You are on page 1of 63

EMA 4666C - Polymer Processing Blow Molding Operations

Dr. Anthony Brennan University of Florida Department of Materials Science & Engineering
8/24/2012
EMA 4666C - Polymer Processing

1

Agenda
• Introduction
Examples of blow molded products General Principles Equipment Design

• Process Parameters
Troutonian Viscosity Flow Properties
8/24/2012
EMA 4666C - Polymer Processing

2

Blow Molded Products

8/24/2012
EMA 4666C - Polymer Processing

3

Polymer Processing 4 .Blow Molding Examples • Automotive • Bottles • Storage Vessels • Films • Sporting Goods 8/24/2012 EMA 4666C .

Rubber Parts •Automotive 8/24/2012 EMA 4666C .Polymer Processing 5 .

buckhornrubber.Co-extrusion Blow Molding of Thermoplastic Elastomers Phone: (573) 221-8933 Fax: (573) 221-7144 www.com .

Capabilities Overview • 3-D Blow Molding using XY Technology • Produces complex parts with minimal flash • Dual materials are introduced to create hardsoft-hard products for flexibility and high performance • Secondary operations are performed by robotic technology • Reduced cycle times compared to traditional blow molding .

Polymer Processing 8 .XY Manufacturing System 8/24/2012 EMA 4666C .

Total System Cost Reduction – Up to 50% reduction in tool lead time and tool cost. – Buckhorn will design a system based on your parameters. – Reduction in number of system components. – Overall piece price reduction. cost effective material for your application. 8/24/2012 EMA 4666C . – Up to 70% reduction in system weight. – A variety of plastic material formulations are available to select the best. Data transfer capabilities are available. – Complex system designs.Polymer Processing 9 .

Polymer Processing 10 .XY Blow Molding Process • Parts are produced using blow molding process on an XY plane for complex geometries 8/24/2012 EMA 4666C .

XY Blow Molding Cycle Parison enters mold Mold is closed.Polymer Processing 11 . air introduced Mold opens Part is trimmed 8/24/2012 EMA 4666C .

Features & Benefits •Dual durometer •Part consolidation •Seamless parts •Produces complex parts with reduced flash •Parts incorporate both strong. flexible features . rigid and soft.

Inserts in Blow Molded Parts 8/24/2012 EMA 4666C .Polymer Processing 13 .

Secondary Operations 8/24/2012 EMA 4666C .Polymer Processing 14 .

Parts Trimming •Produces consistently trimmed/drilled parts •Quick cycle time 8/24/2012 EMA 4666C .Polymer Processing 15 .

Polymer Processing 16 .Blow Molding Thermoplastic Elastomers •Thermoplastic elastomers for hard-soft-hard applications •A wide range of fillers are available for improving material properties over different temperature ranges 8/24/2012 EMA 4666C .

Blow Molding Material •Polypropylene •Polyethylene (High or low density) •Polyamides (Nylons) •Santoprene •Geolast .

Blow Molded Products • Air Intake Hoses • Air Resonators • Steering Column Cover • Gas Intake Tubes • Automotive Air Ducts • Fluid Reservoirs • HVAC Ducts 8/24/2012 EMA 4666C .Polymer Processing 18 .

Applications •OEM Truck •Agriculture •Lawn & Garden •Marine •Construction Equipment •Recreational Vehicles •Automotive •Industrial •Gen-Set .

Polymer Processing 20 .Tooling High-performance machined aluminum or cast aluminum production tooling 8/24/2012 EMA 4666C .

Polymer Processing 21 .Prototype Tooling High-performance cast aluminum 8/24/2012 EMA 4666C .

Lead Times .

Polymer Processing 23 .Rubber Injection Molded Parts 8/24/2012 EMA 4666C .

Blow Molded Insulated Coolers 8/24/2012 EMA 4666C .Polymer Processing 24 .

Insert Blow Molded Tanks 8/24/2012 EMA 4666C .Polymer Processing 25 .

Polymer Processing 26 .Blow Molding Process Equipment 8/24/2012 EMA 4666C .

5 inch screw •250 gram shot size (HDPE) 8/24/2012 EMA 4666C .com/u nirecip.Bottles •Bottles •http://www.htm Injection Blow IBS 122 Injection Blow •Completely refurbished •2.Polymer Processing 27 .uniloymilacron.

Injection Stretch Blow U750-120 (1) & U750-130 (2) Injection Stretch-Blow for PET .psu.WIDEMOUTH •Single-stage.bd.Polymer Processing 28 .htm 8/24/2012 EMA 4666C . 4-station process (conditioning) •120-ton or 130-ton injection •2 to 10 cavities •Accepts common tooling •Movie of Process: http://engr.edu/pkoch/plasticdesign/Blow_Molding.

Polymer Processing 29 .Extrusion Blow Molding Process 8/24/2012 EMA 4666C .

Polymer Processing 30 .Extrusion Blow Molding Cycle 8/24/2012 EMA 4666C .

Polymer Processing 31 .Continuous Blow Molding Equip EXTRUDER DIE H HEAD MOLD PARISON 8/24/2012 CONTINUOUS EXTRUSION BLOW MOLDING EMA 4666C .

CBM – Ram Accumulator SHUT-OFF VALVE RAM ACCUMULATOR MOLD PARISON 8/24/2012 RAM ACCUMULATOR BLOW MOLDING MACHINE EMA 4666C .Polymer Processing 32 .

jomarcorp.Extrusion Blow Molding Jomar Continuous Extrusion Blow Moulding http://www.asp 8/24/2012 EMA 4666C .com/ebm_process.Polymer Processing 33 .

Parison Molding Parisons 8/24/2012 EMA 4666C .Polymer Processing 34 .

Polymer Processing 8/24/2012 35 .Injection Blow Molding •Station 1: Injection Mold Preform (Parison) •Station 2: Inflate •Station 3: Strip •Time: 32 bottles per cycle. EMA 4666C . 9 to 20 sec per cycle.

Polymer Processing 36 .DIE SWELL BEHAVIOR 8/24/2012 EMA 4666C .

Orientation dependent upon processing conditions 8/24/2012 EMA 4666C . Velocity Profile Change Elastic Recovery • 1. • 2.Polymer Processing 37 . Chains diffuse from elongated to random coil.Basis for Die Swell Die Swell • Two Causes: • 1. Elastic Recovery • 2.

8/24/2012 EMA 4666C .Polymer Processing 38 .

Polymer Processing 39 .Parison Morphology 8/24/2012 EMA 4666C .

Polymer Processing 40 .8/24/2012 EMA 4666C .

Die Swell Behavior: HDPE v ABS 8/24/2012 EMA 4666C .Polymer Processing 41 .

Polymer Processing 42 .Influence of L/D on Die Swell 8/24/2012 EMA 4666C .

Polymer Processing 43 .Process Time line 8/24/2012 EMA 4666C .

Velocity Profiles for Stress Fields 8/24/2012 EMA 4666C .Polymer Processing 44 .

Velocity Profiles – Planar Deformation 8/24/2012 EMA 4666C .Polymer Processing 45 .

Polymer Processing 46 .END OF EXAM 1 Material Spring 2012 EMA 4666C .

Polymer Processing 47 .Viscosity Response 8/24/2012 EMA 4666C .

Viscosity: Temperature Response

8/24/2012
EMA 4666C - Polymer Processing

48

Effect of Blow Up Ratio

8/24/2012
EMA 4666C - Polymer Processing

49

Blow Molding Process Variables
Thermal Properties/History

8/24/2012
EMA 4666C - Polymer Processing

50

Polymer Processing 51 .PPS DSC Profile 8/24/2012 EMA 4666C .

Xtal 8/24/2012 EMA 4666C .Polymer Processing 52 .Effect of Rapid Quench .

Polymer Processing 53 .Crystallization Behavior .PPS 8/24/2012 EMA 4666C .

Polymer Processing Process • High/Low Rate • Planar Extension • Blow Pressure • Stock Temperature • Mold Temperature 54 .Critical Factors for Blow Molding Material • Melt Strength • Die Swell • Impact Strength • ESCR • Chemical Resistance • Printability 8/24/2012 EMA 4666C .

Polymer Processing 55 .Films 8/24/2012 EMA 4666C .Blow Molding .

Polymer Processing 56 .8/24/2012 EMA 4666C .

8/24/2012 EMA 4666C .Polymer Processing 57 .

8/24/2012 EMA 4666C .Polymer Processing 58 .

8/24/2012 EMA 4666C .Polymer Processing 59 .

Polymer Processing 60 .8/24/2012 EMA 4666C .

Polymer Processing 61 .8/24/2012 EMA 4666C .

Trouble Shooting Guide 8/24/2012 EMA 4666C .Polymer Processing 62 .

New York.References • Introduction to Physical Polymer Science. OH. Tim A. Gert Strobl (1996) Springer-Verlag. Lesley H. • The Physics of Polymers. Hanser/Gardner Publications. 8/24/2012 EMA 4666C . Wiley Interscience (1992) ISBN 0-471-53035-2 • Some figures were reproduced from: Polymer Processing Fundamentals. Sperling. Cincinnati.Polymer Processing 63 . Osswald (1998). 2nd Edition.