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Conference Proceedings

Microstructural Characteristics of Micro-Injection Molded Thermoplastics
Jingsong Chu, Andy Hrymak, Musa R. Kamal, May 2007

A micro-injection molding machine was used to obtain micro-moldings of polyethylene, in order to study the effects of processing conditions on some microstructural characteristics of the moldings. The processing variables were estimated, based on experimental data and on simulation results. Polarized light microscopy was used to evaluate morphology. Three-dimensional distribution of shrinkage was measured. Micro-mechanical properties (modulus and hardness) were measured with a nanoindenter. The microstructure and properties will be explained in light of the thermo-mechanical history.

The Effect of Implementing Hybrid Mold Temperature Dependant Heat Characteristics on the Accuracy of 3D Injection Molding Simulation
Ludwig Cardon, Cristoph Hinse, May 2007

When analyzing the thermal behavior of hybrid molds, normally fixed values for thermal characteristics are implemented. This paper will discuss the underestimated effect of temperature dependant heat characteristics of hybrid mold materials on the accuracy of 3D injection molding simulation via obtained results of a former PhD work and implementation of this knowledge into Moldex3D (M3D).A hybrid mold of a technical part was designed to analyze this problem. It also resulted in a better understanding of the mold design strategy and 3D simulation advantages for multiple material molds related to filling, warpage, cooling and final part quality.

Influence of Process Parameters on the Weld Lines of a Micro Injection Molded Component
G. Tosello, A. Gava, H.N. Hansen, G. Lucchetta, May 2007

The insufficient entanglement of the molecular chains and the stress amplification at the v-notch of a weld line compromise the mechanical strength of a plastic product, also in the micro scale. To investigate the influence of process parameters on the weld lines formation, a special micro cavity was designed and manufactured by ?EDM (Electro Discharge Machining). Weld lines were quantitatively characterized both in the two-dimensional (direction and position) and three-dimensional range (surface topography characterization). Results showed that shape and position of weld lines are mainly influenced by mold temperature and injection speed.

Laser Transmission Welding of Electro-Pneumatic Valves
D. Hänsch, May 2007

Laser welding has proved an appropriate method for joining plastic parts. The increasing trend towards greater freedom of design, integration of ever more functions, and therefore more complex modules is putting increasing pressure on joining technology, and is thereby promoting the development and introduction of novel technologies.Laser welding of plastics is a suitable complement to established joining processes, and thereby opens up new fields of application. This has been demonstrated by numerous applications for small and even for larger components.Compared to alternative joining methods the contact free method has the advantage that hardly any flash or no flash is being produced, which means that joints with a high quality visual appearance can be produced. The laser is clearly superior to alternative processes, even for joining 3D geometries produced by coupling to a robot. The heat-affected zone is only a few #m deep and reduces the risk of surface flaws.The following paper is a case study for the introduction of the Laser welding process for electro-pneumatic valves. It describes the process development from the initial tests to the In-Line integration in mass production.

Birefringence Distribution in Gas-Assisted Tubular Injection Moldings: Simulation and Experiment
A.J. Carrillo, A.I. Isayev, May 2007

Measurements and simulation of three birefringence components and of the gas/polymer interface distribution in gas-assisted injection molding (GAIM) of a tubular geometry are presented. The governing equations of the process are derived using a nonlinear viscoelastic model and solved using a hybrid finite element/finite difference/control volume method (FEM/FD/CV). The measurements were carried out on polystyrene moldings before and after annealing. Simulation and experimental results indicate that the birefringence is high in the gas penetration region and low in the region where the gas did not penetrate.

Radiation Cross Linking Engineering Thermoplastics for Tribological Applications
Zaneta Brocka, Ernst Schmachtenberg, Gottfried W. Ehrenstein, May 2007

Electron beam irradiation primarily leads to cross linking in the amorphous fraction of semi-crystalline thermoplastics. As a result, there is a change in morphology and an improvement in mechanical and thermo dynamical properties. This effect can be utilized for tribologically stressed parts as micro parts and gear wheels. These parts feature an unfavorable relationship of part/volume leading to a disadvantageous formation of morphology and crystallinity. Experimental work shows the potentials of radiation cross linked polyamides. Due to cross linking in particular the thermal-mechanical and tribological properties are shifted into a range, which enables the employment of this substrate for application at elevated temperatures. Furthermore, the investigations on PA6 and PA66 show that a lower crystallinity degree leads to better results of cross linking via electron beam radiation and to an improvement of abrasion resistance.

Failure Analysis and Prevention – A New European SIG
Jan Spoormaker, Erik Andreassen, Anton Heidweiller, May 2007

The new European Failure Analysis and Prevention Special Interest Group (FAPSIG) is creating a database with failure cases. The members share this database and contribute with their own failure investigations. The two main groups are Failure Causes and Failure Mechanisms. Failure Causes are subdivided in: Stress concentrations, low mass and/or mould temperature, highly stressed weld lines, faulty ribbing; too high stiffness of construction elements, incorrect joining, and incorrect material selection.Failure Mechanisms are subdivided in: Creep and stress relaxation, wear, fatigue, UV degradation, chemical attack, environmental stress cracking.The paper will present some examples for designers of plastic products.

Measurement of the High Frequency Viscoelastic Properties of Polypropylene Using a Sliding Plate Rheometer
Chelsea A. Braybrook, Jennifer A. Lee, Philip J. Bates, Marianna Kontopoulou, May 2007

A newly constructed sliding plate rheometer (SPR) is used to investigate the high frequency linear viscoelastic properties of two polypropylene (PP) resins with widely differing melt flow rates. Extrapolation of rheological measurements obtained on a traditional parallel plate rheometer to frequencies obtained on the SPR, through use of the generalized Maxwell and Cross models, was used to assess the performance of the high frequency SPR. Good agreement between the extrapolated and measured data demonstrates the ability of the SPR to measure the high frequency rheological properties of PP.

Development of Rubber Mould Inline Process and Offline Process Inspection by Touch Probe
Suchada Rianmora, Chana Raksiri, Supasit Rodkwan, Kunnayut Eiamsa-ard, May 2007

Development in design of mould using reverse engineering can reduce lead time and increase the quality of mould inspection. For two methods used: touch probe on machining center and portable arm coordinate measuring machine, these are used along software that is capable of measuring three-dimensional coordinate and analyzing the results. The first inspection is done on the machine during production (inline) then another is examined after production (offline). The experiment result demonstrates in terms of accuracy there is no significant difference between two measurement methods. Nevertheless, the portable arm CMM has an advantage in its simplicity, and require less operation and lead time.

Optimization of Quality and Throughput at Low Revolution Speeds in an Advanced Two Stage Compounding System
Ralf Kühn, U. Burkhardt, Peter Heidemeyer, May 2007

Melting and incorporation of high viscous particles into a low molecular matrix is a difficult process due to differing requirements for melting and homogenizing. Melting is preferably done by using high shear rate and stress in combination with a small residence time. These facts lead to a fast turning small machine. Homogenizing on the other hand requires elongational flow, high viscosity and a significant amount of residence time which leads to a low revolution speed. By using a two step compounding system one can meet the differing constraints at the same time. Optimization of efficiency in pressure build-up can be done effectively by using state of the art CFD calculation methods.

Numerical Balancing of Coextrusion Dies : A Validation Study with a TPV-Based Hose
T. Marchal, T. Burton, G. Franceschetti, J. De rijcke, C. Chauvin, H.M. Metwally, May 2007

In some industrial applications, like hydraulic hoses, a two-layer structure may be produced from the coextrusion of a soft Engineering Polyamide Alloy and a Thermoplastic Vulcanizate (TPV), like Santoprene™ Thermoplastic Rubber. As the inner layer, the polyamide component provides a barrier against oil at high temperatures; the TPV provides flexibility, resistance to abrasion as well as adhesion to the inner layer.Reaching a die design that yields the required concentricity and homogeneous material distribution in each layer is a challenge. The following two-step approach is here proposed. First a 3D numerical simulation using the POLYFLOW code confirms the current unsatisfactory extruded profile quality. A second extrusion simulation is next carried on a modified geometry to ensure proper flow balancing. A validation is performed for the coextrusion of a relevant Thermoplastic Rubber grade compatible with an Engineering Polyamide Alloy.

Engineering Plastics for Laser Welding
Eric van der Vegte, Marnix van Gurp, Hans Hoekstra, Alexander Stroeks, May 2007

The use of laser light energy to very locally weld plastic surfaces together has opened new possibilities for flexible design and assembly of plastics parts. However, this poses the challenge of applying a combination of transparent and absorbing plastic parts in order to use the laser light efficiently for local melting at the interface. Transparency is still a challenge in some cases, due to the scattering nature of certain plastics. This paper will focus on the optical requirements of the welded parts, but also on the physical aspects of the interface to form a strong weld.

Plane Stress Rapid Fracture Resistance of Pipe Grade PE: Estimation from Tensile Drawing Data
Pemra Ozbek, Patrick Leevers, May 2007

The Rapid Crack Propagation régime in pressurised polyethylene pipe is limited by a critical temperature, which is determined mainly by the increasing resistance of the material to plane stress fracture. The Reversed Charpy and ASTM F2231 ‘Thin Charpy’ test methods are designed to index this property, at appropriately high rates, for quality control and material development purposes. This paper demonstrates that equivalent information can be derived from a procedure based on basic tensile drawing tests, via material properties which are more accessible to material design.

Heat-Aging Performance of Metallized Thermoplastics for Automotive Lighting
Adam Zerda, Kathryn Guggenheim, Beatrice Grau, Theo Hoeks, May 2007

Driven by weight savings, design freedom, manufacturing economics and pedestrian impact considerations, the use of plastics in automotive lighting has grown over the last decade to include all aspects of forward and rear lighting. Among these is the use of plastics in reflector applications where the molded plastic part is metallized, heated and expected to maintain high reflectivity and tight dimensional stability over time at use temperatures. In addition to the thermal properties of the plastic, other factors can affect the use temperature in such an application. The effects of metallization conditions, moisture and post-metallization aging are discussed as they affect the use temperature of a variety of high temperature thermoplastics.

Synergistic Effect of PP-g-MA and SEBS-g-MA on Polypropylene-based Wood-Plastic Composites Reinforced with Nanoclay
Shu-Kai Yeh, Kwang-Jea Kim, Rakesh K. Gupta, May 2007

In this study, polypropylene grafted maleic anhydride (PP-g-MA) and styrene ethylene-co-butylene styrene block copolymer grafted maleic anhydride (SEBS-g-MA) were employed as coupling agents for polypropylene-based wood-plastic composites containing 50 wt% wood flour. Adding PP-g-MA to wood flour increased the tensile strength of the wood-plastic composite (WPC) by 60% and the reversed-notch Izod impact strength by 100%; the modulus remained essentially unchanged. By contrast, SEBS-g-MA had a greater effect on the impact strength but a smaller influence on the tensile strength; in addition, the modulus was reduced. On adding both PP-g-MA and SEBS-g-MA to the WPC, the impact strength increased by a factor of more than 2.5, but the tensile strength was not reduced. Since the incorporation of nanoclay increases the modulus of WPCs without decreasing the impact strength, the use of all three additives affords the possibility of manufacturing WPCs with high modulus and high impact strength.

Development of Semi-Interpenetrating Polymer Network Electrolytes of Polyurethane and Polysiloxane
Shanshan Wang, Kyonsuku Min, May 2007

A novel semi-interpenetrating polymer network (semi-IPN) electrolyte of polyurethane (PU) and polyether modified polysiloxane (PEMPS) with salt, LiClO4, were developed by using a solvent-free reactive process. The dissolution of LiClO4 in monomer and PEMPS was studied by using optical microscopy (OP), differential scanning calorimeter (DSC) and Fourier transform infra-red (FTIR) spectroscopy. The semi-IPN electrolytes of TPU/PEMPS were characterized by DSC and FTIR. The effect of PEMPS on the ionic conductivity of PU was also determined by using the modified LCR meter.

Thermal Stability and Rheological Properties of Multiwall Carbon Nanotube Reinforced Thermotropic Liquid Crystalline Polymer Nanocomposites
Sang Ki Park, Seong Hun KIM, Jin Taek Hwang, May 2007

Multiwall carbon nanotube (MWCNT) reinforced thermotropic liquid crystalline polymer (TLCP) nanocomposites were prepared by a melt compounding process. Incorporation of small quantity of the MWCNT improved the thermal stability of MWCNT reinforced TLCP nanocomposites. The rheological behavior of TLCP/MWCNT nanocomposites was dependent on the MWCNT content. The complex viscosity and storage modulus of TLCP/MWCNT nanocomposites increased with increasing MWCNT, resulting from physical interactions such as the nanotube-polymer matrix interactions and the nanotube-nanotube interactions. This increment effect was more significant at lower frequencies.

Experimental Investigations on the Plasticating Process of Polymers in a Short Single Screw Extruder and Energy Efficiency of the Process
Helmut Potente, Hans-Peter Heim, Sebastian Kleineheismann, May 2007

In comparison to normal single screw extruders, the short extruder has completely different screw and barrel geometries that allow the plasticization of polymers over a very short screw length (L/D < 5). Experimental investigations demonstrated the influence of screw speed, throughput and die pressure on the plasticization process. Due to the fact that this extruder does not require external heating, except heating of the die, a characterization of the operating point is carried out with help of an energy balance of the extruder.

Effect of Moisture Absorption on the Properties of Clay-Reinforced Polypropylene Nanocomposites
Hachmi Ben Daly, Hend Ben Hadj Salah, Kenneth Cole, Johanne Denault, Abdelwaheb Dogui, May 2007

The behavior of two polypropylene nanocomposites when immersed in distilled water or sea water at four different temperatures was studied and compared with that of neat PP. The nanocomposites showed a higher water diffusion rate and equilibrium moisture content. Nevertheless, because of their superior initial mechanical properties, after 42 days exposure they were still equivalent to unexposed PP. X-ray diffraction and infrared spectroscopy were applied to characterize the surfaces of the exposed specimens.

Numerical Simulation and Experimental Investigation on Parison Formation from a Varying Die Gap in Extrusion Blow Molding
Han-Xiong Huang, Geng-Qun Huang, Jiong-Cheng Li, Deng-Hui Ling, May 2007

The use of simulation software to predict the process of blow molding can save considerable time and money in the product development and is becoming more widespread. However, for parison formation simulation, the current finite element (FE) software is suitable only for the situation where the die gap is fixed. In this work, a new method was proposed to apply the FE simulation to the varying die gap parison formation. In order to evaluate the availability of the new method, the predicted parison thickness distributions were compared with the experimental results. It is demonstrated that the new method has certain accuracy and reliability in predicting the parison thickness from a varying die gap.







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