Numerical simulation for insert injection molding of oneconstituent polypropylene single-polymer composites

One-constituent polypropylene single-polymer composites (PP SPCs) possess matrix and reinforcement which are from the same kind of PP with identical chemical structure. One-constituent SPCs are characterized by lower density, lighter weight and better interfacial adhesion, which can fulfill the demands for fully recyclable engineering composites. Traditional SPCs preparation processes like hot compaction, film stacking, co-extruding have long cycle, narrow processing temperature window and difficult control of processing temperature. Insert injection molding can solve these issues with high effectiveness of preparing SPCs. In this article, we simulated and analyzed the insert injection molding process of one-constituent PP SPCs for testing the processing temperature window and mastering the temperature distribution inside the mold cavity. Numerical results of the insert injection molding process for oneconstituent PP SPCs were also compared with those of injection molding process for pure PP. Results of temperature, viscosity and warpage were all discussed which could be used to determine the optimum injection molding conditions.