Development of Thermal Residual Stresses in Film Insert Molding

Abstract

Thermal residual stresses are generated in injection molded parts due to non-uniform temperature distribution in the cavity during filling, packing and cooling. Thermally induced residual stresses are studied for a thin plate that is produced by film insert molding(FIM). A thin film is attached on the cavity wall and the resin is injected into the thin plate-like cavity. Development of residual stresses in the film insert molding is modeled and predicted. Thermal history of the part is calculated in the cavity by using a finite difference method to determine the boundary conditions for the flow and residual stress analyses. The moment of the film inserted part is calculated and measured.