Araştırma Makalesi
BibTex RIS Kaynak Göster

Optimization of material and process parameters in the injection molding of piezoresistive card-type pressure sensors using the finite element method

Yıl 2025, Sayı: 061, 100 - 115, 30.06.2025

Fuat Tan , Burak Birişik

Öz

The purpose of this study is to determine the most suitable material and process parameters for piezoresistive card-type pressure sensors during the injection molding process. Simulation analyzes done with different engineering plastics Polyamide (PA), Polybutylene Terephthalate (PBT) and Polycarbonate (PC) focus on the optimization of critical parameters such as fill time, injection pressure, volumetric shrinkage and cooling efficiency during the production process. Cooling channel diameter was 10 mm, cooling water temperature was 25°C and Reynolds number was 10,000 designed to provide the minimum time of delivery from the mold by using idle times. Results indicate that PA has the shortest filling time of 0.0548 sec, PC has a volume shrinkage of 6.63%, among the lowest ones and PBT shows the best thermal stability of 252.8°C PA, which operates at lower injection pressure (132.3 MPa), increases throughput, while PBT has exhibited a proper balance between mechanical and thermal performance and PC is the most suitable material for high-dimensional accuracy applications. This study serves as a guide for optimizing the material selection and molding parameters in the production of plastic-based pressure sensors.

Anahtar Kelimeler

Piezoresistive pressure sensor FEM injection molding process parameters

Kaynakça

  • [1] H. Fu et al., “Overview of Injection Molding Technology for Processing Polymers and Their Composites,” ES Materials & Manufacturing, vol. 8, no. 20, pp. 3–23, 2020, doi: 10.30919/esmm5f713.
  • [2] M. Czepiel, M. Bańkosz, and A. Sobczak-Kupiec, “Advanced Injection Molding Methods: Review,” Materials, vol. 16, no. 17, p. 5802, Aug. 2023, doi: 10.3390/ma16175802.
  • [3] G. Wang, Y. Wang, and D. Yang, “Study on Automotive Back Door Panel Injection Molding Process Simulation and Process Parameter Optimization,” Advances in Materials Science and Engineering, vol. 2021, no. 1, pp. 1–13, Jan. 2021, doi: 10.1155/2021/9996423.
  • [4] A. L. N. Vieira, R. D. S. G. Campilho, F. J. G. Silva, and L. P. Ferreira, “Increasing the Environmental Sustainability of an Over-Injection Line for the Automotive Component Industry,” Sustainability, vol. 13, no. 22, pp. 1–23, Nov. 2021, doi: 10.3390/su132212692.
  • [5] S. S. Abubaker, S. A. Gashout, A. O. Alghazali, M. T. Albarouni, and A. M. Elbarouni, “Design and Simulation of Polymer Needles to Produce by Injection Molding Machine,” Surman Journal of Science and Technology, vol. 6, no. 1, pp. 1–15, Jan. 2024
  • [6] C. Yang, G. Wang, J. Zhao, G. Zhao, and A. Zhang, “Lightweight and strong glass fiber reinforced polypropylene composite foams achieved by mold-opening microcellular injection molding,” Journal of Materials Research and Technology, vol. 14, no. 1, pp. 2920–2931, Sep. 2021, doi: 10.1016/j.jmrt.2021.08.052.
  • [7] S. Ramesh et al., “Simulation Process of Injection Molding and Optimization for Automobile Instrument Parameter in Embedded System,” Advances in Materials Science and Engineering, vol. 2021, no. 1, pp. 1–10, Jan. 2021, doi: 10.1155/2021/9720297.
  • [8] S. Formentin, L. Onesto, T. Colombo, A. Pozzato, and S. M. Savaresi, “h-TPMS: a hybrid tire pressure monitoring system for road vehicles,” Mechatronics, vol. 74, no. 1, p. 102492, Apr. 2021, doi: 10.1016/j.mechatronics.2021.102492.
  • [9] H. Soy and İ. Toy, “Design and implementation of smart pressure sensor for automotive applications,” Measurement, vol. 176, p. 109184, May 2021, doi: 10.1016/j.measurement.2021.109184.
  • [10] B. Adam, T. Brandt, R. Henn, S. Reiss, M. Lang, and C. Ohl, “A New Micromechanical Pressure Sensor for Automotive Airbag Applications,” in VDI-Buch, Berlin, Heidelberg: Springer Berlin Heidelberg, 2008, pp. 259–284. Accessed: May 07, 2025. [Online]. Available: https://doi.org/10.1007/978-3-540-77980-3_20
  • [11] C.-W. Su et al., “Optimization process parameters and adaptive quality monitoring injection molding process for materials with different viscosity,” Polymer Testing, vol. 109, no. 1, p. 107526, May 2022, doi: 10.1016/j.polymertesting.2022.107526
  • [12] J. Gim and L.-S. Turng, “A review of current advancements in high surface quality injection molding: Measurement, influencing factors, prediction, and control,” Polymer Testing, vol. 115, no. 1, p. 107718, Nov. 2022, doi: 10.1016/j.polymertesting.2022.107718.
  • [13] R. Farooque, M. Asjad, and S. J. A. Rizvi, “A current state of art applied to injection moulding manufacturing process – A review,” Materials Today: Proceedings, vol. 43, no. 1, pp. 441–446, 2021, doi: 10.1016/j.matpr.2020.11.967.
  • [14] N. Zhao, J. Lian, P. Wang, and Z. Xu, “Recent progress in minimizing the warpage and shrinkage deformations by the optimization of process parameters in plastic injection molding: a review,” The International Journal of Advanced Manufacturing Technology, vol. 120, no. 1–2, pp. 85–101, Feb. 2022, doi: 10.1007/s00170-022-08859-0.
  • [15] H. L. Wu and Y. H. Wang, “Using Taguchi Method to Optimize Molding Process Parameters of Chair Base,” Applied Mechanics and Materials, vol. 271–272, no. 1, pp. 1190–1194, Dec. 2012, doi: 10.4028/www.scientific.net/amm.271-272.1190.
  • [16] M. Zhiguo et al., “Co-simulation technology of mold flow and structure for injection molding reinforced thermoplastic composite (FRT) parts,” Advanced Composites and Hybrid Materials, vol. 5, no. 2, pp. 960–972, Jan. 2022, doi: 10.1007/s42114-021-00407-w.
  • [17] Q. Su, N. Zhang, and M. D. Gilchrist, “Precision injection moulding of micro components: Determination of heat transfer coefficient and precision process simulation,” International Journal of Mechanical Sciences, vol. 269, no. 1, p. 109065, May 2024, doi: 10.1016/j.ijmecsci.2024.109065.
  • [18] F. Tan. “Experimental investigation of mechanical properties for injection molded pa66+ pa6i/6t composite using rsm and grey wolf optimization.” Al-Jazari, vol. 7, no. 2, pp. 835-847, May. 2020, doi: 10.31202/ecjse.705212.
  • [19] M. A. Md Ali et al., “Fill Time Optimization Analysis In Flow Simulation Of Injection Molding Using Response Surface Method,” Malaysian Journal on Composites Science and Manufacturing, vol. 4, no. 1, pp. 28–39, Mar. 2021, doi: 10.37934/mjcsm.4.1.2839.
  • [20] F. Tan and A.K. Alkan. “Effect of Cooling Parameters on In-Mold Flow Behavior in the Microinjection Molding of Piezoelectric Pumps.” International Journal of Automotive Science and Technology, vol. 8, pp. 467-475, December. 2024, doi: 10.30939/ijastech..1566495.
  • [21] C. Fernandes, A. J. Pontes, J. C. Viana, and A. Gaspar‐Cunha, “Modeling and Optimization of the Injection‐Molding Process: A Review,” Advances in Polymer Technology, vol. 37, no. 2, pp. 429–449, Mar. 2016, doi: 10.1002/adv.21683.
  • [22] M. Baum, D. Anders, and T. Reinicke, “Approaches for Numerical Modeling and Simulation of the Filling Phase in Injection Molding: A Review,” Polymers, vol. 15, no. 21, p. 4220, Oct. 2023, doi: 10.3390/polym15214220.
  • [23] H. K. Lee, J. C. Huang, G. E. Yang, and H. G. Kim, “Analysis of Residual Stress in Thin Wall Injection Molding,” Key Engineering Materials, vol. 306–308, no. 1, pp. 1331–1336, Mar. 2006, doi: 10.4028/www.scientific.net/kem.306-308.1331.
  • [24] V. Chauhan, T. Kärki, and J. Varis, “Review of natural fiber-reinforced engineering plastic composites, their applications in the transportation sector and processing techniques,” Journal of Thermoplastic Composite Materials, vol. 35, no. 8, pp. 1169–1209, Nov. 2019, doi: 10.1177/0892705719889095.
  • [25] Y. Xu et al., “Self‐optimization of the V/P switchover and packing pressure for online viscosity compensation during injection molding,” Polymer Engineering & Science, vol. 62, no. 4, pp. 1114–1123, Jan. 2022, doi: 10.1002/pen.25910.
  • [26] L.L. Shu, J.-W. Zhou, M.-W. Wang, X.-H. Ye, D. Wu, and J.-W. Yu, “Optimization of Injection Molding Process Parameters for Left Front Bumper of Automobile Based on Entropy Weight Method,” Plastics Science & Technology/Suliao Ke-Ji, vol. 51, no. 7, 2023, doi: 10.15925/j.cnki.issn1005-3360.2023.07.017.
  • [27] T. Lucyshyn, L.-V. Des Enffans d’Avernas, and C. Holzer, “Influence of the Mold Material on the Injection Molding Cycle Time and Warpage Depending on the Polymer Processed,” Polymers, vol. 13, no. 18, p. 3196, Sep. 2021, doi: 10.3390/polym13183196.

Yıl 2025, Sayı: 061, 100 - 115, 30.06.2025

Fuat Tan , Burak Birişik

Öz

Kaynakça

  • [1] H. Fu et al., “Overview of Injection Molding Technology for Processing Polymers and Their Composites,” ES Materials & Manufacturing, vol. 8, no. 20, pp. 3–23, 2020, doi: 10.30919/esmm5f713.
  • [2] M. Czepiel, M. Bańkosz, and A. Sobczak-Kupiec, “Advanced Injection Molding Methods: Review,” Materials, vol. 16, no. 17, p. 5802, Aug. 2023, doi: 10.3390/ma16175802.
  • [3] G. Wang, Y. Wang, and D. Yang, “Study on Automotive Back Door Panel Injection Molding Process Simulation and Process Parameter Optimization,” Advances in Materials Science and Engineering, vol. 2021, no. 1, pp. 1–13, Jan. 2021, doi: 10.1155/2021/9996423.
  • [4] A. L. N. Vieira, R. D. S. G. Campilho, F. J. G. Silva, and L. P. Ferreira, “Increasing the Environmental Sustainability of an Over-Injection Line for the Automotive Component Industry,” Sustainability, vol. 13, no. 22, pp. 1–23, Nov. 2021, doi: 10.3390/su132212692.
  • [5] S. S. Abubaker, S. A. Gashout, A. O. Alghazali, M. T. Albarouni, and A. M. Elbarouni, “Design and Simulation of Polymer Needles to Produce by Injection Molding Machine,” Surman Journal of Science and Technology, vol. 6, no. 1, pp. 1–15, Jan. 2024
  • [6] C. Yang, G. Wang, J. Zhao, G. Zhao, and A. Zhang, “Lightweight and strong glass fiber reinforced polypropylene composite foams achieved by mold-opening microcellular injection molding,” Journal of Materials Research and Technology, vol. 14, no. 1, pp. 2920–2931, Sep. 2021, doi: 10.1016/j.jmrt.2021.08.052.
  • [7] S. Ramesh et al., “Simulation Process of Injection Molding and Optimization for Automobile Instrument Parameter in Embedded System,” Advances in Materials Science and Engineering, vol. 2021, no. 1, pp. 1–10, Jan. 2021, doi: 10.1155/2021/9720297.
  • [8] S. Formentin, L. Onesto, T. Colombo, A. Pozzato, and S. M. Savaresi, “h-TPMS: a hybrid tire pressure monitoring system for road vehicles,” Mechatronics, vol. 74, no. 1, p. 102492, Apr. 2021, doi: 10.1016/j.mechatronics.2021.102492.
  • [9] H. Soy and İ. Toy, “Design and implementation of smart pressure sensor for automotive applications,” Measurement, vol. 176, p. 109184, May 2021, doi: 10.1016/j.measurement.2021.109184.
  • [10] B. Adam, T. Brandt, R. Henn, S. Reiss, M. Lang, and C. Ohl, “A New Micromechanical Pressure Sensor for Automotive Airbag Applications,” in VDI-Buch, Berlin, Heidelberg: Springer Berlin Heidelberg, 2008, pp. 259–284. Accessed: May 07, 2025. [Online]. Available: https://doi.org/10.1007/978-3-540-77980-3_20
  • [11] C.-W. Su et al., “Optimization process parameters and adaptive quality monitoring injection molding process for materials with different viscosity,” Polymer Testing, vol. 109, no. 1, p. 107526, May 2022, doi: 10.1016/j.polymertesting.2022.107526
  • [12] J. Gim and L.-S. Turng, “A review of current advancements in high surface quality injection molding: Measurement, influencing factors, prediction, and control,” Polymer Testing, vol. 115, no. 1, p. 107718, Nov. 2022, doi: 10.1016/j.polymertesting.2022.107718.
  • [13] R. Farooque, M. Asjad, and S. J. A. Rizvi, “A current state of art applied to injection moulding manufacturing process – A review,” Materials Today: Proceedings, vol. 43, no. 1, pp. 441–446, 2021, doi: 10.1016/j.matpr.2020.11.967.
  • [14] N. Zhao, J. Lian, P. Wang, and Z. Xu, “Recent progress in minimizing the warpage and shrinkage deformations by the optimization of process parameters in plastic injection molding: a review,” The International Journal of Advanced Manufacturing Technology, vol. 120, no. 1–2, pp. 85–101, Feb. 2022, doi: 10.1007/s00170-022-08859-0.
  • [15] H. L. Wu and Y. H. Wang, “Using Taguchi Method to Optimize Molding Process Parameters of Chair Base,” Applied Mechanics and Materials, vol. 271–272, no. 1, pp. 1190–1194, Dec. 2012, doi: 10.4028/www.scientific.net/amm.271-272.1190.
  • [16] M. Zhiguo et al., “Co-simulation technology of mold flow and structure for injection molding reinforced thermoplastic composite (FRT) parts,” Advanced Composites and Hybrid Materials, vol. 5, no. 2, pp. 960–972, Jan. 2022, doi: 10.1007/s42114-021-00407-w.
  • [17] Q. Su, N. Zhang, and M. D. Gilchrist, “Precision injection moulding of micro components: Determination of heat transfer coefficient and precision process simulation,” International Journal of Mechanical Sciences, vol. 269, no. 1, p. 109065, May 2024, doi: 10.1016/j.ijmecsci.2024.109065.
  • [18] F. Tan. “Experimental investigation of mechanical properties for injection molded pa66+ pa6i/6t composite using rsm and grey wolf optimization.” Al-Jazari, vol. 7, no. 2, pp. 835-847, May. 2020, doi: 10.31202/ecjse.705212.
  • [19] M. A. Md Ali et al., “Fill Time Optimization Analysis In Flow Simulation Of Injection Molding Using Response Surface Method,” Malaysian Journal on Composites Science and Manufacturing, vol. 4, no. 1, pp. 28–39, Mar. 2021, doi: 10.37934/mjcsm.4.1.2839.
  • [20] F. Tan and A.K. Alkan. “Effect of Cooling Parameters on In-Mold Flow Behavior in the Microinjection Molding of Piezoelectric Pumps.” International Journal of Automotive Science and Technology, vol. 8, pp. 467-475, December. 2024, doi: 10.30939/ijastech..1566495.
  • [21] C. Fernandes, A. J. Pontes, J. C. Viana, and A. Gaspar‐Cunha, “Modeling and Optimization of the Injection‐Molding Process: A Review,” Advances in Polymer Technology, vol. 37, no. 2, pp. 429–449, Mar. 2016, doi: 10.1002/adv.21683.
  • [22] M. Baum, D. Anders, and T. Reinicke, “Approaches for Numerical Modeling and Simulation of the Filling Phase in Injection Molding: A Review,” Polymers, vol. 15, no. 21, p. 4220, Oct. 2023, doi: 10.3390/polym15214220.
  • [23] H. K. Lee, J. C. Huang, G. E. Yang, and H. G. Kim, “Analysis of Residual Stress in Thin Wall Injection Molding,” Key Engineering Materials, vol. 306–308, no. 1, pp. 1331–1336, Mar. 2006, doi: 10.4028/www.scientific.net/kem.306-308.1331.
  • [24] V. Chauhan, T. Kärki, and J. Varis, “Review of natural fiber-reinforced engineering plastic composites, their applications in the transportation sector and processing techniques,” Journal of Thermoplastic Composite Materials, vol. 35, no. 8, pp. 1169–1209, Nov. 2019, doi: 10.1177/0892705719889095.
  • [25] Y. Xu et al., “Self‐optimization of the V/P switchover and packing pressure for online viscosity compensation during injection molding,” Polymer Engineering & Science, vol. 62, no. 4, pp. 1114–1123, Jan. 2022, doi: 10.1002/pen.25910.
  • [26] L.L. Shu, J.-W. Zhou, M.-W. Wang, X.-H. Ye, D. Wu, and J.-W. Yu, “Optimization of Injection Molding Process Parameters for Left Front Bumper of Automobile Based on Entropy Weight Method,” Plastics Science & Technology/Suliao Ke-Ji, vol. 51, no. 7, 2023, doi: 10.15925/j.cnki.issn1005-3360.2023.07.017.
  • [27] T. Lucyshyn, L.-V. Des Enffans d’Avernas, and C. Holzer, “Influence of the Mold Material on the Injection Molding Cycle Time and Warpage Depending on the Polymer Processed,” Polymers, vol. 13, no. 18, p. 3196, Sep. 2021, doi: 10.3390/polym13183196.
Toplam 27 adet kaynakça vardır.

Ayrıntılar

Birincil Dil İngilizce
Konular Akışkan Akışı, Isı ve Kütle Transferinde Hesaplamalı Yöntemler (Hesaplamalı Akışkanlar Dinamiği Dahil), Enerji, Makine Mühendisliğinde Sayısal Yöntemler, Polimerler ve Plastikler
Bölüm Research Articles
Yazarlar

Fuat Tan 0000-0002-4194-5591

Burak Birişik 0009-0004-4978-7008

Yayımlanma Tarihi 30 Haziran 2025
Gönderilme Tarihi 27 Şubat 2025
Kabul Tarihi 23 Nisan 2025
Yayımlandığı Sayı Yıl 2025 Sayı: 061

Kaynak Göster

IEEE F. Tan ve B. Birişik, “Optimization of material and process parameters in the injection molding of piezoresistive card-type pressure sensors using the finite element method”, JSR-A, sy. 061, ss. 100–115, Haziran 2025.
 Kapak Resmi İndir