Study on the Influence of Runner and Overflow Area Design on Flow-Fiber Coupling in a Multi-Cavity System.

Fiber-reinforced composites (FRPs) are characterized by their lightweight nature and superior mechanical characteristics, rendering them extensively utilized across various sectors such as aerospace and automotive industries. Nevertheless, the precise mechanisms governing the interaction between the fibers present in FRPs and the polymer melt during industrial processing, particularly the manipulation of the flow-fiber coupling effect, remain incompletely elucidated. Hence, this study introduces a geometrically symmetrical 1 × 4 multi-cavity mold system, where each cavity conforms to the ASTM D638 Type V standard specimen. The research utilizes theoretical simulation analysis and experimental validation to investigate the influence of runner and overflow design on the flow-fiber coupling effect. The findings indicate that the polymer melt, directed by a geometrically symmetrical runner, results in consistent fiber orientation within each mold cavity. Furthermore, in the context of simulation analysis, the inclusion of the flow-fiber coupling effect within the system results in elevated sprue pressure levels and an expanded core layer region in comparison to systems lacking this coupling effect. This observation aligns well with the existing literature on the subject. Moreover, analysis of fiber orientation in different flow field areas reveals that the addition of an overflow area alters the flow field, leading to a significant delay in the flow-fiber coupling effect. To demonstrate the impact of overflow area design on the flow-fiber effect, the integration of fiber orientation distribution analysis highlights a transformation in fiber arrangement from the flow direction to cross-flow and thickness directions near the end-of-fill region in the injected part. Additionally, examination of the geometric dimensions of the injected part reveals asymmetrical geometric shrinkage between upstream and downstream areas in the end-of-fill region, consistent with microscopic fiber orientation changes influenced by the delayed flow-fiber coupling effect guided by the overflow area. In brief, the introduction of the overflow area extends the duration in which the polymer melt exerts control in the flow direction, consequently prolonging the period in which the fiber orientation governs in the flow direction (A11). This leads to the impact of fiber orientation on the flow of the polymer melt, with the flow reciprocally affecting the fibers. Subsequently, the interaction between these two elements persists until a state of equilibrium is achieved, known as the flow-fiber coupling effect, which is delayed.

Novel CO2-encapsulated Pluronic F127 hydrogel for the treatment of Achilles tendon injury.

Nonsurgical treatment and surgical repairment of injured Achilles tendons seldom restore the wounded tendon to its original elasticity and stiffness. Therefore, we hypothesized that the surgically repaired Achilles tendon can achieve satisfactory regeneration by applying multi-drug encapsulated hydrogels. In this study, a novel bupivacaine-eluting carbon dioxide-encapsulated Pluronic F127 hydrogel (BC-hydrogel) was developed for the treatment of Achilles tendon injuries. The rheological properties of BC-hydrogel were measured. A high-performance liquid chromatography assay was used to assess the release characteristics of bupivacaine in both in vitro and in vivo settings. Furthermore, the effectiveness of BC-hydrogel in treating torn tendons was examined in a rat model, and histological analyses were conducted. Evidently, the degradable hydrogels continuously eluted bupivacaine for more than 14 days. The animal study results revealed that the BC-hydrogel improved the post-surgery mobility of the animals compared with pristine hydrogels. Histological assay results demonstrated a significant reaction to high vascular endothelial growth factor in the surrounding tissues and expression of collagen I within the repaired tendon. This demonstrates the potential of this novel BC-hydrogel as an effective treatment method for Achilles tendon injuries.

Anti-Adhesive Resorbable Indomethacin/Bupivacaine-Eluting Nanofibers for Tendon Rupture Repair: In Vitro and In Vivo Studies.

The treatment and surgical repair of torn Achilles tendons seldom return the wounded tendon to its original elasticity and stiffness. This study explored the in vitro and in vivo simultaneous release of indomethacin and bupivacaine from electrospun polylactide-polyglycolide composite membranes for their capacity to repair torn Achilles tendons. These membranes were fabricated by mixing polylactide-polyglycolide/indomethacin, polylactide-polyglycolide/collagen, and polylactide-polyglycolide/bupivacaine with 1,1,1,3,3,3-hexafluoro-2-propanol into sandwich-structured composites. Subsequently, the in vitro pharmaceutic release rates over 30 days were determined, and the in vivo release behavior and effectiveness of the loaded drugs were assessed using an animal surgical model. High concentrations of indomethacin and bupivacaine were released for over four weeks. The released pharmaceutics resulted in complete recovery of rat tendons, and the nanofibrous composite membranes exhibited exceptional mechanical strength. Additionally, the anti-adhesion capacity of the developed membrane was confirmed. Using the electrospinning technique developed in this study, we plan on manufacturing degradable composite membranes for tendon healing, which can deliver sustained pharmaceutical release and provide a collagenous habitat.

Study on the Flow, Foaming Characteristics and Structural Strength of Polypropylene Structural Foam Injection Molding by Innovative Nitrogen and Molten Plastic Mixing Mechanism.

Plastic foam molding methods include thermoforming, extrusion and injection molding. Injection foam molding is a one-time molding method with high production efficiency and good product quality. It is suitable for foamed plastic products with complex shapes and strict size requirements. It is also the main method for producing structural bubbles. In this investigation, we developed a structural foam injection molding technology using the gas supply equipment connected to the unique plasticizing mechanism of the injection machine and studied its influence on the specimens' melt rheology quality and foam structures. In the experiment, the forming material was polypropylene (PP), and the gas for mixing/forming foaming characteristics was nitrogen (N2). Additionally, in order to observe the rheological properties of N2/melt mixing, a melt flow specimen mold cavity was designed and the change in the melt viscosity index was observed using a melt pressure sensing element installed at the nozzle position. With the nitrogen supply equipment connected to a unique plasticizing mechanism, the mixing of gas and molten plastic can be achieved at the screw plasticizing stage, where the foaming effect is realized during the melt-filling process due to the thermodynamic instability of the gas. It was also found that an increase in N2 fill content increased melt fluidity, and the trend of melt pressure and melt viscosity index showed that the higher the gas content, the lower the trend. The foaming characteristic depends on the gas thermodynamic instability and the pressure release, so it can be seen from the melt fill path that, the greater the pressure near the gate, the lower the foaming amount and the internal structure (SEM) after molding; the farther from the gate, the greater the relative increase in the foaming growth/amount. This phenomenon will be more obvious when the N2 fill content is increased.

Investigation of Parameter Sensitivity and the Physical Mechanism for the Formation of a Core-Skin-Core (CSC) Structure in Two-Stage Co-Injection Molding.

One of the main challenges in co-injection molding is how to predict the skin to core morphology accurately and then manage it properly, especially after skin material has been broken through. In this study, the formation of the Core-Skin-Core (CSC) structure and its physical mechanism in a two-stage co-injection molding has been studied based on the ASTM D638 TYPE V system by using both numerical simulation and experimental observation. Results showed that when the skin to core ratio is selected properly (say 30/70), the CSC structure can be observed clearly at central location for 30SFPP/30SFPP system. When the skin to core ratio and operation conditions are fixed, regardless of material arrangement (including 30SFPP/30SFPP; PP/PP; 30SFPP/PP; and PP/30SFPP systems), the morphologies of the CSC structures are very close for all systems. This CSC structure can be further validated by using µ-CT scan and image analysis technologies perfectly. Furthermore, the influences of various operation parameters on the CSC structure variation have been investigated. Results exhibited that the CSC structure does not change significantly irrespective of the flow rate changing, melt temperature varying, or even mold temperature being modified. Moreover, the mechanism to generate the CSC structure can be derived using the melt front movement of the numerical simulation. It is worth noting that after the skin material was broken through, the core material travelled ahead with fountain flow to occupy the flow front. In the same period, the proper amount of skin material with certain inertia of enough kinetic energy will keep going to penetrate the new coming core material to travel until the end of filling. It ends up with this special CSC structure.

Fabrication and Property Characterization of Long-Glass-Fiber-Reinforced Polypropylene Composites Processed Using a Three-Barrel Injection Molding Machine.

Processing equipment and parameters will highly influence the properties of long-fiber-reinforced injection-molded thermoplastic composites, leading to different fiber lengths and orientations. Thus, maintaining fiber length during the injection molding process is always a big challenge for engineers. This study uses long-glass-fiber-reinforced polypropylene with 25 mm fiber length and a special-built novel injection molding machine with a three-barrel injection unit, including a plasticizing screw, an injection plunger, and a packing plunger, to fabricate injection molding parts while retaining long fiber length. This study also discusses the influence of process parameters, such as back pressure, screw speed, melt temperature, and different flow paths, on the properties of long-glass-fiber-reinforced composites. The experiment results show that a higher screw speed and back pressure will reduce the fiber length in the injection-molded parts. However, using appropriate parameter settings can maintain the fiber length to more than 10 mm. It was found that by increasing the back pressure, the cross direction of the fiber orientation can be increased by up to 15% and the air trap volume fraction can be decreased by up to 86%. Setting appropriate back pressure under a low screw speed will increase the tensile strength. Finally, it was found that the single-edge-gate path results in a higher tensile strength than that of the single-sprue-gate path due to the retainment of longer fiber length in the injection-molded part.

A Methodology to Predict and Optimize Ease of Assembly for Injected Parts in a Family-Mold System.

In this study, the assembly behavior for two injected components made by a family mold system were investigated. Specifically, a feasible method was proposed to evaluate the characteristic length of two components within a family mold system using numerical simulation and experimental validation. Results show that as the packing pressure increases, the product index (characteristic length) becomes worse. This tendency was consistent for both the simulation prediction and experimental observation. However, for the same operation condition setting through a basic test, there were some differences in the product index between the simulation prediction and experimental observation. Specifically, the product index difference of the experimental observation was 1.65 times over that of the simulation prediction. To realize that difference between simulation and experiment, a driving force index (DFI) based on the injection pressure history curve was proposed. Through the DFI investigation, the internal driving force of the experimental system was shown to be 1.59 times over that of the simulation. The DFI was further used as the basis for machine calibration. Furthermore, after finishing machine calibration, the integrated CAE and DOE (called CAE-DOE) strategy can optimize the ease of assembly up to 20%. The result was validated by experimental observation.

The Low Breaking Fiber Mechanism and Its Effect on the Behavior of the Melt Flow of Injection Molded Ultra-Long Glass Fiber Reinforced Polypropylene Composites.

In this study, fiber breaking behavior, fiber orientation, length variation, and changes in melt flow ability of long glass fiber reinforced polypropylene (L-FRP) composites under different mold cavity geometry, melt fill path, and plasticization parameters were investigated. The matrix material used was polypropylene and the reinforcement fibers were 25 mm long. An ultra-long-fiber composite injection molding machine (with a three-stage plunger and injection mechanism design) was used with different mold cavity geometry and plasticization parameters. Different screw speeds were used to explore the changes in fiber length and to provide a reference for setting fiber length and parameter combinations. Flow-length specimen molds with different specimen thickness, melt fill path, and gate design were used to observe the effect of plasticizing properties on the flow ability of the L-FRP composite materials. The experimental results showed that the use of an injection molding machine with a mechanism that reduced the amount of fiber breakage was advantageous. It was also found that an increase in screw speed increased fiber breakage, and 25 mm long fibers were shortened by an average of 50% (to 10 mm). Long fibers were more resistant to melt filling than short fibers. In addition, the thickness of the specimen and the gate design were also found to affect the filling process. The rounded angle gate and thick wall product decreased the flow resistance and assisted the flow ability and fiber distribution of the L-FRP injection molding.

Investigation on the Coupling Effects between Flow and Fibers on Fiber-Reinforced Plastic (FRP) Injection Parts.

Glass or carbon fibers have been verified that can enhance the mechanical properties of the polymeric composite injection molding parts due to their orientation distribution. However, the interaction between flow and fiber is still not fully understood yet, especially for the flow-fiber coupling effect. In this study, we have tried to investigate the flow-fiber coupling effect on fiber reinforced plastics (FRP) injection parts utilizing a more complicated geometry system with three ASTM D638 specimens. The study methods include both numerical simulation and experimental observation. Results showed that in the presence of flow-fiber coupling effect, the melt flow front advancement presents some variation, specifically the "convex-flat-flat" pattern will change to a "convex-flat-concave" pattern. Furthermore, through the fiber orientation distribution (FOD) study, the flow-fiber coupling effect is not significant at the near gate region (RG). It might result from the strong shear force to repress the appearance of the flow-fiber interaction. However, at the end of filling region (ER), the flow-fiber coupling effect tries to diminish the flow direction orientation tensor component A11 and enhance the cross-flow orientation tensor component A22 simultaneously. It results in the dominance in the cross-flow direction at the ER. This orientation distribution behavior variation has been verified using a micro-computerized tomography (micro-CT) scan and image analysis technology.

Investigation on the Fiber Orientation Distributions and Their Influence on the Mechanical Property of the Co-Injection Molding Products.

In recent years, due to the rapid development of industrial lightweight technology, composite materials based on fiber reinforced plastics (FRP) have been widely used in the industry. However, the environmental impact of the FRPs is higher each year. To overcome this impact, co-injection molding could be one of the good solutions. But how to make the suitable control on the skin/core ratio and how to manage the glass fiber orientation features are still significant challenges. In this study, we have applied both computer-aided engineering (CAE) simulation and experimental methods to investigate the fiber feature in a co-injection system. Specifically, the fiber orientation distributions and their influence on the tensile properties for the single-shot and co-injection molding have been discovered. Results show that based on the 60:40 of skin/core ratio and same materials, the tensile properties of the co-injection system, including tensile stress and modulus, are a little weaker than that of the single-shot system. This is due to the overall fiber orientation tensor at flow direction (A11) of the co-injection system being lower than that of the single-shot system. Moreover, to discover and verify the influence of the fiber orientation features, the fiber orientation distributions (FOD) of both the co-injection and single-shot systems have been observed using micro-computerized tomography (µ-CT) technology to scan the internal structures. The scanned images were further utilizing Avizo software to perform image analyses to rebuild the fiber structure. Specifically, the fiber orientation tensor at flow direction (A11) of the co-injection system is about 89% of that of the single-shot system in the testing conditions. This is because the co-injection part has lower tensile properties. Furthermore, the difference of the fiber orientation tensor at flow direction (A11) between the co-injection and the single-shot systems is further verified based on the fiber morphology of the µ-CT scanned image. The observed result is consistent with that of the FOD estimation using µ-CT scan plus image analysis.

Investigation of the Viscoelastic Behavior Variation of Glass Mat Thermoplastics (GMT) in Compression Molding.

Compression molding is a lightweight technology that allows to preserve fiber length and retain better mechanical properties compared to injection molding. In compression molding development, a suitable material such as glass fiber mat thermoplastics (GMT) is often used. However, because of the complicated micro-structure of the fibers and the fiber⁻resin matrix interactions, it is still quite challenging to understand the mechanism of compression molding and it is very difficult to obtain a uniformly compressed GMT product. In this study, we propose a method to measure the rheological properties of GMT through a compression system. Specifically, we utilized a compression molding system to record the relation between the loading force and the displacement. This quantitative information was used to estimate the power-law index and viscoelastic parameters and predict viscosity. Moreover, the estimated viscoelastic parameters of GMT were implemented into Moldex3D to evaluate the flow behavior under compression. The results showed that the trend of the loading force variation was consistent in numerical simulation and experiments. However, at the final stage of compression molding, the experimental loading force was much higher than that estimated by simulation. To find out the mechanism causing this deviation, a series of studies were performed. Through TGA measurement, we found that the fiber content of the center portion of the compressed part increased from 63% to 85% during compression. This was expected, as a result of the fiber⁻polymer matrix separation effect. This fiber⁻polymer matrix separation effect influenced the power-law index and rheological parameters of GMT, making them fluctuate. Specifically, the power-law index changed from 1.0 to 0.62. These internal changes of the rheological properties further induced a much higher loading force in the real experimental GMT system. We further verified the rheological properties variation using pure polyamide (PA) and found that since there is no fiber⁻polymer matrix interactions the power-law index and curve-fitting rheological parameters were almost constant. The mechanism causing the deviation was therefore validated.