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Injection Molding of Elastomers (DR Hans-Joachim Graf)
Injection Molding of Elastomers (DR Hans-Joachim Graf)
Injection Molding of Elastomers (DR Hans-Joachim Graf)
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Introduction
Factors Influencing Injection Molding
Building a Process Model
Operating Window
Process Evaluation and Design
Practical Implementation
Conclusion
Thesis
G. Hellberg at University Hamburg in
1995
1. Plastification
2. Injection
Filling of cavity
Reduced pressure
After pressure phase
1. Vulcanization
2. De-molding
Advantages:
Homogeneous
crosslinking
Shorter vulcanization
Time
Limit: Heat Rise
a -not-vulcanized
b -under vulcanized
c - vulcanized
d - over cured
1,2 – Plastification
2,3 - Time in plunger (before injection)
3,4 – Injection (with heat rise)
4,5 – Mold (heat rise by Temperature conductivity)
End of injection
Time
Dr. Hans-Joachim Graf 6
Introduction
Factors of Injection Molding Process
Building a Process Model
Operating Window
Process Evaluation and Design
Practical Implementation
Conclusion
Temperatures
The Important and
Plunger cylinder temperature
Independent factors in
Injection Molding: Screw temperature
Heating time is Mold temperature
dependent from Mold /
Compound temperature
Speeds
(or vice verse) Screw speed
Injection Pressure is a Plunger speed
response of plunger Opening and closing speed
speed!
Ejection speed
After Pressure and
Back pressure with no Pressures
effect on heat rise!
Injection pressure
After pressure
Back pressure
Times
Heating time
Dr. Hans-Joachim Graf 7
Introduction
Factors of Injection Molding Process
Building a Process Model
Operating Window
Process Evaluation and Design
Practical Implementation
Conclusion
Screw temperature
No of experiments
Mold temperature
Speeds
Screw speed
Plunger speed
Screw temperature
No of experiments
Mold temperature
Speeds
Screw speed
Plunger speed
Machine capability
Process repeat-ability
Plastification temperature
Injection speed
Mold temperature
Pressures, at least in-mold-pressures
tvulc = f C(TMinj )
tvulc = f C(Vinj, TRunner, Tmplast )
tvulc = f C*(Vinj, VSc, PStau, Tcyl )
Scorch
Underfill
190
180
Best Mold Temperature
0 10 15
time (sec)
Dr. Hans-Joachim Graf 18
Introduction
Factors of Injection Molding Process
Building a Process Model
Operating Window
Process Evaluation and Design
Practical Implementation Source: Graf, DESMA
Conclusion
Stages of Processing.
Shortest possible cycle
time at maximum mold
Tcmpd 105C and compound
temperature
Mold Temperature (Grad C)
170
0 10 15 2 3
time (sec) time (min)
Dr. Hans-Joachim Graf 19
Introduction
Factors of Injection Molding Process
Building a Process Model
Operating Window
Process Evaluation and Design
Practical Implementation
Conclusion
1. Trial
Vulcanization time until pores observed
2. Trial
None pores time +20 sec
None pores time +40 sec
None pores time +60 sec
Measurement of
Crosslink density with equilibrium swelling (Flory
Rehner)
Compression set
LL UL
Mold Temp °C 170 200
Compound Temp °C 105 125
Injection Speed % 30 90
LL UL
Mold Temp °C 170 200
Compound Temp °C 90 110
Injection Speed % 30 90
LL UL
Mold Temp °C 170 200
Compound Temp °C 90 120
Injection Speed % 30 90
force
EPDM
NBR
NR
t90 time
As a rule of thumb the following can be concluded:
●
NR + 55 sec (for 10 mm thickness)
●
EPDM / NBR + 40 sec for 10 mm thickness)
This is in line with experience
Number of Experiments:
30 Experiments:
(5 trials per evaluation point X 3 mold temperature settings X 2 Compound temperature,
all Samples have to tested in the laboratory)
No Information about general relation between factor and process
possible (One Step a Time - Strategy)
In
Incase
casethat the TTmold
thatthe is a constant as well as the compound
mold is a constant as well as the compound
((VVcure ))vulcanization
vulcanizationtimetimedepends
dependson
onfour
four[[44!]!]factors.
factors.
cure
The
Thedifficulty
difficultyis,
is,totodetermine
determinethe
thevulcanization
vulcanizationtime
timewhich
which
corresponds
correspondstotothe
themold
moldtemperature
temperature
T-mold
●
Regression equation:
●
Experimental Procedure to achieve best molding Cycle:
●
t
Design of Experiment with vulc as the additional Factor:
[A] = A + BCD
[B] = B + ACD
[C] = C + ABD
[D] = D + ABC
X1 = A: T mass
X2 = B: T mold
Name Units Low High
Actual Factors 220
C: V inj = 20.00
D: t vulc = 75.00
210
T mass °C 95 115
200
swell
T mold °C 160 200 190
180
V inj mm/sec 15 25
200.00
X1 = A: WKZ Temp
Design-Expert® Software
X2 = C: Cure Time 126.00
Factor Coding: Actual Overlay Plot
Overlay Plot 170.00
Actual Factor Hardness: 71.000 Quellung: 115.000 DVR: 28.000
B: Drossel = 0.00 M100: 4.800 DVR
Quellung
104.00 Hardness
tanDelta: 9.500 M 100 148.00
tan Delta
Design Points
82.00
C: Cure Time
Design-Expert® Software
DVR: 35.000 X1 = A: WKZ Temp
X2 = C: Cure Time 126.00 Factor Coding: Actual Overlay Plot
Overlay Plot 170.00
tanDelta: 10.000 Hardness: 69.000
Actual Factor Quellung: 115.000 Quellung: 121.000 DVR
B: Drossel = 40.00
60.00 tanDelta: 9.500 M100: 4.500 Quellung
Hardness
160.00 165.00 170.00 175.00 180.00 104.00 M 100 148.00
tan Delta
C: Cure Time
DVR: 35.000
82.00 126.00
Actual Factor
B: Drossel = 69.19 Hardness: 69.000
Quellung: 115.000 Quellung: 121.000
tanDelta: 9.500 tanDelta: 10.000
60.00 104.00 M100: 4.500 DVR: 35.000
160.00 165.00 170.00 175.00 180.00
60.00
160.00 165.00 170.00 175.00 180.00
A: WKZTemp
Conclusion
Precondition for DoE Operating window identification
Plastification:
Knowledge about influence of plastification process on compound
temperature.
Consider dependency from Compound and plastification unit.
Porous Point
Dependency of Compound
Normally this is known from traditional machine start-up
Conclusion
Optimum cycle time depends on temperatures in injection
molding:
Compound cavity entrance temperature
Mold temperature
None porous point depends on compound modulus at a time,
when the vulcanization has progressed to prevent expansion of
volatiles and enclosed air
Porous point is different for each compound / polymer
With the knowledge about the correlation between porous point
an physical properties a optimum cycle time can be determined.
In production the knowledge about the process window is
important for a safe but fast cure cycle with shortest possible
vulcanization time.