A05!01!004 Introduction To Plastic Materials

A05-01-004
Introduction to Plastic Materials
August, 2019
CoreTech System Co., Ltd. www.moldex3d.com

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2
What to learn
> Learning objectives

– Basic Plastic Materials properties
– Moldex3D Material Databank searching and usage
> Moldex3D version
– All Moldex3D product
> Recommended user

– All Moldex3D user
3
Outline
> Introduction to Plastic Materials
> Classification of Plastics
> Some key material properties to affect Injection Molding

Development
– Rheological property
– PVT property
– Thermal property : Cp and K
– Mechanical property
> Description of Moldex3D Material Databank
4
Applications of Injection Molding
Semiconductor Aerospace Computer
Components Automobiles
Opto-electronics
Others
Appliances Telecom Household
5
Why People Choose Plastic Materials
> Lightweight Material

– Density: 0.8-2.2g/cm3
> Wide Range of Mechanical Properties
– Young’s modulus (1-100,000 N/mm2 for elastomer-
GF/thermosets, for steel: 500,000 N/mm2 )
> Easy Processability
– processing temperature < 400 oC
> Modifiability by Additives
– Fillers, reinforcing materials, color pigments, plasticizers,
flame retardants, stabilizers
6
Why People Choose Plastic Materials
> Low Thermal and Electrical Conductivity

– k (Thermal Conductivity) :
0.1-1W/m/K; metal:100-1000W/m/K,
thermal/electric good insulator
– k (Thermal Conductivity):
0.1-1W/m/K (Plastics)/ 0.25 ~ 0.04W/m/K (Foamed Plastics)
– Electrical Resistance:
1010 ~ 1018Ω (Plastics)/ ＜ 1Ω (Metals)
> Transparency for Amorphous Plastics
– PC for lenses/ CDs
– PMMA for boards/ lamp
> Permeable
– permit permeation and diffusion
> Recyclability and Reusability
7
Classification of Plastics
PLASTICS
Thermoplastics T h e rm a ls e t/ E la s to m e rs
not crosslinked
Amorphous (Semi)crystalline Slightly Strongly

Crosslinked Crosslinked
PC,PS,PVC, HDPE,LDPE, PUR, Epoxy,Melamine,

PMMA,... PP,PA,POM, Polybutadiene, Phenolics,
PTFE... Natural Rubber... Polyester,...
8
Thermoplastics
> Microstructure:
– No chemical connection (crosslinking) between molecules
– Chains held together by intermolecular forces and physical
entanglement
> Properties:
– Meltable, Moldable
– Soluble
– Variety in physical properties at room temperature
9
Morphology of Thermoplastics:
Amorphous and Semi-Crystalline
Amorphous
Specific Volume
Melting State
Semi-Crystalline
Temperature
10
Complexity of an Injection Molding Process
Process: Material:
• Non-Newtonial flow • Non-Newtonian flow (melt)
• Coupling heat transfer • Process-variable dependent properties
• Free surface (melt front) • Phase-transition (solid/melt)
• Interactions • Anisotropy (+FR/CF)
Design: Viscosity
• Complicated wall thickness variation Shear Rate
• Mold design consideration
• Cooling consideration
• Mechanics consideration
11
Material Physical Properties Affect
Injection Molding Product Development
pvT
Property
Rheological Thermal
(Viscosity) Property
Property
Polymer
Material
Properties
Kinetics Mechanical
Property Property
12
Effects of Rheological Properties

Rheological Properties
Viscosity is modeled as a function of shear rate and temperature
14
Viscosity comparison
PP PS PMMA
A：Newtonian (ex. water) C：PP
3 mm
1 mm
2 mm
B：PMMA D：PS
15
Effect of Rheological Properties
PP (Polypropylene)
3mm
1mm
2mm
PS (Polystyrene)
3mm
1mm
2mm
16
Effect of Rheological Properties
PMMA (Polymethylmethacrylate)
3mm
1mm
2mm
Newtonian (ex. water)
3mm
1mm
2mm
17
Effects of PVT Properties

Effect of PVT Properties
> Effect on Part Shrinkage

Specific Volume (cc/g)

PP PMMA
V
V
Temperature (oC) Temperature (oC)
Semi-crystalline Amorphous
Linear Shrinkage:1%~3% Linear Shrinkage:0.5%~0.8%
Volumetric Shrinkage: 0.5~3% Volumetric Shrinkage: 0.4~0.6%
19
Effect of PVT Properties
V
V
increasing
pressure P
Temperature (oC)
thermal expansion
20
Effects of Thermal Properties

Effect of Thermal Properties
k
CP
 Cp

Tg , Tm
22
Typical Thermal Conductivity Values
Material Thermal Conductivity

(x105 erg/sec-cm-oC)
Copper 418
Aluminum 210
Zinc 110
Iron 47
Steel 44
Quartz 10
Window Glass 0.86
Polyamide 0.25
Polycarbonate 0.20
Acrylic 0.18
Wood 0.17
23
Thermal Conductivity of Plastics
Thermal Conductivity
semi-crystalline
amorphous e.g.,LDPE=0.35x105 erg/cm-sec-oC
e.g.,PS=0.16x105 erg/cm-sec-oC
Tm
Temperature
24
Typical Specific Heat Values
Specific Heat
Material (x107 erg/g-oC)
Lead 0.13
Copper and Brass 0.38
Carbon Steel 0.48
Aluminium 0.88
Borosilicate glass 0.78
1oC
Building Brick 0.8
Water 4.2 Energy?
Solid Polymers 0.4~2.7
1g
Polyurethane (PU) 0.4
25
Heat Capacity of Plastics
discontinuity
Amorphous
Heat Capacity
Semi-crystalline
Tg Tm
Temperature
26
Effects of Mechanical Properties

Effect of Mechanical Properties
Poisson’s
Viscoelastic Ratio
Properties
Mechanical
Properties
Other
Elastic
Modulus
Modulus
28
Elastic Modulus
L L+ L
A
F F
Tensile Stress Tensile Strain L

F L
 
A L
Elastic Modulus or Young s Modulus

Tensile st ress 
E =
Tensile st rain 
Force per unit cross sectional area FA
= =
Strain per unit leng th L L [dyne/cm2]
29
Elastic Modulus
warpage
analysis
Necking
Stress Yield Point
Plastic deformation
Slope = Elastic Modulus Non-linear elastic deformation


E

Linear elastic deformation
Strain 
30
Poisson’s Ratio
F F
F F
L
W-W L+ L
W
L
axial (lateral) strain =  x 
L
W
longitudin al strain =  y 
W
Poisson s Ratio
− Lateral strain (contraction) −  y
  =
axial strain x
Change in width per unit width − W W
= =
Change in length per unit length L L [dimensionless]
31
Effect of Mechanical Properties
Volumetric Shrinkage=6.87%
PP,
E=1.65x1010 dyne/cm2,v=0.46
deformed shape
original shape
Volumetric Shrinkage=5.61% Volumetric Shrinkage=0.38%

POM, E=6.2x1010 dyne/cm2,v=0.35 LCP, E=1.1x1011 dyne/cm2,v=0.37
32
Description of Moldex3D Material
Databank

Moldex3D Material Databank
> User Interface
> Quick Search
> How to Establish Personal Material Databank
34
User Interface
Open Moldex3D Material Wizard
In the material tag, click “New” to open Moldex3D material wizard.
35
User Interface NO fiber
Choose Material WITH fiber
Moldex3D Material Databank is created with tree

structure. Its main menu is classified with material
family name.
Secondary menu are classified according to

different manufacturers.
Click the desired material
36
User Interface
Choose Material
Select “STYLAC VA29”, and right

click ”Add to Project”.
37
Quick Search
Click “find” to launch

Search function.
38
Quick Search
Search Tips-1
Check and enter Grade

Name, and then
click ”Find”.
Search result
39
Quick Search
Search Tips-2
Check and enter Melt flow

index, and then click
“Find”.
Search result
40
Quick Search
Search Tips-3
Check and enter Fiber

content, and then click “Find”.
Search result
41
How to Establish Personal Material
Databank
Click ”Edit” on the toolbar,

and choose ”New…” to open
the Edit interface.
42
Establish Personal Material Databank-
Complete Setting
43

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A05-01-004

Introduction to Plastic Materials

CoreTech System Co., Ltd. www.moldex3d.com

The following content is provided for educational purposes by CoreTech

Copyright for the following material is primarily held by the CoreTech

> Learning objectives

– Moldex3D Material Databank searching and usage

> Moldex3D version

– All Moldex3D product

> Recommended user

> Introduction to Plastic Materials

> Classification of Plastics

> Some key material properties to affect Injection Molding

– Thermal property : Cp and K

> Description of Moldex3D Material Databank

Semiconductor Aerospace Computer

Appliances Telecom Household

> Lightweight Material

> Low Thermal and Electrical Conductivity

Amorphous (Semi)crystalline Slightly Strongly

PC,PS,PVC, HDPE,LDPE, PUR, Epoxy,Melamine,

CoreTech System Co., Ltd. www.moldex3d.com

Viscosity is modeled as a function of shear rate and temperature

A：Newtonian (ex. water) C：PP

Newtonian (ex. water)

CoreTech System Co., Ltd. www.moldex3d.com

> Effect on Part Shrinkage

Specific Volume (cc/g)

Temperature (oC) Temperature (oC)

CoreTech System Co., Ltd. www.moldex3d.com

Material Thermal Conductivity

amorphous e.g.,LDPE=0.35x105 erg/cm-sec-oC

CoreTech System Co., Ltd. www.moldex3d.com

Tensile Stress Tensile Strain L

Elastic Modulus or Young s Modulus

Slope = Elastic Modulus Non-linear elastic deformation

Linear elastic deformation

Volumetric Shrinkage=5.61% Volumetric Shrinkage=0.38%

CoreTech System Co., Ltd. www.moldex3d.com

> User Interface

> Quick Search

> How to Establish Personal Material Databank

In the material tag, click “New” to open Moldex3D material wizard.

Choose Material WITH fiber

Moldex3D Material Databank is created with tree

Secondary menu are classified according to

Click the desired material

Select “STYLAC VA29”, and right

Click “find” to launch

Check and enter Grade

Check and enter Melt flow

Check and enter Fiber

Click ”Edit” on the toolbar,

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