2.810 This Week: Casting and Additive Processes

• Injection Molding & FDM

• Metal Casting & Laser Powder Bed

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2.810 Project Teams, 2019

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Casting Processes

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• Flowable material

• Tooling

• Heat transfer

• Solidification

Material Properties ComparisonProperty units TP polymers Al Alloys

k W/m-K 0.1-0.4 121-239

C J/kg-K 1000-2000 880-920

𝜌 kg/m3 900-2000 2630-2820

Tm (℃) 110-330 476-654

𝛼 =𝑘

𝜌𝐶

cm2/sec 1.2x10-3 0.7

𝜇 Pa-sec = (N/m2)-s

~103 ~10-3

4

Most of these values come from Table 3.1 in your text.The viscosity of polymers is very temperature and strain rate dependent, furthermore even for a given polymer is in alsodependent on the molecular weight.

More Material PropertiesProperty units TP polymers Al Alloys

k W/m-K 0.1-0.4 121-239

C J/kg-K 1000-2000 880-920

𝜌 kg/m3 900-2000 2630-2820

Tm (℃) 110-330 476-654

𝛼 =𝑘

𝜌𝐶

cm2/sec 1.2x10-3 0.7

𝜇 Pa-sec = (N/m2)-sec

~103 ~10-3

E GPa 0.1-10 70-80

UTS MPa 10-200 100-500

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Values for E and UTS come from Table 2.2 (p 58)

Injection Molding

2.810

T. Gutowski

D. Roylance 6

Readings (first 3) & Refs

Tadmore and Gogos

Molding and Casting pp 584 -610

Boothroyd Dewhurst

Design for Injection Molding pp 319 - 359

Kalpakjian Ch 7 & 19

Thiriez et al, "An Environmental Analysis of Injection

Molding“

"Injection Molding Case Study“ (Gas Assist)

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V-6 air intake manifold

Water control valveBrass Vs injection moldwww.mnrubber.com

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Short history of plastics

1866 Celluloid

1891 Rayon

1907 Bakelite

1913 Cellophane

1926 PVC

1933 Polyethylene

1938 Teflon

1939 Nylon stockings

1957 velcro

1967 “The Graduate”

1970 Earth Day recycling

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Ref Kalpakjian and Schmid McCrum, Buckley, Bucknall 10

Outline

Basic operation

Cycle time and heat transfer

Flow and solidification

Part design

Tooling

New developments

Environment

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30 ton, 1.5 fl oz (45 cm3) Engel

Engel Injection Molding Machine in building 35

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Process & machine schematics*

* Source: http://www.idsa-mp.org/proc/plastic/injection/injection_process.htm

*

Schematic of thermoplastic Injection molding machine

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Process OperationTemperature: barrel zones, tool, die zone

Pressures: injection max, hold

Times: injection, hold, tool opening

Shot size: screw travel

Flash

Melt

Thermaldegradation

Short-shot

Temp.

Pressure

Processing window

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Typical pressure/temperature cycle

Time(sec)

Cooling time generally dominates cycle time

Time(sec)

* Source: http://islnotes.cps.msu.edu/trp/inj/inj_time.html

**

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Calculate clamp force, & shot size

F=P X A = 420 tons

3.8 lbs = 2245 cm3

=75 oz

Actual ; 2 cavity 800 ton

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Clamp force and machine cost

Boothroyd/Busch

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Heat transfer Note; aTool > apolymer

Boundary Conditions:

1-dimensional heat conduction equation :

The boundary condition of 1st kind applies to injection molding since the tool is often maintained at a constant temperature

qx qx + Dqx

Fourier’s law

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Heat transfer

TW

Tii

t

x+L-L

Let Lch = H/2 (half thickness) = L ; tch = L2/a ;DTch = Ti – TW (initial temp. – wall temp.)

Non-dimensionalize:

Dimensionless equation:

Initial condition

Boundary condition

Separation of variables ; matching B.C.; matching I.C.

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Centerline, q = 0.1, Fo = at/L2 = 1

Temperature in a slab

Bi-1 =k/hL

See Heat Transfer Text

By Lienhard on line, alsocylinders and spheres 20

Reynolds Number

* Source: http://www.idsa-mp.org/proc/plastic/injection/injection_process.htm

Reynolds Number:

For typical injection molding

For Die casting

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Viscous Shearing of Fluidsv

F

h

F/A

v/h

1

m

Newtonian Viscosity

Generalization:

Injection molding

Typical shear rate for Polymer processes (sec)-1

Extrusion 102~103

Calendering 10~102

Injection molding 103~104

Comp. Molding 1~10

“Shear Thinning”

~ 1 sec-1 for PE 22

Viscous Heating: Brinkman No.

Rate of Heating = Rate of Viscous Work

Rate of Temperature rise

Rate of Conduction out

Brinkman number

For injection molding, order of magnitude ~ 0.1 to 1023

Br=

Non-Isothermal Flow

v

Flow rate: 1/t ~V/Lx

Heat transfer rate: 1/t ~a/(Lz/2)2

For injection molding

For Die casting of aluminum*

* Very small, therefore it requires thick runners

Small value=> Short shot

Péclet No.

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x

z

Non-Isothermal Flow

v

Flow rate: 1/t ~V/Lx

Heat transfer rate: 1/t ~a/(Lz/2)2

For injection molding

For Die casting of aluminum

Very small value for aluminum requires thicker runners

Small value=> Short shot

Péclet No.

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Injection mold die cast mold

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Fountain Flow

* Source: http://islnotes.cps.msu.edu/trp/inj/flw_froz.html ; ** Z. Tadmore and C. Gogos, “Principles of Polymer Processing”

*

**

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Shrinkage distributions

* Source: G. Menges and W. Wubken, “Influence of processing conditions on Molecular Orientation in Injection Molds”

V=3.5cm/s

V=8cm/s

sample Transverse direction

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Anisotropic shrinkage and Warping

Sprue

2.0

2.0 60

Before shrinkage

60.321.96

1.976

After shrinkage

ShrinkageDirection of flow – 0.020 in/inPerpendicular to flow – 0.012

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Gate Location and Warping

Center gate: radial flow – severe distortion

Diagonal gate: radial flow – twisting End gates: linear flow – minimum warping

Gate

Air entrapment

Edge gate: warp free, air entrapment

Sprue

2.0

2.0 60

Before shrinkage

60.321.96

1.976

After shrinkage

ShrinkageDirection of flow – 0.020 in/inPerpendicular to flow – 0.012

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Effects of mold temperature and pressure on shrinkage

0.030

0.000

0.010

0.005

0.015

0.020

0.025

100 120 140 160 180 200 220 240

Mold Temperature (F)

LDPE PP

Nylon 6/6

PMMA

Acetal

Sh

rin

ka

ge

0.030

0.000

0.010

0.005

0.015

0.020

0.025

Sh

rin

ka

ge

6000

8000

10000

12000

14000

16000

Pressure on injection plunger (psi)

Acetal

LDPE

Nylon 6/6

PP with flow

18000

PP across flow

PMMA

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Where would you gate this part?

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Design Features*

*

* Source: http://www.idsa-mp.org/proc/plastic/injection/injection_design_2.htm 33

Weld line, Sink mark

* Source: http://www.idsa-mp.org/proc/plastic/injection/injection_design_7.htm

Weld line

Mold Filling

Gate

Solidified part

Sink markBasic rules in designing ribs

to minimize sink marks34

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Where is injection molding?

Controlled by shrinkageand warping. Hence,polymer, fillers, moldgeometry and processingconditions can allinfluence the finaltolerance.Shrinkage is of order10-100/1000 for unfilledand1-10/1000 for filled acrossthe thickness

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Tooling Basics

Cavity Plate

Cavity

MouldingCore

Core Plate

Basic mould consisting of cavity and core plate

Runner

Cavity

Gate

NozzleSprue

Melt Delivery

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Part

Cavity

Core

Stripper plate

Tooling for a plastic cup

Runner

Knob

Nozzle

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Tooling for a plastic cup

Runner

Part

Cavity

Nozzle

Part

Cavity

Knob

Stripper plate

Runner

Part

Cavity

Nozzle

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Toy tooling example

from Protomold

partSide pull

Side pull in position

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Tooling

* Source: http://www.idsa-mp.org/proc/plastic/injection/; ** http://www.hzs.co.jp/english/products/e_trainer/mold/basic/basic.htm (E-trainer by HZS Co.,Ltd.)

**

*

*

*

* **

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Tooling Alternatives

Kalpakjian & Schmid

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Undercut features to hold tape on

Evidence of tooling

feature

Injection Molding Homework

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Part design rules

Simple shapes to reduce tooling cost No undercuts, etc.

Draft angle to remove part In some cases, small angles (1/4) will do

Problem for gears

Even wall thickness

Minimum wall thickness ~ 0.025 in

Avoid sharp corners

Hide weld lines Holes may be molded 2/3 of the way through the

wall only, with final drilling to eliminate weld lines44

Novel development- Gas assisted injection molding

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Novel development ; injection molding with cores

Cores and Part Molded in Clear Plastic

Cores used in Injection Molding

Injection Molded Housing

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Micro injection molding

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Conformal Cooling Channels

Innomis.cz

Tooling built usingAdditive Manufacturing

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Environmental issues

Energy

Polymer production

Compounding

Machine types

Recycling

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Polymer ProductionLargest Player in the Injection Molding LCI

What is a polymer:

How much energy does it take to make 1 kg of polymer = a lot !!!

Values are in MJ per kg of polymer produced. Thiriez ‘0651

Gold ~ 250 GJ/kg

Ashby 2009

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Compounding - extrusion

An extruder is used to mix additives with a polymer base, to bestow the polymer with the required characteristics.

Similar to an injection molding machine, but without a mold and continuous production.

Thus it has a similar energy consumption profile.

Environmentally Unfriendly Additives:

•Fluorinated blowing agents (GHG’s)

•Phalates (some toxic to human

liver, kidney and testicles)

•Organotin stabilizers (toxic and

damage marine wildlife)

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Injection Molding Process

Source:

http://cache.husky.ca/pdf/br

ochures/br-hylectric03a.pdf

Machine types: Hydraulic, electric, hydro-electric

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All-electric vs. hybrid

The hydraulic plot would be even higher than the hybrid curve

Source: [Thiriez]

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For Hydraulics and Hybrids as throughput increases, SEC k.

Enthalpy value to melt plastics is just 0.1 to 0.7 MJ/kg !!!

Does not account for the electric grid. Source: [Thiriez]

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All-electrics have very low fixed energy costs (small idling power). SEC is constant as throughput

increases.

Source: [Thiriez]57

DriersUsed to dry internal moisture in hygroscopic polymers and external moisture in non-hygroscopic ones. It is done before extruding and injection molding.

Source: [Thiriez]

Same as

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LCI Summarized Results

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Source: [Thiriez]60

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Do Polymers get recycled?

Ref Ashby 2009

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The printer goes in the hopper…

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And comes out….

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