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Numerical simulation and experimental analysis for evaluating warpage of a 3D thin-walled polymeric part using the injection compression molding process

Deniz Sönmez and Ayşegül Akdoğan Eker


Injection compression molding (ICM) is a nontraditional hybrid injection molding (IM) process that has been utilized to mold a wide range of the latest and difficult-to-manufacture precision parts that require high dimensional accuracy and no residual stresses. This paper introduces the accurate calculation of warpage for ICM by numerical simulation via Moldflow software, and a comparison of results with products produced experimentally by ICM. To begin with, the process parameters of ICM were discussed based on the numerical simulations. The effects of process parameters, namely melt temperature, mold temperature, compression pressure, and compression distance, on warpage behavior of a molded 3D BJ356MO polypropylene (PP) (100MFI) part were investigated using Taguchi analysis. The obtained warpage results with optimum process parameters were compared with experimental measurements to test the validity of the simulation model of ICM. It was found that the numerical simulations of the ICM show good agreement with experimental measurements.

Corresponding author: Deniz Sönmez, Department of Mechanical Engineering, Yildiz Technical University, Besiktas, Istanbul, 34349, Turkey, E-mail:

  1. Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.

  2. Research funding: None declared.

  3. Conflict of interest statement: The authors declare no conflicts of interest regarding this article.


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Received: 2021-10-26
Accepted: 2021-12-19
Published Online: 2022-03-03
Published in Print: 2022-05-25

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