2014 Molding Innovation Day - Moldex3D · 2014 Molding Innovation Day 10 Luglio 2014 POINT Polo per...

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Moldex3D Italia srl Corso Promessi Sposi 23/D - 23900 Lecco (LC) www.moldex3d.com 2014 Molding Innovation Day 10 Luglio 2014 POINT Polo per Innovazione Tecnologica Dalmine Bergamo MuCell Capacità di predizione di Moldex3D Dal processo alla riduzione di peso e di deformazione L’esperienza di laboratorio sui processi microcellulari Ing. Andrea Romeo - Proplast

Transcript of 2014 Molding Innovation Day - Moldex3D · 2014 Molding Innovation Day 10 Luglio 2014 POINT Polo per...

Page 1: 2014 Molding Innovation Day - Moldex3D · 2014 Molding Innovation Day 10 Luglio 2014 POINT Polo per Innovazione Tecnologica Dalmine Bergamo MuCell ... Silver streaks (Only) reduced

Moldex3D Italia srlCorso Promessi Sposi 23/D -

23900 Lecco (LC)www.moldex3d.com

2014 Molding Innovation Day

10 Luglio 2014POINT Polo per Innovazione TecnologicaDalmine Bergamo

MuCellCapacità di predizione di Moldex3D

Dal processo alla riduzione di peso e di deformazioneL’esperienza di laboratorio sui processi microcellul ari

Ing. Andrea Romeo - Proplast

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Moldex3D : il Processo Microcellulare – Gli attori

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Proplast was founded in 1998

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210 associates

The Consortium

184 Companies9 Associations

3 Public Entities and foundations13 Universities

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Research and development activities

for polymer processes

Goals

Reference point to develop research

and development activities between

Universities and Companies

Training and HR

activities

Technical consultancy and

technological tranfer

Laboratory services

and analysis

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PROPLAST, Trexel, ENGEL partnershipTo promote and disseminate the Mucell technology

Demo installationAt Proplast’s site (Tortona, Italy) IMM: Engel 180 tons, screw: 55 mm Shot weight: 100-500 gMucell unit - Co2 or Nitrogen

GoalSupport customers at every stage of the technology implementation and application•Part design for Mucell•Support to mould design•Mucell moulding trials / mould piloting

Technological developmentAestethical surfaces on Mucell parts (material design and optimization)Combination with H&C technologies (pressurised water, induction)

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EUROPEAN FUND FOR REGIONAL DEVELOPMENT

P.O.R. 2007 – 2013

GoalResearch and experimentation on Microcrellular Injection Moulding

Consortium5 Industrial partners (Moldmakers, End Users, Compounders)

Reference Research and Technical Centre

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Onni-Stamp S.r.l. mainly focuses on:

� design� management� production� maintenance

of plastics injection moulds.

Established in 1980, Onni-Stamp is able to balance the most innovative technologies and the expertise and skills of its technologists acquired in over 30 years of activity and production.

Its mission is to follow up the customer from the scratch over all the phases of a plastics component development: from part design to maintenance of tools and equipments.

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Conventional moulding

Mucell

Heat and cool

Mucell + Heat and

cool

Combining 2 different innovative technologies:

Mucellmicrocellular injection moulding

Heat and cooldynamic mould conditioning

Focus on:→ Mouldability and process conditions→ Aesthetics→ Warpage→ Materials→ Eventual pit falls evaluation

Concept

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Different surface finish(mirror polishing,

textures)

Ribs

Measurementreference points

U-shaped part toamplify warpage

Holes to generate welding lines

max rib/wallthickness ratio 2:1

Specific features to evaluate , measure , compare

The moulded part

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Simulating the process• Conventional

moulding

• Mucell injectionmoulding

• Heat and cool injection moulding

Prevision of the Microstructure• Cell dimensions

• Cell density and distribution

Building the material model• Accurate

Mechanical model sensitive to morphology

Structural simulation• Stiffness

• Strength

• Performance

Process ↔↔↔↔ Material ↔↔↔↔ Structure

Virtual run

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Rheological simulations with Mucell

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Mucell Process Chance to accurately simulate the Microcellular Moulding Processwith Moldex 3D

The Microcellular Injection Moulding Process can be analysed, predict, optimised via simulation softwares

STRUCTURAL FEM ANALYSIS

FillingCells

nucleation/growth

Ejection

PROCESS QUALITY

Global part quality

Localresults

Cooling(average/transien

t)

- Expansion / weightreduction

- Volum. shrinkage/sinkmarks

- Warpage / residualstresses

- Cells density- Cells size

- Cycle time- Injection pressure- Clamping force

Rheology

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The Microcellular Injection Moulding Process can be analysed, predict, optimised via simulation softwares

Mucell Process Chance to accurately simulate the Microcellular Moulding Processwith Moldex 3D

FillingCells

nucleation/growth

EjectionGlobal part

qualityLocal

results

Cooling(average/transien

t)

STRUCTURAL FEM ANALYSIS

PROCESS QUALITY

- Cycle time- Injection pressure- Clamping force

- Expansion / weightreduction

- Volum. shrinkage/sinkmarks

- Warpage / residualstresses

- Cells density- Cells size

ECONOMICAL ANALYSIS

PERFORMANCE ANALYSIS

- Moulding- Specs Check- Working

- Investiments- Productivity- Production costs- Consumptions

COMPARISON TO COMPACT

MOULDING

Rheology

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Virtual MucellInjection moulding Mucell Compact

tinj (s) 0,9 0,9

Tmelt (°C) 260 260

Tmould (°C) 40/40 70/70

Gas dosing (%) 0,5 --

Switch over point (%) 99 99

thold (s) -- 7

Phold (bar) -- 1600

tcooling (s) 20 23

tcycle (s) 26 36

Shot weight (g) 92,9 100,3

Pinj max (bar) 1428 1768

Clamping force(ton)

90 220

Variation (%)

-28

-7,4

-19

-59

Rheology

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Sink marksreduction

Mucell

Rheology

Compact moulding

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Warpage reduction

Rheology

BA

D

C

MucellCompact Moulding

nominal compact Mucell

simulated

measured simulated measured

A 110 108,76 109,17 109,22 109,16

B 200 198,10 198,64 198,76 198,72

C 200 198,61 198,92 199,18 198,86

D 110 109,21 109,30 109,52 109,20

predictionCorner effect

prediction

Variation (%)

- 0,05

- 0,02

- 0,29

- 0,29

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Warpage reduction

Rheology

MucellCompact moulding

planarityPrediction of

planarity

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RheologyExpansionprediction

Global weight reduction: 5.5% Global weight reduction: 7.4%

Cells density

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RheologyExpansionprediction Cells size

Global weight reduction: 5.5% Global weight reduction: 7.4%

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1.

2.

3.

2. 3.

1.

Reduced cell sizeHigh cell density

Medium cell sizeMedium cell

density

High cell sizeLow cell density

* Global weight reduction: 5.5%

Cells size prediction

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2.

3.

1.

1. 2. 3.

Cells density prediction

Reduced cell sizeHigh cell density

Medium cell sizeMedium cell

density

High cell sizeLow cell density

* Global weight reduction: 5.5%

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SEM validation: average cell size 2 µm

Cells size near the gate

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SEM validation: average cell size 33 µm

SEM validation: average cell size 22 µm

Cells size at a half of flow lenght

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SEM validation: average cell size 77 µm

SEM validation: average cell size 58 µm

Cells size at the end of flow

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SEM

Cells density near the gate

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SEM

Cells density at a half of flow lenght

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SEM

SEM

Cells density at the end offlow

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Structural simulations on Mucell components

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Simulation workflow

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� Central technology for structural engineering� Integration of local predicted microstructure

– Matrix + fibers + cells– Additional information about material microstructure

Material modeling

The result: Material model sensitive to its morphology

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� Mapping software• Exchanges data between dissimilar meshes

Mesh mapping

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Mesh mapping

Density of porosity Size of porosity Volume Fraction of porosity

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Mucell test case 1

Accurate component’s mechanical prediction

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Mucell test case 2

Accurate component’s mechanical prediction

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Mucell test case 3

Accurate component’s mechanical prediction

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Mucell + Heat and Cool

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Thermal analysis

Mucell + Heat and cool

Target: heat and cool on the aesthetical surface- Conformal channels design optimization (layout, position, cross

sections)- Prediction of the temperature uniformity over the cavity- Prediction of heating and cooling times- Exstimation of total cycle time

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The mould

Variable injectionsystems and flow

lenghts

Kistler pressure and temperature

sensors

Conformal coolingchannels

Pressure and TemperatureSensors to efficiently control the process

Conformal cooling channelsFor temperature uniformity and for reducing the mould’s thermal inertia making heat and cool affordable

Variable injection systemFor evaluating different flow lengths and the effect of welding lines

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Several moulding trials were perfomed at Proplast’s, at different process conditions and on different materials (amorphous and semicrystalline):

Tested materials

� ABS, ELIX P2 - HAT � ABS Thermo-resistant, ABS CILAC TBB� PC-ABS, BAYBLEND T85 XF

� PA6, AQUAMID NAT� PA6 da from regenerated monomer, ECONYL 6FLH� PA6 + nano fillers, PANCH 1015 UCT2 HN

Injection conditions

� 1 central gate� 2 lateral gates� 1 lateral gate

Expansion conditions

� Compact (100% density)� Weight reduction: -5%� Max achievable weight reduction

Moulding trials

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0

100

200

300

400

500

600

0 5 10 15 20

Pre

ssio

ni [B

ar]

Tempo [sec]

pressione 1estremità

pressione 2centrale

pressione 3estremità

Evaluating:

• Max injection pressure• Holding pressure• Cavity pressure (at 3 sensors positions)

• Clamping force

• Injection time• Cooling time• Total cycle time• Melt temperature

• Mould temperature• Cavity temperature

Process

Statistical analysis of defects and rating of gloss

Aesthetics

Shrinkage and warpage analysis

Dimensional stability

Assessment and metrics

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Compact Mucell Variation %

Shot weight g 100 92,9 -7,1%

Clamping force kN 2200 900 -59,1%

Max injection pressure Bar 1770 1442 -18,5%

Injection time sec 0,88 0,85

Cycle time sec 36 26 -27,8%

Melt temperature °C 260 260

Mould temperature °C 60 40

Process

0

100

200

300

400

500

600

700

800

0 10 20 30

Pre

ssio

ni [B

ar]

Tempo [sec]

pressione 1estremitàpressione 2centralepressione 3estremità

0

100

200

300

400

500

600

700

800

0 10 20 30

Pre

ssio

ni [B

ar]

Tempo [sec]

pressione 1estremitàpressione 2centralepressione 3estremità

Compact MucellReduced by -24%

725 bar

548 bar

Pressure sensors

Max injection pressure reducedVery uniform packing occurs with Mucell, driven by cells growth pressure

Trials performed on thermoresistant ABS CILAC TBB, 1 central gate

Pressure at tip1Pressure atcentrePressure at tip2

Pressure at tip1Pressure atcentrePressure at tip2

Outcomes (I)

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Lman central

Lman bracci

Lm

anla

tera

l1

Lm

anla

tera

l2

Compatto Mucell Variation %

L centrale mm 198,96 198,80

L bracci mm 198,54 198,56

L lateral 1 mm 218,74 218,63

L lateral 2 mm 218,75 218,65

Warpage mm 0,42 0,23 -45%

Overall Warpage [adim] 0,0021 0,0012 -43%

Ritiro central % 0,527 0,607

Ritiro lateral 1 % 0,574 0,623

Ritiro lateral 2 % 0,568 0,615

∆ shrinkage % -0,045 -0,012 -73%

Warpage and shrinkage

Trials performed on thermoresistant ABS CILAC TBB, 1 central gate

Mucell trials always provided improvements about warpage and distribution of shrinkage, both as average value and as standard deviation.

Values depend on material and condition process, as well.

Warpage and shrinkage parameters calculation

Outcomes (II)

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Compact conventional Mucell

Heat and cool

Mucell + Heat and cool

Deep sink marks� High gloss

� No sink marksSilver streaks

(Only) reduced sink marks� Very high gloss

� No sink marks� No silver streaks� Very high gloss

AestheticsMucell prevent sink marks very effectively but generates silver streaks.

Heat and cool gives a very high glossy surface but is not able to eliminate sink marks.

Mucell and heat and cool combined solve dimensional issues, sink marks and produce a very high gloss surfaces

Outcomes (III)

Trials performed on thermoresistant ABS CILAC TBB, 1 central gate

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ABS TermoresistenteABS CILAC TBB

0

5

10

15

20

25

30

35

40

45

50

0 5 10 15 20 25 30

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ssio

ni [B

ar]

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pressione 1estremità

pressione 2centrale

pressione 3estremità

0

5

10

15

20

25

30

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40

45

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0 5 10 15 20 25 30

Pre

ssio

ni [B

ar]

Tempo [sec]

pressione 1estremità

pressione 2centrale

pressione 3estremità

Compatto Mucell

Analisi di un caso particolare

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Conclusions

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Conclusions (I)

ProcessGeneral reduction of clamping forceGeneral decrease of max injection pressureGeneral reduction of mould temperatureGeneral reduction of cycle time

Dimensional stabilityMucell trials always provided improvements about warpage and distribution of shrinkage, both as average value and as standard deviation.

Values depend on material and condition process, as well.

AestheticsAt every condition Mucell removed sink marksThe use of combined Heat and cool technology eliminates aesthetical defects, as well.

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Simulations

• Chance to simulate and predict Mucell with Moldex 3D (process, part quality, expansion properties)

- Process settings- Cycle time- Pressures- Clamping force

- Expansion / weight reduction- Volumetric shrinkage / sink marks- Warpage / residual stress distribution- Local cell size- Cell distribution and density

• Chance to interface process results from Moldex to structural simulation s of Mucellcomponents

- Material model sensitive to Mucell microstructure- Stiffness/ strength prediction- Prediction of the component’s performance

• Chance to design/simulate the Mucell + Heat and Cool process for high aesthetical applications

- Design/optimization cooling channels- Temperature distribution prediction- Heating and cooling time prediction- Total cycle time estimation

Conclusions (II) – Predictive coherence

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Moldex3D Italia srl

Corso Promessi Sposi 23/D

23900 Lecco (LC)

www.moldex3d.it