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Conference Proceedings

The Novel Silver Based Antimicrobial For Plastics
Luiz Gustavo Pagotto Simoes, March 2019

The use of silver and silver compounds as antimicrobial agents has been known since ancient times. There are several kinds of silver materials like colloidal silver, silver glass, titanium oxide with silver and silver zeolites. In this work, a different silver based antimicrobial for plastics, using carrier a silica to promote the bactericide and fungicide effect of the silver. The silver particles are anchored on silica ceramic particles using chemical process and it composite can be incorporated directly to the polymers. The process of obtaining these additives with antibacterial property is performed by homogenization of the melt (composting), to produce concentrates of Ag particles (masterbatch) in various types of plastic resins. After preparing the masterbatch, the compound can be used, with recommended percentages in accordance to evidentiary tests of its effectiveness, in all types of plastic transformation processes. Plastics samples in different resins was submitted ISO 22196 test and the silica/silver material eliminated 99.99% of the E. Coli. Eye irritation test was conducted with rabbits to determine the potential for the silver based antimicrobial to produce irritation from a single instillation via the ocular route. Skin irritation test was conducted with rabbits to determine the potential for composite to produce irritation after a single topical application. Under the conditions of this study, the test substance is classified as slightly irritating to the skin. Migration tests was conducted to the composite and the results showed that the migration in polyolefins is according to permit regulatory agency like FDA.

Influences Of Process Parameters On Penetration In A Hybrid Single Shot Manufacturing Of Carbon Fiber/Epoxypolypropylene Structure
Hakan Kazan, March 2019

The authors detail the creation of a hybrid material structure via the injection of polypropylene (PP) with high ductility into a robust CF/Epoxy thermoset sheet. The purpose of this hybrid method involved combining the inherent properties of both thermoset and thermoplastic materials in a new hybrid structure while reducing the cycle time. The effect of pre-heating time, blank holder force, injection temperature, and injection speed rate on the deformation of prepreg and polymer penetration through prepreg sheets were evaluated. The results of the experimental design based on the Taguchi L18 orthogonal array indicated that the hybrid structures were manufactured with no penetration present in any combinations of parameters. An inadequate deformation characterized the samples created at a lower injection temperature, and pre-heating time, with insufficient adhesion as a result. Although the high injection speed enhanced formability and joinability, no significant effect on deformation and joining occurred from an increase in blank holder force.

Automotive Lightweighting Via Supercritical Foam Injection Molding Of Thermoplastic Olefin
Sai Aditya Pradeep, March 2019

The automotive industry has been transitioning from a primarily metals-based assembly towards a multi-material architecture driven by the need to meet the Corporate Average Fuel Economy (CAFE) standards that mandate automakers to have a fuel economy of 54.5 MPG by 2025. Polypropylene (PP) based Thermoplastic Olefins (TPO) blends constitute a significant portion of the automotive market due to its extensive use in many interiors, exterior and under-the-hood applications. However, lightweighting of PP based TPO blends by foaming often presents numerous challenges - most widely known is a resulting poor A-surface appearance. In this work, Clemson University and our OEM partner are investigating the impact of foamability on PP based TPO, via supercritical assisted foam injection molding. The study investigates the effect of foam injection molding processing conditions (e.g., melt temperatures, injection speed, etc.) on the microscale part performance level (e.g., mechanical properties, cellular morphology, etc.).

Hybrid Process Of Forming-Injection Molding – Investigation Of Polymer Melt Behavior On The Final Injected Part
Saeed Farahani, March 2019

Due to global competition, manufacturing firms must target innovation in production processes and technologies that allow the mass manufacturing of customized products through highly efficient processes. Motivated by the concept of the hybrid production system, an innovative platform technology, known as Polymer Injection Forming (PIF), was recently developed. In the PIF process, the best-in-class manufacturing technologies in polymers and metals, viz., injection-molding and sheet metal forming, are integrated to manufacture sheet metal-polymer hybrids in a single operation. In this process, the polymer melt serves as a forming medium and deforms the inserted sheet metal during the filling phase of the injection molding process. So far, most studies have focused on the influence of the injection molding process parameters on blank deformation and specification of the final deformed sheet metal part. While doing so, these studies have either totally neglected the polymer part or have only considered its rheological characterization as a forming medium. In this work, for the first time, the melt flow development of the PIF process is investigated, and a schematic flow field is presented. Subsequently, this investigation is extended to the online process parameters which are acquired with a set of in-mold instrumentations. Finally, morphology and crystallinity of cross-section of the samples produced by this process is investigated and compared with the sample produced via conventional injection molding condition.

Failure Analysis Of Automotive Air Conditioning Connectors
Jeffrey Jansen, March 2019

Failures occurred within automotive air conditioning system connectors. The cracking was observed within connectors that had been installed in automobiles, which were part of a durability testing program. The focus of this investigation was a determination of the nature and cause of the failures. The results obtained during the evaluation of the cracked connectors indicated that the failures occurred through a brittle fracture, slow crack initiation creep rupture mechanism of the material. However, the cause of the failure was severe molecular degradation as a result of the durability test program conditions. This paper will review the testing performed to characterize the failure mode and identify the cause of the cracking, while demonstrating the analytical procedures used in the investigation.

Investigation Of The Foamability And Resulting Mechanical Properties Of Foamed Thermooplastic Elastomers
Yuxiao Zhang, March 2019

Thermoplastic foam injection molding offers various advantages in regard of processing and product design. Due to the foamed core structure, the mechanical part properties differ from the compact references and can be significantly influenced by the processing parameters. At IKV, different thermoplastic elastomers (TPE) with different molecular structures were foamed to investigate the impact of processing parameters on the foam structure and the mechanical properties. Both static and dynamic behavior of the foamed TPE parts was determined. It was found that the mechanical properties of foamed TPE parts change significantly in comparison to compact references.

A Study On The Effects Of The Processing Parameters On The Flatness Quality Of Blown Films Using Laser Triangulation
Can Bakir, March 2019

Blown film extrusion is one of the most commonly used processes for the mass production of thin gauge general purpose films. The vast majority of consumer commodity products, including grocery bags, agricultural films and flexible food packaging films, are produced using this process. Blown films, like many other plastic films, are produced in continuous webs and made available to customers as film rolls. Both for flawless further processing and for the required mechanical and optical properties, plastic films and rolls must meet numerous quality requirements. Among the quality features, the flatness, which describes the planarity of the plastic films in a tension-free state, is gaining in importance with the increasing automation of production lines. The increasing quality demands are mainly the result of the demanding requirements in the further processing steps such as printing or laminating. Non-uniformities in flatness, such as waviness or wrinkles, can limit the printability and laminability of the films and thus lead to product rejects. Although flatness is a critical quality feature for blown films, flatness quality is currently only monitored by visual inspection on a subjective basis using random sampling. The measurement method presented in this study allows a fast, quantitative and objective evaluation of the flatness quality by measuring the surface topology of plastic films, opening up a new possibility for the quality assurance. By measuring and digitalizing the surface geometry of plastic films, different characteristic values can be derived to assess the flatness quality. In addition, a quantitative measurement of the film flatness allows a comprehensive characterization of the underlying causes of flatness errors. Accordingly, the measurement method was applied successfully as part of a preliminary investigation to determine the influence of different collapsing geometries on the flatness quality.

Development Of A Temperature Displacement Law For Viscosity Fluctuations Integrated Into The Control Setup Of The Injection Molding Process
Hanna Dornebusch, March 2019

Modern injection molding machine technology is able to reproduce machine parameters, such as the movement of the axes, with high accuracy. Nevertheless, different boundary conditions, such as fluctuations in material properties or changes in ambient conditions, influence the quality of injection molded parts. Innovative control concepts can enable a production with a constant part quality despite changing and non-optimal boundary conditions. But these concepts do not take viscosity fluctuation into account although it changes the pressure distribution and thus the shrinkage behavior of the molded parts. Within this paper, a temperature control setup of the hot runner for compensating different melt viscosities is introduced and implemented. Therefore, a temperature displacement law that regulates the temperature of the hot runner is developed and used to control the injection molding process. Its influence on the process and the part quality are investigated.

Simulative And Experimental Validation Of An Inversed Cooling Channel Design For Injection Molds
Torben Fischer, March 2019

Thermal mold design is an important phase during mold construction and determines strongly the resulting part quality and cycle time. Nowadays, part geometries become more complex as well as cycle time becomes an increasingly important requirement. To support the mold designer in generating an efficient cooling channel design with less iteration loops, a methodology is under development to indicate the location of the cooling channels. Based on the local cooling demand of the part, this methodology proposes an inverse approach where an optimal thermal state of the mold is calculated and a corresponding cooling channel design is derived. A objective function is used to calculate and evaluate the cooling quality of the resulting design. In a process simulation, the developed cooling channel design shows a reduction in part warpage of up to 75 % compared to a conventional thermal mold design.

Effect Of Long Chain Branching On The Rheology And Flame Properties In Polycarbonate Resins
Himanshu Asthana, March 2019

It is known from literature [1, 2] that the rheological properties of polymer melts are influenced by the degree of long chain branching (LCB). Therefore, it is very important to understand the influence of LCB on the solid-state properties to help improve material design for unique applications. The objective of the present study is to demonstrate the use of extensional rheology as a tool to understand FR performance pertaining to dripping. Further, we also demonstrate the synergistic role of LCB in polycarbonate resins for improving FR performance.

Specialty Discharge Methods For Continuous Compounders
Amanda Erickson, March 2019

A brief overview of discharge methods for continuous compounders is presented covering single-screw extruders, melt pumps, centrifugal pelletizers, pressure vessels, counter-rotating twin-screws, along with the B&P Littleford XLT twin-screw mechanism and Rotofeed System. These seven systems are critical subsystems of the entire extrusion process. Discharge methods for specialty processes, if designed correctly, can provide a constant pressure great enough for profile extrusion, continue mixing and/or reacting, cool, or pelletize the product. The correct subsystem can mean the success or failure of the entire process and is highly dependent on material properties.

Process Monitoring Of Induction-Based Adhesively Bonded Lap-Joints
Rajendra Prasath Palanisamy, March 2019

Adhesively bonded joints are an excellent replacement of traditional mechanical joints in the automobile industry. In comparison to mechanical joints, adhesively bonded joints are lightweight and cost-effective in fabrication. Induction-based bonding is gaining popularity as they are relatively quicker than conventional oven techniques. However, the temperature distribution, phase change, and cure time are not as straightforward as conventional oven prepared joints. Thus, it is necessary to understand these parameters in an induction based heating method to produce better joints. In this research work, stress waves are transmitted between adherents that pass through the adhesive interface. The changes in transmission coefficient and Time of Flight (TOF) of guided waves (GW) helps in understanding joint conditions properties such as adhesive phase transition and time of cure during fabrication. A qualitative analysis is reported in this paper to prove the application of guided waves in process monitoring.

Two Concepts For Extending The 3D-Simulation Technique Of Melting Processes In High-Speed-Extrusion Based On A Custom Material Model
Mirco Janben, March 2019

This paper investigates the potential of two concepts to extend an existing technique for simulating the melting process in high-speed-extrusion operations. The first concept is based on the so called Enthalpy- Porosity-Technique. A momentum sink will be implemented in the momentum equations to influence the velocity of the solid and umolten phase. The second concept deals with an adjustment of the current computation of the dissipated energy during phase change from solid to liquid. It is based on the idea that in a partially molten cell only the melt is exposed to shearing. A comparison of simulation results and microtom cut views from real experiment is carried out.

Advanced Additive Manufacturing Of Functionally Gradient Multi Material Polymer Components With Single Extrusion Head: Melt Rheology Analysis
Alaauldeen Duhduh, March 2019

Additive manufacturing (AM) has revolutionized the way in which products are designed and manufactured, where parts are built from the ground up, layer upon layer. For polymer based additive manufacturing, we have improved upon that by applying an innovative strategy that allows for functionally gradient multi material printing with single extrusion head. The innovation incorporates a rotating nozzle that introduces a controllable shear rate of the polymer melt, altering the melt rheology. 3-D printing a couple of materials that have different melting temperatures into a single part is challenging, since the temperature of the nozzle has to be tuned constantly to match the melt temperature of the material being extruded to achieve a desired performance. Otherwise, over extrusion or under extrusion will occur due to the different viscosities of the materials. In this study, a 3-D printer with single extrusion head that can print different materials into one part without changing the temperature of the melt is proposed. The proposed technique also allows extrusion based 3D printing to precisely optimize products performance by mixing different materials. Keywords: Additive manufacturing, 3D printing, Multi material printing, PLA.

Polyester Fibers And Their Mass Coloration For Automotive Applications
Fang Wang, March 2019

Polyester is the single largest fiber product globally. Owing to its physical properties, price, recyclability, and versatility, which offer a unique set of advantages unmatched by any other fiber like nylon and polypropylene, polyester BCF and staple fiber has become the fiber of choice in wide variety of applications, including in automotive applications. This market segment is projected to continue its growth at a faster pace in the next five years. We will review the key drivers, polymer and fiber process and product requirements, followed by test methods used for colorant selection and qualification. In the end, we will highlight colorants that are suitable and recommended for solution dyed polyester applications.

Evaluation Of Methodoligies Utilized To Determine The Ideal Fill Speed For An Injection Molding Process
David Hoffman, March 2019

Fill time has long been regarded as the primary parameter to monitor and control during first stage filling of the injection molding process. Fill time is the result of a given first stage mold volume (shot volume) that is to be filled at a given volumetric flow rate. The most common industry method for evaluating the recommended fill time on the molding floor is known as the Rheology Curve or Relative Viscosity vs. Relative Shear Rate Curve (RV Curve). The RV Curve is one of the main principles taught worldwide in scientific molding courses in the injection molding industry. A company’s processing policies and procedures often reference the RV Curve as the method of choice for establishing an ideal volumetric flow rate and resulting fill time. Other methods may include the utilization of mold filling simulation software, personal experience based on similar parts and molds, or comprehensive Design of Experiments (DOE). This study focuses on the RV Curve and calls the method into question from a mathematical standpoint based on the formulas used to derive the RV curve. The study also discusses an alternative method as a potential replacement to the RV Curve.

Chemical Modification Of Polybutene-1 Resins Through Reactive Processing
Costas Tzoganakis, March 2019

A commodity polybutene-1 (PB-1) resin has been chemically modified through reactive processing. Samples produced by using various amounts of peroxide have been analyzed in terms of their molecular and rheological properties. Molecular weight distributions (MWD) as determined by gel permeation chromatography (GPC) indicate that polydispersity (PDI) remains constant but weight-average molecular weight (Mw) decreases with increasing peroxide amount. Linear viscoelastic measurements indicate that the modified samples are thermo-rheologically simple, zero-shear viscosity decreases with increasing peroxide concentration and flow activation energy remains constant.

Thermoplastic Elastomers: An Overview
Anil Bhowmick, March 2019

Thermoplastic elastomers (TPEs) can be defined as a class of special type of polymers, which exhibit hybrid behavior of thermoplastics and rubbers [1-3]. They can be processed like thermoplastics and at the same time can perform like rubber over a broad use temperature range. The thermoplastic elastomers’ sector has expanded at a compound annual growth rate of 5.4% since 2012 to reach 4.24 million tonnes in 2017. Even though TPEs are an increasingly mature market, Smithers-RAPRA research shows that this growth would continue at a rate of 5.5% across the next five years to hit 5.53 million tonnes in 2022 [4].

Comparison Of The Conventional And The Disperse Melting Model Regarding Different Process Parameters
Marius Dörner, March 2019

The melting behaviour in the single-screw extruder has to date been thoroughly researched, starting with MADDOCK, for example, who was already involved with this topic experimentally in the 1950s. The subsequent modelling of TADMOR in the 1960s also brought the melting to a mathematical background. The model considered was based on conventional melting, in which a solid bed and a melt eddy are formed. Another melting model is disperse melting, in which the solid particles are evenly distributed in the melt. This can be caused, for example, by high screw speeds or special screw geometries. However, the mathematical treatment of this model is not yet fully developed. Nevertheless, a higher melting capacity is predicted for the disperse melting model. Whether this statement is also independent of the extruder size will be investigated in the following, using an analytical mathematical comparison. For this purpose, the models of PAPE and POTENTE are used.

3D Printing Of Biodegradable Polymeric Blend By Fused Filament Fabrication (Fff): Processing & Characterization
Mawath Qahtani, March 2019

The target of this research was to fabricate and optimize a new 3D printable biobased material that can be used for biomedical applications that require biodegradability, biocompatibility and good mechanical properties. This research was successful in preparing a biobased filament made of 70% Poly (lactic acid) (PLA) and 30% Poly (butylene succinate) (PBS) and 3D printing this filament using Fused Filament Fabrication (FFF) technique. The rheological properties were investigated prior to 3D printing and the 3D printed specimens’ mechanical properties were compared to control specimen processed with injection molding method. The V-notched Izod impact testing of the 3D specimens showed about 30% higher impact toughness in comparison to the injection molded specimens.

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