| Gas assisted injection molding (GIM) is an innovative net shape manufacturing process for producing parts with special features normally unachievable through conventional injection molding methods. Although GIM is being used in many applications, there is still a lack of understanding of this new technology due to relatively complicated two-phase flow phenomena inherent in the process. In the present study, an efficient, reliable, and systematic experimental and analytical methodology was established to analyze the gas bubble distribution in the GIM process. A complete experimental system for GIM was designed and constructed. The relationship between processing variables, design geometries, material properties and gas bubble formation was explored through a series well designed experiments. Dynamic motion of two phase flow inside the cavity was recorded and analyzed. A fundamental knowledge base for GIM was established through this research. Based on the experimental results, an empirical model was developed to predict the size of the gas bubble for polystyrene material. The results from this research will contribute to the foundation of knowledge in the North America for this new technology. |
