Residual thermal stresses in injection molded products

Abstract Nonisothermal flow of a polymer melt in a cold mold cavity introduces stresses that are partly frozen‐in during solidification. Flow‐induced stresses cause anisotropy of mechanical, thermal, and optical properties, while the residual thermal stresses induce warpage and stress‐cracking. In this study, the influence of the holding stage on the residual thermal stress distribution is investigated. Calculations with a linear viscoelastic constitutive law are compared with experimental results obtained with the layer removal method for specimens of polystyrene (PS) and acrylonitrile butadiene‐styrene (ABS). In contrast to slabs cooled at ambient pressures, which show the well‐known tensile stresses in the core and compressive stresses at the surfaces, during the holding stage in injection molding, when extra molten polymer is added to the mold to compensate for the shrinkage, tensile stresses may develop at the surface, induced by the pressure during solidification.