Compression Molding

ver 2

ENG 4793: Composite Materials and Processes

ENG 4793: Composite Materials and Processes

Schematic of a Compression Molding Press

ENG 4793: Composite Materials and Processes

ENG 4793: Composite Materials and Processes

Matched Die Mold

ENG 4793: Composite Materials and Processes

ENG 4793: Composite Materials and Processes

Typical products
Front and rear end automobile panels Hoods Roofs Scoops Fenders Spoilers Air deflectors Lift gates Battery trays
ENG 4793: Composite Materials and Processes

Lightweight Durable IAerodynamic styling

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>100 SMC parts 450 lb/truck 114 million lb, 1996

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ENG 4793: Composite Materials and Processes

Car parts by SMC - Prowler

Advantages and disadvantages Advantages:

Short cycle time (typically 1-6 minutes) High volume production Class A (high quality) surfaces

Disadvantages:
High initial capital investment Labor intensive Secondary operations are sometimes required
ENG 4793: Composite Materials and Processes

ENG 4793: Composite Materials and Processes

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Three Thermoset Material Types

Preform Molding
Shaped dry reinforcement Binder Matrix as liquid or powder

Thermoplastic SMC
Azdel
PP matrix glass fiber mat (30-40% by weight)
continuous chopped directionalized

BMC (Bulk Molding Compound) Molding

Fibers < 30 % and < 1 inch Resin about 25 % Filler about 40 % Log or rope form Fibers 30-50 % by weight (Fibers 1-3 inches to continuous) Resin about 25 % Filler 25-45 % Thin, flat Sheet Molding Compound
ENG 4793: Composite Materials and Processes

SMC Molding

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SMC manufacture using a configuration that can make chopped-fiber SMC-R; continuous fiber SMC-C; or continuous, random SMC-C/R material

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ENG 4793: Composite Materials and Processes

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SMC
Component Styrene Polyester Glass fiber Calcium carbonate Low profile agent (LPA) Initiator Magnesium hydroxide Zinc stearate Weight Percent 13.4 10.5 30.0 40.0 3.45 1.00 0.70 1.00 Function Reactive monomers that provide a cross-linking structure Reactive monomers that provide a cross-linking structure Reinforcement Filler--increases bulk volumeand reduces part cost Controls part shrinkage--a thermoplastic additive Provides free radicals to initiate polymerization Increases viscosity Lubricant / mold release agent
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High Strength SMC

ENG 4793: Composite Materials and Processes

ENG 4793: Composite Materials and Processes

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Polyester
Polyesters can be thermosets or thermoplastics.
Thermoset polyesters, such as those used in compression molding, are formed from linear, unsaturated, thermoplastic polyesters which are crosslinked during a cure reaction.

Epoxy
Do not emit gases during cure Compared to polyesters:
Higher mechanical properties Longer cycle times Less desirable surface appearance

Special features of polyester resins:

Does not emit gases (byproducts) during cure Most common

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ENG 4793: Composite Materials and Processes

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Other resins
Phenolic Urea Melamine All three of these emit gases (condensation products) during cure. Gas emission can lead to voids in the final product, an obvious disadvantage.
ENG 4793: Composite Materials and Processes

Molding process

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SMC cycle

Geometry factors
Wall thickness of part Charge area vs. mold area Charge placement (location) Single or multiple charges

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ENG 4793: Composite Materials and Processes

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Manufacturing Factors
Mold wall heating Closing rate Maximum clamping force Gel time (Mold filling should be complete before the resin gels) De-molding time (Time to attain a sufficient degree of cure to demold the part)
ENG 4793: Composite Materials and Processes

Curing Time vs. Mold Temperature for SMC sheets

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Viscosity variation of an SMC before and during the compression molding operation

Flow of various layers of an SMC charge during compression molding

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Fiber orientation
Planar (two-dimensional) fiber orientation Fibers aggregate to form bundles Compaction of bundles to produce "swirling" Principal direction changes throughout plaque because flow direction varies Most affected by amount of flow
ENG 4793: Composite Materials and Processes

Fiber orientation

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Effect of cure time on the development of flexural strength in a compression molded SMC-R laminate

Various defects in a compression-molded SMC part

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Common Surface Defects in Compression Molded SMC

Matched Die Molding Evaluation

Investment
High Capital equipment High tooling

Quality
Smooth surfaces (both sides) Voids, cracking common Consistent parts Properties modest

Materials
Fast cure preferred Low or no volatiles New for thermoplastics Mostly chopped fibers

Products
High volume Low cost Small projected areas Fairly complex shapes (avoid undercuts)

Processing
Fast (1-10 min cycles) Low labor (automated) Hazards remote (mold closed) High Pressure (> 1,000 psi, 7 MPa)
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ENG 4793: Composite Materials and Processes

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