Undergraduate Research in Plastics Engineering and Processing

We are conducting research on a number of interrelated issues pertaining to the processing of thermoplastics. One area under investigation is measurement, modeling and simulation of stress-induced crystallization kinetics in injection molding. Experiments are conducted on semi-crystalline plastics in order to obtain process modeling parameters for simulation of flow-induced crystallization in injection-molding. In another area, we measure and model thermal contact resistance due to an imperfect contact between thermoplastics and metal surfaces. We are also investigating self-reinforcing composites.

All the experimental studies also involve both numerical simulations and analytical calculations. Undergraduates usually work with a graduate student whose dissertation topic relates to the projects. Some past students’ projects were either published in peer reviewed journals, or presented at professional society meetings such as the Society of Plastics Engineers Annual Technical Conference (SPE ANTEC). A background in plastic materials is an advantage but not a pre-requisite for the projects.  However, the following senior level courses are offered as Introduction to Engineering properties of plastics (ME-470), and Introduction to plastics processing techniques (ME-471).

All students working on any of the projects listed below will be first trained on the use of C-MOLD, which is a computer aided engineering (CAE) software, for simulation of plastic product manufacturing by an injection molding process. A knowledge on the use of Pro/Engineer (or IDEAS) for drawing CAD models is a must for all the design-related projects.

Projects

The following is a list of current and past projects:

• Comparing Computer Predictions of Injection Molding Parameters and Experimental Data for Parts From Computer Housings
  
  Using C-MOLD the student will determine the optimum processing conditions for products from used computer housings. Then compare the results with measured data for these products.         

• Product Design and Analysis with Recyclable Plastic Wastes
  
  Evaluate the design of thin-walled plastic products using available software for stress and mold cavity flow analysis and carry out productivity analysis in order to optimize both the product and processing parameters.  Compare the properties of the recycled and virgin polymers.  Suggested product designs are remote control cases and printer toner cartridges.     

• Measurement of Thermal Contact Resistance at Plastic-Metal and Ceramic Metal Interface.
  
  Thermal contact resistance (TCR) is a resistance to the flow of heat across an interface of two surfaces that are in contact, due to surface imperfections. The value of TCR is dependent on a number of parameters, which are pressure, temperature, and the nature of the sample’s material and the metal surface characteristics it is in contact with.
  
  The objective of this project was (1) to measure experimentally the Thermal contact resistance (TCR) at a plastic- mold steel, and ceramic-mold steel interface using a one-dimensional heat meter type apparatus and (2) to prepare specimens to use in measuring its TCR at a mold steel interface.         

• Design of Optimal Transient Experiment for the Determination of K and C by an Inverse Method.
  
  The primary objective is to simultaneously calculate the thermal conductivity (K) and heat capacity (C) of a specimen through computer simulation, and to study the factors which affect the accuracy of the results. The results from this undergraduate project were presented at the 1999 SPE ANTEC in New York City.

Contact:

Dr. Kwabena Narh
Room: MEC 330
Phone: 973-596-3353
Email: kwabena.a.narh@njit.edu