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    stresses on product dimension. Thermally induced stresses
    develop principally during the cooling stage of an injection
    molded  part,  mainly  as  a  consequence  of  its  low  thermal
    conductivity and the difference in temperature between the
    molten  resin  and  the  mould.  An  uneven  temperature  field
    exists around product cavity during cooling [7].
     
    260    S.H. Tang et al. / Journal of Materials Processing Technology 171 (2006) 259–267
     
    During cooling, location near the cooling channel experi-
    ences more cooling than location far away from the cooling
    channel.  This  different  temperature  causes  the  material  to
    experience  differential  shrinkage  causing  thermal  stresses.
    Significant thermal stress can cause warpage problem. There-
    fore, it is important to simulate the thermal residual stress field
    of the injection-molded part during the cooling stage [8]. By
    understanding the characteristics of thermal stress distribu-
    tion, deformation caused by the thermal residual stress can
    be predicted.
    In this paper the design of a plastic injection mould for
    producing warpage testing specimen and for performing ther-
    mal analysis for the mould to access on the effect of thermal
    residual stress in the mould is presented.

    2.  Methodology

    2.1.  Design of warpage testing specimen

    This section illustrates the design of the warpage testing
    specimen  to  be  used  in  plastic  injection  mould.  It  is  clear
    that warpage is the main problem that exists in product with
    thin shell feature. Therefore, the main purpose of the prod-
    uct development is to design a plastic part for determining
    the effective factors in the warpage problem of an injection-
    moulded part with a thin shell.
    The  warpage  testing  specimen  is  developed  from  thin
    shell plastics. The overall dimensions of the specimen were
    120 mm in length, 50 mm in width and 1 mm in thickness. The
    material  used  for  producing  the  warpage  testing  specimen
    was acrylonitrile butadiene stylene (ABS) and the injection
    temperature, time and pressure were 210 ◦C, 3 s and 60 MPa,
    respectively. Fig. 1 shows the warpage testing specimen pro-
    duced.

    2.2.  Design of plastic injection mould for warpage
    testing specimen

    This section describes the design aspects and other consid-
    erations involved in designing the mould to produce warpage
    testing specimen. The material used for producing the plastic
    Fig. 1. Warpage testing specimen produced.

    injection mould for warpage testing specimen was AISI 1050
    carbon steel.
    Four design concepts had been considered in designing of
    the mould including:
    i.  Three-plate mould (Concept 1) having two parting line
    with single cavity. Not applicable due to high cost.
    ii.  Two-plate mould (Concept 2) having one parting line with
    single cavity without gating system. Not applicable due
    to low production quantity per injection.
    iii.  Two-plate  mould  (Concept  3)  having  one  parting  line
    with double cavities with gating and ejection system. Not
    applicable as ejector pins might damage the product as
    the product is too thin.
    iv.  Two-plate mould (Concept 4) having one parting line with
    double cavities with gating system, only used sprue puller
    act as ejector to avoid product damage during ejection.
    In designing of the mould for the warpage testing spec-
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