Article 104186. https://doi.org/10.1016/j.jnnfm.2019.104186.

• Finkeldey, F., Volke, J., Zarges, J. C., Heim, H. P., & Wiederkehr, P. (2020). Learning quality characteristics for plastic injection molding processes using a combination of simulated and measured data. Journal of Manufacturing Processes, 60, 134-143. https://doi.org/10.1016/j.jmapro.2020.10.028.

• Gou, G., Xie, P., Yang, W., & Ding, Y. (2011). Online measurement of rheological properties of polypropylene based on an injection molding machine to simulate the injection-molding process. Polymer Testing, 30(8), 826-832. https://doi.org/10.1016/j.polymertesting.2011.08.005.

• Hassan, H., Regnier, N., Pujos, C., Arquis, E., & Defaye, G. (2010). Modeling the effect of cooling system on the shrinkage and temperature of the polymer by injection molding. Applied Thermal Engineering, 30(13), 1547-1557. https://doi.org/10.1016/j.applthermaleng.2010.02.025.

• Khor, C. Y., Ariff, Z. M., Ani, F. C., Mujeebu, M. A., Abdullah, M. K., Abdullah, M. Z., & Joseph, M. A. (2010). Three-dimensional numerical and experimental investigations on polymer rheology in meso-scale injection molding. International Communications in Heat and Mass Transfer, 37(2), 131-139. https://doi.org/10.1016/j.icheatmasstransfer.2009.08.011.

• Khosravani, M. R., Nasiri, S., & Reinicke, T. (2022). Intelligent knowledge-based system to improve injection molding process. Journal of Industrial Information Integration, 25, Article 100275. https://doi.org/10.1016/j.jii.2021.100275.

• Köhn, C., van Laethem, D., Deconinck, J., & Hubin, A. (2021). A simulation study of steric effects on the anodic dissolution at high current densities. Materials and Corrosion, 72(4), 610-619. https://doi.org/10.1002/maco.202012051.

• Koszkul, J., & Nabialek, J. (2004). Viscosity models in simulation of the filling stage of the injection molding process. Journal of Materials Processing Technology, 157(2), 183-187. https://doi.org/10.1016/j.jmatprotec.2004.09.027.

• Kwon, Y. I., Lim, E., & Song, Y. S. (2018). Simulation of injection-compression molding for thin and large battery housing. Current Applied Physics, 18(11), 1451-1457. https://doi.org/10.1016/j.cap.2018.08.017.

• Malgarinos, I., Nikolopoulos, N., Marengo, M., Antonini, C., & Gavaises, M. (2014). VOF simulations of the contact angle dynamics during the drop spreading: Standard models and a new wetting force model. Advances in Colloid and Interface Science, 212, 1-20. https://doi.org/10.1016/j.cis.2014.07.004.

• Nagasundaram, N., Devi, R. S., Rajkumar, M. K., Sakthivelrajan, K., & Arravind, R. (2021). Experimental investigation of injection moulding using thermoplastic polyurethane. Materials Today: Proceedings, 45, 2286-2288. https://doi.org/10.1016/j.matpr.2020.10.264.

• Patil, D. C., Kelageri, N. K., Janawade, S. A., & Mishrikoti, M. S. (2021). Design and analysis of 25 T injection molding machine. Materials Today: Proceedings, 46, 2596-2601. https://doi.org/10.1016/j.matpr.2021.02.262.

• Rusdi, M. S., Abdullah, M. Z., Mahmud, A. S., Khor, C. Y., Aziz, A., Ariff, Z. M., & Abdullah, M. K. (2016). Numerical investigation on the effect of pressure and temperature on the melt filling during injection molding process. Arabian Journal for Science and Engineering, 41(5), 1907-1919. https://doi.org/10.1007/s13369-016-2039-0.

• Sahli, M., Barriere, T., & Roizard, X. (2020). Experimental and numerical investigations of bi-injection moulding of PA66/LSR peel test specimens. Polymer Testing, 90, Article 106748. https://doi.org/10.1016/j.polymertesting.2020.106748.

• Szabó, F., Suplicz, A., & Kovács, J. G. (2021). Development of injection molding simulation algorithms that take into account segregation. Powder Technology, 389, 368-375. https://doi.org/10.1016/j.powtec.2021.05.053.

• Tosello, G., & Costa, F. S. (2019). High precision validation of micro injection molding process simulations. Journal of Manufacturing Processes, 48, 236-248. https://doi.org/10.1016/j.jmapro.2019.10.014.

• Trad, M. A. B., Demers, V., Côté, R., Sardarian, M., & Dufresne, L. (2020). Numerical simulation and experimental investigation of mold filling and segregation in low-pressure powder injection molding of metallic feedstock. Advanced Powder Technology, 31(3), 1349-1358. https://doi.org/10.1016/j.apt.2020.01.018.

• Tran, N. T., & Gehde, M. (2019). Creating material data for thermoset injection molding simulation process. Polymer Testing, 73, 284-292. https://doi.org/10.1016/j.polymertesting.2018.11.042.

• Wang, J., Hopmann, C., Kahve, C., Hohlweck, T., & Alms, J. (2020). Measurement of specific volume of polymers under simulated injection molding processes. Materials & Design, 196, Article 109136. https://doi.org/10.1016/j.matdes.2020.109136

• Zhang, H., Fang, F., Gilchrist, M. D., & Zhang, N. (2019). Precision replication of micro features using micro injection moulding: Process simulation and validation. Materials & Design, 177, Article 107829. https://doi.org/10.1016/j.matdes.2019.107829.