Professional Documents
Culture Documents
Outline
Basic operation
Cycle time and heat transfer
Flow and solidification
Part design
Tooling
New developments
Environment
Readings
Tadmore and Gogos
Molding and Casting pp584 -610
Boothroyd Dewhurst
Design for Injection Molding pp 319 - 359
Process Operation
Thermal
degradation
Flash
Shortshot
Melt
Pressure
Time(sec)
Time(sec)
tcool
* Source: http://islnotes.cps.msu.edu/trp/inj/inj_time.html
2
(
half thickness )
=
Tool
> polymer
qx + qx
Fouriers law
Boundary Conditions:
( c p T )xy = x xy
t
x
T
q x = k
x
T
2T
T
2T
cp
= k 2 or
= 2
t
x
t
x
1st kind
2nd kind
3rd kind
T ( x = x' ) = constant
T
( x = x' ) = constant
k
x
T
k
( x = x' ) = h (T T )
x
The boundary condition of 1st kind applies to injection molding since the
tool is often maintained at a constant temperature
Heat transfer
Tii
t
TW
-L
+L
T TW
t
x
; = + 1; FO = 2
Non-dimensionalize: =
Ti TW
L
L
Dimensionless equation:
Initial condition
Boundary condition
Separation of variables ;
matching B.C.; matching I.C.
= 2
FO
FO = 0
=1
=0
=2
=0
=0
( , FO ) = f ( FO ) g ( )
Temperature in a slab
Centerline, = 0.1, Fo = t/L2 = 1
Bi-1 =k/hL
Reynolds Number
Reynolds Number:
V2
inertia
VL
L
=
Re =
V
2 viscous
L
Part length 10
=
;
Fill time
1s
= 103 N s m 2
3 103 10 1 10 3
Re
= 300
3
10
* Source: http://www.idsa-mp.org/proc/plastic/injection/injection_process.htm
Re = 10 4
F/A
v
=
h
F v
A h
v/h
Newtonian Viscosity
Generalization:
= &
= (& )
&
Shear Thinning
~ 1 sec-1 for PE
&
102~103
10~102
103~104
1~10
Viscous Heating
P
F v F v
v
=
= =
Vol Vol
A h
h
Rate of Heating
= Rate of Viscous Work
Rate of Temperature rise
cp
dT
v
=
dt
h
or
dT
=
dt c p
v
h
dT
k d 2T
k T
~
=
dt c p dx 2 c p h 2
Viscous heating v 2
=
Conduction
kT
Brinkman number
Non-Isothermal Flow
Flow rate: 1/t ~V/Lx
Flow rate
V L2z
1 VLz Lz
~
=
Small value
=> Short shot
Flow rate
1 10cm / s 0.1cm 0.1cm
~
= 2.5
3
2
Heat xfer rate 4 10 cm / s
10cm
For Die casting of aluminum
Flow rate
1 10cm / s 0.1cm 0.1cm
2
~
10
Heat xfer rate 4 0.3cm 2 / s
10cm
* Very small, therefore it requires thick runners
Injection mold
Fountain Flow
*
**
Shrinkage distributions
sample
Transverse direction
V=3.5cm/s
V=8cm/s
* Source: G. Menges and W. Wubken, Influence of processing conditions on Molecular Orientation in Injection Molds
2.0
60
2.0
Before shrinkage
1.96
Shrinkage
Direction of flow 0.020 in/in
Perpendicular to flow 0.012
60.32
1.976
After shrinkage
Air entrapment
Gate
LDPE
0.030
PP
0.025
Acetal
0.025
0.020
Nylon 6/6
0.020
Shrinkage
Shrinkage
0.030
0.015
0.010
0.015
Acetal
PP with
flow
PP across
flow
0.010
0.005
0.005
Nylon
6/6
PMMA
PMMA
0.000
0.000
100
120
140
160
180
200
220
240
6000
10000
8000
14000
12000
18000
16000
Weld line
Mold Filling
Solidified part
Sink mark
* Source: http://www.idsa-mp.org/proc/plastic/injection/injection_design_7.htm
Injection Molding
*
* Source: http://www.idsa-mp.org/proc/plastic/injection/injection_design_2.htm
Where is injection
molding?
0.030
Acetal
PP with
flow
0.025
Shrinkage
0.020
0.015
PP across
flow
Nylon
6/6
0.010
0.005
PMMA
0.000
6000
10000
8000
14000
12000
18000
16000
Tooling Basics
Sprue
Nozzle
Core Plate
Cavity Plate
Moulding
Core
Cavity
Cavity
Gate
Runner
Melt Delivery
Knob
Runner
Cavity
Part
Stripper plate
Core
Knob
Runner
Cavity
Runner
Part
Cavity
Cavity
Part
Part
Stripper
plate
Tooling
*
*
*
*
**
Cores and
Part Molded in Clear Plastic
Environmental issues
System boundaries
Polymer production
Compounding
Machine types
Out gassing & energy during processing
Additives
CRADLE
Naphtha, Oil.
Natural Gas
Ancilliary Raw
Materials
Compounder
Thermoplastic Production
(Boustead)
Polymer
Delivery
Internal Transport
Drying
Extrusion
Pelletizing
Emissions
to air,
water &
land
Polymer
Delivery
Injection Molder
Energy Production Industry
Internal Transport
Drying
Injection Molding
Emissions to air, water, & land
Scrap
Anciliary Raw
Materials
Emissions
to air,
water &
land
Note to Reader:
= Focus of this Analysis
Service Period
Waste Management
Polymer Production
Largest Player in the Injection Molding LCI
What is a polymer:
HDPE
76.56
111.50
-------
LLDPE
77.79
-------------
LDPE
73.55
92.00
64.60
PP
72.49
111.50
-------
PVC
58.41
79.50
53.20
PS
86.46
118.00
70.80
PC
115.45
------80.30
PET
77.14
------59.40
-------
-------
71.00
-------
53.00
81.00
107.00
96.00
-------
-------
67.80
-------
52.40
82.70
78.20
131.65
121.18
136.07
126.07
33.24
-------
-------
-------
80.00
-------
68.00
64.00
57.00
84.00
-------
81.00
Compounding - extrusion
Source:
http://cache.husky.ca/pdf/br
ochures/br-hylectric03a.pdf
SEC pv
9
8
7
SEC (MJ/kg)
All-Electric - 85 tons
6
Hydraulic - 85 tons
5
Material: PP
4
3
2
1
0
0
10
Throughput (kg/hr)
15
20
Source: [Thiriez]
8
7
SEC (MJ/kg)
6
5
4
3
2
1
0
0
50
100
Throughput (kg/hr)
150
200
Source: [Thiriez]
120
Power Required (kW)
Cool
100
Clamp open-close
Plasticize
Inject high
80
60
Inject low
40
20
0
0
6
7
8
9
10
11
Time (seconds)
MM 550 Hybrid
NT 440 All-Electric
12
13
14
Source: [Thiriez]
The hydraulic plot would be even higher than the hybrid curve
Driers
Power Trendline
W300
1.6
R2 = 0.8225
W400
1.4
1.2
W200
1
0.8
W150
0.6
W3200
W1600
W600
0.4
W5000
W800
0.2
W1000
W2400
0
0
500
1000
1500
2000
2500
3000
3500
Throughput (kg/hr)
Source: [Thiriez]
Same as
P0
P E
= = SEC =
+k
m& m
m&
Thermoplastic Production
avg
low
high
PP
83.0
64.0
111.5
PVC
59.2
52.4
79.5
PS
87.2
70.8
118.0
Polymer Delivery
Extras
Generic by Amount
PET
Consumed Inj. Molded PC
81.2
74.6
95.7
78.8
69.7
62.8
78.2
59.4
102.7
97.6
117.4
96.0
avg
low
high
0.19
0.12
0.24
Compounder
avg
low
high
Subtotal
Internal
Transport
0.09
--------avg
low
high
Drying
0.70
0.30
1.62
Extrusion
3.57
1.82
5.00
Building (lights,
heating, ect..)
0.99
---------
Pelletizing
0.16
0.06
0.31
5.51
3.25
8.01
Polymer Delivery
avg
low
high
0.19
0.12
0.24
Injection Molder
avg
low
high
Internal
Transport
0.04
---------
avg
low
high
Subtotal
TOTAL w/
Generic Inj.
Molded
Polymer
TOTAL w/o
Polymer Prod
Notes
Drying
Injection Molding
(look below)
Scrap (Granulating)
0.70
0.30
1.62
0.05
0.03
0.12
Building (lights,
heating, ect..)
0.99
---------
avg
low
high
13.08
5.35
72.57
7.35
4.47
11.22
6.68
3.17
18.06
avg
low
high
Hydraulic
93.60
71.65
178.68
Hybrid
87.87
70.77
117.34
All-Electric
87.20
69.46
124.18
avg
low
high
18.97
8.84
81.04
13.24
7.96
19.70
12.57
6.66
26.54
Drying - the values presented assume no knowledge of the materials' hygroscopia. In order words, they are
averages between hygroscopic and non-hygroscopic values. For hygroscopic materials such as PC and PET
additional drying energy is needed (0.65 MJ/kg in the case of PC and 0.52 MJ/kg in the case of PET)
Pelletizing - in the case of pelletizing an extra 0.3 MJ/kg is needed for PP
Granulating - a scarp rate of 10 % is assumed
Source: [Thiriez]
Nuclear
19.6%
Other
0.0%
Coal
50.7%
Oil
3.1%
Gas
16.7%
Waste/
Renewable
2.2%
Scale
HDPE,
LDPE,
LLDPE,
PP, PS,
PVC
U.S.
GJ/year
9.34E+07
2.06E+08
Global
GJ/year
4.01E+08
6.68E+08
Readings
1.
2.
3.
4.
5.
6.