Thermoset Processing Manual

Compression Molding

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 General Overview

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 Description

 Urochem-Compounded from Urea Formaldehyde

Resin, Cellulose Filler, Pigments, Flow Promoters
,lubricants
 Melochem- Compounded from Melamine
Formaldehyde Resin, Cellulose Filler, Pigments, Flow
Promoters ,lubricants
 Fenochem- Compounded from Phenolic Resin, organic
and inorganic fillers, Pigments, Flow promoters,
Lubricants

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 Material Properties
 Flow-Measures how fluid and soft material is.
Lower Number= Easier Flow.
 Cure Value- Measures how fast material is
formed into a Blister Free Part .
 Density- Measurement of weight per volume.
Good data for charge weight considerations.
Typical Urochem range 64 +/- 4 grams/100 cc.

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 SAFETY FIRST
Guide to Safety
Around The Press
And Machinery

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 Ten Commandments of Safety
 Safety Glasses & Ear Protection

 No Loose clothing, Neckties/Necklace outside clothing

 Turn off all electrical switches when investigating

malfunction

 Never use Compressed air Gun

to clean hands or clothing

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 Ten Commandments of Safety
 Know Location of Fire Extinguisher

 Do not tie down or Block Safety Switch

 Do not reach around or remove safety guards

 Before starting press Make sure all people are clear of moving
parts

 Maintain good housekeeping and avoid dust collection

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 Thermoset Molding
Terms
Compression
Molding

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 Terms & Definitions
Blister Raised Section in molded part
Gas Trap

Under cure or overcure

Breathe (Degassing) Opening and closing of mold to

allow escape of gas

Cavity Part of mold which forms outer

surface of molded part

Charge Amount of material required to fill

cavity

Charging The Mold Placing required amount in mold.

Only automatic at CWD.

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 Terms & Definitions
Cure Time required to polymerize to a
hard blister free surface under heat
and pressure
Cycle Time it takes to complete one
operation
Loading and close of mold

Breathe cycle

Open and discharge of parts

Draft Amount of taper on side of

mold/molded part for easy removal

Ejector Pins Steel pins in cavity or force for

removal of parts

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 Terms & Definitions
Family Mold A multi-cavity mold containing
several cavities of different sizes and
shapes
Flash The excess material that flows out of
the mold cavity under pressure

Guide Pins Pin or bars in mold to assure proper

alignment of mold halves

Parting Line Part of mold which provides the cut-

off of the flash from molded part

Plasticity/Flow Term to describe degree that material

flow under heat and pressure

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 Terms & Definitions
Platens Top and bottom plates on press to
which mold halves are bolted

Polymerization Chemical reaction that starts with

closing of mold and ends with cure
of part

Pressure Pads Steel blocks outside cavity which

meet during mold closure to prevent
tooling contact at parting line

Vent Small channels of groves to allow air

and gas to escape during molding

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 Material Handling
Storage and Rotation

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 Material Handling
 Store material in cool, dry place
 First in first out (limited shelf life)
 Verify material before loading
 Use single batch at a time
 Avoid mixing batches
 Avoid contamination
 Avoid pressurized air for cleaning
 Maintain good housekeeping
 Shield presses running light colors from dark colors

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 Compression Molding
General Overview

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 Compression Molding
 Molding of thermoset plastic using a compression
press
 Two halves of mold brought together under high
pressure
 Mold is heated at 290-350°F depending on material
 Application of required breathe cycle
 Temperature and pressure cause material to melt and
flow into spaces between cavity and force
 Material is set and ejected after appropriate cure time

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 Compression Press
 Molding press consisting of hydraulic ram
housed in large cylinder
 Cylinder located at bottom for upward acting
press and in the top for downward
 Hydraulic pressure drives ram with platen and
mold halves attached
 Force is applied depending on size of mold and
output size of press

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 Molding Temperatures
 Urea molding compound, Urochem
 290 to 310°F
 Melamine molding compound, Melochem
 310 to 350°F
 Phenolic molding compound,
Fenochem
 325 to 350°F

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 Press Controls
 Understand function of all controls, buttons,
switches prior to operating press
 Always be aware of the location of emergency
button/controls
 Never touch any unfamiliar controls
 Always use safety devices

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 Compression Molding
Process
Step-By-Step Start Up Guide

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 STEP ONE
Verify double load safeties are functional&
Properly set. This ensures molding process
remains in low pressure until the mold closes to
the proper position. If there is a part or foreign
object stuck in the mold, the press cannot close
to safety position and go into high pressure.
These safeties are actually part of the molding
process

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 Step TWO
 Check mold temperature with pyrometer
290 to 310°F for urea
5 to 10 degrees lower in cavity part
 Check that temperature is even across cavities and
make adjustments.
 If temperature is not correct, contact supervisor to
ensure thermocouples are properly working
 Maintaining correct temperature is essential to quality
and workmanship

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 STEP THREE
CLOSE MOLD EMPTY AND CHECK TO
ENSURE PSI IS WITHIN ACCEPTABLE
LIMITS.
 25 Ton: 90 PSI Minimum
 75 Ton: 2500 PSI Max and
lower on some
operations
 150-300 Ton: 1000 PSI Maximum

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 STEP FOUR

 Check standards for cure time specified for

part
 Charge Material
 Close Press and hold closed at specified
cure time
 No Breath

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 STEP FIVE
 Open Mold and Check Molding for uniform
Flash
 If Heavy, Reduce weight
 If Short, add weight

 Repeat Steps Three and Four until you are

satisfied visually and based on experience that
you have correct weight

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 STEP SIX
 Finalize Weight by referring to standard weight specified for
each part using accurate scale to weigh parts
 Allowable limit of +/- 7%
 Make adjustments based on loading board capability
 Bolt and screw
 Insert
 Check all cavities for uniformity
 If flash heavy but weight is correct recheck temperature &
pressure
 If still heavy try softer batch
 Correct weights are key to quality and waste control

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 STEP SEVEN
 Adjust cycle for good densified, bright, gas free, blister
free parts
 Know your material and choose settings based on
experience
 Traditional setting
 Initial closing of press followed by one or two breath.
Optimal breath spacing based on set up trial
 Stop & Go setting
 Initial STOP for preheating of various duration followed by
press closing and perhaps short early breath.

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 STEP EIGHT
 Finalize cure by referring again to part standard
as a guide
 Adjust until you have blister free part
 Add five to ten seconds to insure continuous
blister free operation.
 Beware that over curing can cause warpage,
brittleness and discoloration
 Maintaining optimal cycle is key to productivity
and profitability
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 Common Quality Defects
 Blister  Warped Parts
 Short Shots  Contamination
 Porous Parts  Molded in Flash
 Orange peel or  Heavy or thick Flash
wrinkly surface  Broken parts
 Gas Burns  Off Color Parts
 Gas Blush  Excess flash
 Low Gloss
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 Trouble Shooting Techniques
 Temperature uniformity is Key. Always check with a
pyrometer
 Note cycles, cavity layout and settings prior to
trouble shooting
 Watch out for any unusual and erratic occurrences
 One change at a time
 Choose type of cycle and stick to process guidelines
 Use the trouble shooting guide
 Check all possible causes including material, tooling,
equipment and operator set up.

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