In the summer of 2013 I interned with LORD Corporation in their Engineering Technologies Team. One of my primary responsibilities was to help launch a database on fluid flow within a variety of mold filling patterns. I developed and researched methods for optimal injection molding of non-newtonian fluids, and modeled the flow of specific elastomers using Autodesk Inventor and ANSYS CFX.
I began by modeling a specific fluid flowing through two well-known plastics gating systems (one geometrically balanced, and one balanced to evenly distribute shear thinning effects) in order to prove that our modeling software capabilities were sensitive enough to pick up on the shear heating effects.
I then modeled the fluid flowing through the current runner/gate system in order to match the known mold-fill output. From there, I geometrically altered the gating system in an attempt to produce a vertically even material output, and avoid back-grinding.
My research will be used as the starting point of a large database that will be used to simulate any type of fluid flowing into any molding system in order to optimize mold design before going into production, and reducing post production work. The ultimate goal of this database is to input material properties and geometric constraints, and produce a molding system that allows for 100% material transfer and avoids knit lines for an optimal molding pattern.