Molding processes process considerations

Performance requirements for other large plastic parts like fascia, hoods, and deck Hds would most likely eliminate one or another of these polymers and/or molding processes from consideration. For example, SMC 1s not considered to have sufficient Impact resistance for fascia and RIM and engineering thermoplastic materials have yet to be developed for structural applications which also require a high surface quality, 1.e. hoods and deck lids. These other parts were thus not chosen for this study. 

Polymer-matrix materials include a wide range of specific materials. Perhaps the most commonly used polymer is epoxy. Other polymers include vinyl ester and polyester. Polymers can be either of the thermoset type, where cross-linking of polymer chains is irreversible, or of the thermoplastic type, where cross-linking does not take place but the matrix only hardens and can be softened and hardened repeatedly. For example, thermoplastics can be heated and reheated, as is essential to any injection-molding process. In contrast, thermosets do not melt upon reheating, so they cannot be injection molded. Polyimides have a higher temperature limit than epoxies (650°F versus 250°F or 350°F) (343°C versus 121°C or 177°C), but are much more brittle and considerably harder to process. 

Understand the critical properties of the mixed compound that affect processability. It should be understood that the properties and acceptable operating values of those properties, which control the compound processability, are dependent on the processes under consideration, e.g., hot or cold feed extrusion, compression or injection molding. 

The operating pressures and shear rates in the extrusion process are considerably lower than they are in molding. As it exits the die, but not necessarily when it leaves the process, the material is in an essentially stress-free condition. Depending on the wall thickness of the material and the particular material, there is orientation of the plastic to a greater or lesser controllable degree. Thin walls produce higher orientation in materials such as PP, that is a highly crystalline polyolefin, and which orients much more than materials such as PVC. 

The study and control of a chemical process may be accomplished by measuring the concentrations of the reactants and the properties of the end-products. Another way is to measure certain quantities that characterize the conversion process, such as the quantity of heat output in a reaction vessel, the mass of a reactant sample, etc. Taking into consideration the special features of the chemical molding process (transition from liquid to solid and sometimes to an insoluble state), the calorimetric method has obvious advantages both for controlling the process variables and for obtaining quantitative data. Calorimetric measurements give a direct correlation between the transformation rates and heat release. This allows to monitor the reaction rate by observation of the heat release rate. For these purposes, both isothermal and non-isothermal calorimetry may be used. In the first case, the heat output is effectively removed, and isothermal conditions are maintained for the reaction. This method is especially successful when applied to a sample in the form of a thin film of the reactant. The temperature increase under these conditions does not exceed IK, and treatment of the experimental results obtained is simple the experimental data are compared with solutions of the differential kinetic equation. 

The molds in a RIM-process plant are located in a separate assembly, which has devices for opening and clamping a mold and, in some cases, for changing it. The pressure in the RIM-process is considerably lower than in traditional injection molding of thermoplastics thus, the requirements for the mold material are less rigid. Molds may be made from aluminum or reinforced plastics, since high-strength steel is not necessary. 

The feed system is the flow melt passage in the mold, between the nozzle of the IMM and the mold cavity (Figure 17.1). This feature has a considerable effect on both the quality and economy of the molding process. The feed system must conduct the plastics melt to the cavity via a sprue, runner and gate at the correct temperature/pressure/time period, must not impose an excessive pressure drop or shear input, and should not result in non-uniform conditions at the cavities of multiimpression molds. 

The feed system is an unwanted by-product of the molding process, so a further requirement is to keep the mass of the feed system at a minimum to reduce the amount of plastic used. This last consideration is a major point of difference between cold and hot runner systems. The cold runner feed system is maintained at the same temperature as the rest of the mold. In other words, it is cold with respect to the melt temperature. The cold runner solidifies along with the molding and is ejected with it as a waste product in every cycle. The hot runner system is maintained at melt temperature as a separate thermal system within the cool mold. Plastic material within the hot runner system remains as a melt throughout the cycle, and is eventually used on the next cycle. Consequently, there is little or no feed system waste with a hot runner system. Effectively, a hot runner system moves the melt between the machine plasticizing system and the mold to a point at or near the cavity(s).3 32> 326-332,490... 

With these considerations and with experience demonstrating that there is no standard design for the injection molding process, one is led to the conclusion that each process must be uniquely optimized. 

Various process steps were used to determine their Influence on the morphological nature of liquid crystalline copolyester films. Compression molding was used to form quiescent films, while extenslonal deformation above and below the onset of fluidity, as well as shear deformation above the onset of fluidity was used to make non-quies-cent films. It Is a basic result that molecular orientation can only be achieved when the deformation is done while the polymer is In a liquid crystalline melt state. Experimental details are given In the subsection Materials and Processing, while an interpretation is offered in the discussion in the subsection Morphological and Process Consideration. ... 

Fassett, J. Thin wall molding how its processing considerations differ from standard injection molding. Plast. Eng. 1995, 51, 35-37. 

Exertion of pressure on the bag is multidirectional which conforms the resin powder to all patterns and nonuniformities in the bag. Consequently, the surfaces adjacent to the bag are less smooth than those adjacent to the smooth metallic surfaces. The importance of surface formation is one of the considerations that determines the selection of the t5q)e of molding process. 

In the injection molding process, setting the temperature involves optimization of the temperature profile of the plasticating unit (extruder barrel), temperatures of the mnners and gates, (aU these determine the molten polymer temperature) as well as the mold temperature. The temperature setpoints depend on the material type (viscosity profile, thermal and shear stability, thermal properties) as well as machine or process considerations (machine capacity to shot size ratio, screw design, mold and part design, cycle time, etc.). Temperatures of the two basic units, the injection system and the mold, should be discussed separately since their selection stems from very different considerations. 

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