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Hot-runner is getting more popular in injection molding process especially for the high surface-quality product. This work is to develop a navigating system for the hot-runner design with knowledge management. This web-based system provides step-by-step functions to guide the user through the sub-processes of product specification, manifold design, component assembly, spacer design and cylinder plate. Moreover, the knowledge database provides easy access of standard components which can be assembled automatically or semi-automatically. The system can provide the proven 3D hot-runner design with much shorter time.
An organically modified montmorillonite (MMT) was compounded with Polybutylene Terephthalate (PBT) in a twin-screw extruder. The organoclay PBT nanocomposites were then injection molded by conventional and microcellular methods. Nitrogen was used as the blowing agent. The effect of organoclaycontent, organoclay size (8 and 35 ?¬m), and speed of thescrew (80 and 100 rpm) on the mechanical and thermal properties were investigated.The results showed that when the MMT content was 1.0 wt%, the nanocomposites have maximum tensile strength, wear resistance, and cell density. Moreover, the larger the particle size, the greater the tensile strength. The screw speed during compounding also affected the mechanical strength. The higher speed of the screw increased the tensile strength of the nanocomposites. The addition of MMT also helped the thermal stability of the PBT/Clay nanocomposites. The WXRD results showed that when MMT loading is 1.0 wt%, the nanocomposites have maximum d-spacing structure. TEM results showed that MMT is well dispersed on the nanocomposites at a MMT loading of 1 .0 wt%.
The fused deposition modeling rapid prototyping system is based on the manufacturing principle of layer by layer. The sprayer is the key component. Based on the polymer rheological properties, the structure design and theoretical analysis of the mini-plunger sprayer of SW2502 fused deposition modeling system are studied. The plasticizing capacity of the mini-plunger sprayer is analyzed in theoretically. It is very important for the fused deposition modeling process to maintain a stable plasticizing capacity. The driving force of ABS feed is related to several parameters such as structure form of sprayer and material property, etc. The barrel and nozzle design should be fit for mobility, purity, and mechanical property of ABS feed. The modified ABS feed adopts self-pressure-adding driving method to decrease the pressure losses of barrel and nozzle. The plasticizing capacity of the sprayer is more than 20g/h.
This work studied bio-plastics such as polylactic acid (PLA) and protein based plastics form corn and compared to petroleum based plastics such polyethylene (PE) and polystyrene in terms of their ecological as well as economical performance from a “Cradle to Grave” perspective. This study included energy input emissions output of green house gases and costs from their life cycle steps of raw material acquisition to the final product disposal. It was found that products manufactured from bio-based feedstocks were relatively higher in cost they resulted in less green house gas emissions.
This work studied bio-plastics such as polylactic acid (PLA) and protein based plastics form corn and compared to petroleum based plastics such polyethylene (PE) and polystyrene in terms of their ecological as well as economical performance from a 'Cradle to Grave' perspective. This study included energy input, emissions output of green house gases and costs from their life cycle steps of raw material acquisition to the final product disposal. It was found that products manufactured from bio-based feedstocks were relatively higher in cost, they resulted in less green house gas emissions.
A novel analytical computational model was developed to predict Top Load and Side Load performance of oval containers. The performance of oval and other non round containers is dependent on the thickness distribution achieved during blow molding. Simulating blow molding and performance of containers using Virtual Prototypingƒ?› Software and feeding the input for Finite Element Analysis provides an accurate mechanism to predict container performance. A 24oz. generic oval container with aspect ratio of 1.58 was simulated for empty and filled top load performance. A critical part of blow molding oval containers is the ability to achieve a more uniform thickness profile along the circumference of the container at any given height. This isachieved by using preferential heating where the infra-red?ÿ heating ovens have special slotted reflector plates that allow the preform to be heated differently 90?ø apart. For the 24oz. oval container with a high aspect ratio it was observed that the use of preferential heating is necessary to achieve uniform thickness distribution in the range of 0.3mm-0.4mm. A non preferentially heated preform resulted in container thickness being 0.4-0.6mm in a concentrated region adjoining the minor axis. The preferentially heated performs resulted in containers having better empty and filled Top load. The side grip load was the only performance characteristic that was higher for the non preferentially heated containers but that works only in a small region and the non uniformity of thickness makes the container not aesthetically pleasing and would not be acceptable in a production process due to inconsistency in material distribution.
Food containers such as cups can be made by injection molding (IM) or thermoforming (TF). Typical materials are high density polyethylene (HDPE) polypropylene (PP) and high impact polystyrene (HIPS). For many years the preferred choice for polypropylene cups was IM because it produces a high quality part with excellent part-to-part consistency. Conventional TF to make similar containers in PP results in wider dimensional tolerances. On the other hand in-line trimin- place thermoforming overcomes many of the limitations of conventional TF and allows for the production of high quality containers. This paper outlines the conversion from IM to trim-in-place for a 235-ml cup and compares the physical properties of cups from each process.
Polyphenylene Sulfide (PPS) is a semi-crystalline engineering thermoplastic recognized for its unique combination of properties including chemical resistance, dimensional stability and thermal stability. The exceptional performance of this material in these environments has lead to extensive use in automotive ƒ??under the hoodƒ? applications. To maximize these material properties and make the high quality parts demanded by the automotive industry, it is very important that certain guidelines are followed in the molding process, failure to do so can result in premature part failure. This paper outlines one of the basic molding requirements, mold temperature, and the effect it has on the finished part.
The effect of talcs on PolyLactic Acid (PLA) performance has been studied with a focus on properties of fully crystallized PLA. The results show that talc could be used as an effective nucleation agent to improve mechanical properties of PLA including stiffness, heat deflection temperature and impact strength. It is shown that optimum crystallization of PLA could result in a maximum impact performance that is independent of the type of talc if complete crystallization is achieved. However, utilizing high performing talc such as the high-aspect ratio Luzenac HAR?? talc could allow maximum impact performance of crystallized PLA to be achieved at lower talc loading. It is also shown that the addition of plasticizers and impact modifiers could further improve impact properties through modifying the amorphous phase of PLA.
Rotationally molded polyethylene parts filled with polyurethane foam have been used for various applications in different marketplaces worldwide. However one of the main deficiencies of these two-component parts is a weak interface between both materials which often causes delamination of the polyurethane foam from the polyethylene skin.New polyethylene powders, developed by ICO Polymers using a unique and innovative low pressure plasma technology, successfully overcome the issues related to poor PE/PU foam adhesion without any modification to the current molding practices used by molders.An introduction to the technology, along with actual results achieved by the use, will be presented.
A simulation optimization methodology based on design of experiments and metamodeling is applied to injection molding in this work. The proposed method is used first to select the best processing conditions for injection molding a Kodak disposable camera front plate; and, secondly to decide on the best injection gates configuration from three different injection scenarios, as well as the values of mold temperature and melt temperature for a real automotive part in order to minimize variability. The optimization results are discussed in light of the qualities of the simulation optimization method.
As a kind of thermoplastic with excellent performance, polycarbonate is an ideal substitute for traditional glass applied in many optical products for its lightness and good transparency. Most of the products are made by injection molding, but yield of the products couldn't be improved for the problems on residual stress.Transparent polycarbonate will be used in the experiments; photoelasticity is to be used to calculate residual stress of specimen. The results indicate that residual stress decreases as the heating time increases during the heat treatment. In addition, thickness of specimens also may exert an influence on the effect of heat treatment.
The continuing trend toward metallic surfaces on plastics has motivated hartec to further develop PVD metallization by magnetron sputtering.Specifically, the combination of PVD + Topcoat (paint) appears to be a viable alternative to electroplated surfaces and real metals. Ecologically, the PVD process is sustainable, 100% non-toxic and emission free.PVD metallization offers a wide range of applications with advanced functionalities: Daynight design realized by laser-etching; optically and electromagnetically translucent coatings for 'hidden' displays and sensor technology; flexible substrates like TPU or TPE, for example used for safety components like airbag emblems in the automotive industry etc.
Residential and commercial piping systems often experience complex failures from freeze events. In this paper the freezing failures are studied by replicating pipe freezing conditions in a laboratory setting. Testing was performed on ?« inch (12.5mm) PVC and CPVC pipes. Pressure and temperature during the freeze event were monitored and the fracture modes of failed pipes were examined. Freeze events result in excessively high pressures. It has been shown that during a freeze event, the properties of plastic pipes are advantageous over other more rigid piping systems. In this study, it was observed that PVC and CPVC pipes were able to sustain over thirty times the typical household water pressure before bursting occurred.
An in-mold shrinkage sensor having a deflectable diaphragm under melt pressure, instrumented with strain gages connected in a full bridge circuit is designed and validated for conventional and thin wall parts. Molded part shrinkage is then measured as the polymer melt solidifies, shrinks, and retracts from the mold wall. The DOE was conducted using HIPS to validate the sensor performance for the thickness of 2.5 mm and 1.5 mm. With a 2.5 mm and 1.5 mm cavity thickness, the coefficient of correlation, R2, to the final part thickness was 0.939 and with 0.966 respectively for the in-mold shrinkage sensor.
The diluent effect of the amorphous (rubbery) PEP block upon the SSA thermal fractionation of the PE component as compared with the PE homopolymer was evaluated. The shape and distribution of the melting peaks obtained after applying the SSA protocol is notably different in the PE-b-PEP diblock copolymers. It has been established how the presence of a diluent blended with the amorphous zones of this semicrystalline polymer trends to increase the molecular mobility of PE chains in such a way that fractions closer to thermodynamic equilibrium can be generated.
In this work, microcellular extrusion foaming for both linear and long-chain-branched (LCB) polylactide (PLA) was processed on a single-screw extrusion system with CO2 as a blowing agent. The rheological experiments were conducted on an advanced rheometric expansion system (ARES) rheometer to compare the rheological properties among linear and LCB-PLAs without blowing agent. The characterization for foamed samples shows that in comparison to the linear PLA, the LCB-PLA foams have larger volume expansion ratios, decreased cell-opening, smaller average cell sizes and higher cell densities, due to the higher viscosity, higher melt strength and higher crystallinity derived from long-chain branching.
High-speed passenger ferry service is attractive in many communities due to its convenience and expedience but has in certain instances caused problems related to pollution and shoreline erosion. One approach to mitigating these problems is to switch from widely used metals to lighter composite materials in vessel construction. This shift in materials would increase efficiency and decrease wake generation. This research addresses several challenges that have been faced when incorporating composite materials into a hydrofoil for a passenger ferry and describes a potential solution.
High-speed passenger ferry service is attractive in many communities due to its convenience and expedience, but has, in certain instances, caused problems related to pollution and shoreline erosion. One approach to mitigating these problems is to switch from widely used metals to lighter composite materials in vessel construction. This shift in materials would increase efficiency and decrease wake generation. This research addresses several challenges that have been faced when incorporating composite materials into a hydrofoil for a passenger ferry and describes a potential solution.
To identify dimensional thermoformability indicators, high-temperature tensile and differential scanning calorimetry (DSC) methods were studied. It was found that a new indicator ADR(TD) minus ADR(MD), i.e., the differential of the area draw ratios (ADR) between transverse direction (TD) and machine direction (MD) of a multilayer film can rank or predict thermoformability of the multilayer films with good resolution. This new indicator and a derived dimensional thermoformability index (DTI) can differentiate between different nylons, polyethylenes and multilayer structures. The ranking correlates well with the overall first-heat of fusion of the multilayer films. Thus, these indicators can be used as tools to help design multilayer structures.
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