Numerical investigation on the effect of heat transfer coefficient in injection molding

In injection molding, the heat transfer coefficient (HTC) is a parameter defined as the polymer-mold interface's heat transferring ability. HTC depends on many factors, including polymer properties and processing conditions. Computer-Aided Engineering approaches use a constant preset value of HTC, which might lead to incorrect prediction of simulation results. In this work, a new approach is developed to validate and calibrate HTC using a numerical model. The model is based on Fourier's heat conduction law applied at the interface between the plastic part and the steel mold. Different HTC values on part temperature distribution, fill pressure, and fill time are studied. Moreover, the model is used to validate an injection mold design that could be used for experimental HTC measures using in-mold sensors. The results highlight the effect of HTC on the prediction of crucial injection molding parameters, suggesting the importance of experimental calibration.