PREDICTION ON THE WARPAGE OF INJECTION MOLDED GLASS FIBER REINFORCED POLYMERS WITH COMPOSITE MECHANICS

P. Gutmann, D.S. Bangarusampath, V. Altstädt, H. Schmalz, A.H.E. Müller, May 2010

Based on the microstructure characteristics of injection molded short fiber reinforced polymers, a model was developed to predict the warpage. Multiscale composite mechanics was used to describe the materials properties during the processing. A shin shell element composed improved Allman membrane element and discrete Kirchhoff bending element was put forward to calculate the warpage of injection molded products. The results of prediction were compared with experimental results.

INFLUENCE OF THE MICROSTRUCTURE ON THE FOAMING BEHAVIOR OF AN IMMISCIBLE BLEND

P. Gutmann , D.S. Bangarusampath , V. Altstädt , H. Ruckdäschel , H. Schmalz , A.H.E. Müller, May 2010

The foaming behavior of immiscible blends is affected by many factors as the morphology or the viscosity ratio. To investigate the influence of the microstructure on the foaming behavior of an immiscible blend the morphology of a blend was systematically changed by varying the phase content. The blends were foamed using a batch-foaming process and the achieved foam structures were correlated to the blend morphology and the properties of the blend phases.

APPLIED RHEOLOGY FOR HDPE DIE DROOL PHENOMENON

Siqiang Zhu, Rahul Rasal, Douglas Hirt, May 2010

In this work, two different HDPEs were investigated from rheological as well as die drool phenomenon point of view. It has been revealed that long-chain branching and low polymer melt elasticity significantly reduce die drool phenomena at the die exit region.

CONICAL COUNTER-ROTATING TWIN SCREW EXTRUDER DESIGNS FOR NON-PVC APPLICATIONS

Lei Xie, Gerhard Ziegmann, May 2010

Conical counter-rotating twin screw extruders have traditionally been used for PVC profile extrusion. With adjustments to screw configuration and barrel design, the counter rotating twin screw extruder can process other resins as well. Process advantages such as lower discharge temperature and residence time control can be realized as compared to other extrusion devices such as single screw extruders.

STUDY OF OPTIMAL THERMAL DISTRIBUTION DESIGN FOR MANIFOLD HEATER

Mike Barnstead, Frank Wagner, May 2010

A uniform heat distribution in the manifold temperature is a key factor in a successful hot runner system. In this study, a CAE software simulation was used to help visualize the design of the adapter placed on the cartridge heater and working on the manifold as the interface of the heat source. Using the CAE simulation, we determined the optimal thermal distribution by designing a grooved adapter to handle the heat flow orientation.

CONSIDERATIONS FOR PRODUCING HIGH QUALITY PLATED PLASTIC COMPONENTS

Mike Barnstead , Frank Wagner, May 2010

The plating of plastic components for use on automobiles and other items is increasing due to the cost and the many desirable properties of the plated plastic component such as weight reduction. The goal of this paper is to examine the process cycle of preparing plastic components prior to plating as well as design molding and racking concerns specific to electroplating.

CONSIDERATIONS FOR PRODUCING HIGH QUALITY PLATED PLASTIC COMPONENTS

Mike Barnstead , Frank Wagner, May 2010

The plating of plastic components for use on automobiles and other items is increasing due to the cost and the many desirable properties of the plated plastic component, such as weight reduction. The goal of this paper is to examine the process cycle of preparing plastic components prior to plating, as well as design, molding and racking concerns specific to electroplating.

DETERMINATION OF VALID MINIMUM DIMENSIONS OF DDENT SPECIMENS TO EVALUATE THE ESSENTIAL WORK OF FRACTURE (EWF) OF POLYETHYLENES

Mariselis Trujillo , Karina G. Izquierdo , Johan J. Sánchez , Alejandro J. Müller, May 2010

We studied how the dimensions of test specimens affect EWF results. One grade of commercial HDPE was evaluated. We demonstrate that reductions of 20 to 30% of conventional dimensions used for DDENT geometry allow reproducible and valid results, similar to those obtained with larger specimens. Results show that it is not possible to reduce dimensions more than 30% and still comply with geometric validations related to EWF.

POLYETHYLENE TEREPHTHALATE REINFORCED THERMOPLASTIC COMPOSITES

Gowri Dorairaju, Gregory Morose, Daniel F. Schmidt, May 2010

Fiber-reinforced polypropylene (PP) composites represent an attractive solution for industries to produce tailor-made materials. Poly-ethylene terephthalate (PET) fibers are chosen in this work. PET fibers are cable-wired by using a PP matrix and the final composites show good balance between high impact properties, even at very low temperatures, improved stiffness and fracture strain. The effects of fiber concentration, types of PP matrices, types and concentrations of dispersing agents are investigated.

BLENDING OF RECYCLE PE BLOWN FILM AND INJECTION MOULDING GRADES

Jeremy R. Austin, May 2010

The affects on the mechanical and rheological properties of blends of recycled blown film (BM) and injection moulded milk containers (IM) were studied. Tensile, flexural and thermal properties remained unchanged with resultant increasing MFI. Anomalous results appear to occur between the 80/20% w/w (BM/IM) and 60/40% w/w (BM/IM) blends as confirmed by GPC, MFI and density.

ANALYSIS OF METALLOCENE BASED LLDPE FLOW WITH RESPECT TO DIE DROOL PHENOMENON BY USING FEM AND FLOW VISUALIZATION EXPERIMENT

M. Zatloukal , K. Chaloupkova , M. Martyn , P. Coates, May 2010

In this work the relationship between die exit geometry and die drool phenomenon for metallocene based LLDPE has been investigated experimentally by using laboratory extrusion line equipped by specially designed capillary die and flow visualization cell as well as theoretically by using viscoelastic Finite Element Method.

SAFETY FACTORS IN PLASTIC PARTS USING LINEAR ANALYSIS

Jesús Fuenmayor , Joel Bohórquez, May 2010

The factor of safety (FOS) is a key design parameter for any part subjected to stress. FOS is of special interest when a plastic part is designed because of the highly variable plastic properties. Several experimental tests were conducted to end-user parts, manufactured with HDPE, PP and PVC, which were exposed to different kind of loads until part failure. Mechanical simulations considering a linear material behavior were performed under the same loads and restraints conditions employed in the experimental tests, in order to determine the proper FOS to be considered.

AN OVERVIEW OF INTERNAL COOLING IN ROTATIONAL MOULDING

S.B. Tan , P.R. Hornsby , M. McAfee , M.P. Kearns , M. McCourt , P.R. Hanna, May 2010

Internal cooling is an attractive way to reduce the cycle times and enhance the product properties in rotational moulding. A review on the different internal cooling approaches undertaken by various researchers in the past is presented. Internal water spray cooling is considered as an alternative cooling technique and the important process parameters for this technique are highlighted. These parameters are believed to affect the cooling efficiency and product quality when internal water spray cooling is applied.

INTUITIVE THERMAL ANALYSIS SOFTWARE IS EASY TO USE IN AN ACADEMIC SETTING

Andrew W. Salamon , Peng Ye , Kevin Menard, May 2010

Ethernet instrument communications with an intuitive user interface easily manages an academic laboratory environment. Controlling a thermal analytical instrument whether it is a DSC TGA or a STA is simply a one touch interaction. Students quickly learn method setup and data analysis. A rainbow of colors and line types makes it is easy to compare and contrast curves. Polymer glass transitions and endothermic and exothermic graphical events are easily included in reports.

INTUITIVE THERMAL ANALYSIS SOFTWARE IS EASY TO USE IN AN ACADEMIC SETTING

Andrew W. Salamon , Peng Ye , Kevin Menard, May 2010

Ethernet instrument communications with an intuitive user interface easily manages an academic laboratory environment. Controlling a thermal analytical instrument, whether it is a DSC, TGA, or a STA, is simply a one touch interaction. Students quickly learn method setup and data analysis. A rainbow of colors and line types makes it is easy to compare and contrast curves. Polymer glass transitions and endothermic and exothermic graphical events are easily included in reports.

FIBER ORIENTATION AND FIBER-MATRIX SEPARATION PHENOMENA DURING COMPRESSION MOLDING

Yin-Jiun Lin, Sheng-Jye Hwang, Huei-Huang Lee, Durn-Yuan Huang, May 2010

Fiber Orientation and Fiber-Matrix Separation Phenomena during Compression Molding

BISPHENOL E CYANATE ESTER NANOCOMPOSITES WITH LOW COEFFICIENT OF THERMAL EXPANSION

Prashanth Badrinarayanan , Michael R. Kessler, May 2010

HIGHLY OIL-EXTENDED OLEFIN BLOCK COPOLYMERS

Ashish Batra , Lisa Madenjian , Wenbin Liang , Gary Marchand , Dan Moldovan , Jacob Jones, May 2010

INFUSE' Olefin Block Copolymers (OBCs) are a family of new materials which are finding increasing utility in soft compounds that have traditionally been dominated by Styrenic Block Copolymers (SBCs). In this paper we will elucidate the fundamental differences in processing OBCs and SBCs to achieve low Shore A products. Comparisons of similar Shore A compounds show that OBC soft compounds can achieve the performance of traditional SBC-based compounds based on mechanical property comparisons.

WATER VAPOR BARRIER AND TRANSPARENCY PROPERTIES OF CYCLIC OLEFIN COPOLYMER CAST FILMS

Sean T. Flowers, Avraham Benatar, George W. Ritter, May 2010

A cyclic olefin copolymer (COC) was investigated as a superior water vapor barrier material for possible use in multilayer, high barrier packaging structures for military rations. The COC was processed via cast film extrusion, while chill roll temperatures and take-off speeds were varied, to determine the effects on the barrier properties and transmittance of the films. Characterization of the cast films included, water vapor permeation testing, ultraviolet-visible spectroscopy and differential scanning calorimetry (DSC).

EVALUATION OF PATTERNED JOINT DESIGNS FOR ULTRASONIC WELDING OF HDPE NANOCOMPOSITES

Sean T. Flowers , Avraham Benatar , George W. Ritter, May 2010

The ultrasonic weldability of high-density polyethylene (HDPE) nanocomposites was investigated using four different energy director butt joint designs with loadings of 0 3 and 6 wt% nanoclay. Patterned surfaces were incorporated in an attempt to allow nanoclay platelet alignment on multiple planes inside the weld region.Samples were welded using a one-factor-at-a-time approach varying weld time weld amplitude and weld force. Weld tensile strengths were compared for the different clay contents and joint patterns.