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Conference Proceedings

CONFORMAL COOLING CHANNEL DESIGNS TO REDUCE TEMPERATURE DEVIATION BY USING CONSTRUCTAL DESIGN
S.-H. Zhu, C. Tzoganakis, May 2010

Conformal cooling channel could make the temperature distribution in the mold uniform, reducing cycle time and improving part quality. However, design principle for the conformal cooling channel has not been established yet. In this study, a constructal design principle was tried with hexagonal cooling channel. The size and the depth of the hexagonal cooling channel were optimized to minimize the temperature deviation of the mold surface. Constraint was pressure drop through the cooling channel limited by the pumping capability. The CAE tool for mold cooling analysis was Moldflow Cool.

THE MORPHOLOGY AND MECHANICAL PROPERTIES OF TPU/PP TPE FROM EXTRUDED AND INJECTION-MOLDED SAMPLES
S.-H. Zhu , C. Tzoganakis, May 2010

A thermoplastic elastomer (TPE) blend of thermoplastic polyurethane (TPU) and polypropylene (PP) was sampled from extruded strands and injection molded plaques. Highly stretched strands of the PP phase are aligned parallel to each other along the extrusion direction in the extruded samples while in the injection-molded samples the PP phase is in ellipsoidal domains residing in the shear plane of the mold. Subjecting the samples to a tension load leads to rupture of the elongated strands, resulting in increased tensile set and reduced moduli. Annealing the extruded specimen at 150 oC for 30 min. can create cracks in the blend similar to those generated during tensile testing.

STUDY ON DYNAMIC MOULD OF PMMA MICROCELLULAR FOAM WITH VARIOUS SHEARING FIELD
Oludolapo Shobanjo, Stuart Blackburn, Owen Draper, Richard Greenwood, May 2010

The foaming process of PMMA in specially designed rotor system with screws and previously designed rotor system without screw was studied respectively. In this study, with supercritical carbon dioxide (ScCO2) as a blowing agent, microcellular foam of PMMA was made in traditional steady process and dynamic vibration field respectively by using the isobarical feeding equipment of supercritical carbon dioxide and microcellular foaming simulator. The effects of processing parameters such as pressure, time of saturation, shear stress were investigated, in order to study and analyze the effects of processing conditions on PMMA microcellular plastics. Foamed samples with the cell density of 78.7??107 cell/cm3, average cell size of 12.6 ?¬m have been produced by using the screw system.

INFLUENCE OF MECHANICALLY BLENDED INVESTMENT CASTING WAX FORMULATIONS ON QUALITY OF INJECTION MOULDED PARTS
Oludolapo Shobanjo , Stuart Blackburn , Owen Draper , Richard Greenwood, May 2010

Wax formulations prepared using paraffin wax (PW) and hydrogenated resin (HR) were studied to identify effects of temperature and composition on phase homogeneity. A phase diagram was constructed showing regions of PW/HR miscibility and tracking changes in PW crystallisation as HR is added. Polarised optical microscopy identified changes in nucleation and crystal growth mechanisms of the PW semi-crystalline phase promoted by HR. A simplified wax injection system was used to investigate conditions for defect formation. Results, to be validated using a ProCAST model, showed defects occurred by injecting blend compositions corresponding to regions of PW/HR phase separation as shown by the phase diagram.

THE FOAMING PROCESS OF PMMA IN SPECIALLY COMPOUNDS UNDER HIGH PRESSURE, VELOCITY AND TEMPERATURE CONDITIONS
Reema Sinha, Sangita Nandi, Arun Sikder, Radha Kamalakaran, Susanta Mitra and Edward Kung*, May 2010

In the present study, the friction and wear properties of high temperature resistant polymers, Polyetherimide (PEI) and Polyetheretherketone (PEEK), have been investigated at specific combinations of high pressure, velocity and temperature against smooth steel counterparts. The effects of internal lubricant, polytetrafluoroethylene (PTFE) and PTFE with short fiber reinforcements (carbon fiber) are outlined. The tests were performed on a thrustwasher testing machine under dry sliding conditions. Different analytical techniques were employed to study the correlation between the transfer layer and friction properties. Lubricated and lubricated-reinforced compounds showed excellent wear resistance compared to pristine resins.

RESEARCHES ON MECHANICAL PROPERTIES AND MICRO-STRUTURES OF SBS/AS TOUGHENED HIPS
Han-Xiong Huang, Kun Li, Sha Li, May 2010

The mechanical properties and misconstrues of high impact polystyrene (HIPS) toughened by styrenebutadiene-styrene (SBS) were studied to find the Brittle-Ductile Transition Point. At the Brittle-Ductile Transition point, HIPS and SBS alloys were prepared using melt intercalation technique by blending HIPS and SBS while used acrylonitrile-styrene (AS) powder, gaining higher impact and tensile strength. Their microstructures near the Transition Point were characterized by scanning electron microscope (SEM) to investigate the toughening mechanism of HIPS/SBS/AS composites. The toughening mechanism is similar to the mechanism of RIF toughening rather than the cold-drawing theory which applied to ductile matrixes toughed by rigid organic filler (ROF).

EFFECTS OF PROCESSING PARAMETERS ON SHRINKAGE UNIFORMITY OF INJECTION-COMPRESSION MOLDED PART
Han-Xiong Huang , Kun Li , Sha Li, May 2010

Both polypropylene (PP) and polystyrene (PS) parts were molded by injection-compression molding. The Taguchi method was utilized to investigate the effects of six processing parameters including mold temperature compression speed compression time compression distance delay time and compression force on part shrinkage uniformity. Analyses of means and variance showed that the compression force is the most important parameter for part shrinkage uniformity of both parts. The compression distance is the second most significant parameter on shrinkage uniformity of PS part but not significant parameter on PP part. The optimal processing parameters for improving the shrinkage uniformity of both parts are found and verified experimentally.

THERMAL ANALYSIS AND RHEOLOGICAL STUDIES ON THERMOPLASTIC URETHANES
Lecon Woo , William Anderson, May 2010

Thermoplastics urethanes (TPU) offer broad property range, processing flexibility, and biocompatibility for medical applications. We have undertaken a thermal and rheological study on thermal transitions which influence physical characteristics and oxidative degradation. In addition, possible effects from hydrolytic degradation with long term exposure to alcoholic solvents are sought. Techniques used include Thermal analysis and oxidative induction time (OIT) by differential scanning calorimetry (DSC), and melt rheology. It was found, for selected but not the majority of TPUs, OIT onsets were difficult to obtain. However, melt rheology, with proper sample conditioning, was capable in quantifying the hydrolytic molecular weight degradation process.h

ENHANCING THE PERFORMANCE OF POLYMERIC DYES IN POLYPROPYLENE
John F. Waters , Thomas C. DiPietro, May 2010

Clarified polypropylene (PP) continues to find increasing uses as polymer and additive improvements allow for its incorporation into applications where resins such as polystyrene or acrylics have traditionally been used [1]. Second and third generation clarifiers have improved the clarity, processing properties, and the organoleptic properties (residual odor and taste), opening the way for more extensive food contact applications [2,3]. With the expanded use of clarified polypropylene comes the need appropriate colorants which will give high clarity, low haze, deep coloration, and no migration. Polymeric colorants have shown to possess these properties, further expanding the market potential for clarified polypropylene. This paper will explore the use of various modified wax compounds and their effects on the residual haze of clarified PP molded with GemToneTM Polymeric Colorants.

POLYOLEFIN/CLAY NANOCOMPOSITES: COMPARISON OF DIFFERENT TYPES OF FILLERS AND USING OF MATHEMATIC MODEL
Hana Kubisova , Dagmar Merinska, May 2010

This work reported the comparative study on polypropylene/clay nanocomposites. Commercial filler Dellite and modified micronized calcium were used as a nanocomposite filler for the PP-based composite. All nanocomposites were prepared by using Brabender kneader at different speeds of rotation; however, the compounding time was the same. X-ray diffraction and scanning electron microscopy (SEM) were used for evaluation of morphology. The mechanical properties were evaluated by results of tensile strength and the results were presented in graph. The model was used to predict of tensile strength.

PRODUCTION OF POLYSTYRENE MICROCELLULAR FOAM: EFFECT OF MOLECULAR WEIGHT
Lu Feng, Bin Zhu, David L. Tomasko, Isamu Kusaka, Kurt W. Koelling, L. James Lee, May 2010

Polymer foams prepared with supercritical carbon dioxide as a blowing agent have attracted much interest in recent years. Yet, a thorough understanding of the foaming process, especially nucleation, is absent. In this article, the influence of one characteristic property of polymer, molecular weight, on the nucleation rate and cell growth rate is investigated by an in-situ observation introduced by high speed camera. Moreover, the influence of these two properties on the solubility of carbon dioxide in the polymer is investigated by using a magnetic suspension balance while simultaneously measuring the swelling coefficient during adsorption.

WEB-BASED NAVIGATING SYSTEM FOR MOLD- QUOTATION
Eldridge M. Mount III, May 2010

This work is to make the quotation of injection mold to be easy and transparent. This web-based mold-quotation system is integrated with conceptual design in CAD tool. It systemizes and customizes each step of mold quotation. After the user decide the number of cavities and choose the suitable moldbase, he can follow the navigating steps to design gates, slides, inserts, and lifters on the CAD model. After the manufacturing processes for each component is decided, the system can calculate the machining time and cost intuitively. Finally, a detailed material and machining quotation report can be generated automatically.

EXPERIMENTS WITH DUAL-PRESSURE ULTRASONIC WELDING OF THERMOPLASTICS
Abbass Mokhtarzadeh, Avraham Benatar, May 2010

Ultrasonic welding of thermoplastics is a popular joining technique because it is fast, economical and easily automated. It has been observed that during welding, rapid squeeze out of the molten energy director occurs, resulting in lower weld strength. Therefore, single and dual-pressure ultrasonic welding were compared to see if weld strength could be improved. It was found that for dual-pressure ultrasonic welding it was better to have a higher second pressure than a lower second pressure. However, using dual-pressure ultrasonic welding resulted in no improvement in weld strength.

THE ADAPTION OF MICROWAVE HEATING TO THE ROTATIONAL MOULDING PROCESS
M.P. McCourt, M.P. Kearns, P.R. Hanna, May 2010

This paper details the results from a large European Union rotomoulding research project on the adaptation and development of industrial microwave oven technology to the rotational moulding process. Following computer modelling, an industrial scale microwave oven was specifically designed, manufactured and attached to the drop-arm of a convention rotational moulding machine where extensive moulding trials were carried out. The design and development of the microwave oven and test mould, together with the savings in terms of energy efficiency and mould heating rate that were achieved are discussed.

THE ADAPTION OF MICROWAVE HEATING TO THE ROTATIONAL MOULDING PROCESS
M.P. McCourt , M.P. Kearns , P.R. Hanna, May 2010

Durability and performance of membranes under alternating relative humidity conditions are very important for fuel cells in automobile applications. This work proposed a wet/dry (W/D) cycle test and studied the effect of W/D cycles on the dimension and properties of polymer membranes. It was found that solution cast films shrunk stepwise in both machine and transverse directions when they underwent wet/dry cycles. The water swelling and water take-up of membranes are also a function of W/D cycles. Based on these results, one might use W/D cycling as a post-processing scheme to reduce the shrinking stress and water uptake of the membranes and thus extend the life of membranes.

MECHANICAL PROPERTIES OF POLYCAPROLACTONE/THERMOPLASTIC STARCH BLOWN FILMS
Daniel E. Ramírez-Arreola , Jorge R. Robledo-Ortiz , Martín Arellano , Rubén González-Núñez , Denis Rodrigue, May 2010

The processing and mechanical properties of blown films prepared from thermoplastic corn starch (TPS) and polycaprolactone (PCL) has been studied. The aim was to determinate the influence of processing parameters on mechanical properties in order to establish the relationship between mechanical properties of the films, PCL concentration and processing. In addition, the influence of moisture content on mechanical properties during the first days of storage was also studied. The results showed that the effect of moisture absorbed during storage over the mechanical properties was not significant for blends that contained up to 60% PCL.

POST-CONSUMER HDPE/AGAVE FIBRE COMPOSITES COATED WITH CHITOSAN USED FOR REMOVAL OF HEAVY METALS
Milton O. Vázquez , César Gómez , Sergio Gómez-Salazar , R. González-Núñez, May 2010

Composites of post-consumer high density polyethylene (HDPE) with agave fibre were prepared by extrusion and coated with chitosan. A chemical pretreatment was applied to the composite to enhance chitosan gel compatibility. The adsorption capacity of the composite coated with chitosan was evaluated for Cd(II) and Cu(II). The coated composites were characterized by SEM, ATR-IR and XPS. Atomic Absorption Spectroscopy (AA) was used to measure metal uptake in batch studies. Adsorption Isotherms were obtained at three different pH values. The results of this study demonstrate the composite's ability to immobilize chitosan on its surface and its capacity to adsorb metal ions.

A STUDY OF DEMOULDING FORCE PREDICTION APPLIED TO PERIODIC MOULD SURFACE PROFILES
Daniel E. Ramírez-Arreola, Guillermo Sandoval-Hernández, Martín Arellano, Cesar Gomez, Rubén González-Núñez, Denis Rodrigue, May 2010

Demoulding components without damage to either the components or tool is critical to successful replication processes. Accurate demoulding force prediction prior to tool fabrication helps designers optimize replication tools to minimize the demoulding force and resultant stress on replicated parts. Various models have been proposed to predict demoulding forces. One such model, the stair-step model, was developed by Colton et al for stereolithographic moulding tools. This paper investigates applying the model to other periodic surfaces with validation using published experimental data. In addition validity of the model for application to micro mould surfaces produced by micro milling is discussed.

MECHANICAL PROPERTIES OF INJECTED MOLDED PCL/TPS NANOCOMPOSITE BLENDS
Daniel E. Ramírez-Arreola , Guillermo Sandoval-Hernández , Martín Arellano , Cesar Gomez , Rubén González-Núñez , Denis Rodrigue, May 2010

Injected molded nanocomposite blends based on PCL/TPS and Cloisite 15A (C15A) were prepared and its mechanical properties were studied. The injected samples were exposed to the environment in order to analyze the influence of exposure time and moisture uptake over mechanical properties. The results showed that samples tested right after molding exhibit low mechanical resistance to impact and high Young modulus, while increasing the environmental exposure time reduced the Young modulus and substantially increased the medium failure energy. On the other hand, using C15A increases the medium failure energy, and an important interaction between TPS, moisture and clay was observed.

ACCELERATED CYCLIC FRACTURE MECHANICS TESTS TO ANALYSE MOLECULAR AND MORPHOLOGICAL EFFECTS ON SLOW CRACK GROWTH IN MODERN PE PIPE GRADES
Lubomír Benícek, Lenka Chvátalová, Roman Cermák, Vincent Verney, May 2010

Three different polyethylene pipe grades and three different lots of one PE pipe material were investigated with fracture mechanics procedures under cyclic and impact loads. The cyclic tests with Cracked Round Bars allowed a ranking of the different PE pipe grades and lots concerning crack resistance as a function of failure time as well as of crack initiation time. The ranking corresponded to the expectations based on the molecular and morphological properties of the materials. Concerning lot-to-lot variations, in particular, a correlation to crystallization kinetics, melt flow rate and density measurements could be established.







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