Computer-aided injection molding system

Science.gov (United States)

Wang, K. K.; Shen, S. F.; Cohen, C.; Hieber, C. A.; Isayev, A. I.

1982-10-01

Achievements are reported in cavity-filling simulation, modeling viscoelastic effects, measuring and predicting frozen-in birefringence in molded parts, measuring residual stresses and associated mechanical properties of molded parts, and developing an interactive mold-assembly design program and an automatic NC maching data generation and verification program. The Cornell Injection Molding Program (CIMP) consortium is discussed as are computer user manuals that have been published by the consortium. Major tasks which should be addressed in future efforts are listed, including: (1) predict and experimentally determine the post-fillin behavior of thermoplastics; (2) simulate and experimentally investigate the injection molding of thermosets and filled materials; and (3) further investigate residual stresses, orientation and mechanical properties.

Ceramic injection molding

International Nuclear Information System (INIS)

Agueda, Horacio; Russo, Diego

1988-01-01

Interest in making complex net-shape ceramic parts with good surface finishing and sharp tolerances without machining is a driving force for studying the injection molding technique. This method consists of softhening the ceramic material by means of adding some plastic and heating in order to inject the mixture under pressure into a relatively cold mold where solidification takes place. Essentially, it is the same process used in thermoplastic industry but, in the present case, the ceramic powder load ranges between 80 to 90 wt.%. This work shows results obtained from the fabrication of pieces of different ceramic materials (alumina, barium titanate ferrites, etc.) in a small scale, using equipments developed and constructed in the laboratory. (Author) [es

A Novel CAE Method for Compression Molding Simulation of Carbon Fiber-Reinforced Thermoplastic Composite Sheet Materials

Directory of Open Access Journals (Sweden)

Yuyang Song

2018-06-01

Full Text Available Its high-specific strength and stiffness with lower cost make discontinuous fiber-reinforced thermoplastic (FRT materials an ideal choice for lightweight applications in the automotive industry. Compression molding is one of the preferred manufacturing processes for such materials as it offers the opportunity to maintain a longer fiber length and higher volume production. In the past, we have demonstrated that compression molding of FRT in bulk form can be simulated by treating melt flow as a continuum using the conservation of mass and momentum equations. However, the compression molding of such materials in sheet form using a similar approach does not work well. The assumption of melt flow as a continuum does not hold for such deformation processes. To address this challenge, we have developed a novel simulation approach. First, the draping of the sheet was simulated as a structural deformation using the explicit finite element approach. Next, the draped shape was compressed using fluid mechanics equations. The proposed method was verified by building a physical part and comparing the predicted fiber orientation and warpage measurements performed on the physical parts. The developed method and tools are expected to help in expediting the development of FRT parts, which will help achieve lightweight targets in the automotive industry.

Highly conductive thermoplastic composite blends suitable for injection molding of bipolar plates

International Nuclear Information System (INIS)

Mighri, F.; Huneault, M.A.; Champagne, M.F.

2003-01-01

This study aimed at developing highly conductive, lightweight, and low-cost bipolar plates for use in proton exchange membranes (PEM) fuel cells. Injection and compression molding of highly filled polypropylene, PP, and polyphenylene sulfide, PPS, based blends were used as a mean for mass production of bipolar plates. Loadings up to 60-wt% in the form of graphite, conductive carbon black and carbon fibers were investigated. The developed formulations have a combination of properties and processability suitable for bipolar plate manufacturing, such as good chemical resistance, sufficient fluidity, and good electrical and thermal conductivity. Electrical resistivities around 0.15 and 0.09 Ohm-cm were respectively achieved for the PP and PPS-based blends, respectively. Two bipolar plate designs were successfully fabricated by molding the gas flow channels over aluminum plates to form a metallic/polymer composite plate, or simply by direct injection molding of the conductive polymer composite. For the first design, overall plate resistivities of 0.2 and 0.1 Ohm-cm were respectively attained using PP and PPS based blends as conductive skin. A lower volume resistivity of around 0.06 Ohm-cm was attained for the second injected plate design with PPS based blend. (author)

Study on the Mechanical and Interfacial Property of Injection Molded Fiber Reinforced Thermoplastics

OpenAIRE

王, 存涛

2014-01-01

Fiber reinforced polymer (FRP) composites have been used widely in the land transportation, aerospace, marine structures and characteristically conservative infrastructure construction industries and generally, the interface plays very important role in the properties of FRP materials. Therefore, this research studied the mechanical and interfacial property involved in the non-weld samples, weld samples and adhesive samples of insert moldings. Green composites as one of environment-friendly m...

Optimizing Injection Molding Parameters of Different Halloysites Type-Reinforced Thermoplastic Polyurethane Nanocomposites via Taguchi Complemented with ANOVA

Directory of Open Access Journals (Sweden)

Tayser Sumer Gaaz

2016-11-01

Full Text Available Halloysite nanotubes-thermoplastic polyurethane (HNTs-TPU nanocomposites are attractive products due to increasing demands for specialized materials. This study attempts to optimize the parameters for injection just before marketing. The study shows the importance of the preparation of the samples and how well these parameters play their roles in the injection. The control parameters for injection are carefully determined to examine the mechanical properties and the density of the HNTs-TPU nanocomposites. Three types of modified HNTs were used as untreated HNTs (uHNTs, sulfuric acid treated (aHNTs and a combined treatment of polyvinyl alcohol (PVA-sodium dodecyl sulfate (SDS-malonic acid (MA (treatment (mHNTs. It was found that mHNTs have the most influential effect of producing HNTs-TPU nanocomposites with the best qualities. One possible reason for this extraordinary result is the effect of SDS as a disperser and MA as a crosslinker between HNTs and PVA. For the highest tensile strength, the control parameters are demonstrated at 150 °C (injection temperature, 8 bar (injection pressure, 30 °C (mold temperature, 8 min (injection time, 2 wt % (HNTs loading and mHNT (HNTs type. Meanwhile, the optimized combination of the levels for all six control parameters that provide the highest Young’s modulus and highest density was found to be 150 °C (injection temperature, 8 bar (injection pressure, 32 °C (mold temperature, 8 min (injection time, 3 wt % (HNTs loading and mHNT (HNTs type. For the best tensile strain, the six control parameters are found to be 160 °C (injection temperature, 8 bar (injection pressure, 32 °C (mold temperature, 8 min (injection time, 2 wt % (HNTs loading and mHNT (HNTs type. For the highest hardness, the best parameters are 140 °C (injection temperature, 6 bar (injection pressure, 30 °C (mold temperature, 8 min (injection time, 2 wt % (HNTs loading and mHNT (HNTs type. The analyses are carried out by coordinating

Fiber-Based, Injection-Molded Optofluidic Systems: Improvements in Assembly and Applications

Directory of Open Access Journals (Sweden)

Marco Matteucci

2015-12-01

Full Text Available We present a method to fabricate polymer optofluidic systems by means of injection molding that allow the insertion of standard optical fibers. The chip fabrication and assembly methods produce large numbers of robust optofluidic systems that can be easily assembled and disposed of, yet allow precise optical alignment and improve delivery of optical power. Using a multi-level chip fabrication process, complex channel designs with extremely vertical sidewalls, and dimensions that range from few tens of nanometers to hundreds of microns can be obtained. The technology has been used to align optical fibers in a quick and precise manner, with a lateral alignment accuracy of 2.7 ± 1.8 μm. We report the production, assembly methods, and the characterization of the resulting injection-molded chips for Lab-on-Chip (LoC applications. We demonstrate the versatility of this technology by carrying out two types of experiments that benefit from the improved optical system: optical stretching of red blood cells (RBCs and Raman spectroscopy of a solution loaded into a hollow core fiber. The advantages offered by the presented technology are intended to encourage the use of LoC technology for commercialization and educational purposes.

Influence of the Processing Parameters on the Fiber-Matrix-Interphase in Short Glass Fiber-Reinforced Thermoplastics

Directory of Open Access Journals (Sweden)

Anna Katharina Sambale

2017-06-01

Full Text Available The interphase in short fiber thermoplastic composites is defined as a three-dimensional, several hundred nanometers-wide boundary region at the interface of fibers and the polymer matrix, exhibiting altered mechanical properties. This region is of key importance in the context of fiber-matrix adhesion and the associated mechanical strength of the composite material. An interphase formation is caused by morphological, as well as thermomechanical processes during cooling of the plastic melt close to the glass fibers. In this study, significant injection molding processing parameters are varied in order to investigate the influence on the formation of an interphase and the resulting mechanical properties of the composite. The geometry of the interphase is determined using nano-tribological techniques. In addition, the influence of the glass fiber sizing on the geometry of the interphase is examined. Tensile tests are used in order to determine the resulting mechanical properties of the produced short fiber composites. It is shown that the interphase width depends on the processing conditions and can be linked to the mechanical properties of the short fiber composite.

On the effect of the fiber orientation on the flexural stiffness of injection molded short fiber reinforced polycarbonate plates

NARCIS (Netherlands)

Neves, N.M.; Isdell, G.; Pouzada, A.S.; Powell, P.C.

1998-01-01

The through-thickness fiber orientation distribution of injection molded polycarbonate plates was experimentally determined by light reflection microscopy and manual digitization of polished cross sections. Fiber length distribution was determined by pyrolysis tests followed by image analysis. A

Microinjection molding of thermoplastic polymers: morphological comparison with conventional injection molding

International Nuclear Information System (INIS)

Giboz, Julien; Mélé, Patrice; Copponnex, Thierry

2009-01-01

The skin–core crystalline morphology of injection-molded semi-crystalline polymers is well documented in the scientific literature. The thermomechanical environment provokes temperature and shear gradients throughout the entire thickness of the part during molding, thus influencing the polymer crystallization. Crystalline morphologies of a high-density polyethylene (HDPE) micromolded part (μpart) and a classical part (macropart) are compared with optical, thermal and x-ray diffraction analyses. Results show that the crystalline morphologies with regard to thickness vary between the two parts. While a 'skin–core' morphology is present for the macropart, the μpart exhibits a specific 'core-free' morphology, i.e. no spherulite is present at the center of the thickness. This result seems to be generated under the specific conditions used in microinjection molding that lead to the formation of smaller and more oriented crystalline entities

Injection molded polymer chip for electrochemical and electrophysiological recordings from single cells

DEFF Research Database (Denmark)

Tanzi, Simone; Larsen, Simon Tylsgaard; Taboryski, Rafael J.

We present a novel method to fabricate an all in polymer injection molded chip for electrochemical cell recordings and lateral cell trapping. The complete device is molded in thermoplastic polymer and it results from assembling two halves. We tested spin-coated conductive polymer poly(3,4-ethylen...

Development of plastic pulley by injection molding; Shashutsu keisei ni yoru jushi pulley no kaihatsu

Energy Technology Data Exchange (ETDEWEB)

Yoshizumi, F; Funatsu, A; Yazawa, H [Sumitomo Bakelite Co. Ltd., Tokyo (Japan)

1997-10-01

We developed plastic pulley for automobile manufactured by injection molding which will reduce manufacturing cost. We have developed product design, injection molding technology especially to improve mechanical strength and phenolic molding compound with good wear resistance and high mechanical strength. We have established `Injection Compression molding` technology to improve mechanical strength of weld portion. We also developed phenolic molding compound which is composed of one step resin and long organic fiber to obtain good wear resistance and high mechanical strength. Manufacturing cost will be reduced by using injection molding combined with lower material cost of the newly developed compound. 12 figs., 2 tabs.

Integration of Fiber-Reinforced Polymers in a Life Cycle Assessment of Injection Molding Process Chains with Additive Manufacturing

DEFF Research Database (Denmark)

Hofstätter, Thomas; Bey, Niki; Mischkot, Michael

2017-01-01

Additive manufacturing technologies applied to injection molding process chain have acquired an increasingly important role in the context of tool inserts production, especially by vat polymerization. Despite the decreased lifetime during their use in the injection molding process, the inserts come...... with improvements in terms of production time, costs, exibility, as well as potentially improved environmental performance as compared to conventional materials in a life cycle perspective.This contribution supports the development of additively manufactured injection molding inserts with the use of fiber...

Experimental Study of Fiber Length and Orientation in Injection Molded Natural Fiber/Starch Acetate Composites

DEFF Research Database (Denmark)

Peltola, Heidi; Madsen, Bo; Joffe, Roberts

2011-01-01

Composite compounds based on triethyl citrate plasticized starch acetate and hemp and flax fibers were prepared by melt processing. Plasticizer contents from 20 to 35 wt% and fiber contents of 10 and 40 wt% were used. The compounded composites were injection molded to tensile test specimens...... was noticed. A reduction of fiber length along the increasing fiber content and the decreasing plasticizer content was also detected. This reduction originated from the increasing shear forces during compounding, which again depended on the increased viscosity of the material. Hemp fibers were shown to remain...... longer and fibrillate more than flax fibers, leading to higher aspect ratio. Thus, the reinforcement efficiency of hemp fibers by the processing was improved, in contrast with flax fibers. In addition, the analysis of fiber dispersion and orientation showed a good dispersion of fibers in the matrix...

Tool application CAD / CAM for design and construction of a prototype of plastic injection mold

Directory of Open Access Journals (Sweden)

Albert Miyer Suárez Castrillón

2015-11-01

Full Text Available The study, development and production of injection molds comes with the implementation of CAD and CAM tools available on the market; using these tools, a prototype injection mold for thermoplastic materials was designed and built, based on a mold is injection in the laboratory of the University of Pamplona, in which a couple of modifications were made in order to experiment with its design. The prototype was manufactured through a 3D scan of the original mold to provide the CAD / CAM files with the simulated 3D printing technique for performing an experimental study with the prototype for adjusting temperature and pressure sensors and for coatings metallic materials for use in the injection molding process.

Micromechanical modeling of short glass-fiber reinforced thermoplastics-Isotropic damage of pseudograins

International Nuclear Information System (INIS)

Kammoun, S.; Brassart, L.; Doghri, I.; Delannay, L.; Robert, G.

2011-01-01

A micromechanical damage modeling approach is presented to predict the overall elasto-plastic behavior and damage evolution in short fiber reinforced composite materials. The practical use of the approach is for injection molded thermoplastic parts reinforced with short glass fibers. The modeling is proceeded as follows. The representative volume element is decomposed into a set of pseudograins, the damage of which affects progressively the overall stiffness and strength up to total failure. Each pseudograin is a two-phase composite with aligned inclusions having same aspect ratio. A two-step mean-field homogenization procedure is adopted. In the first step, the pseudograins are homogenized individually according to the Mori-Tanaka scheme. The second step consists in a self-consistent homogenization of homogenized pseudograins. An isotropic damage model is applied at the pseudograin level. The model is implemented as a UMAT in the finite element code ABAQUS. Model is shown to reproduce the strength and the anisotropy (Lankford coefficient) during uniaxial tensile tests on samples cut under different directions relative to the injection flow direction.

Experimental Investigation into Suitable Process Conditions for Plastic Injection Molding of Thin-Sheet Parts

Directory of Open Access Journals (Sweden)

Dyi-Cheng Chen

2014-04-01

Full Text Available This study performs an experimental investigation into the effects of the process parameters on the surface quality of injection molded thin-sheet thermoplastic components. The investigations focus specifically on the shape, number and position of the mold gates, the injection pressure and the injection rate. It can be seen that the gravity force entering point improved filling of the cavity for the same forming time and injection pressure. Moreover, it shows the same injection pressure and packing time, the taper-shape gate yields a better surface appearance than the sheet-shape gate. The experimental results provide a useful source of reference in suitable the process conditions for the injection molding of thin-sheet plastic components.

Genome Regions Associated with Functional Performance of Soybean Stem Fibers in Polypropylene Thermoplastic Composites.

Directory of Open Access Journals (Sweden)

Yarmilla Reinprecht

Full Text Available Plant fibers can be used to produce composite materials for automobile parts, thus reducing plastic used in their manufacture, overall vehicle weight and fuel consumption when they replace mineral fillers and glass fibers. Soybean stem residues are, potentially, significant sources of inexpensive, renewable and biodegradable natural fibers, but are not curretly used for biocomposite production due to the functional properties of their fibers in composites being unknown. The current study was initiated to investigate the effects of plant genotype on the performance characteristics of soybean stem fibers when incorporated into a polypropylene (PP matrix using a selective phenotyping approach. Fibers from 50 lines of a recombinant inbred line population (169 RILs grown in different environments were incorporated into PP at 20% (wt/wt by extrusion. Test samples were injection molded and characterized for their mechanical properties. The performance of stem fibers in the composites was significantly affected by genotype and environment. Fibers from different genotypes had significantly different chemical compositions, thus composites prepared with these fibers displayed different physical properties. This study demonstrates that thermoplastic composites with soybean stem-derived fibers have mechanical properties that are equivalent or better than wheat straw fiber composites currently being used for manufacturing interior automotive parts. The addition of soybean stem residues improved flexural, tensile and impact properties of the composites. Furthermore, by linkage and in silico mapping we identified genomic regions to which quantitative trait loci (QTL for compositional and functional properties of soybean stem fibers in thermoplastic composites, as well as genes for cell wall synthesis, were co-localized. These results may lead to the development of high value uses for soybean stem residue.

Effect of starch types on properties of biodegradable polymer based on thermoplastic starch process by injection molding technique

Directory of Open Access Journals (Sweden)

Yossathorn Tanetrungroj

2015-04-01

Full Text Available In this study effects of different starch types on the properties of biodegradable polymer based on thermoplastic starch (TPS were investigated. Different types of starch containing different contents of amylose and amylopectin were used, i.e. cassava starch, mungbean starch, and arrowroot starch. The TPS polymers were compounded and shaped using an internal mixer and an injection molding machine, respectively. It was found that the amount of amylose and amylopectin contents on native starch influence the properties of the TPS polymer. A high amylose starch of TPMS led to higher strength, hardness, degree of crystallization than the high amylopectin starch of TPCS. In addition, function group analysis by Fourier transforms infrared spectrophotometer, water absorption, and biodegradation by soil burial test were also examined.

High-rate production of micro- and nanostructured surfaces: Injection molding and novel process for metal tooling manufacturing

Science.gov (United States)

De Jesus Vega, Marisely

Devices containing micro and nanostructured surfaces are developing and constantly finding new applications, especially for medical diagnostics, point-of-care applications, and microneedles. They are also employed in the functionalization of surfaces for superhydrophobicity, drag reduction, or reversible adhesion by mimicking bio-inspired surfaces. This research provides a thorough investigation on the effects of different polymeric materials and processing conditions on the replication of micro and nanostructured surfaces via injection molding. In addition, this dissertation also presents a novel approach for the production of durable microstructured metal tooling to be used for the production of surfaces with microchannels via injection molding. Materials such as thermoplastic vulcanizates are substituting regular thermoplastic materials and vulcanized elastomers in many applications due to their outstanding properties and ease of processability. These material properties broaden the scope of applications for microstructured surfaces. However, there is a need for understanding how these materials behave in microinjection molding since thermoplastic elastomers' behavior during injection molding have been shown to differ from that of the widely understood behavior of thermoplastics. Replication of microstructured surfaces using thermoplastic vulcanizates (TPV) was studied in the first part of this thesis. TPVs with different hardness's were molded using microinjection molding with various processing conditions and the replication and surface details of 20 microm pillars (aspect ratio of 1:1) were characterized. In the second part of this research liquid silicone rubber (LSR) was studied as a material for the production of micro and nanostructured surfaces. LSR is a silicone based material such as polydimethylsiloxane (PDMS), which is widely used for research and development of micro and nanostructured devices, and thus provides all the benefits of PDMS but can be

Thermo-hydroforming of a fiber-reinforced thermoplastic composites considering fiber orientations

Science.gov (United States)

Ahn, Hyunchul; Kuuttila, Nicholas Eric; Pourboghrat, Farhang

2018-05-01

The Thermoplastic woven composites were formed using a composite thermal hydroforming process, utilizing heated and pressurized fluid, similar to sheet metal forming. This study focuses on the modification of 300-ton pressure formation and predicts its behavior. Spectra Shield SR-3136 is used in this study and material properties are measured by experiments. The behavior of fiber-reinforced thermoplastic polymer composites (FRTP) was modeled using the Preferred Fiber Orientation (PFO) model and validated by comparing numerical analysis with experimental results. The thermo-hydroforming process has shown good results in the ability to form deep drawn parts with reduced wrinkles. Numerical analysis was performed using the PFO model and implemented as commercial finite element software ABAQUS / Explicit. The user subroutine (VUMAT) was used for the material properties of the thermoplastic composite layer. This model is suitable for working with multiple layers of composite laminates. Model parameters have been updated to work with cohesive zone model to calculate the interfacial properties between each composite layer. The results of the numerical modeling showed a good correlation with the molding experiment on the forming shape. Numerical results were also compared with experimental results on punch force-displacement curves for deformed geometry and forming processes of the composite layer. Overall, the shape of the deformed FRTP, including the distribution of wrinkles, was accurately predicted as shown in this study.

Effects of Styrene-Acrylic Sizing on the Mechanical Properties of Carbon Fiber Thermoplastic Towpregs and Their Composites.

Science.gov (United States)

Bowman, Sean; Jiang, Qiuran; Memon, Hafeezullah; Qiu, Yiping; Liu, Wanshuang; Wei, Yi

2018-03-01

Thermoplastic towpregs are convenient and scalable raw materials for the fabrication of continuous fiber-reinforced thermoplastic matrix composites. In this paper, the potential to employ epoxy and styrene-acrylic sizing agents was evaluated for the making of carbon fiber thermoplastic towpregs via a powder-coating method. The protective effects and thermal stability of these sizing agents were investigated by single fiber tensile test and differential scanning calorimetry (DSC) measurement. The results indicate that the epoxy sizing agent provides better protection to carbon fibers, but it cannot be used for thermoplastic towpreg processing due to its poor chemical stability at high temperature. The bending rigidity of the tows and towpregs with two styrene-acrylic sizing agents was measured by cantilever and Kawabata methods. The styrene-acrylic sized towpregs show low torque values, and are suitable for further processing, such as weaving, preforming, and winding. Finally, composite panels were fabricated directly from the towpregs by hot compression molding. Both of the composite panels show superior flexural strength (>400 MPa), flexural modulus (>63 GPa), and interlaminar shear strength (>27 MPa), indicating the applicability of these two styrene-acrylic sizing agents for carbon fiber thermoplastic towpregs.

Effects of Styrene-Acrylic Sizing on the Mechanical Properties of Carbon Fiber Thermoplastic Towpregs and Their Composites

Directory of Open Access Journals (Sweden)

Sean Bowman

2018-03-01

Full Text Available Thermoplastic towpregs are convenient and scalable raw materials for the fabrication of continuous fiber-reinforced thermoplastic matrix composites. In this paper, the potential to employ epoxy and styrene-acrylic sizing agents was evaluated for the making of carbon fiber thermoplastic towpregs via a powder-coating method. The protective effects and thermal stability of these sizing agents were investigated by single fiber tensile test and differential scanning calorimetry (DSC measurement. The results indicate that the epoxy sizing agent provides better protection to carbon fibers, but it cannot be used for thermoplastic towpreg processing due to its poor chemical stability at high temperature. The bending rigidity of the tows and towpregs with two styrene-acrylic sizing agents was measured by cantilever and Kawabata methods. The styrene-acrylic sized towpregs show low torque values, and are suitable for further processing, such as weaving, preforming, and winding. Finally, composite panels were fabricated directly from the towpregs by hot compression molding. Both of the composite panels show superior flexural strength (>400 MPa, flexural modulus (>63 GPa, and interlaminar shear strength (>27 MPa, indicating the applicability of these two styrene-acrylic sizing agents for carbon fiber thermoplastic towpregs.

Fiber webs

Science.gov (United States)

Roger M. Rowell; James S. Han; Von L. Byrd

2005-01-01

Wood fibers can be used to produce a wide variety of low-density three-dimensional webs, mats, and fiber-molded products. Short wood fibers blended with long fibers can be formed into flexible fiber mats, which can be made by physical entanglement, nonwoven needling, or thermoplastic fiber melt matrix technologies. The most common types of flexible mats are carded, air...

Modeling and Simulation of Fiber Orientation in Injection Molding of Polymer Composites

Directory of Open Access Journals (Sweden)

Jang Min Park

2011-01-01

Full Text Available We review the fundamental modeling and numerical simulation for a prediction of fiber orientation during injection molding process of polymer composite. In general, the simulation of fiber orientation involves coupled analysis of flow, temperature, moving free surface, and fiber kinematics. For the governing equation of the flow, Hele-Shaw flow model along with the generalized Newtonian constitutive model has been widely used. The kinematics of a group of fibers is described in terms of the second-order fiber orientation tensor. Folgar-Tucker model and recent fiber kinematics models such as a slow orientation model are discussed. Also various closure approximations are reviewed. Therefore, the coupled numerical methods are needed due to the above complex problems. We review several well-established methods such as a finite-element/finite-different hybrid scheme for Hele-Shaw flow model and a finite element method for a general three-dimensional flow model.

Modelling of the glass fiber length and the glass fiber length distribution in the compounding of short glass fiber-reinforced thermoplastics

Science.gov (United States)

Kloke, P.; Herken, T.; Schöppner, V.; Rudloff, J.; Kretschmer, K.; Heidemeyer, P.; Bastian, M.; Walther, Dridger, A.

2014-05-01

The use of short glass fiber-reinforced thermoplastics for the production of highly stressed parts in the plastics processing industry has experienced an enormous boom in the last few years. The reasons for this are primarily the improvements to the stiffness and strength properties brought about by fiber reinforcement. These positive characteristics of glass fiber-reinforced polymers are governed predominantly by the mean glass fiber length and the glass fiber length distribution. It is not enough to describe the properties of a plastics component solely as a function of the mean glass fiber length [1]. For this reason, a mathematical-physical model has been developed for describing the glass fiber length distribution in compounding. With this model, it is possible on the one hand to optimize processes for the production of short glass fiber-reinforced thermoplastics, and, on the other, to obtain information on the final distribution, on the basis of which much more detailed statements can be made about the subsequent properties of the molded part. Based on experimental tests, it was shown that this model is able to accurately describe the change in glass fiber length distribution in compounding.

Fabrication and physical properties of glass-fiber-reinforced thermoplastics for non-metal-clasp dentures.

Science.gov (United States)

Nagakura, Manamu; Tanimoto, Yasuhiro; Nishiyama, Norihiro

2017-11-01

Recently, non-metal-clasp dentures (NMCDs) made from thermoplastic resins such as polyamide, polyester, polycarbonate, and polypropylene have been used as removable partial dentures (RPDs). However, the use of such RPDs can seriously affect various tissues because of their low rigidity. In this study, we fabricated high-rigidity glass-fiber-reinforced thermoplastics (GFRTPs) for use in RPDs, and examined their physical properties such as apparent density, dynamic hardness, and flexural properties. GFRTPs made from E-glass fibers and polypropylene were fabricated using an injection-molding. The effects of the fiber content on the GFRTP properties were examined using glass-fiber contents of 0, 5, 10, 20, 30, 40, and 50 mass%. Commercially available denture base materials and NMCD materials were used as controls. The experimental densities of GFRTPs with various fiber contents agreed with the theoretical densities. Dynamic micro-indentation tests confirmed that the fiber content does not affect the GFRTP surface properties such as dynamic hardness and elastic modulus, because most of the reinforcing glass fibers are embedded in the polypropylene. The flexural strength increased from 55.8 to 217.6 MPa with increasing glass-fiber content from 0 to 50 mass%. The flexural modulus increased from 1.75 to 7.42 GPa with increasing glass-fiber content from 0 to 50 mass%, that is, the flexural strength and modulus of GFRTP with a fiber content of 50 mass% were 3.9 and 4.2 times, respectively, those of unreinforced polypropylene. These results suggest that fiber reinforcement has beneficial effects, and GFRTPs can be used in NMCDs because their physical properties are better than those of controls. © 2016 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 105B: 2254-2260, 2017. © 2016 Wiley Periodicals, Inc.

Internal Fiber Structure of a High-Performing, Additively Manufactured Injection Molding Insert

DEFF Research Database (Denmark)

Hofstätter, Thomas; Baier, Sina; Trinderup, Camilla H.

A standard mold is equipped with additively manufactured inserts in a rectangular shape produced with vat photo polymerization. While the lifetime compared to conventional materials such as brass, steel, and aluminum is reduced, the prototyping and design phase can be shortened significantly...... by using flexible and cost-effective additive manufacturing technologies. Higher production volumes still exceed the capability of additively manufactured inserts, which are overruled by the stronger performance of less-flexible but mechanically advanced materials. In this contribution, the internal...... structure of a high-performing, fiber-reinforced injection molding insert has been analyzed. The insert reached a statistically proven and reproducible lifetime of 4,500 shots, which significantly outperforms any other previously published additively manufactured inserts. Computer tomography, tensile tests...

Characterization of thermoplastic polyurethane/polylactic acid (TPU/PLA) tissue engineering scaffolds fabricated by microcellular injection molding

International Nuclear Information System (INIS)

Mi, Hao-Yang; Salick, Max R.; Jing, Xin; Jacques, Brianna R.; Crone, Wendy C.; Peng, Xiang-Fang; Turng, Lih-Sheng

2013-01-01

Polylactic acid (PLA) and thermoplastic polyurethane (TPU) are two kinds of biocompatible and biodegradable polymers that can be used in biomedical applications. PLA has rigid mechanical properties while TPU possesses flexible mechanical properties. Blended TPU/PLA tissue engineering scaffolds at different ratios for tunable properties were fabricated via twin screw extrusion and microcellular injection molding techniques for the first time. Multiple test methods were used to characterize these materials. Fourier transform infrared spectroscopy (FTIR) confirmed the existence of the two components in the blends; differential scanning calorimetry (DSC) and dynamic mechanical analysis (DMA) confirmed the immiscibility between the TPU and PLA. Scanning electron microscopy (SEM) images verified that, at the composition ratios studied, PLA was dispersed as spheres or islands inside the TPU matrix and that this phase morphology further influenced the scaffold's microstructure and surface roughness. The blends exhibited a large range of mechanical properties that covered several human tissue requirements. 3T3 fibroblast cell culture showed that the scaffolds supported cell proliferation and migration properly. Most importantly, this study demonstrated the feasibility of mass producing biocompatible PLA/TPU scaffolds with tunable microstructures, surface roughnesses, and mechanical properties that have the potential to be used as artificial scaffolds in multiple tissue engineering applications. - Highlights: • Microcellular injection molding was used to fabricate tissue engineering scaffolds. • TPU/PLA tissue engineering scaffolds with tunable properties were fabricated. • Multiple test methods were used to characterize the scaffolds. • The biocompatibility of the scaffolds was confirmed by fibroblast cell culture. • Scaffolds produced have the potential to be used in multiple tissue applications

Effects of short fiber reinforcement and mean stress on tensile fatigue strength characteristics of polyethersulfone; Tansen`i kyoka porieterusaruhon no hippari hiro tokusei ni oyobosu heikin oryoku no eikyo

Energy Technology Data Exchange (ETDEWEB)

Furue, H.; Nonaka, K. [Mechanical Engineering Lab., Tsukuba, Ibaraki (Japan)

1996-01-15

Thermoplastics are often reinforced with short fibers with aims of improvement of their strengths, rigidities and hardness or maintenance of their dimensional stabilities. Such short fiber reinforced plastic materials have more expectation for high performance plastics. Authors already examined of some effects of reinforced fiber and of orientation in injection molding on flexural fatigue characteristics of the injection-molded high performance thermoplastic materials. However, the examination of short fiber reinforced effects on fatigue strength characteristics was not always sufficient. In this study, in order to obtain a guiding principle for fatigue resistant design of the short fiber reinforced injection molding materials, polyethersulfones (PES) was examined on its tensile fatigue strength and an effect of short fiber reinforcement for improvement of its fundamental dynamic properties on its fatigue characteristics. Especially, its fatigue life characteristics was elucidated mainly on relationship of mean stress, stress amplitude and number of repeating fracture in tensile fatigue behavior. 10 refs., 15 figs., 2 tabs.

Enhanced Injection Molding Simulation of Advanced Injection Molds

Directory of Open Access Journals (Sweden)

Béla Zink

2017-02-01

Full Text Available The most time-consuming phase of the injection molding cycle is cooling. Cooling efficiency can be enhanced with the application of conformal cooling systems or high thermal conductivity copper molds. The conformal cooling channels are placed along the geometry of the injection-molded product, and thus they can extract more heat and heat removal is more uniform than in the case of conventional cooling systems. In the case of copper mold inserts, cooling channels are made by drilling and heat removal is facilitated by the high thermal conductivity coefficient of copper, which is several times that of steel. Designing optimal cooling systems is a complex process; a proper design requires injection molding simulations, but the accuracy of calculations depends on how precise the input parameters and boundary conditions are. In this study, three cooling circuit designs and three mold materials (Ampcoloy 940, 1.2311 (P20 steel, and MS1 steel were used and compared using numerical methods. The effect of different mold designs and materials on cooling efficiency were examined using calculated and measured results. The simulation model was adjusted to the measurement results by considering the joint gap between the mold inserts.

Effect of carrageenan on properties of biodegradable thermoplastic cassava starch/low-density polyethylene composites reinforced by cotton fibers

International Nuclear Information System (INIS)

Prachayawarakorn, Jutarat; Pomdage, Wanida

2014-01-01

Highlights: • We prepared the TPCS/LDPE composites modified by carrageenan and/or cotton fibers. • The IR O–H stretching peak of the modified composites shifts to lower wavenumber. • Stress and Young’s modulus of the modified composites increase significantly. • The modified composites degrade faster than the non-modified composite. - Abstract: Applications of biodegradable thermoplastic starch (TPS) have been restricted due to its poor mechanical properties, limited processability and high water uptake. In order to improve properties and processability, thermoplastic cassava starch (TPCS) was compounded with low-density polyethylene (LDPE). The TPCS/LDPE blend was, then, modified by a natural gelling agent, i.e. carrageenan and natural fibers, i.e. cotton fibers. All composites were compounded and processed using an internal mixer and an injection molding machine, respectively. It was found that stress at maximum load and Young’s modulus of the TPCS/LDPE composites significantly increased by the addition of the carrageenan and/or the cotton fibers. The highest mechanical properties were obtained from the TPCS/LDPE composites modified by both the carrageenan and the cotton fibers. Percentage water absorption of all of the TPCS/LDPE composites was found to be similar. All modified composites were also degraded easier than the non-modified one. Furthermore, all the composites were analyzed using Fourier-transform infrared spectroscopy (FTIR), X-ray diffraction (XRD) and Scanning electron microscopy (SEM)

Life Cycle Assessment of Fiber-Reinforced Additive Manufacturing for Injection Molding Insert Production

DEFF Research Database (Denmark)

Hofstätter, Thomas; Stotz, Philippe Maurice; Bey, Niki

2017-01-01

Additively manufactured (AM) injection molding (IM) inserts have proved to be capable to substitute conventionally manufactured metal inserts with polymer-based insert enforced with short, virgin, unseized carbon fibers (CFs). It has been shown that the implementation of AM technology resulted......, this contribution provides a comparison of environmental performance of conventionally vs. additively manufactured inserts in a full life cycle perspective indicated in Figure 1, including materials, production, use and end-of-life (EoL) stages....

Relationship between fiber degradation and residence time distribution in the processing of long fiber reinforced thermoplastics

Directory of Open Access Journals (Sweden)

2008-08-01

Full Text Available Long fiber reinforced thermoplastics (LFT were processed by in-line compounding equipment with a modified single screw extruder. A pulse stimulus response technique using PET spheres as the tracer was adopted to obtain residence time distribution (RTD of extrusion compounding. RTD curves were fitted by the model based on the supposition that extrusion compounding was the combination of plug flow and mixed flow. Characteristic parameters of RTD model including P the fraction of plug flow reactor (PFR and d the fraction of dead volume of continuous stirred tank reactor (CSTR were used to associate with fiber degradation presented by fiber length and dispersion. The effects of screw speed, mixing length and channel depth on RTD curves, and characteristic parameters of RTD models as well as their effects on the fiber degradation were investigated. The influence of shear force with different screw speeds and variable channel depth on fiber degradation was studied and the main impetus of fiber degradation was also presented. The optimal process for obtaining the balance of fiber length and dispersion was presented.

Implementation of New Process Models for Tailored Polymer Composite Structures into Processing Software Packages

International Nuclear Information System (INIS)

Nguyen, Ba Nghiep; Jin, Xiaoshi; Wang, Jin; Phelps, Jay; Tucker, Charles L. III; Kunc, Vlastimil; Bapanapalli, Satish K.; Smith, Mark T.

2010-01-01

This report describes the work conducted under the Cooperative Research and Development Agreement (CRADA) (Nr. 260) between the Pacific Northwest National Laboratory (PNNL) and Autodesk, Inc. to develop and implement process models for injection-molded long-fiber thermoplastics (LFTs) in processing software packages. The structure of this report is organized as follows. After the Introduction Section (Section 1), Section 2 summarizes the current fiber orientation models developed for injection-molded short-fiber thermoplastics (SFTs). Section 3 provides an assessment of these models to determine their capabilities and limitations, and the developments needed for injection-molded LFTs. Section 4 then focuses on the development of a new fiber orientation model for LFTs. This model is termed the anisotropic rotary diffusion - reduced strain closure (ARD-RSC) model as it explores the concept of anisotropic rotary diffusion to capture the fiber-fiber interaction in long-fiber suspensions and uses the reduced strain closure method of Wang et al. to slow down the orientation kinetics in concentrated suspensions. In contrast to fiber orientation modeling, before this project, no standard model was developed to predict the fiber length distribution in molded fiber composites. Section 5 is therefore devoted to the development of a fiber length attrition model in the mold. Sections 6 and 7 address the implementations of the models in AMI, and the conclusions drawn from this work is presented in Section 8.

Heat transfer analytical models for the rapid determination of cooling time in crystalline thermoplastic injection molding and experimental validation

Science.gov (United States)

Didier, Delaunay; Baptiste, Pignon; Nicolas, Boyard; Vincent, Sobotka

2018-05-01

Heat transfer during the cooling of a thermoplastic injected part directly affects the solidification of the polymer and consequently the quality of the part in term of mechanical properties, geometric tolerance and surface aspect. This paper proposes to mold designers a methodology based on analytical models to provide quickly the time to reach the ejection temperature depending of the temperature and the position of cooling channels. The obtained cooling time is the first step of the thermal conception of the mold. The presented methodology is dedicated to the determination of solidification time of a semi-crystalline polymer slab. It allows the calculation of the crystallization time of the part and is based on the analytical solution of the Stefan problem in a semi-infinite medium. The crystallization is then considered as a phase change with an effective crystallization temperature, which is obtained from Fast Scanning Calorimetry (FSC) results. The crystallization time is then corrected to take the finite thickness of the part into account. To check the accuracy of such approach, the solidification time is calculated by solving the heat conduction equation coupled to the crystallization kinetics of the polymer. The impact of the nature of the contact between the polymer and the mold is evaluated. The thermal contact resistance (TCR) appears as significant parameter that needs to be taken into account in the cooling time calculation. The results of the simplified model including or not TCR are compared in the case of a polypropylene (PP) with experiments carried out with an instrumented mold. Then, the methodology is applied for a part made with PolyEtherEtherKetone (PEEK).

Optimization of Blending Parameters and Fiber Size of Kenaf-Bast-Fiber-Reinforced the Thermoplastic Polyurethane Composites by Taguchi Method

Directory of Open Access Journals (Sweden)

Y. A. El-Shekeil

2013-01-01

Full Text Available “Kenaf-fibers- (KF-” reinforced “thermoplastic polyurethane (TPU” composites were prepared by the melt-blending method followed by compression molding. Composite specimens were cut from the sheets that were prepared by compression molding. The criteria of optimization were testing the specimens by tensile test and comparing the ultimate tensile strength. The aim of this study is to optimize processing parameters (e.g., processing temperature, time, and speed and fiber size using the Taguchi approach. These four parameters were investigated in three levels each. The L9 orthogonal array was used based on the number of parameters and levels that has been selected. Furthermore, analysis of variance (ANOVA was used to determine the significance of different parameters. The results showed that the optimum values were 180°C, 50 rpm, 13 min, and 125–300 micron for processing temperature, processing speed, processing time, and fiber size, respectively. Using ANOVA, processing temperature showed the highest significance value followed by fiber size. Processing time and speed did not show any significance on the optimization of TPU/KF.

Building Block Approach' for Structural Analysis of Thermoplastic Composite Components for Automotive Applications

Science.gov (United States)

Carello, M.; Amirth, N.; Airale, A. G.; Monti, M.; Romeo, A.

2017-12-01

Advanced thermoplastic prepreg composite materials stand out with regard to their ability to allow complex designs with high specific strength and stiffness. This makes them an excellent choice for lightweight automotive components to reduce mass and increase fuel efficiency, while maintaining the functionality of traditional thermosetting prepreg (and mechanical characteristics) and with a production cycle time and recyclability suited to mass production manufacturing. Currently, the aerospace and automotive sectors struggle to carry out accurate Finite Elements (FE) component analyses and in some cases are unable to validate the obtained results. In this study, structural Finite Elements Analysis (FEA) has been done on a thermoplastic fiber reinforced component designed and manufactured through an integrated injection molding process, which consists in thermoforming the prepreg laminate and overmolding the other parts. This process is usually referred to as hybrid molding, and has the provision to reinforce the zones subjected to additional stresses with thermoformed themoplastic prepreg as required and overmolded with a shortfiber thermoplastic resin in single process. This paper aims to establish an accurate predictive model on a rational basis and an innovative methodology for the structural analysis of thermoplastic composite components by comparison with the experimental tests results.

Initial verification of an induction heating set-up for injection molding

DEFF Research Database (Denmark)

Menotti, Stefano; Hansen, Hans Nørgaard; Bissacco, Giuliano

2013-01-01

Molding of thin and long parts by injection molding leads to special requirements for the mold in order to ensure proper filling and acceptable cycle time. This paper investigates the applicability of embedded induction heating for the improvement of the filling of thin long parts. The object...... selected for the investigation is a thin spiral. For the complete molding of the component, elevated mold temperatures are required. For this propose a new injection molding set-up was developed, which allows rapid heating of the cavity wall by an induction heating system. The temperature was measured...

Properties and performance of flax yarn/thermoplastic polyester composites

DEFF Research Database (Denmark)

Madsen, Bo; Mehmood, Shahid

2012-01-01

Aiming at demonstrating the potential of unidirectional natural fiber-reinforced thermoplastic composites in structural applications, textile flax yarn/thermoplastic polyester composites with variable fiber volume fractions have been manufactured by a filament-winding process followed by a vacuum......-assisted compression molding process. The microstructure of the composites shows that the flax fiber yarns are well impregnated by the polyester matrix, and this supports the measured low porosity content of the composites. The experimental tensile modulus and ultimate tensile stress of the composites in the axial...

Surface Replication of Molded Products with Microneedle Features in Injection Molding

Science.gov (United States)

Uchiumi, Kazuyasu; Takayama, Tetsuo; Ito, Hiroshi; Inou, Akinori

Micro-molding of microneedle features was conducted using several injection-molding techniques. Injection compression molding and injection molding were performed with supercritical carbon dioxide fluid and with or without vacuum processing inside the mold cavity. Effects of process parameters on processability and surface replication of the molded parts were evaluated. The height replication ratio for microneedles was improved using injection compression molding. At a shorter compression stroke, the needle height was improved, and the influence of compression delay time was also small. Moreover, the effects of vacuum processing inside the mold cavity under the filling process were slight. The height replication ratio for microneedles showed the highest values using injection molding using supercritical carbon dioxide fluid with vacuum inside the mold cavity.

Fiber breakage phenomena in long fiber reinforced plastic preparation

International Nuclear Information System (INIS)

Huang, Chao-Tsai; Tseng, Huan-Chang; Chang, Rong-Yeu; Vlcek, Jiri

2015-01-01

Due to the high demand of smart green, the lightweight technologies have become the driving force for the development of automotives and other industries in recent years. Among those technologies, using short and long fiber-reinforced plastics (FRP) to replace some metal components can reduce the weight of an automotive significantly. However, the microstructures of fibers inside plastic matrix are too complicated to manage and control during the injection molding through the screw, the runner, the gate, and then into the cavity. This study focuses on the fiber breakage phenomena during the screw plastification. Results show that fiber breakage is strongly dependent on screw design and operation. When the screw geometry changes, the fiber breakage could be larger even with lower compression ratio. (paper)

Dynamic of taking out molding parts at injection molding

Directory of Open Access Journals (Sweden)

E. Ragan

2012-10-01

Full Text Available Most plastic parts used in automobile production are manufactured by injection molding. Their quality depends also on taking out molding and on the manipulators for it. Task of this contribution is to theoretically describe a transport of molding at taking out after injection molding in relation on its regulation. The following quantities are derived at it: the transition characteristic of the taking out system, the blocking diagram of taking out molding regulation, the amplitude and phase characteristic and the transition characteristic of action quantity at taking out molding regulation.

Injection molded polymer optics in the 21st Century

Science.gov (United States)

Beich, William S.

2005-08-01

Precision polymer optics, manufactured by injection molding techniques, has been a key enabling technology for several decades now. The technology, which can be thought of as a subset of the wider field of precision optics manufacturing, was pioneered in the United States by companies such as Eastman Kodak, US Precision Lens, and Polaroid. In addition to suppliers in the U.S. there are several companies worldwide that design and manufacture precision polymer optics, for example Philips High Tech Plastics in Europe and Fujinon in Japan. Designers who are considering using polymer optics need a fundamental understanding of exactly how the optics are created. This paper will survey the technology and processes that are employed in the successful implementation of a polymer optic solution from a manufacturer's perspective. Special emphasis will be paid to the unique relationship between the molds and the optics that they produce. We will discuss the key elements of production: molding resins, molds and molding equipment, and metrology. Finally we will offer a case study to illustrate just how the optics designer carries a design concept through to production. The underlying theme throughout the discussion of polymer optics is the need for the design team to work closely with an experienced polymer optics manufacturer with a solid track record of success in molded optics. As will be seen shortly, the complex interaction between thermoplastics, molds, and molding machines dictates the need for working closely with a supplier who has the critical knowledge needed to manage all aspects of the program.

Compression molding of chopped woven thermoplastic composite flakes

NARCIS (Netherlands)

Abdul Rasheed, Mohammed Iqbal

2016-01-01

Continuous fiber reinforced composites with high-performance thermoplastic polymer matrices have an enormous potential in terms of performance, production rate, cost efficiency and recyclability. The use of this relatively new class of materials by the aerospace and automotive industry has been

Determination of adhesion between thermoplastic and liquid silicone rubbers in hard-soft-combinations via mechanical peeling test

Science.gov (United States)

Kühr, C.; Spörrer, A.; Altstädt, V.

2014-05-01

The production of hard-soft-combinations via multi injection molding gained more and more importance in the last years. This is attributed to different factors. One principle reason is that the use of two-component injection molding technique has many advantages such as cancelling subsequent and complex steps and shortening the process chain. Furthermore this technique allows the combination of the properties of the single components like the high stiffness of the hard component and the elastic properties of the soft component. Because of the incompatibility of some polymers the adhesion on the interface has to be determined. Thereby adhesion is not only influenced by the applied polymers, but also by the injection molding parameters and the characteristics of the mold. Besides already known combinations of thermoplastics with thermoplastic elastomers (TPE), there consists the possibility to apply liquid silicone rubber (LSR) as soft component. A thermoplastic/LSR combination gains in importance due to the specific advantages of LSR to TPE. The faintly adhesion between LSR and thermoplastics is currently one of the key challenges when dealing with those combinations. So it is coercively necessary to improve adhesion between the two components by adding an adhesion promoter. To determine the promoters influence, it is necessary to develop a suitable testing method to investigate e.g. the peel resistance. The current German standard "VDI Richtlinie 2019', which is actually only employed for thermoplastic/TPE combinations, can serve as a model to determine the adhesion of thermoplastic/LSR combinations.

A comparison of molding procedures - Contact, injection and vacuum injection

Science.gov (United States)

Cathiard, G.

1980-06-01

The technical and economic aspects of the contact, injection and vacuum injection molding of reinforced plastic components are compared for the example of a tractor roof with a gel-coated surface. Consideration is given to the possibility of reinforcement, number of smooth faces, condition of the gel-coated surface, reliability, and labor and workplace requirements of the three processes, and advantages of molding between the mold and a countermold in smooth faces, reliability, labor requirements, working surface and industrial hygiene are pointed out. The times and labor requirements of each step in the molding cycles are examined, and material requirements and yields, investment costs, amortization and product cost prices of the processes are compared. It is concluded that, for the specific component examined, the processes of vacuum injection and injection molding appear very interesting, with injection molding processes resulting in lower cost prices than contact molding for any production volume.

CAE for Injection Molding — Past, Present and the Future

Science.gov (United States)

Wang, Kuo K.

2004-06-01

It is well known that injection molding is the most effective process for mass-producing discrete plastic parts of complex shape to the highest precision at the lowest cost. However, due to the complex property of polymeric materials undergoing a transient non-isothermal process, it is equally well recognized that the quality of final products is often difficult to be assured. This is particularly true when a new mold or material is encountered. As a result, injection molding has often been viewed as an art than a science. During the past few decades, numerical simulation of injection molding process based on analytic models has become feasible for practical use as computers became faster and cheaper continually. A research effort was initiated at the Cornell Injection Molding Program (CIMP) in 1974 under a grant from the National Science Foundation. Over a quarter of the century, CIMP has established some scientific bases ranging from materials characterization, flow analysis, to prediction of part quality. Use of such CAE tools has become common place today in industry. Present effort has been primarily aimed at refinements of many aspects of the process. Computational efficiency and user-interface have been main thrusts by commercial software developers. Extension to 3-dimensional flow analysis for certain parts has drawn some attention. Research activities are continuing on molding of fiber-filled materials and reactive polymers. Expanded molding processes such as gas-assisted, co-injection, micro-molding and many others are continually being investigated. In the future, improvements in simulation accuracy and efficiency will continue. This will include in-depth studies on materials characterization. Intelligent on-line process control may draw more attention in order to achieve higher degree of automation. As Internet technology continues to evolve, Web-based CAE tools for design, production, remote process monitoring and control can come to path. The CAE

Porous media heat transfer for injection molding

Science.gov (United States)

Beer, Neil Reginald

2016-05-31

The cooling of injection molded plastic is targeted. Coolant flows into a porous medium disposed within an injection molding component via a porous medium inlet. The porous medium is thermally coupled to a mold cavity configured to receive injected liquid plastic. The porous medium beneficially allows for an increased rate of heat transfer from the injected liquid plastic to the coolant and provides additional structural support over a hollow cooling well. When the temperature of the injected liquid plastic falls below a solidifying temperature threshold, the molded component is ejected and collected.

Digital Twin concept for smart injection molding

Science.gov (United States)

Liau, Y.; Lee, H.; Ryu, K.

2018-03-01

Injection molding industry has evolved over decades and became the most common method to manufacture plastic parts. Monitoring and improvement in the injection molding industry are usually performed separately in each stage, i.e. mold design, mold making and injection molding process. However, in order to make a breakthrough and survive in the industrial revolution, all the stages in injection molding need to be linked and communicated with each other. Any changes in one stage will cause a certain effect in other stage because there is a correlation between each other. Hence, the simulation should not only based on the input of historical data, but it also needs to include the current condition of equipment and prediction of future events in other stages to make the responsive decision. This can be achieved by implementing the concept of Digital Twin that models the entire process as a virtual model and enables bidirectional control with the physical process. This paper presented types of data and technology required to build the Digital Twin for the injection molding industry. The concept includes Digital Twin of each stage and integration of these Digital Twin model as a thoroughgoing model of the injection molding industry.

Examination of injection moulded thermoplastic maize starch

Directory of Open Access Journals (Sweden)

2007-12-01

Full Text Available This paper focuses on the effect of the different injection moulding parameters and storing methods on injection moulded thermoplastic maize starch (TPS. The glycerol and water plasticized starch was processed in a twin screw extruder and then with an injection moulding machine to produce TPS dumbbell specimens. Different injection moulding set-ups and storing conditions were used to analyse the effects on the properties of thermoplastic starch. Investigated parameters were injection moulding pressure, holding pressure, and for the storage: storage at 50% relative humidity, and under ambient conditions. After processing the mechanical and shrinkage properties of the manufactured TPS were determined as a function of the ageing time. While conditioning, the characteristics of the TPS changed from a soft material to a rigid material. Although this main behaviour remained, the different injection moulding parameters changed the characteristics of TPS. Scanning electron microscope observations revealed the changes in the material on ageing.

Manufacturing a 9-Meter Thermoplastic Composite Wind Turbine Blade: Preprint

Energy Technology Data Exchange (ETDEWEB)

Murray, Robynne [National Renewable Energy Laboratory (NREL), Golden, CO (United States); Snowberg, David R [National Renewable Energy Laboratory (NREL), Golden, CO (United States); Berry, Derek S [National Renewable Energy Laboratory (NREL), Golden, CO (United States); Beach, Ryan [National Renewable Energy Laboratory (NREL), Golden, CO (United States); Rooney, Samantha A [National Renewable Energy Laboratory (NREL), Golden, CO (United States); Swan, Dana [Arkema Inc.

2017-12-06

Currently, wind turbine blades are manufactured from a combination of glass and/or carbon fiber composite materials with a thermoset resin such as epoxy, which requires energy-intensive and expensive heating processes to cure. Newly developed in-situ polymerizing thermoplastic resin systems for composite wind turbine blades polymerize at room temperature, eliminating the heating process and significantly reducing the blade manufacturing cycle time and embodied energy, which in turn reduces costs. Thermoplastic materials can also be thermally welded, eliminating the need for adhesive bonds between blade components and increasing the overall strength and reliability of the blades. As well, thermoplastic materials enable end-of-life blade recycling by reheating and decomposing the materials, which is a limitation of existing blade technology. This paper presents a manufacturing demonstration for a 9-m-long thermoplastic composite wind turbine blade. This blade was constructed in the Composites Manufacturing Education and Technology facility at the National Wind Technology Center at the National Renewable Energy Laboratory (NREL) using a vacuum-assisted resin transfer molding process. Johns Manville fiberglass and an Arkema thermoplastic resin called Elium were used. Additional materials included Armacell-recycled polyethylene terephthalate foam from Creative Foam and low-cost carbon- fiber pultruded spar caps (manufactured in collaboration with NREL, Oak Ridge National Laboratory, Huntsman, Strongwell, and Chomarat). This paper highlights the development of the thermoplastic resin formulations, including an additive designed to control the peak exothermic temperatures. Infusion and cure times of less than 3 hours are also demonstrated, highlighting the efficiency and energy savings associated with manufacturing thermoplastic composite blades.

Injection Molding of High Aspect Ratio Nanostructures

DEFF Research Database (Denmark)

Matschuk, Maria; Larsen, Niels Bent

We present a process for injection molding of 40 nm wide and >100 nm high pillars (pitch: 200 nm). We explored the effects of mold coatings and injection molding conditions on the replication quality of nanostructures in cyclic olefin copolymer. We found that optimization of molding parameters...

Phenolic Molding Compounds

Science.gov (United States)

Koizumi, Koji; Charles, Ted; de Keyser, Hendrik

Phenolic Molding Compounds continue to exhibit well balanced properties such as heat resistance, chemical resistance, dimensional stability, and creep resistance. They are widely applied in electrical, appliance, small engine, commutator, and automotive applications. As the focus of the automotive industry is weight reduction for greater fuel efficiency, phenolic molding compounds become appealing alternatives to metals. Current market volumes and trends, formulation components and its impact on properties, and a review of common manufacturing methods are presented. Molding processes as well as unique advanced techniques such as high temperature molding, live sprue, and injection/compression technique provide additional benefits in improving the performance characterisitics of phenolic molding compounds. Of special interest are descriptions of some of the latest innovations in automotive components, such as the phenolic intake manifold and valve block for dual clutch transmissions. The chapter also characterizes the most recent developments in new materials, including long glass phenolic molding compounds and carbon fiber reinforced phenolic molding compounds exhibiting a 10-20-fold increase in Charpy impact strength when compared to short fiber filled materials. The role of fatigue testing and fatigue fracture behavior presents some insight into long-term reliability and durability of glass-filled phenolic molding compounds. A section on new technology outlines the important factors to consider in modeling phenolic parts by finite element analysis and flow simulation.

Non-contact inline monitoring of thermoplastic CFRP tape quality using air-coupled ultrasound

Science.gov (United States)

Essig, W.; Fey, P.; Meiler, S.; Kreutzbruck, M.

2017-02-01

Beginning with the aerospace industry, fiber reinforced plastics have spread towards many applications such as automotive, civil engineering as well as sports and leisure articles. Their superior strength and stiffness to mass ratio made them the number one material for achieving high performance. Especially continuous fiber reinforced plastics allow for the construction of structures which are custom tailored to their mechanical loads by adjusting the paths of the fibers to the loading direction. The two main constituents of CFRP are carbon fibers and matrix. Two possibilities for matrix material exist: thermosetting and thermoplastic matrix. While thermosetting matrix may yield better properties with respect to thermal loads, thermoplasticity opens a wide range of applications due to weldability, shapeability, and compatibility to e.g. injection molded thermoplastic materials. Thin (0.1 mm) thermoplastic continuous fiber CFRP tapes with a width of 100 mm were examined using air-coupled ultrasound. Transducers were arranged in reflection as well as transmission setup. By slanted incidence of the ultrasound on the tape surface, guided waves were excited in the material in fiber direction and perpendicular to the fiber direction. Artificial defects - fiber cuts, matrix cuts, circular holes, low velocity impacts from tool drop, and sharp bends - were produced. Experiments on a stationary tape showed good detectability of all artificial defects by guided waves. Also the effects of variation in material properties, fiber volume content and fiber matrix adhesion being the most relevant, on guided wave propagation were examined, to allow for quality assessment. Guided wave measurements were supported by destructive analysis. Also an apparatus containing one endless loop of CFRP tape was constructed and built to simulate inline testing of CFRP tapes, as it would be employed in a CFRP tape production environment or at a CFRP tape processing facility. The influences of tape

Functional nanostructures on injection molded plastic

DEFF Research Database (Denmark)

Johansson, Alicia Charlotte; Søgaard, Emil; Andersen, Nis Korsgaard

Nanotechnology can be used to make inexpensive plastic parts with functional surfaces. The plastic parts can be molded using a standard injection molding process. The nanostructures are directly transferred from the surface of the molding tool to the surface of the molded plastic part during...

Glass fiber-reinforced thermoplastics for use in metal-free removable partial dentures: combined effects of fiber loading and pigmentation on color differences and flexural properties.

Science.gov (United States)

Tanimoto, Yasuhiro; Nagakura, Manamu; Nishiyama, Norihiro

2018-02-21

The purpose of this study was to investigate the combined effects of fiber loading and pigmentation on the color differences and flexural properties of glass fiber-reinforced thermoplastics (GFRTPs), for use in non-metal clasp dentures (NMCDs). The GFRTPs consisted mainly of E-glass fibers, a polypropylene matrix, and a coloring pigment: the GFRTPs with various fiber loadings (0, 10, and 20mass%) and pigmentations (0, 1, 2, and 4mass%) were fabricated by using an injection molding. The color differences of GFRTPs were measured based on the Commission Internationale de l'Eclairage (CIE) Lab color system, by comparing with a commercially available NMCD. The flexural properties of GFRTPs were evaluated by using a three-point bending test, according to International Standards Organization (ISO) specification number 20795-1. The visible colors of GFRTPs with pigment contents of 2mass% were acceptable for gingival color, and the glass fibers harmonized well with the resins. The ΔE* values of the GFRTPs with pigment contents of 2mass% obtained by using the CIE Lab system were lowest at all fiber loadings. For GFRTPs with fiber contents of 10 and 20mass% at 2mass% pigment content, these GFRTPs surpassed the ISO 20795-1 specification regarding flexural strength (> 60MPa) and modulus (> 1.5GPa). A combination of the results of color difference evaluation and mechanical examination indicates that the GFRTPs with fiber contents of 10 or 20mass%, and with pigment contents of 2mass% have acceptable esthetic appearance and sufficient rigidity for NMCDs. Copyright © 2018 Japan Prosthodontic Society. Published by Elsevier Ltd. All rights reserved.

Fast prototyping of injection molded polymer microfluidic chips

DEFF Research Database (Denmark)

Hansen, Thomas Steen; Selmeczi, David; Larsen, Niels Bent

2010-01-01

We present fast prototyping of injection molding tools by the definition of microfluidic structures in a light-curable epoxy (SU-8) directly on planar nickel mold inserts. Optimized prototype mold structures could withstand injection molding of more than 300 replicas in cyclic olefin copolymer (COC...

Effect of jute and kapok fibers on properties of thermoplastic cassava starch composites

International Nuclear Information System (INIS)

Prachayawarakorn, Jutarat; Chaiwatyothin, Sudarat; Mueangta, Suwat; Hanchana, Areeya

2013-01-01

Highlights: ► TPCS matrix was reinforced by the low (jute) and high (kapok) absorbency cellulosic fibers. ► Water absorption of the TPCS/jute and TPCS/kapok fiber composites decreases. ► Stress and Young’s modulus of the TPCS/jute and TPCS/kapok fiber composites increase. ► Thermal degradation temperature of the TPCS/kapok fiber composite decreases. - Abstract: Since mechanical properties and water uptake of biodegradable thermoplastic cassava starch (TPCS) was still the main disadvantages for many applications. The TPCS matrix was, therefore, reinforced by two types of cellulosic fibers, i.e. jute or kapok fibers; classified as the low and high oil absorbency characteristics, respectively. The TPCS, plasticized by glycerol, was compounded by internal mixer and shaped by compression molding machine. It was found that water absorption of the TPCS/jute fiber and TPCS/kapok fiber composites was clearly reduced by the addition of the cellulosic fibers. Moreover, stress at maximum load and Young’s modulus of the composites increased significantly by the incorporation of both jute and kapok fibers. Thermal degradation temperature, determined from thermogravimetric analysis (TGA), of the TPCS matrix increased by the addition of jute fibers; however, thermal degradation temperature decreased by the addition of kapok fibers. Functional group analysis and morphology of the TPCS/jute fiber and TPCS/kapok fiber composites were also examined using Fourier Transform Infrared Spectroscopy (FTIR) and Scanning Electron Microscopy (SEM) techniques

Numerical modeling of magnetic induction and heating in injection molding tools

DEFF Research Database (Denmark)

Guerrier, Patrick; Hattel, Jesper Henri

2013-01-01

the temperatures as close as possible to the cavity surface, by means of an integrated induction heating system in the injection molding tool, to improve the fluidity of the polymer melt hereby ensuring that the polymer melt will continue to flow until the mold cavity is completely filled. The presented work uses......Injection molding of parts with special requirements or features such as micro- or nanostructures on the surface, a good surface finish, or long and thin features results in the need of a specialized technique to ensure proper filling and acceptable cycle time. The aim of this study is to increase...

Thermogravimetric Characterization of the Microstructui Composition of Polyamide Injection Molded Denture Base Material vs Conventional Compression Molded Heat-cured Denture Base Material.

Science.gov (United States)

Al-Dharrab, Ayman; Shinawi, Lana

2016-02-01

Thermoplastic resin polymers are widely used in medicine due to their biostability and hypoallergenic properties, making them a possible alternative to poly-methylmethacrylate (PMMA). The current research examined the microstructure of a rapid injection molding system thermoplastic resin for construction of flexible denture compared with that of heat-cured PMMA. A total of 40 disk-shaped specimens (25 mm in diameter and 3 mm in thickness) were prepared and divided into two groups of 20 disks each (group I samples were of thermoplastic acrylic resin while group II was heat-cured PMMA resin). In group I, thermogravimetric analyzer showed that increasing the temperature up to 169°C resulted in about 1.3% of the material loss, and after that the material remains thermally stable up to 200°C. Group 11 showed 2.24% weight loss at 171°C, and further weight loss (12.025%) was observed on heating to 230°C. Fourier transform infrared (FTIR) spectrophotometer analysis in the range of 400-4000 cm(-1) detected the presence of an amine group (N-H) in group I samples and the presence of methylene group attached to inorganic Si as reinforcement filler (Si-CH3). Thermoplastic resin displayed excellent thermal stability and the absence of residual monomer within the polymerized material, suggesting its suitability for the fabrication dentures.

Nanostructuring steel for injection molding tools

International Nuclear Information System (INIS)

Al-Azawi, A; Smistrup, K; Kristensen, A

2014-01-01

The production of nanostructured plastic items by injection molding with ridges down to 400 nm in width, which is the smallest line width replicated from nanostructured steel shims, is presented. Here we detail a micro-fabrication method where electron beam lithography, nano-imprint lithography and ion beam etching are combined to nanostructure the planar surface of a steel wafer. Injection molded plastic parts with enhanced surface properties, like anti-reflective, superhydrophobic and structural colors can be achieved by micro- and nanostructuring the surface of the steel molds. We investigate the minimum line width that can be realized by our fabrication method and the influence of etching angle on the structure profile during the ion beam etching process. Trenches down to 400 nm in width have been successfully fabricated into a 316 type electro-polished steel wafer. Afterward a plastic replica has been produced by injection molding with good structure transfer fidelity. Thus we have demonstrated that by utilizing well-established fabrication techniques, nanostructured steel shims that are used in injection molding, a technique that allows low cost mass fabrication of plastic items, are produced. (paper)

Applications of thin carbon coatings and films in injection molding

Science.gov (United States)

Cabrera, Eusebio Duarte

In this research, the technical feasibility of two novel applications of thin carbon coatings is demonstrated. The first application consists of using thin carbon coatings on molds for molding ultra-thin plastic parts (graphene coating with carbide bonding to the mold surface. The coating resulted in a significant decrease of surface friction and consequently easiness of flow when compared to their uncoated counterparts. Thermoplastic polymers and their composites are a very attractive alternative but are hindered by the non-conductive nature of polymers. There are two general approaches used to date to achieve EMI shielding for plastic products. One is to spray a conductive metal coating onto the plastic surface forming a layer that must maintain its shielding effectiveness (SE), and its adhesion to the plastic throughout the expected life of the product. However, metal coatings add undesirable weight and tend to corrode over time. Furthermore, scratching the coating may create shielding failure; therefore, a protective topcoat may be required. The other approach is to use polymer composites filled with conductive fillers such as carbon black (CB), carbon nanofiber (CNF), and carbon nanotube (CNT). While conductive fillers may increase the electrical conductivity of polymer composites, the loading of such fillers often cannot reach a high level (painting using carbon black (CB). Such process can also be applied to injection molding for creating a top conductive layer. Increasing the amount of CB will increase the surface conductivity of the coated part, thus improving the paint transfer efficiency. However the CB levels needed to achieve the conductivity levels required for achieving EMI shielding would make the coating viscosity too large for proper coating. Nanopaper based composites are excellent candidates for EMI shielding because of the nanopaper's high concentration of carbon nanofibers (CNFs) (~2 wt% to 10 wt% depending on nanopaper/thermoplastic thickness

Green composites of thermoplastic corn starch and recycled paper cellulose fibers

Directory of Open Access Journals (Sweden)

Amnuay Wattanakornsiri

2011-08-01

Full Text Available Ecological concerns have resulted in a renewed interest in environmental-friendly composites issues for sustainabledevelopment as a biodegradable renewable resource. In this work we used cellulose fibers from recycled newspaper as reinforcementfor thermoplastic starch in order to improve its mechanical, thermal and water resistance properties. The compositeswere prepared from corn starch plasticized by glycerol (30% wt/wt of glycerol to starch as matrix that was reinforcedwith micro-cellulose fibers, obtained from used newspaper, with fiber content ranging from 0 to 8% (wt/wt of fibers to matrix.Physical properties of composites were determined by mechanical tensile tests, differential scanning calorimetry, thermogravimetricanalysis, water absorption measurement and scanning electron microscopy. The results showed that higherfibers content raised the tensile strength and elastic modulus up to 175% and 292%, respectively, when compared to thenon-reinforced thermoplastic starch. The addition of the fibers improved the thermal resistance and decreased the waterabsorption up to 63%. Besides, scanning electron microscopy illustrated a good adhesion between matrix and fibers. Theseresults indicated that thermoplastic starch reinforced with recycled newspaper cellulose fibers could be fruitfully used ascommodity plastics being strong, cheap, abundant and recyclable.

Influence of mold temperature associated with glass fiber on the mechanical and thermal properties of a (PA6/GF/MMT) nanocomposite

International Nuclear Information System (INIS)

Damiani, Renato Adriano

2017-01-01

This work describes the second of a series of studies of the effects of injection molding conditions on the mechanical and thermal properties of Polyamide 6/Glass Fiber/Montmorillonite (PA6/GF/MMT) composites and was motivated by the lack of information about how the processing variables influence on the properties of three-phase composites containing fiber glass. By this time, the effects of the injection molding temperature associated with the fiber glass percentage on the mechanical and thermal properties of the composite are investigated. Some samples were processed, following a statistical experimental factorial planning, varying the mold temperature and the fiber glass percentage and maintaining 5 wt % of the MMT. The samples were submitted to tensile and flexural tests, XRD, SEM and DSC. The studies showed that an increase in the mold temperature and the fiber percentage improves the maximum tensile and flexural stresses. The increased mold temperature slows the cooling rate, which, over time, decreases the degree of crystallinity. However, there is an increase in the intercalation of the polymeric chains and the nanoclay lamellae, and the structure forms with fewer defects. (author)

Influence of mold temperature associated with glass fiber on the mechanical and thermal properties of a (PA6/GF/MMT) nanocomposite

Energy Technology Data Exchange (ETDEWEB)

Damiani, Renato Adriano, E-mail: eng.damiani@hotmail.com [Universidade do Extremo Sul Catarinense (UNESC), Criciuma, SC (Brazil). Programa de Pos-Graduacao em Ciencias e Engenharia de Materiais; Duarte, Glaucea Warmeling; Riella, Humberto Gracher, E-mail: gwduarte@gmail.com, E-mail: huberto.riella@ufsc.br [Universidade Federal de Santa Catarina (UFSC), Florianopolis, SC (Brazil). Programa de Pos-Graduacao em Engenharia Quimica; Silva, Luciano Luiz; Mello, Josiane Maria Muneron de; Fiori, Marcio Antonio; Batiston, Eduardo Roberto, E-mail: marciofiori@gmail.com, E-mail: lucianols@unochapeco.edu.br, E-mail: josimello@unochapeco.edu.br, E-mail: erbatiston@unochapeco.edu.br [Universidade Comunitaria da Regiao de Chapeco (UNOCHAPECO), Chapeco, SC (Brazil)

2017-01-15

This work describes the second of a series of studies of the effects of injection molding conditions on the mechanical and thermal properties of Polyamide 6/Glass Fiber/Montmorillonite (PA6/GF/MMT) composites and was motivated by the lack of information about how the processing variables influence on the properties of three-phase composites containing fiber glass. By this time, the effects of the injection molding temperature associated with the fiber glass percentage on the mechanical and thermal properties of the composite are investigated. Some samples were processed, following a statistical experimental factorial planning, varying the mold temperature and the fiber glass percentage and maintaining 5 wt % of the MMT. The samples were submitted to tensile and flexural tests, XRD, SEM and DSC. The studies showed that an increase in the mold temperature and the fiber percentage improves the maximum tensile and flexural stresses. The increased mold temperature slows the cooling rate, which, over time, decreases the degree of crystallinity. However, there is an increase in the intercalation of the polymeric chains and the nanoclay lamellae, and the structure forms with fewer defects. (author)

Prediction of Mold Spoilage for Soy/Polyethylene Composite Fibers

Directory of Open Access Journals (Sweden)

Chinmay Naphade

2015-01-01

Full Text Available Mold spoilage was determined over 109 days on soy/PE fibers held under controlled temperatures (T ranging from 10°C to 40°C and water activities (aw from 0.11 to 0.98. Water activities were created in sealed containers using saturated salt solutions and placed in temperature-controlled incubators. Soy/PE fibers that were held at 0.823 aw or higher exhibited mold growth at all temperatures. As postulated, increased water activity (greater than 0.89 and temperature (higher than 25°C accelerated mold growth on soy/PE fibers. A slower mold growth was observed on soy/PE fibers that were held at 0.87 aw and 10°C. A Weibull model was employed to fit the observed logarithmic values of T, aw, and an interaction term log⁡T×log⁡aw and was chosen as the final model as it gave the best fit to the raw mold growth data. These growth models predict the expected mold-free storage period of soy/PE fibers when exposed to various environmental temperatures and humidities.

Structural Reorganization of CNC in Injection-Molded CNC/PBAT Materials under Thermal Annealing.

Science.gov (United States)

Mariano, Marcos; El Kissi, Nadia; Dufresne, Alain

2016-10-04

Composite materials were prepared by extrusion and injection molding from polybutyrate adipate terephthalate (PBAT) and high aspect ratio cellulose nanocrystals (CNCs) extracted from capim dourado fibers. Three CNC contents were used, corresponding to 0.5, 1, and 2 times the theoretical percolation threshold. Small-amplitude oscillary shear (SAOS) experiments show that as the CNC content increases, a more elastic behavior is observed but no percolating network can form within the polymeric matrix as a result of the high shear rates involved during the injection-molding process. Annealing of the samples at 170 °C was performed, and the possible reorganization of the nanofiller was investigated. This reorganization was further elucidated using 2D-SAOS and creep experiments.

Resin Flow in Fiber Preformed by Vacuum Assisted Resin Transfer Molding with Flexible Tools

Directory of Open Access Journals (Sweden)

M.M. Shokrieh

2008-12-01

Full Text Available Vacuum assisted resin transfer molding, as a sub-branch of RTM is a method of manufacturing composite specimens. Considering the industrial development of this method, different modified techniques are designed to improve its performance. Among these techniques, using a half flexible mold is regarded as an important method. In this work, dominant equations of resin flow through the mold in polar coordinates are solved analytically. Based on this approach, closed-form solutions have been presented for different parameters such as thickness variation of preformed fiber, resin pressure, resin velocity and fiber volume fraction as functions of two variables, namely, time and the distance from injection port. After verification of the approach employed in this work, the results are presented. Important parameters influencing the quality and the rate production are studied in detail.

Injection molded self-cleaning surfaces

DEFF Research Database (Denmark)

Søgaard, Emil

that are superhydrophobic based on topography rather than chemical compounds. Therefore, a novel method for fabricating superhydrophobic polymer surfaces with excellent water-repellant properties is developed. The method is based on microstructure fabrication and superposed nanostructures on silicon wafers. The nano......- and microstructured silicon is electroplated with nickel and the resulting nickel shim with inverse polarity is used in an injection molding process. A versatile injection molding process capable of producing different nano- and microstructures on areas larger than 10 cm2 is developed. Variotherm mold heating is used...... hierarchical structures with nanograss and holes. Water wetting tests are carried out using a pressure cell to control the water pressure. Microscopic wetting behavior of the structures is studied by optical transmission microscopy. Interestingly, it is found that the surface chemistry of the polymer changes...

Behavioral variation by ionizing irradiation of recycled thermoplastic elastomer reinforced with natural fibers or inorganic fillers

International Nuclear Information System (INIS)

Mohamed, H.A.A.

2015-01-01

Plastics are organic polymeric materials consisting of giant organic molecules. Plastic materials can be formed into shapes by one of a variety of processes, such as extrusion, molding, casting or spinning. Modern plastics possess a number of extremely desirable characteristics; high strength to weight ratio, excellent thermal properties, electrical insulation, resistance to acids, alkalis and solvents. These polymers are made of a series of repeating units known as monomers. The structure and degree of polymerisation of a given polymer determine its characteristics. Linear polymers, a single linear chain of monomers, and branched polymers, linear with side chains, are thermoplastic that is they soften when heated. Thermoplastics make up 80% of the plastics produced today. Examples of thermoplastics include: • High density polyethylene (HDPE) used in piping, automotive fuel tanks, bottles, toys, • Low density polyethylene (LDPE) used in plastic bags, cling film, flexible containers; • Polyethylene terephthalate (PET) used in bottles, carpets and food packaging; • Polypropylene (PP) used in food containers, battery cases, bottle crates, automotive parts and fibers; • Polystyrene (PS) used in dairy product containers, tape cassettes, cups and plates; • Polyvinyl chloride (PVC) used in window frames, flooring, bottles, packaging film, cable insulation, credit cards and medical products.

Surface microstructure replication in injection molding

DEFF Research Database (Denmark)

Theilade, Uffe Arlø; Hansen, Hans Nørgaard

2006-01-01

topography is transcribed onto the plastic part through complex mechanisms. This replication, however, is not perfect, and the replication quality depends on the plastic material properties, the topography itself, and the process conditions. This paper describes and discusses an investigation of injection...... molding of surface microstructures. The fundamental problem of surface microstructure replication has been studied. The research is based on specific microstructures as found in lab-on-a-chip products and on rough surfaces generated from EDM (electro discharge machining) mold cavities. Emphasis is put...... on the ability to replicate surface microstructures under normal injection-molding conditions, i.e., with commodity materials within typical process windows. It was found that within typical process windows the replication quality depends significantly on several process parameters, and especially the mold...

An improved compression molding technology for continuous fiber reinforced composite laminate. Part 1: AS-4/LaRC-TPI 1500 (HFG) Prepreg system

Science.gov (United States)

Hou, Tan-Hung; Kidder, Paul W.; Reddy, Rakasi M.

1991-01-01

Poor processability of fiber reinforced high performance polyimide thermoplastic resin composites is a well recognized issue which, in many cases, prohibits the fabrication of composite parts with satisfactorily consolidated quality. Without modifying the resin matrix chemistry, improved compression modeling procedures were proposed and investigated with the AS-4/LaRC-TPI 1500 High Flow Grade (HFG) prepreg system. Composite panels with excellent C-scans can be consistently molded by this method under 700 F and a consolidation pressure as low as 100 psi. A mechanism for the consolidation of the composite under this improved molding technique is discussed. This mechanism reveals that a certain degree of matrix shear and tow filament slippage and nesting between plies occur during consolidation, which leads to a reduction of the consolidating pressure necessary to offset the otherwise intimate inter fiber-fiber contact and consequently achieves a better consolidation quality. Outstanding short beam shear strength and flexural strength were obtained from the molded panels. A prolonged consolidation step under low pressure, i.e., 100 psi at 700 F for 75 minutes, was found to significantly enhance the composite mechanical properties.

Long-term performance of thermoplastic composite material with cotton burr and stem (CBS) as a partial filler

Science.gov (United States)

Rationale: Cotton burr and stem (CBS) fraction of cotton gin byproducts has shown promise as a fiber filler in thermoplastic composites, with physical and mechanical properties comparable to that made with wood fiber fillers. However, the long-term performance of this composite material is not known...

Wood thermoplastic composites

Science.gov (United States)

Daniel F. Caulfield; Craig Clemons; Roger M. Rowell

2010-01-01

The wood industry can expand into new sustainable markets with the formation of a new class of composites with the marriage of the wood industry and the plastics industry. The wood component, usually a flour or fiber, is combined with a thermoplastic to form an extrudable, injectable or thermoformable composite that can be used in many non-structural applications....

Three-dimensional numerical simulation for plastic injection-compression molding

Science.gov (United States)

Zhang, Yun; Yu, Wenjie; Liang, Junjie; Lang, Jianlin; Li, Dequn

2018-03-01

Compared with conventional injection molding, injection-compression molding can mold optical parts with higher precision and lower flow residual stress. However, the melt flow process in a closed cavity becomes more complex because of the moving cavity boundary during compression and the nonlinear problems caused by non-Newtonian polymer melt. In this study, a 3D simulation method was developed for injection-compression molding. In this method, arbitrary Lagrangian- Eulerian was introduced to model the moving-boundary flow problem in the compression stage. The non-Newtonian characteristics and compressibility of the polymer melt were considered. The melt flow and pressure distribution in the cavity were investigated by using the proposed simulation method and compared with those of injection molding. Results reveal that the fountain flow effect becomes significant when the cavity thickness increases during compression. The back flow also plays an important role in the flow pattern and redistribution of cavity pressure. The discrepancy in pressures at different points along the flow path is complicated rather than monotonically decreased in injection molding.

Progress in Titanium Metal Powder Injection Molding

Directory of Open Access Journals (Sweden)

Randall M. German

2013-08-01

Full Text Available Metal powder injection molding is a shaping technology that has achieved solid scientific underpinnings. It is from this science base that recent progress has occurred in titanium powder injection molding. Much of the progress awaited development of the required particles with specific characteristics of particle size, particle shape, and purity. The production of titanium components by injection molding is stabilized by a good understanding of how each process variable impacts density and impurity level. As summarized here, recent research has isolated the four critical success factors in titanium metal powder injection molding (Ti-MIM that must be simultaneously satisfied—density, purity, alloying, and microstructure. The critical role of density and impurities, and the inability to remove impurities with sintering, compels attention to starting Ti-MIM with high quality alloy powders. This article addresses the four critical success factors to rationalize Ti-MIM processing conditions to the requirements for demanding applications in aerospace and medical fields. Based on extensive research, a baseline process is identified and reported here with attention to linking mechanical properties to the four critical success factors.

Rapid control of mold temperature during injection molding process

Energy Technology Data Exchange (ETDEWEB)

Liparoti, Sara; Titomanlio, Giuseppe [Department of Industrial Engineering, University of Salerno Via Giovanni Paolo II, 132, 84084 Fisciano (Italy); Hunag, Tsang Min; Cakmak, Mukerrem [Department of Polymer Engineering, The University of Akron, Akron, OH 44325 (United States); Sorrentino, Andrea [Institute for Polymers, Composite and Biomaterials (IPCB) - CNR, P. Enrico Fermi 1, 80055 Portici (Italy)

2015-05-22

The control of mold surface temperature is an important factor that determines surface morphology and its dimension in thickness direction. It can also affect the frozen molecular orientation and the mold surface replicability in injection molded products. In this work, thin thermally active films were used to quickly control the mold surface temperature. In particular, an active high electrical conductivity carbon black loaded polyimide composites sandwiched between two insulating thin polymeric layers was used to condition the mold surface. By controlling the heating time, it was possible to control precisely the temporal variation of the mold temperature surface during the entire cycle. The surface heating rate was about 40°C/s and upon contact with the polymer the surface temperature decreased back to 40°C within about 5 s; the overall cycle time increased only slightly. The effect on cross section sample morphology of samples of iPP were analyzed and discussed on the basis of the recorded temperature evolution.

Rapid and Low-cost Prototyping of Medical Devices Using 3D Printed Molds for Liquid Injection Molding

Science.gov (United States)

Chung, Philip; Heller, J. Alex; Etemadi, Mozziyar; Ottoson, Paige E.; Liu, Jonathan A.; Rand, Larry; Roy, Shuvo

2014-01-01

Biologically inert elastomers such as silicone are favorable materials for medical device fabrication, but forming and curing these elastomers using traditional liquid injection molding processes can be an expensive process due to tooling and equipment costs. As a result, it has traditionally been impractical to use liquid injection molding for low-cost, rapid prototyping applications. We have devised a method for rapid and low-cost production of liquid elastomer injection molded devices that utilizes fused deposition modeling 3D printers for mold design and a modified desiccator as an injection system. Low costs and rapid turnaround time in this technique lower the barrier to iteratively designing and prototyping complex elastomer devices. Furthermore, CAD models developed in this process can be later adapted for metal mold tooling design, enabling an easy transition to a traditional injection molding process. We have used this technique to manufacture intravaginal probes involving complex geometries, as well as overmolding over metal parts, using tools commonly available within an academic research laboratory. However, this technique can be easily adapted to create liquid injection molded devices for many other applications. PMID:24998993

Effect of processing conditions on shrinkage in injection moulding

NARCIS (Netherlands)

Jansen, K.M.B.; van Dijk, D.J.; Husselman, M.H.

1998-01-01

A systematic study on the effect of processing conditions on mold shrinkage was undertaken for seven common thermoplastic polymers. It turned out that the holding pressure was always the key parameter. The effect of the melt temperature is slightly less important. Injection velocity and mold

Hydrophobicity Tuning by the Fast Evolution of Mold Temperature during Injection Molding

Directory of Open Access Journals (Sweden)

Sara Liparoti

2018-03-01

Full Text Available The surface topography of a molded part strongly affects its functional properties, such as hydrophobicity, cleaning capabilities, adhesion, biological defense and frictional resistance. In this paper, the possibility to tune and increase the hydrophobicity of a molded polymeric part was explored. An isotactic polypropylene was injection molded with fast cavity surface temperature evolutions, obtained adopting a specifically designed heating system layered below the cavity surface. The surface topology was characterized by atomic force microscopy (AFM and, concerning of hydrophobicity, by measuring the water static contact angle. Results show that the hydrophobicity increases with both the temperature level and the time the cavity surface temperature was kept high. In particular, the contact angle of the molded sample was found to increase from 90°, with conventional molding conditions, up to 113° with 160 °C of cavity surface temperature kept for 18 s. This increase was found to be due to the presence of sub-micro and nano-structures characterized by high values of spatial frequencies which could be more accurately replicated by adopting high heating temperatures and times. The surface topography and the hydrophobicity resulted therefore tunable by selecting appropriate injection molding conditions.

Design and Checking Analysis of Injection Mold for a Plastic Cup

Science.gov (United States)

Li, Xuebing

2018-03-01

A special injection mold was designed for the structural characteristics of a plastic cup part. The mold was simulated by Moldflow software and verified by calculating the stripping force, the pulling force and the clamping force of the mold so that to determine the appropriate injection parameters. It has been proved that the injection mold is effective and practical in the actual producing and can meet the quality requirements during the course of using it, which solved some problems for injection molding of this kind of parts and can provide some reference for the production of other products in the same industry.

Deformation analysis considering thermal expansion of injection mold

International Nuclear Information System (INIS)

Kim, Jun Hyung; Yi, Dae Eun; Jang, Jeong Hui; Lee, Min Seok

2015-01-01

In the design of injection molds, the temperature distribution and deformation of the mold is one of the most important parameters that affect the flow characteristics, flash generation, and surface appearance, etc. Plastic injection analyses have been carried out to predict the temperature distribution of the mold and the pressure distribution on the cavity surface. As the input loads, we transfer the temperature and pressure results to the structural analysis. We compare the structural analysis results with the thermal expansion effect using the actual flash and step size of a smartphone cover part. To reduce the flash problem, we proposed a new mold design, and verified the results by performing simulations

Deformation analysis considering thermal expansion of injection mold

Energy Technology Data Exchange (ETDEWEB)

Kim, Jun Hyung; Yi, Dae Eun; Jang, Jeong Hui; Lee, Min Seok [Samsung Electronics Co., LTD., Seoul (Korea, Republic of)

2015-09-15

In the design of injection molds, the temperature distribution and deformation of the mold is one of the most important parameters that affect the flow characteristics, flash generation, and surface appearance, etc. Plastic injection analyses have been carried out to predict the temperature distribution of the mold and the pressure distribution on the cavity surface. As the input loads, we transfer the temperature and pressure results to the structural analysis. We compare the structural analysis results with the thermal expansion effect using the actual flash and step size of a smartphone cover part. To reduce the flash problem, we proposed a new mold design, and verified the results by performing simulations.

Process and part filling control in micro injection molding

DEFF Research Database (Denmark)

Tosello, Guido; Hansen, Hans Nørgaard; Schoth, Andreas

2008-01-01

The influence of process parameters on μ-injection molding (μIM) and on μ-injection molded parts has been investigated using Design of Experiments. A mold with a sensor applied at injection location was used to monitor actual injection pressure and to determine the cavity filling time. Flow markers...... position was measured on the polymer μ-parts to evaluate filling behavior of the polymer melt flowing through μ-features. Experimental results obtained under different processing conditions were evaluated to correlate the process parameter levels influence on the selected responses. Results showed...... that the injection speed in one of the most influencing process parameters on the μIM process and on the μ-parts filling....

The effect of α-cellulose fiber on the properties of melamine-formaldehyde molding compounds

International Nuclear Information System (INIS)

Khatibi, M. A.; Beheshti, M. A.; Morshedian, J.

2001-01-01

Melamine-formaldehyde molding compounds have found different industrial applications. This is due to their good mechanical properties such as hardness, gloss and high modulus and strength. One of the major components of these compounds is α-cellulose fiber and has a major effect on the mechanical properties. Although this fiber is being used in these compounds for a long time, there is not much data available of α-cellulose fibers on the physical and mechanical properties of melamine-formaldehyde molding compounds being investigated. Results show that although the microstructures of these two fibers are quite different from each other, but they do not have any effect on the mechanical properties of the molding. Whereas, it has a significant effect on the wettability (processing condition) and glossiness of the mol dings. Since this latter property is very important in house wares applications, the darker mol dings can not be used in domestic applications

Two component micro injection molding for MID fabrication

DEFF Research Database (Denmark)

Islam, Mohammad Aminul; Hansen, Hans Nørgaard; Tang, Peter Torben

2009-01-01

Molded Interconnect Devices (MIDs) are plastic substrates with electrical infrastructure. The fabrication of MIDs is usually based on injection molding and different process chains may be identified from this starting point. The use of MIDs has been driven primarily by the automotive sector......, but recently the medical sector seems more and more interested. In particular the possibility of miniaturization of 3D components with electrical infrastructure is attractive. The paper describes possible manufacturing routes and challenges of miniaturized MIDs based on two component micro injection molding...

Durability-Based Design Criteria for a Quasi-Isotropic Carbon-Fiber-Reinforced Thermoplastic Automotive Composite

Energy Technology Data Exchange (ETDEWEB)

Naus, Dan J [ORNL; Corum, James [ORNL; Klett, Lynn B [ORNL; Davenport, Mike [ORNL; Battiste, Rick [ORNL; Simpson, Jr., William A [ORNL

2006-04-01

This report provides recommended durability-based design properties and criteria for a quais-isotropic carbon-fiber thermoplastic composite for possible automotive structural applications. The composite consisted of a PolyPhenylene Sulfide (PPS) thermoplastic matrix (Fortron's PPS - Ticona 0214B1 powder) reinforced with 16 plies of carbon-fiber unidirectional tape, [0?/90?/+45?/-45?]2S. The carbon fiber was Hexcel AS-4C and was present in a fiber volume of 53% (60%, by weight). The overall goal of the project, which is sponsored by the U.S. Department of Energy's Office of Freedom Car and Vehicle Technologies and is closely coordinated with the Advanced Composites Consortium, is to develop durability-driven design data and criteria to assure the long-term integrity of carbon-fiber-based composite systems for automotive structural applications. This document is in two parts. Part 1 provides design data and correlations, while Part 2 provides the underlying experimental data and models. The durability issues addressed include the effects of short-time, cyclic, and sustained loadings; temperature; fluid environments; and low-energy impacts (e.g., tool drops and kickups of roadway debris) on deformation, strength, and stiffness. Guidance for design analysis, time-independent and time-dependent allowable stresses, rules for cyclic loadings, and damage-tolerance design guidance are provided.

Nanostructuring steel for injection molding tools

DEFF Research Database (Denmark)

Al-Azawi, A.; Smistrup, Kristian; Kristensen, Anders

2014-01-01

The production of nanostructured plastic items by injection molding with ridges down to 400 nm in width, which is the smallest line width replicated from nanostructured steel shims, is presented. Here we detail a micro-fabrication method where electron beam lithography, nano-imprint lithography...... and ion beam etching are combined to nanostructure the planar surface of a steel wafer. Injection molded plastic parts with enhanced surface properties, like anti-reflective, superhydrophobic and structural colors can be achieved by micro-and nanostructuring the surface of the steel molds. We investigate...... the minimum line width that can be realized by our fabrication method and the influence of etching angle on the structure profile during the ion beam etching process. Trenches down to 400 nm in width have been successfully fabricated into a 316 type electro-polished steel wafer. Afterward a plastic replica...

Injection Molding Parameters Calculations by Using Visual Basic (VB) Programming

Science.gov (United States)

Tony, B. Jain A. R.; Karthikeyen, S.; Alex, B. Jeslin A. R.; Hasan, Z. Jahid Ali

2018-03-01

Now a day’s manufacturing industry plays a vital role in production sectors. To fabricate a component lot of design calculation has to be done. There is a chance of human errors occurs during design calculations. The aim of this project is to create a special module using visual basic (VB) programming to calculate injection molding parameters to avoid human errors. To create an injection mold for a spur gear component the following parameters have to be calculated such as Cooling Capacity, Cooling Channel Diameter, and Cooling Channel Length, Runner Length and Runner Diameter, Gate Diameter and Gate Pressure. To calculate the above injection molding parameters a separate module has been created using Visual Basic (VB) Programming to reduce the human errors. The outcome of the module dimensions is the injection molding components such as mold cavity and core design, ejector plate design.

Inexpensive 3dB coupler for POF communication by injection-molding production

Science.gov (United States)

Haupt, M.; Fischer, U. H. P.

2011-01-01

POFs (polymer optical fibers) gradually replace traditional communication media such as copper and glass within short distance communication systems. Primarily, this is due to their cost-effectiveness and easy handling. POFs are used in various fields of optical communication, e.g. the automotive sector or in-house communication. So far, however, only a few key components for a POF communication network are available. Even basic components, such as splices and couplers, are fabricated manually. Therefore, these circumstances result in high costs and fluctuations in components' performance. Available couplers have high insertion losses due to their manufacturing method. This can only be compensated by higher power budgets. In order to produce couplers with higher performances new fabrication methods are indispensable. A cheap and effective way to produce couplers for POF communication systems is injection molding. The paper gives an overview of couplers available on market, compares their performances, and shows a way to produce couplers by means of injection molding.

Optical Characterization of Doped Thermoplastic and Thermosetting Polymer-Optical-Fibers

Directory of Open Access Journals (Sweden)

Igor Ayesta

2017-03-01

Full Text Available The emission properties of a graded-index thermoplastic polymer optical fiber and a step-index thermosetting one, both doped with rhodamine 6G, have been studied. The work includes a detailed analysis of the amplified spontaneous emission together with a study of the optical gains and losses of the fibers. The photostability of the emission of both types of fibers has also been investigated. Comparisons between the results of both doped polymer optical fibers are presented and discussed.

Study of injection moulded long glass fibre-reinforced polypropylene and the effect on the fibre length and orientation distribution

Science.gov (United States)

Parveeen, B.; Caton-Rose, P.; Costa, F.; Jin, X.; Hine, P.

2014-05-01

Long glass fibre (LGF) composites are extensively used in manufacturing to produce components with enhanced mechanical properties. Long fibres with length 12 to 25mm are added to a thermoplastic matrix. However severe fibre breakage can occur in the injection moulding process resulting in shorter fibre length distribution (FLD). The majority of this breakage occurs due to the melt experiencing extreme shear stress during the preparation and injection stage. Care should be taken to ensure that the longer fibres make it through the injection moulding process without their length being significantly degraded. This study is based on commercial 12 mm long glass-fibre reinforced polypropylene (PP) and short glass fibre Nylon. Due to the semi-flexiable behaviour of long glass fibres, the fibre orientation distribution (FOD) will differ from the orientation distribution of short glass fibre in an injection molded part. In order to investigate the effect the change in fibre length has on the fibre orientation distribution or vice versa, FOD data was measured using the 2D section image analyser. The overall purpose of the research is to show how the orientation distribution chnages in an injection moulded centre gated disc and end gated plaque geometry and to compare this data against fibre orientation predictions obtained from Autodesk Moldflow Simulation Insight.

Injection molding of high aspect ratio sub-100 nm nanostructures

DEFF Research Database (Denmark)

Matschuk, Maria; Larsen, Niels B

2013-01-01

We have explored the use of mold coatings and optimized processing conditions to injection mold high aspect ratio nanostructures (height-to-width >1) in cyclic olefin copolymer (COC). Optimizing the molding parameters on uncoated nickel molds resulted in slight improvements in replication quality...... as described by height, width and uniformity of the nanoscopic features. Use of a mold temperature transiently above the polymer glass transition temperature (Tg) was the most important factor in increasing the replication fidelity. Surface coating of the nickel molds with a fluorocarbon-containing thin film...... (FDTS) greatly enhanced the quality of replicated features, in particular at transient mold temperatures above Tg. Injection molding using the latter mold temperature regime resulted in a bimodal distribution of pillar heights, corresponding to either full or very poor replication of the individual...

Effect of Functional Nano Channel Structures Different Widths on Injection Molding and Compression Molding Replication Capabilities

DEFF Research Database (Denmark)

Calaon, M.; Tosello, G.; Garnaes, J.

The present study investigates the capabilities of the two employed processes, injection molding (IM) and injection compression molding (ICM) on replicating different channel cross sections. Statistical design of experiment was adopted to optimize replication quality of produced polymer parts wit...

UTILIZATION OF MICRO SISAL FIBERS AS REINFORCEMENT AGENT AND POLYPROPYLENE OR POLYLACTIC ACID AS POLYMER MATRICES IN BIOCOMPOSITES MANUFACTURE

Directory of Open Access Journals (Sweden)

Subyakto Subyakto

2013-06-01

Full Text Available Sisal (Agave sisalana as a perennial tropical plant grows abundantly in Indonesia. Its fibers can be used as the reinforcement agent of biocomposite products. Utilization of sisal as natural fiber has some notable benefits compared to synthetic fibers, such as renewable, light in weight, and low in cost. Manufacture of biocomposite requires the use of matrix such as thermoplastic polymer, e.g. polypropylene (PP and polylactic acid (PLA to bond together with the reinforcement agent (e.g. sisal fibers. In relevant, experiment was conducted on biocomposites manufacture that comprised sisal fibers and PP as well as PLA. Sisal fibers were converted into pulp, then refined to micro-size fibrillated fibers such that their diameter reduced to about 10 μm, and dried in an oven. The dry microfibrillated sisal pulp fibers cellulose (MSFC were thoroughly mixed with either PP or PLA with varying ratios of MSFC/PP as well as MSFC/PLA, and then shaped into the mat (i.e. MSFC-PP and MSFC-PLA biocomposites. Two kinds of shaping was employed, i.e. hot-press molding and injection molding. In the hot-press molding, the ratio of  MSFC/PP as well as MSFC/PLA ranged about 30/70-50/50. Meanwhile in the injection (employed only on assembling the MSFC-PLA biocomposite, the ratio of MSFC/PLA varied about 10/90-30/70. The resulting shaped MSFC-PP and MSFC-PLA biocomposites were then tested of its physical and mechanical properties. With the hot-press molding device, the physical and mechanical (strength properties of MSFC-PLA biocomposite were higher than those of  MSFC-PP biocomposite. The optimum ratio of  MSFC/PP as well as MSFC/PLA reached concurrently at 40/60. The strengths of MSFC-PP as well as MSFC-PLA biocomposites were greater than those of individual polymer (PP and PLA. With the injection molding device, only the MSFC-PLA  biocomposite  was formed  and its strengths  reached  maximum  at 30/70  ratio.  The particular strengths (MOR and MOE of MSFC

CO2-laser-assisted processing of glass fiber-reinforced thermoplastic composites

Science.gov (United States)

Brecher, Christian; Emonts, Michael; Schares, Richard Ludwig; Stimpfl, Joffrey

2013-02-01

To fully exploit the potential of fiber-reinforced thermoplastic composites (FRTC) and to achieve a broad industrial application, automated manufacturing systems are crucial. Investigations at Fraunhofer IPT have proven that the use of laser system technology in processing FRTC allows to achieve high throughput, quality, flexibility, reproducibility and out-of-autoclave processing simultaneously. As 90% of the FRP in Europe1 are glass fiber-reinforced a high impact can be achieved by introducing laser-assisted processing with all its benefits to glass fiber-reinforced thermoplastics (GFRTC). Fraunhofer IPT has developed the diode laser-assisted tape placement (laying and winding) to process carbon fiber-reinforced thermoplastic composites (CFRTC) for years. However, this technology cannot be transferred unchanged to process milky transparent GFRTC prepregs (preimpregnated fibers). Due to the short wavelength (approx. 980 nm) and therefore high transmission less than 20% of the diode laser energy is absorbed as heat into non-colored GFRTC prepregs. Hence, the use of a different wave length, e.g. CO2-laser (10.6 μm) with more than 90% laser absorption, is required to allow the full potential of laser-assisted processing of GFRTC. Also the absorption of CO2-laser radiation at the surface compared to volume absorption of diode laser radiation is beneficial for the interlaminar joining of GFRTC. Fraunhofer IPT is currently developing and investigating the CO2-laser-assisted tape placement including new system, beam guiding, process and monitoring technology to enable a resource and energy efficient mass production of GFRP composites, e.g. pipes, tanks, masts. The successful processing of non-colored glass fiber-reinforced Polypropylene (PP) and Polyphenylene Sulfide (PPS) has already been proven.

Multi-height structures in injection molded polymer

DEFF Research Database (Denmark)

Andersen, Nis Korsgaard; Taboryski, Rafael J.

2015-01-01

of different geometries, and electroforming a nickel mold from a polymer foil. The injection-molded samples are characterized by contact angle hysteresis obtained by the tilting method. We find that the receding contact angle depends on the surface coverage of the random surface structure, while the advancing...

Production application of injection-molded diffractive elements

Science.gov (United States)

Clark, Peter P.; Chao, Yvonne Y.; Hines, Kevin P.

1995-12-01

We demonstrate that transmission kinoforms for visible light applications can be injection molded in acrylic in production volumes. A camera is described that employs molded Fresnel lenses to change the convergence of a projection ranging system. Kinoform surfaces are used in the projection system to achromatize the Fresnel lenses.

Effect of injection molding parameters on nanofillers dispersion in masterbatch based PP-clay nanocomposites

Directory of Open Access Journals (Sweden)

J. Soulestin

2012-03-01

Full Text Available The effect of injection molding parameters (screw rotational speed, back pressure, injec-tion flow rate and holding pressure on the nanofiller dispersion of melt-mixed PP/clay nanocomposites was investigated. The nanocomposites containing 4 wt% clay were obtained by dilution of a PP/clay masterbatch into a PP matrix. The evaluation of the dispersion degree was obtained from dynamic rheological measurements. The storage modulus and complex viscosity exhibit significant dependence on the injection molding parameters. PP/clay nanocomposite molded using more severe injection parameters (high shear and long residence time displays the highest storage modulus and complex viscosity, which illustrates the improved dispersion of clay platelets. This better dispersion leads to better mechanical properties particularly higher Young modulus, tensile strength and unnotched impact strength. A Taguchi analysis was used to identify the influence of individual process parameters. The major individual parameter is the injection flow rate, whose increase improves nanoclay dispersion. The combination of high back pressure and high screw rotational speed is also necessary to optimize the dispersion of clay nanoplatelets.

Injection molded polymeric hard X-ray lenses

DEFF Research Database (Denmark)

Stöhr, Frederik; Simons, Hugh; Jakobsen, Anders Clemen

2015-01-01

of the etching profile and were removed after DRIE. By electroplating, an inverse nickel sample was obtained, which was used as a mold insert in a commercial polymer injection molding machine. A prototype lens made of polyethylene with a focal length of 350 mm was tested using synchrotron radiation at photon...

Ultrasonic assisted consolidation of commingled thermoplastic/glass fibers rovings

Directory of Open Access Journals (Sweden)

Francesca eLionetto

2015-04-01

Full Text Available Thermoplastic matrix composites are finding new applications in different industrial area thanks to their intrinsic advantages related to environmental compatibility and processability. The approach presented in this work consists in the development of a technology for the simultaneous deposition and consolidation of commingled thermoplastic rovings through to the application of high energy ultrasound. An experimental equipment, integrating both fiber impregnation and ply consolidation in a single process, has been designed and tested. It is made of an ultrasonic welder, whose titanium sonotrode is integrated on a filament winding machine. During winding, the commingled roving is at the same time in contact with the mandrel and the horn. The intermolecular friction generated by ultrasound is able to melt the thermoplastic matrix and impregnate the reinforcement fibers. The heat transfer phenomena occurring during the in situ consolidation were simulated solving by finite element (FE analysis an energy balance accounting for the heat generated by ultrasonic waves and the melting characteristics of the matrix. To this aim, a calorimetric characterization of the thermoplastic matrix has been carried out to obtain the input parameters for the model. The FE analysis has enabled to predict the temperature distribution in the composite during heating and cooling The simulation results have been validated by the measurement of the temperature evolution during ultrasonic consolidation.The reliability of the developed consolidation equipment was proved by producing hoop wound cylinder prototypes using commingled continuous E-glass rovings and Polypropylene (PP filaments. The consolidated composite cylinders are characterized by high mechanical properties, with values comparable with the theoretical ones predicted by the micromechanical analysis.

Computer Texture Mapping for Laser Texturing of Injection Mold

Directory of Open Access Journals (Sweden)

Yongquan Zhou

2014-04-01

Full Text Available Laser texturing is a relatively new multiprocess technique that has been used for machining 3D curved surfaces; it is more flexible and efficient to create decorative texture on 3D curved surfaces of injection molds so as to improve the surface quality and achieve cosmetic surface of molded plastic parts. In this paper, a novel method of laser texturing 3D curved surface based on 3-axis galvanometer scanning unit has been presented to prevent the texturing of injection mold surface from much distortion which is often caused by traditional texturing processes. The novel method has been based on the computer texture mapping technology which has been developed and presented. The developed texture mapping algorithm includes surface triangulation, notations, distortion measurement, control, and numerical method. An interface of computer texture mapping has been built to implement the algorithm of texture mapping approach to controlled distortion rate of 3D texture math model from 2D original texture applied to curvature surface. Through a case study of laser texturing of a high curvature surface of injection mold of a mice top case, it shows that the novel method of laser texturing meets the quality standard of laser texturing of injection mold.

Comparison of two setups for induction heating in injection molding

DEFF Research Database (Denmark)

Menotti, Stefano; Hansen, Hans Nørgaard; Bissacco, Giuliano

2015-01-01

To eliminate defects and improve the quality of molded parts, increasing the mold temperature is one of the applicable solutions. A high mold temperature can increase the path flow of the polymer inside the cavity allowing reduction of the number of injection points, reduction of part thickness......, and moulding of smaller and more complex geometries. The last two aspects are very important in micro injection molding. In this paper, a new embedded induction heating system is proposed and validated and two different coil setups were tested and compared. An experimental investigation was performed based...

Influence of fiber content on mechanical, morphological and thermal properties of kenaf fibers reinforced poly(vinyl chloride)/thermoplastic polyurethane poly-blend composites

International Nuclear Information System (INIS)

El-Shekeil, Y.A.; Sapuan, S.M.; Jawaid, M.; Al-Shuja’a, O.M.

2014-01-01

Highlights: • Increasing fiber content decreased tensile strength and strain. • Tensile modulus was increasing with increase in fiber content. • SEM showed fiber/matrix poor adhesion. • Impact strength was decreasing with increase in fiber content. • Lower thermal stability with increase in fiber content was observed. - Abstract: Kenaf (Hibiscus Cannabinus) bast fiber reinforced poly(vinyl chloride) (PVC)/thermoplastic polyurethane (TPU) poly-blend was prepared by melt mixing method using Haake Polydrive R600 internal mixer. The composites were prepared with different fiber content: 20%, 30% and 40% (by weight), with the processing parameters: 140 °C, 11 min, and 40 rpm for temperature, time and speed, respectively. After mixing, the composite was compressed using compressing molding machine. Mechanical properties (i.e. tensile properties, flexural properties, impact strength) were studied. Morphological properties of tensile fracture surface were studied using Scanning electron microscope (SEM). Thermal properties of the composites were studied using Thermogravimetric Analyses (TGA). PVC/TPU/KF composites have shown lower tensile strength and strain with increase in fiber content. Tensile modulus showed an increasing trend with increase in fiber content. Impact strength decreased with increase in fiber content; however, high impact strength was observed even with 40% fiber content (20.2 kJ/m 2 ). Mean while; the 20% and 30% fiber contents showed higher impact strength of 34.9, 27.9 kJ/m 2 ; respectively. SEM showed that there is poor fiber/matrix adhesion. Thermal degradation took place in three steps. In the first step, composites as well as the matrix had a similar stability. At the second step, matrix showed a slightly better stability than the composites. At the last step, composites showed a better stability than the matrix

Flow visualization and simulation of the filling process during injection molding

DEFF Research Database (Denmark)

Guerrier, Patrick; Tosello, Guido; Hattel, Jesper Henri

2017-01-01

To directly compare experimental moldings from an injection molding machine with simulations, a special mold has been produced with a glass window. The injection plane is perpendicular to the opening and closing planes, in order for the 55. mm thick glass window to be easily visible from the side....... These two had significant effects on the filling times and injection pressure calculated by the simulations. Other effects investigated included transient thermal management of the mold, pressure dependent viscosity and wall slip, but their effect were not remarkably large in this work. The obtained....... A high speed camera recording 500 frames per second was employed, and the mold had three thermocouples and two pressure sensors installed. The molded part is a 2. mm thick plate with a 0.5. mm thin section, which creates a characteristic V-shaped flow pattern. Two different materials were employed...

Injection molding of coarse 316L stainless steel powder

International Nuclear Information System (INIS)

Omar, M.A.; Abdullah, N.S.; Subuki, I; Ali, E.A.G.E.; Ismail, F.; Hassan, N.

2007-01-01

Metal injection molding (MIM) process using 316L stainless steel powder of 45 μm was investigated. The binder system consists of a major fraction of palm stearins and minor fraction of polyethylene with a powder loading of 65 vol. %. The rheological behaviour of the feedstock was determined using Capillary Rheometer. The feedstock then injected using vertical injection molding machine into the tensile test bar. Then molded parts were de bound and sintered in vacuum at temperature of 1360 degree Celsius. The results show that the viscosity of the feedstock decreased with the temperature increased. The best sintered density achieved was about 7.5 g/cm 3 with the tensile strength of more than 460 MPa. The properties of the sintered specimens could be increased with the increasing of sintering temperature. (author)

Computer Aided Design of The Cooling System for Plastic Injection Molds

Directory of Open Access Journals (Sweden)

Hakan GÜRÜN

2009-02-01

Full Text Available The design of plastic injection molds and their cooling systems affect both the dimension, the shape, the quality of a plastic part and the cycle time of process and the cost of mold. In this study, the solid model design of a plastic injection mold and the design of cooling sysytem were possibly carried out without the designer interaction. Developed program permited the use of three types of the cooling system and the different cavity orientations and the multible plastic part placement into the mold cores. The program which was developed by using Visual LISP language and the VBA (Visual BASIC for Application modules, was applicated in the AutoCAD software domain. Trial studies were presented that the solid model design of plastic injection molds and the cooling systems increased the reliability, the flexibility and the speed of the design.

Micro Injection Molding of Thin Walled Geometries with Induction Heating System

DEFF Research Database (Denmark)

Menotti, Stefano; Hansen, Hans Nørgaard; Bissacco, Giuliano

2014-01-01

To eliminate defects and improve the quality of molded parts, increasing the mold temperature is one of the applicable solutions. A high mold temperature can increase the path flow of the polymer inside the cavity allowing reduction of the number of injection points, reduction of part thickness...... and moulding of smaller and more complex geometries. The last two aspects are very important in micro injection molding. In this paper a new embedded induction heating system is proposed and validated. An experimental investigation was performed based on a test geometry integrating different aspect ratios...... of small structures. ABS was used as material and different combinations of injection velocity, pressure and mold temperature were tested. The replicated test objects were measured by means of an optical CMM machine. On the basis of the experimental investigation the efficacy of the embedded induction...

Validation of three-dimensional micro injection molding simulation accuracy

DEFF Research Database (Denmark)

Tosello, Guido; Costa, F.S.; Hansen, Hans Nørgaard

2011-01-01

length, injection pressure profile, molding mass and flow pattern. The importance of calibrated micro molding process monitoring for an accurate implementation strategy of the simulation and its validation has been demonstrated. In fact, inconsistencies and uncertainties in the experimental data must...... be minimized to avoid introducing uncertainties in the simulation calculations. Simulations of bulky sub-100 milligrams micro molded parts have been validated and a methodology for accurate micro molding simulations was established....

Injection molding of bushes made of tribological PEEK composites

Directory of Open Access Journals (Sweden)

2007-12-01

Full Text Available Polyetheretherketone (PEEK composites have been extensively studied because of the excellent tribological behavior among plastics. However, laboratory specimens and tests are generally discussed, whereas application studies on industrial components are infrequent. In this paper, an injection molded bush made of tribological PEEK was analyzed to correlate wear behavior and molded material structure. Bushes were tested under unlubricated sliding conditions by means of a short wear test. Surface analysis, differential scanning calorimetry (DSC and optical microscopy were used to evaluate the distribution of the different composite fillers (polytetrafluoroethylene, PTFE, graphite particles and carbon microfibers and their effect on the final bush behavior. A significant lack of homogeneity was observed in the molded bush and black bands appeared on the shaft surface after testing due to the sliding. The bush geometry and the injection molding process should be optimized to allow the best tribological behavior of the molded material under working conditions.

Low Speed Technology for Small Turbine Development Reaction Injection Molded 7.5 Meter Wind Turbine Blade

Energy Technology Data Exchange (ETDEWEB)

David M. Wright; DOE Project Officer - Keith Bennett

2007-07-31

An optimized small turbine blade (7.5m radius) was designed and a partial section molded with the RIM (reaction-injection molded polymer) process for mass production. The intended market is for generic three-bladed wind turbines, 100 kilowatts or less, for grid-assist end users with rural and semi-rural sites, such as the farm/ranch market, having low to moderate IEC Class 3-4 wind regimes. This blade will have substantial performance improvements over, and be cheaper than, present-day 7.5m blades. This is made possible by the injection-molding process, which yields high repeatability, accurate geometry and weights, and low cost in production quantities. No wind turbine blade in the 7.5m or greater size has used this process. The blade design chosen uses a RIM skin bonded to a braided infused carbon fiber/epoxy spar. This approach is attractive to present users of wind turbine blades in the 5-10m sizes. These include rebladeing California wind farms, refurbishing used turbines for the Midwest farm market, and other manufacturers introducing new turbines in this size range.

Gate Design in Injection Molding of Microfluidic Components Using Process Simulations

DEFF Research Database (Denmark)

Marhöfer, David Maximilian; Tosello, Guido; Islam, Aminul

2016-01-01

Just as in conventional injection molding of plastics, process simulationsare an effective and interesting tool in the area of microinjection molding. They can be applied in order to optimize and assist the design of the microplastic part, the mold, and the actual process. Available simulation...... software is however actually made for macroscopic injection molding. By means of the correct implementation and careful modeling strategy though, it can also be applied to microplastic parts, as it is shown in the present work. Process simulations were applied to two microfluidic devices (amicrofluidic...

Numerical simulation of stress distribution in Inconel 718 components realized by metal injection molding during supercritical debinding

Science.gov (United States)

Agne, Aboubakry; Barrière, Thierry

2018-05-01

Metal injection molding (MIM) is a process combining advantages of thermoplastic injection molding and powder metallurgy process in order to manufacture components with complex and near net-shape geometries. The debinding of a green component can be performed in two steps, first by using solvent debinding in order to extract the organic part of the binder and then by thermal degradation of the rest of the binder. A shorter and innovative method for extracting an organic binder involves the use of supercritical fluid instead of a regular solvent. The debinding via a supercritical fluid was recently investigated to extract organic binders contained in components obtained by Metal Injection Molding. It consists to put the component in an enclosure subjected to high pressure and temperature. The supercritical fluid has various properties depending on these two conditions, e.g., density and viscosity. The high-pressure combined with the high temperature during the process affect the component structure. Three mechanisms contributing to the deformation of the component can been differentiated: thermal expansion, binder extraction and supercritical fluid effect on the outer surfaces of the component. If one supposes that, the deformation due to binder extraction is negligible, thermal expansion and the fluid effect are probably the main mechanisms that can produce several stress. A finite-element model, which couples fluid-structures interaction and structural mechanics, has been developed and performed on the Comsol Multiphysics® finite-element software platform allowed to estimate the stress distribution during the supercritical debinding of MIM component composed of Inconel 718 powders, polypropylene, polyethylene glycol and stearic acid as binder. The proposed numerical simulations allow the estimation of the stress distribution with respect to the processing parameters for MIM components during the supercritical debinding process using a stationary solver.

Demonstration of pharmaceutical tablet coating process by injection molding technology.

Science.gov (United States)

Puri, Vibha; Brancazio, David; Harinath, Eranda; Martinez, Alexander R; Desai, Parind M; Jensen, Keith D; Chun, Jung-Hoon; Braatz, Richard D; Myerson, Allan S; Trout, Bernhardt L

2018-01-15

We demonstrate the coating of tablets using an injection molding (IM) process that has advantage of being solvent free and can provide precision coat features. The selected core tablets comprising 10% w/w griseofulvin were prepared by an integrated hot melt extrusion-injection molding (HME-IM) process. Coating trials were conducted on a vertical injection mold machine. Polyethylene glycol and polyethylene oxide based hot melt extruded coat compositions were used. Tablet coating process feasibility was successfully demonstrated using different coating mold designs (with both overlapping and non-overlapping coatings at the weld) and coat thicknesses of 150 and 300 μm. The resultant coated tablets had acceptable appearance, seal at the weld, and immediate drug release profile (with an acceptable lag time). Since IM is a continuous process, this study opens opportunities to develop HME-IM continuous processes for transforming powder to coated tablets. Copyright © 2017 Elsevier B.V. All rights reserved.

A Mathematical Model for the Non-Stationary Process of Compression Molding of Plates from Granulate of Thermoplastic Composites

Directory of Open Access Journals (Sweden)

Vladimir N. Vodyakov

2017-12-01

Full Text Available Introduction: Mathematical modeling allows assigning optimal parameters for the process of compression molding of plates and calculating the dimensions of the mold without costly and long-term experiments. The options ensure the required precision of pressing. The disadvantages of the known models are the assumptions about the process isothermicity and independence of the thermal-physical coefficients from temperature. The models do not take into account the dependence of the pressure in the cavity of the mold on the excess of the melt; the problem of calculating the dimensions of the mold cavity for given plate dimensions is not posed. The known models do not give a complete description of all stages of the process. The aim of this paper is to develop a perfect mathematical model without limitations for the compression molding of plates from a granulate of highly filled thermoplastic composites. Materials and Methods: The paper proposes a non-stationary mathematical model. The model takes into account the presence of physical states transitions and dependence of the thermophysical characteristics of composites on temperature. The model is based on the known equations of thermal physics and continuum mechanics. Results: Initial and boundary conditions, rheological equations, systems of equations for the material, thermal, and power balance are determined for three stages of the process. The calculation problems are determined too. A program of iterative numerical calculation has been developed because of the resulting system of equations has no analytical solution. A convergence of experimental and theoretical results with the correlation coefficient confirms the adequacy of the developed mathematical model and the calculation program. Discussion and Conclusions: The results of the study allow calculating the dimensions of the mold cavity, the initial granulate required mass, technological losses, the time functions of pressure and temperature

Dimensional accuracy of Acrylonitrile Butadiene Styrene injection molded parts produced in a pilot produc

DEFF Research Database (Denmark)

Mischkot, Michael; Davoudinejad, Ali; Charalambis, Alessandro

of a geometry including micro-features have been injection-molded in Acrylonitrile Butadiene Styrene (ABS) with a single 20x20x2.5 mm^3 injection molding insert manufactured in a photopolymer composite material. This research investigates the dimensional accuracy of the injection molded parts as a function...

Imprinted and injection-molded nano-structured optical surfaces

DEFF Research Database (Denmark)

Christiansen, Alexander Bruun; Højlund-Nielsen, Emil; Clausen, Jeppe Sandvik

2013-01-01

. In this paper, nanostructured polymer surfaces suitable for up-scalable polymer replication methods, such as imprinting/embossing and injection-molding, are discussed. The limiting case of injection-moulding compatible designs is investigated. Anti-reflective polymer surfaces are realized by replication...

Injection molding tools with micro/nano-meter pattern

DEFF Research Database (Denmark)

2011-01-01

The present invention relates to methods for embedded a micrometer and/or nanometer pattern into an injection molding tool. In a first main aspect, a micro/nanometer structured imprinting device is applied in, or on, an active surface so as to transfer the micro/nanometer patterned structure...... to the tool while the imprinting device is, at least partly, within a cavity of the injection molding tool. In a second main aspect, a base plate with a micro/nanometer structured pattern positioned on an upper part is positioned on the active surface within the tool, the lower part of the base plate facing...

Development of integrated control system for smart factory in the injection molding process

Science.gov (United States)

Chung, M. J.; Kim, C. Y.

2018-03-01

In this study, we proposed integrated control system for automation of injection molding process required for construction of smart factory. The injection molding process consists of heating, tool close, injection, cooling, tool open, and take-out. Take-out robot controller, image processing module, and process data acquisition interface module are developed and assembled to integrated control system. By adoption of integrated control system, the injection molding process can be simplified and the cost for construction of smart factory can be inexpensive.

Characterization of thermoset and thermoplastic polyurethane pads, and molded and non-optimized machined grooving methods for oxide chemical mechanical planarization applications

International Nuclear Information System (INIS)

Sampurno, Yasa; Borucki, Leonard; Zhuang, Yun; Misra, Sudhanshu; Holland, Karey; Boning, Duane; Philipossian, Ara

2009-01-01

This paper systematically studies the effect of pad material, grooving method and grooving pattern on interlayer dielectric chemical mechanical planarization. The tested polishing pads consist of thermoplastic and thermoset polyurethanes synthesized using two different processes. Grooves created using a molding technique are compared with grooves formed by mechanical cutting. The concentric groove design is also compared with the logarithmic positive spiral positive grooving design. Experimental data collected include removal rate, coefficient of friction, shear force variance, pad temperature and dynamic mechanical analyzer measurements. Scanning electron microscope images are used to correlate grooving methods with coefficient of friction and shear force variance measurements. Results show that all of the pads polish wafers in boundary lubrication mode with unique friction coefficient, shear force variance and pad temperature characteristics. Simulations using a two-step removal rate mechanism are performed to estimate the chemical and mechanical rate constants. The analysis indicates that the thermoplastic pad is more mechanically controlled than the thermoset pad and that molded grooving induces a more mechanically controlled process than non-optimized machined grooving

Low-Cost Production of Composite Bushings for Jet Engine Applications

Science.gov (United States)

Gray, Robert A.

1998-01-01

The objectives of this research program were to reduce the manufacturing costs of variable stator vane bushings by 1) eliminating the expensive carbon fiber braiding operation, 2) replacing the batch mode impregnation, B-stage, and cutting operations with a continuous process, and 3) reducing the molding cycle and machining operations with injection molding to achieve near-net shapes. Braided bushings were successfully fabricated with both AMB-17XLD and AMB-TPD resin systems. The composite bushings achieved high glass transition temperature after post-cure (+300 C) and comparable weight loss to the PNM-15 bushings. ANM-17XLD bushings made with "batch-mode" molding compound (at 0.5 in. fiber length) achieved a +300 lb-force flange break strength which was superior to the continuous braided-fiber reinforced bushing. The non-MDA resin technology developed in this contract appears attractive for bushing applications that do not exceed a 300 C use temperature. Two thermoplastic polyimide resins were synthesized in order to generate injection molding compound powders. Excellent processing results were obtained at injection temperatures in excess of 300 C. Micro-tensile specimens were produced from each resin type and the Tg measurements (by TMA) for these samples were equivalent to AURUM(R). Thermal Gravimetric Analysis (TGA) conducted at 10 C/min showed that the non-MDA AMB-type polyimide thermoplastics had comparable weight loss to PMR-15 up to 500 C.

Assembly injection moulding joins metal and thermoplastics; Montagespritzgiessen verbindet Metall und Thermoplast

Energy Technology Data Exchange (ETDEWEB)

Drummer, Dietmar; Meister, Steve [Erlangen-Nuernberg Univ., Erlangen (Germany). Lehrstuhl fuer Kunststofftechnik; Reichart, Marc [HBW Gubesch Kunststoff Engineering GmbH, Wilhelmsdorf (Germany)

2010-03-08

Automotive safety restraint system components increasingly use flexible styrenic and olefinic TPEs. With continued evolution in automotive interior design and performance requirements, demands on material technology are concomitantly rising. A growing trend towards molded in color solutions with low gloss aesthetics require TPE materials with ery low gloss, improved scratch resistance, and low temperature ductility. Innovations utilizing Teknor Apex's compounding technology have enabled the development of low gloss styrenic elastomers for airbag door applications that provide an optimized combination of low temperature performance, surface aesthetics (low gloss and improved scratch resistance), and ease of processing. This paper highlights the salient features of these new compounds and the effect of injection molding condition on the gloss at the surface of the cover.

Stability of FDTS monolayer coating on aluminum injection molding tools

International Nuclear Information System (INIS)

Cech, Jiri; Taboryski, Rafael

2012-01-01

Highlights: ► We present novel and highly useful results on FDTS monolayer coating of aluminum. ► The coating is particularly applicable for coating of prototyping injection molding tools, which often are made of Al. ► We have demonstrated that the coating prevails in injection molding conditions and that the coating will prevent wear of the tools. - Abstract: We have characterized perfluorodecyltrichlorosilane (FDTS) molecular coating of aluminum molds for polymer replication via injection molding (IM). X-ray photoelectron spectroscopy (XPS) data, sessile drop contact angles with multiple fluids, surface energies and roughness data have been collected. Samples have been characterized immediately after coating, after more than 500 IM cycles to test durability, and after 7 months to test temporal stability. The coating was deposited in an affordable process, involving near room temperature gas phase reactions. XPS shows detectable fluorine presence on both freshly coated samples as well as on post-IM samples with estimated 30 at.% on freshly coated and 28 at.% on post-IM samples with more than 500 IM cycles with polystyrene (PS) and ABS polymer.

Effects of glass fibers on the properties of micro molded plastic parts

DEFF Research Database (Denmark)

Islam, Aminul; Hansen, Hans Nørgaard; Gasparin, Stefania

2011-01-01

Glass fibers are used to reinforce plastics and to improve their mechanical properties. But plastic filled with glass fibers is a concern for molding of micro scale plastic parts. The aim of this paper is to investigate the effects of glass fiber on the replication quality and mechanical properties...... of polymeric thin ribs. It investigates the effect of feature size and gate location on distribution of glass fibers inside the molded parts. The results from this work indicate that glass filled plastic materials have poor replication quality and nonhomogeneous mechanical properties due to the nonuniform...

Method of forming composite fiber blends and molding same

Science.gov (United States)

McMahon, Paul E. (Inventor); Chung, Tai-Shung (Inventor)

1989-01-01

The instant invention involves a process used in preparing fibrous tows which may be formed into polymeric plastic composites. The process involves the steps of (a) forming a tow of strong filamentary materials; (b) forming a thermoplastic polymeric fiber; (c) intermixing the two tows; and (d) withdrawing the intermixed tow for further use.

Temperature Dependence and Magnetic Properties of Injection Molding Tool Materials Used in Induction Heating

DEFF Research Database (Denmark)

Guerrier, Patrick; Nielsen, Kaspar Kirstein; Hattel, Jesper Henri

2015-01-01

To analyze the heating phase of an induction heated injection molding tool precisely, the temperature-dependent magnetic properties, B–H curves, and the hysteresis loss are necessary for the molding tool materials. Hence, injection molding tool steels, core materials among other materials have...

Damage detection in laminar thermoplastic composite materials by means of embedded optical fibers

Directory of Open Access Journals (Sweden)

Kojović Aleksandar M.

2006-01-01

Full Text Available This paper investigates the possibility of applying optical fibers as sensors for investigating low energy impact damage in laminar thermoplastic composite materials, in real time. Impact toughness testing by a Charpy impact pendulum with different loads was conducted in order to determine the method for comparative measurement of the resulting damage in the material. For that purpose intensity-based optical fibers were built in to specimens of composite materials with Kevlar 129 (the DuPont registered trade-mark for poly(p-phenylene terephthalamide woven fabric as reinforcement and thermoplastic PVB (poly(vinyl butyral as the matrix. In some specimens part of the layers of Kevlar was replaced with metal mesh (50% or 33% of the layers. Experimental testing was conducted in order to observe and analyze the response of the material under multiple low-energy impacts. Light from the light-emitting diode (LED was launched to the embedded optical fiber and was propagated to the phototransistor-based photo detector. During each impact, the signal level, which is proportional to the light intensity in the optical fiber, drops and then slowly recovers. The obtained signals were analyzed to determine the appropriate method for real time damage monitoring. The major part of the damage occurs during impact. The damage reflects as a local, temporary release of strain in the optical fiber and an increase of the signal level. The obtained results show that intensity-based optical fibers could be used for measuring the damage in laminar thermoplastic composite materials. The acquired optical fiber signals depend on the type of material, but the same set of rules (relatively different, depending on the type of material could be specified. Using real time measurement of the signal during impact and appropriate analysis enables quantitative evaluation of the impact damage in the material. Existing methods in most cases use just the intensity of the signal before

Parameter Optimization Of Natural Hydroxyapatite/SS316l Via Metal Injection Molding (MIM)

Science.gov (United States)

Mustafa, N.; Ibrahim1, M. H. I.; Amin, A. M.; Asmawi, R.

2017-01-01

Metal injection molding (MIM) are well known as a worldwide application of powder injection molding (PIM) where as applied the shaping concept and the beneficial of plastic injection molding but develops the applications to various high performance metals and alloys, plus metal matrix composites and ceramics. This study investigates the strength of green part by using stainless steel 316L/ Natural hydroxyapatite composite as a feedstock. Stainless steel 316L (SS316L) was mixed with Natural hydroxyapatite (NHAP) by adding 40 wt. % Low Density Polyethylene and 60 %wt. Palm Stearin as a binder system at 63 wt. % powder loading consist of 90 % wt. of SS316 L and 10 wt. % NHAP prepared thru critical powder volume percentage (CPVC). Taguchi method was functional as a tool in determining the optimum green strength for Metal Injection Molding (MIM) parameters. The green strength was optimized with 4 significant injection parameter such as Injection temperature (A), Mold temperature (B), Pressure (C) and Speed (D) were selected throughout screening process. An orthogonal array of L9 (3)4 was conducted. The optimum injection parameters for highest green strength were established at A1, B2, C0 and D1 and where as calculated based on Signal to Noise Ratio.

A study on compound contents for plastic injection molding products of metallic resin pigment

International Nuclear Information System (INIS)

Park, Young Whan; Kwak, Jae Seob; Lee, Gyu Sang

2016-01-01

Injection molding process is widely used for producing most plastic products. In order to make a metal-colored plastic product especially in modern luxury home alliances, metallic pigments which are mixed to a basic resin material for injection molding are available. However, the process control for the metal-colored plastic product is extremely difficult due to non-uniform melt flow of the metallic resin pigments. To improve the process efficiency, a rapid mold cooling method by a compressed cryogenic fluid and electricity mold are also proposed to decrease undesired compound contents within a molded plastic product. In this study, a quality of the metal-colored plastic product is evaluated with process parameters; injection speed, injection pressure, and pigment contents, and an influence of the rapid cooling and heating system is demonstrated

A study on compound contents for plastic injection molding products of metallic resin pigment

Energy Technology Data Exchange (ETDEWEB)

Park, Young Whan; Kwak, Jae Seob [Dept. of Mechanical Engineering, Pukyong National University, Busan (Korea, Republic of); Lee, Gyu Sang [Alliance Molding Engineering TeamLG Electronics Inc., Osan (Korea, Republic of)

2016-12-15

Injection molding process is widely used for producing most plastic products. In order to make a metal-colored plastic product especially in modern luxury home alliances, metallic pigments which are mixed to a basic resin material for injection molding are available. However, the process control for the metal-colored plastic product is extremely difficult due to non-uniform melt flow of the metallic resin pigments. To improve the process efficiency, a rapid mold cooling method by a compressed cryogenic fluid and electricity mold are also proposed to decrease undesired compound contents within a molded plastic product. In this study, a quality of the metal-colored plastic product is evaluated with process parameters; injection speed, injection pressure, and pigment contents, and an influence of the rapid cooling and heating system is demonstrated.

Coaxial Thermoplastic Elastomer-Wrapped Carbon Nanotube Fibers for Deformable and Wearable Strain Sensors

KAUST Repository

Zhou, Jian; Xu, Xuezhu; Xin, Yangyang; Lubineau, Gilles

2018-01-01

performances in these design requirements. Here, achieving highly stretchable and sensitive strain sensors by using a coaxial structure, prepared via coaxial wet spinning of thermoplastic elastomer-wrapped carbon nanotube fibers, is proposed. The sensors attain

Influence of Hygrothermal Aging on Poisson’s Ratio of Thin Injection-Molded Short Glass Fiber-Reinforced PA6

OpenAIRE

Thomas Illing; Heinrich Gotzig; Marcus Schoßig; Christian Bierögel; Wolfgang Grellmann

2016-01-01

The hygrothermal aging of short glass fiber-reinforced polyamide 6 materials (PA6 GF) represents a major problem, especially in thin-walled components, such as in the automotive sector. In this study, therefore, the thickness and the glass fiber content of PA6 GF materials were varied and the materials were exposed to hygrothermal aging. The temperature and relative humidity were selected in the range from −40 °C up to 85 °C, and from 10% up to 85% relative humidity (RH). In the dry-as-molded...

Development of the computer-aided process planning (CAPP system for polymer injection molds manufacturing

Directory of Open Access Journals (Sweden)

J. Tepić

2011-10-01

Full Text Available Beginning of production and selling of polymer products largely depends on mold manufacturing. The costs of mold manufacturing have significant share in the final price of a product. The best way to improve and rationalize polymer injection molds production process is by doing mold design automation and manufacturing process planning automation. This paper reviews development of a dedicated process planning system for manufacturing of the mold for injection molding, which integrates computer-aided design (CAD, computer-aided process planning (CAPP and computer-aided manufacturing (CAM technologies.

Ultrasound - Aided ejection in micro injection molding

Science.gov (United States)

Masato, D.; Sorgato, M.; Lucchetta, G.

2018-05-01

In this work, an ultrasound-aided ejection system was designed and tested for different polymers (PS, COC and POM) and mold topographies. The proposed solution aims at reducing the ejection friction by decreasing the adhesion component of the frictional force, which is controlled by the contact area developed during the filling stage of the injection molding process. The experimental results indicate a positive effect of ultrasound vibration on the friction force values, with a maximum reduction of 16. Moreover, it is demonstrated that the ultrasound effect is strictly related to both polymer selection and mold roughness. The combined effect on the ejection force of mold surface roughness, melt viscosity during filling and polymer elastic modulus at ejection was modeled to the experimental data, in order to demonstrate that the effect of ultrasound vibration on the ejection friction reduction is due to the heating of the contact interface and the consequent reduction of the polymer elastic modulus.

The effect of mold surface topography on plastic parat in-process shrinkage in injection molding

DEFF Research Database (Denmark)

Arlø, Uffe Rolf; Hansen, Hans Nørgaard; Kjær, Erik Michael

2003-01-01

An experimental study of the effect of mold surface roughness on in-process in-flow linear part shrinkage in injection molding has been carried out. The investigation is based on an experimental two-cavity tool, where the cavities have different surface topographies, but are otherwise identical....... The study has been carried out for typical commercial polystyrene and polypropylene grades. The relationship between mold surface topography and linear shrinkage has been investigated with an experimental two-cavity mold producing simple rectangular parts with the nominal dimensions 1 x 25 x 50 mm (see...... figure 1). The cavities have different surface topographies on one side, but are otherwise identical (see discussion of other contribution factors)....

Modeling and flow analysis of pure nylon polymer for injection molding process

International Nuclear Information System (INIS)

Nuruzzaman, D M; Kusaseh, N; Basri, S; Hamedon, Z; Oumer, A N

2016-01-01

In the production of complex plastic parts, injection molding is one of the most popular industrial processes. This paper addresses the modeling and analysis of the flow process of the nylon (polyamide) polymer for injection molding process. To determine the best molding conditions, a series of simulations are carried out using Autodesk Moldflow Insight software and the processing parameters are adjusted. This mold filling commercial software simulates the cavity filling pattern along with temperature and pressure distributions in the mold cavity. In the modeling, during the plastics flow inside the mold cavity, different flow parameters such as fill time, pressure, temperature, shear rate and warp at different locations in the cavity are analyzed. Overall, this Moldflow is able to perform a relatively sophisticated analysis of the flow process of pure nylon. Thus the prediction of the filling of a mold cavity is very important and it becomes useful before a nylon plastic part to be manufactured. (paper)

Modeling and flow analysis of pure nylon polymer for injection molding process

Science.gov (United States)

Nuruzzaman, D. M.; Kusaseh, N.; Basri, S.; Oumer, A. N.; Hamedon, Z.

2016-02-01

In the production of complex plastic parts, injection molding is one of the most popular industrial processes. This paper addresses the modeling and analysis of the flow process of the nylon (polyamide) polymer for injection molding process. To determine the best molding conditions, a series of simulations are carried out using Autodesk Moldflow Insight software and the processing parameters are adjusted. This mold filling commercial software simulates the cavity filling pattern along with temperature and pressure distributions in the mold cavity. In the modeling, during the plastics flow inside the mold cavity, different flow parameters such as fill time, pressure, temperature, shear rate and warp at different locations in the cavity are analyzed. Overall, this Moldflow is able to perform a relatively sophisticated analysis of the flow process of pure nylon. Thus the prediction of the filling of a mold cavity is very important and it becomes useful before a nylon plastic part to be manufactured.

Mechanical Properties Distribution within Polypropylene Injection Molded Samples: Effect of Mold Temperature under Uneven Thermal Conditions

Directory of Open Access Journals (Sweden)

Sara Liparoti

2017-11-01

Full Text Available The quality of the polymer parts produced by injection molding is strongly affected by the processing conditions. Uncontrolled deviations from the proper process parameters could significantly affect both internal structure and final material properties. In this work, to mimic an uneven temperature field, a strong asymmetric heating is applied during the production of injection-molded polypropylene samples. The morphology of the samples is characterized by optical and atomic force microscopy (AFM, whereas the distribution of mechanical modulus at different scales is obtained by Indentation and HarmoniX AFM tests. Results clearly show that the temperature differences between the two mold surfaces significantly affect the morphology distributions of the molded parts. This is due to both the uneven temperature field evolutions and to the asymmetric flow field. The final mechanical property distributions are determined by competition between the local molecular stretch and the local structuring achieved during solidification. The cooling rate changes affect internal structures in terms of relaxation/reorganization levels and give rise to an asymmetric distribution of mechanical properties.

Optimization of injection molding process parameters for a plastic cell phone housing component

Science.gov (United States)

Rajalingam, Sokkalingam; Vasant, Pandian; Khe, Cheng Seong; Merican, Zulkifli; Oo, Zeya

2016-11-01

To produce thin-walled plastic items, injection molding process is one of the most widely used application tools. However, to set optimal process parameters is difficult as it may cause to produce faulty items on injected mold like shrinkage. This study aims at to determine such an optimum injection molding process parameters which can reduce the fault of shrinkage on a plastic cell phone cover items. Currently used setting of machines process produced shrinkage and mis-specified length and with dimensions below the limit. Thus, for identification of optimum process parameters, maintaining closer targeted length and width setting magnitudes with minimal variations, more experiments are needed. The mold temperature, injection pressure and screw rotation speed are used as process parameters in this research. For optimal molding process parameters the Response Surface Methods (RSM) is applied. The major contributing factors influencing the responses were identified from analysis of variance (ANOVA) technique. Through verification runs it was found that the shrinkage defect can be minimized with the optimal setting found by RSM.

Dimensional accuracy optimization of the micro-plastic injection molding process using the Taguchi design method

Directory of Open Access Journals (Sweden)

Chil-Chyuan KUO KUO

2015-06-01

Full Text Available Plastic injection molding is an important field in manufacturing industry because there are many plastic products that produced by injection molding. However, the time and cost required for producing a precision mold are the most troublesome problems that limit the application at the development stage of a new product in precision machinery industry. This study presents an approach of manufacturing a hard mold with microfeatures for micro-plastic injection molding. This study also focuses on Taguchi design method for investigating the effect of injection parameters on the dimensional accuracy of Fresnel lens during plastic injection molding. It was found that the dominant factor affecting the microgroove depth of Fresnel lens is packing pressure. The optimum processing parameters are packing pressure of 80 MPa, melt temperature of 240 °C, mold temperature of 90 °C and injection speed of 50 m/s. The dimensional accuracy of Fresnel lens can be controlled within ±3 µm using the optimum level of process parameters through the confirmation test. The research results of this study have industrial application values because electro-optical industries are able to significantly reduce a new optical element development cycle time.DOI: http://dx.doi.org/10.5755/j01.ms.21.2.5864

Validation of precision powder injection molding process simulations using a spiral test geometry

DEFF Research Database (Denmark)

Marhöfer, Maximilian; Müller, Tobias; Tosello, Guido

2015-01-01

Like in many other areas of engineering, process simulations find application in precision injection molding to assist and optimize the quality and design of precise products and the molding process. Injection molding comprises mainly the manufacturing of plastic components. However, the variant ....... The necessary data and the implementation procedure of the new material models are outlined. In order to validate the simulation studies and evaluate their accuracy, the simulation results are compared with experiments performed using a spiral test geometry...... for powder injection molding. This characterization includes measurements of rheological, thermal, and pvT behavior of the powder-binder-mixes. The acquired material data was used to generate new material models for the database of the commercially available Autodesk Moldflow® simulation software...

Karakteristik Mekanik Panel Dinding dari Komposit Sabut Kelapa (Coco Fiber)-Sampah Plastik (Thermoplastics)

OpenAIRE

Fajriyanto, Fajriyanto

2009-01-01

The research about utilization of coco fiber and thermoplastic waste to produce partition wall based on fiber reinforced plastic (FRP) composites has been conducted. The research methodology used was experimental research method. There were three steps conducted in the research; the first, preparation of instruments and sampling of raw materials, the second, blending process for producing fiberboard composites, the third, mechanical-waterproof testing and analyzing of products. The obje...

Variation of mechanical and thermal properties of the thermoplastics reinforced with natural fibers by electron beam processing

Energy Technology Data Exchange (ETDEWEB)

Kim, Sok Won [Department of Physics, University of Ulsan, Ulsan 680 749 (Korea, Republic of)], E-mail: sokkim@ulsan.ac.kr; Oh, Seungmin; Lee, Kyuse [Ilkwang Co. Ltd. 1178-6 Goyon-ri, Ungchon-mueon, Ulju-gun 689 871 (Korea, Republic of)

2007-11-15

With restrictions for environmental protection being strengthened, the thermoplastics reinforced with natural fibers (NFs) such as jute, kenaf, flax, etc., appeared as an automobile interior material instead of the chemical plastics. Regardless of many advantages, one shortcoming is the deformation after being formed in high temperature of about 200 deg. C, caused by the poor adhesion between the natural fibers and thermoplastics. Also, the energy saving in connection with car air-conditioning becomes very important. In this study, the thermal conductivity, tensile strength, and deformation of several kinds of thermoplastic composites composing of 50% polypropylene (PP) and 50% natural fiber irradiated by the electron beam (energy: 0.5 MeV, dose: 0-20 kGy) were measured. The length and thickness of PP and NF are 80{+-}10 mm and 40-120 {mu}m, respectively. The results show that the thermal conductivity and the tensile strength changed and became minimum when the dose of electron beam is 10 kGy, and the deformation after the thermal cycle were reduced by the electron beam.

Desain dan Optimasi Injection Mold Sistem Slider pada Produk Stick T15

Directory of Open Access Journals (Sweden)

Lutfi Khoirul Miftakhul Ni'am

2017-12-01

Full Text Available The design of injection molding is the initial process to produce a large-scale product of plastic material which heated and injected into the mold. Design of the preform mold using the plastic material polyethylene terephthalate with the construction of the slider, so that the products which was made have undercut and can’t be made in the core section and cavity. The purpose of this design is to design the slider on the product preform. The software which used for this design using CATIA V5R19 and simulation software production using Autodesk Moldflow Insight 2016. The step on designing a unit injection mold in the preform includes several steps. The first step is identify the product, the calculation of the cooling and input the data calculation result to an moldflow. The second step is design construction slider and determine the mold material as well as calculating the construction mold. The third step is pour the results of the design in figure 2D. Based on the analysis results from moldflow obtained cooling optimal.i.e. the type of cooling series type 2, and if can be concluded construction of the mold said to be safe if the stress, the style and the determination  of material which occurs under the stress and style of permit.

Economic Analysis of Additive Manufacturing Integration in Injection Molding Process Chain

DEFF Research Database (Denmark)

Charalambis, Alessandro; Kerbache, Laoucine; Tosello, Guido

The purpose of this research is to analyze how additive manufacturing can create value when it is utilized as a supportive technology to injection molding by quantifying the cost advantages that can be obtained. Tooling for the product development phase is investigated as pilot integration area...... of additive manufacturing with injection molding. Cost considerations are discussed through the development of a cost estimation model. The study shows that integration of additive manufacturing in the product development phase for fabrication of soft tooling is economically convenient with a cost reduction...... of 79,8% and 89,9%. The cost models on additive manufacturing have been built so far on the idea of substituting injection molding with additive manufacturing. In response to this literature gap, this research addresses the advantages of additive manufacturing utilized in a synergistic rather than...

The reflectivity, wettability and scratch durability of microsurface features molded in the injection molding process using a dynamic tool tempering system

Science.gov (United States)

Kuhn, Sascha; Burr, August; Kübler, Michael; Deckert, Matthias; Bleesen, Christoph

2011-02-01

In this paper the replication qualities of periodically and randomly arranged micro-features molded in the injection molding process and their effects on surface properties are studied. The features are molded in PC, PMMA and PP at different mold wall temperatures in order to point out the necessity and profitability of a variotherm mold wall temperature control system. A one-dimensional heat conduction model is proposed to predict the cycle times of the variotherm injection molding processes. With regard to these processes, the molding results are compared to the molded surface feature heights using an atomic force microscope. In addition, the effects of the molded surface features on macroscopic surfaces are characterized in terms of light reflection using a spectrometer and in terms of water wettability by measuring the static contact angle. Furthermore, due to the sensitivity of the surface features on the molded parts, their durability is compared in a scratch test with a diamond tip. This leads to successful implementation in applications in which the optical appearance, in terms of gloss and reflection, and the water repellence, in terms of drag flow and adhesion, are of importance.

The reflectivity, wettability and scratch durability of microsurface features molded in the injection molding process using a dynamic tool tempering system

International Nuclear Information System (INIS)

Kuhn, Sascha; Burr, August; Kübler, Michael; Deckert, Matthias; Bleesen, Christoph

2011-01-01

In this paper the replication qualities of periodically and randomly arranged micro-features molded in the injection molding process and their effects on surface properties are studied. The features are molded in PC, PMMA and PP at different mold wall temperatures in order to point out the necessity and profitability of a variotherm mold wall temperature control system. A one-dimensional heat conduction model is proposed to predict the cycle times of the variotherm injection molding processes. With regard to these processes, the molding results are compared to the molded surface feature heights using an atomic force microscope. In addition, the effects of the molded surface features on macroscopic surfaces are characterized in terms of light reflection using a spectrometer and in terms of water wettability by measuring the static contact angle. Furthermore, due to the sensitivity of the surface features on the molded parts, their durability is compared in a scratch test with a diamond tip. This leads to successful implementation in applications in which the optical appearance, in terms of gloss and reflection, and the water repellence, in terms of drag flow and adhesion, are of importance.

Welding lines formation in holes obtained by low pressure injection molding of ceramic parts

Directory of Open Access Journals (Sweden)

C. A. Costa

Full Text Available Abstract This work presents a study to evaluate the process of producing internal holes in ceramic disks produced by low pressure injection molding (LPIM process. Two process conditions defined as pre-injection and post-injection were used to test the proposition. In the first one the pin cores that produce the holes were positioned in the cavity before the injection of the feedstock; and in the second one, the pin cores were positioned in the cavity, just after the feeding phase of the injection mold. An experimental injection mold designed and manufactured to test both processes was developed to produce ceramic disk with Ø 50 x 2 mm with four holes of Ø 5 mm, equally and radially distributed through the disk. The feedstock was composed of 86 wt% alumina (Al2O3 and 14 wt% organic vehicle based on paraffin wax. Heating and cooling systems controlled by a data acquisition system were included in the mold. The results showed that there were no welding lines with the post-injection process, proving to be an option for creating holes in the ceramic parts produced by LPIM. It was observed that best results were obtained at 58 °C mold temperature. The pins extraction temperature was about 45 °C, and the injection pressure was 170 kPa.

Experimental Investigation of Comparative Process Capabilities of Metal and Ceramic Injection Molding for Precision Applications

DEFF Research Database (Denmark)

Islam, Aminul; Giannekas, Nikolaos; Marhöfer, David Maximilian

2016-01-01

and discussion presented in the paper will be useful for thorough understanding of the MIM and CIM processes and to select the right material and process for the right application or even to combine metal and ceramic materials by molding to produce metal–ceramic hybrid components.......The purpose of this paper is to make a comparative study on the process capabilities of the two branches of the powder injection molding (PIM) process—metal injection molding (MIM) and ceramic injection molding (CIM), for high-end precision applications. The state-of-the-art literature does...

Desenvolvimento de PVC reforçado com fibras de vidro longas para fabricação de produtos moldados Long glass fiber reinforcement of PVC molding compounds

Directory of Open Access Journals (Sweden)

Leandro H. Grizzo

2011-01-01

Full Text Available Neste trabalho foi desenvolvido um método para reforçar PVC rígido com fibras de vidro longas através da incorporação pelo processo de recobrimento da fibra contínua com um composto de PVC plastificado. Posteriormente o filamento foi picotado para a formação de grânulos, com fibras de vidro já incorporadas, que foram misturados mecanicamente ao PVC rígido granulado para alimentação direta por moldagem. A moldagem por injeção direta foi realizada com sucesso não sendo necessário a compostagem prévia, o que foi considerado conveniente, pois reduziu as etapas de processamento da resina de PVC e que proporcionou, possivelmente, redução de custos, redução da degradação do comprimento médio das fibras de vidro e diminuição da possibilidade de degradação da resina de PVC. O reforçamento do PVC rígido com 20% em massa de fibras de vidro longas de comprimento inicial entre 13 e 14 mm resultou em adequadas propriedades mecânicas, bem superiores ao PVC rígido não reforçado. Os módulos (tração e flexão e a resistência ao impacto Charpy praticamente dobraram, mesmo com os compósitos apresentando grande quantidade de plastificante em sua formulação, que possibilita ao PVC ser utilizado em outras aplicações não antes possíveis como em peças técnicas de engenharia.In this paper, a method to reinforce rigid PVC with long glass fibers (LGF was developed through the incorporation of continuous glass fibers, as rovings, with plasticized vinyl matrix prepared by the wire coating technique. The plasticized vinyl rovings were pelletized. The pellets (13-14 mm were then blended to a granulated rigid PVC formulation and directly injection molded as testing specimens. The direct injection molding, eliminating the preliminary melt-compounding process, was achieved successfully, which was considered convenient because it reduced the number of processing steps, which allowed cutting expenses, reduced the deterioration of the

Reduction of birefringence in a skin-layer of injection molded polymer strips using CO{sub 2} laser irradiation

Energy Technology Data Exchange (ETDEWEB)

Kurosaki, Yasuo; Satoh, Isao; Saito, Takushi [Tokyo Inst. of Tech. (Japan). Dept. of Mechanical Intelligent Systems Engineering

1995-12-31

Injection molding of polymers is currently utilized for numerous industrial applications. Because of high productivity and stable quality of molded products, the injection-molding process makes the production costs lower, and therefore, is expected to spread more widely in the future. This paper deals with a technique for improving the optical quality of injection molded polymer products using radiative heating. The birefringence frozen in a skin-layer of the molded part was reduced by CO{sub 2} laser heating, and the efficiency of this technique was investigated experimentally. Namely, a simple numerical calculation was performed to estimate the heating efficiency of CO{sub 2} laser in the polymer, effects of radiation heating on the skin-layer of the molded polymer were observed by using a mold with transparent windows, and the residual birefringence frozen in the final molded specimen was measured. The results clearly showed that the birefringence in the skin-layer of injection molded polymer strips was reduced with CO{sub 2} laser heating. The authors believe that the proposed method for reducing the birefringence frozen in injection-molded polymer products is suitable for practical molding, because process time required for the injection-molding is only slightly increased with this method.

Preparation of Thermoplastic Polyimide Ultrafine Fiber Nonwovens by Electrospinning

Directory of Open Access Journals (Sweden)

CHEN Jun

2018-02-01

Full Text Available The superfine fiber of thermoplastic polyimide(LPI, whose average diameter ranges from 0.36μm to 1.47μm, was prepared through electrospinning with DMAc as solvent. It lays a good foundation for the mass preparation of LPI non-woven. The influence of electrospinning process conditions, including LPI concentration, flow rate and voltage, on morphology of LPI fiber was investigated systematically. The results show that the average diameter increases and the fibers diameter distribution turns wider with the LPI concentration increasing from 22%(mass fraction, same as below to 30%. Meanwhile, when the concentration is rather lower, some cambiform fibers can be observed. As the concentration increases, the cambiform fiber disappears. While the concentration increases continually, the fibers are adhered to be flakiness. The change of the spinning voltage makes little difference on the average diameter of fibers; the average diameter of fibers increases with the increase of the flow rate of LPI solution; when the flow rate is more than 1.5mL/h, the fibers start to be adhered, the cambiform fibers appear while the flow rate is over 1.8mL/h. Through optimizing the process, the LPI fibers with average diameter of 1.18μm were prepared under 30℃ with the conditions of 28% concentration, 15kV voltage, 1.2mL/h flow rate and the 25cm receiving distance.

Characterization methods of nano-patterned surfaces generated by induction heating assisted injection molding

DEFF Research Database (Denmark)

Tang, Peter Torben; Ravn, Christian; Menotti, Stefano

2015-01-01

An induction heating-assisted injection molding (IHAIM) process developed by the authors is used to replicate surfaces containing random nano-patterns. The injection molding setup is developed so that an induction heating system rapidly heats the cavity wall at rates of up to 10◦C/s. In order...

Three-dimensional numerical modeling of an induction heated injection molding tool with flow visualization

DEFF Research Database (Denmark)

Guerrier, Patrick; Tosello, Guido; Nielsen, Kaspar Kirstein

2016-01-01

, comparison of the induction heating and filling of the cavity is compared and validated with simulations. Two polymer materials ABS and HVPC were utilized during the injection molding experiments carried out in this work. A nonlinear electromagnetic model was employed to establish an effective linear......Using elevated mold temperature is known to have a positive influence of final injection molded parts. Induction heating is a method that allow obtaining a rapid thermal cycle, so the overall molding cycle time is not increased. In the present research work, an integrated multi-turn induction...... heating coil has been developed and assembled into an injection molding tool provided with a glass window, so the effect of induction heating can directly be captured by a high speed camera. In addition, thermocouples and pressure sensors are also installed, and together with the high speed videos...

Electrical and dielectric properties of foam injection-molded polypropylene/multiwalled carbon nanotube composites

Energy Technology Data Exchange (ETDEWEB)

Ameli, A.; Nofar, M.; Saniei, M.; Hossieny, N.; Park, C. B. [Microcellular Plastics Manufacturing Laboratory, Department of Mechanical and Industrial Engineering, University of Toronto, 5 King’s College Road, Toronto, Ontario, Canada M5S 3G8 (Canada); Pötschke, P. [Leibniz-Institut für Polymerforschung Dresden e.V. (IPF), Hohe Strasse 6, D-01069 Dresden (Germany)

2015-05-22

A combination of high dielectric permittivity (ε′) and low dielectric loss (tan δ) is required for charge storage applications. In percolative systems such as conductive polymer composites, however, obtaining high ε′ and low tan δ is very challenging due to the sharp insulation-conduction transition near the threshold region. Due to the particular arrangement of conductive fillers induced by both foaming and injection molding processes, they may address this issue. Therefore, this work evaluates the application of foam injection molding process in fabricating polymer nanocomposites for energy storage. Polypropylene-multiwalled carbon nanotubes (PP-MWCNT) composites were prepared by melt mixing and foamed in an injection molding process. Electrical conductivity (σ), ε′ and tan δ were then characterized. Also, scanning and transmission electron microscopy (SEM and TEM) was used to investigate the carbon nanotube’s arrangement as well as cellular morphology. The results showed that foam injection-molded composites exhibited highly superior dielectric properties to those of solid counterparts. For instance, foamed samples had ε′=68.3 and tan δ =0.05 (at 1.25 vol.% MWCNT), as opposed to ε′=17.8 and tan δ=0.04 in solid samples (at 2.56 vol.% MWCNT). The results of this work reveal that high performance dielectric nanocomposites can be developed using foam injection molding technologies for charge storage applications.

Predicting shrinkage and warpage in injection molding: Towards automatized mold design

Science.gov (United States)

Zwicke, Florian; Behr, Marek; Elgeti, Stefanie

2017-10-01

It is an inevitable part of any plastics molding process that the material undergoes some shrinkage during solidification. Mainly due to unavoidable inhomogeneities in the cooling process, the overall shrinkage cannot be assumed as homogeneous in all volumetric directions. The direct consequence is warpage. The accurate prediction of such shrinkage and warpage effects has been the subject of a considerable amount of research, but it is important to note that this behavior depends greatly on the type of material that is used as well as the process details. Without limiting ourselves to any specific properties of certain materials or process designs, we aim to develop a method for the automatized design of a mold cavity that will produce correctly shaped moldings after solidification. Essentially, this can be stated as a shape optimization problem, where the cavity shape is optimized to fulfill some objective function that measures defects in the molding shape. In order to be able to develop and evaluate such a method, we first require simulation methods for the diffierent steps involved in the injection molding process that can represent the phenomena responsible for shrinkage and warpage ina sufficiently accurate manner. As a starting point, we consider the solidification of purely amorphous materials. In this case, the material slowly transitions from fluid-like to solid-like behavior as it cools down. This behavior is modeled using adjusted viscoelastic material models. Once the material has passed a certain temperature threshold during cooling, any viscous effects are neglected and the behavior is assumed to be fully elastic. Non-linear elastic laws are used to predict shrinkage and warpage that occur after this point. We will present the current state of these simulation methods and show some first approaches towards optimizing the mold cavity shape based on these methods.

Microstructural and mechanical characterization of injection molded 718 superalloy powders

Energy Technology Data Exchange (ETDEWEB)

Özgün, Özgür [Bingol University, Faculty of Engineering and Architecture, Mechanical Eng. Dep., 12000 Bingol (Turkey); Gülsoy, H. Özkan, E-mail: ogulsoy@marmara.edu.tr [Marmara University, Technology Faculty, Metallurgy and Materials Eng. Dep., 34722 Istanbul (Turkey); Yılmaz, Ramazan [Sakarya University, Technology Faculty, Metallurgy and Materials Eng. Dep., 54187 Sakarya (Turkey); Fındık, Fehim [Sakarya University, Technology Faculty, Metallurgy and Materials Eng. Dep., 54187 Sakarya (Turkey) and International University of Sarajevo, Faculty of Engineering and Natural Sciences, Department of Mechanical Engineering, 71000 Sarajevo, Bosnia and Herzegovina (Bosnia and Herzegowina)

2013-11-05

Highlights: •Microstructural and mechanical properties of injection molded Nickel 718 superalloy were studied. •The maximum sintered density achieved this study was 97.3% at 1290 °C for 3 hours. •Tensile strength of 1022 MPa and elongation of 5.3% were achieved for sintered-heat treated samples. -- Abstract: This study concerns with the determination of optimum production parameters for injection molding 718 superalloy parts. And at the same time, microstructural and mechanical characterization of these produced parts was also carried out. At the initial stage, 718 superalloy powders were mixed with a multi-component binder system for preparing feedstock. Then the prepared feedstock was granulated and shaped by injection molding. Following this operation, the shaped samples were subjected to the debinding process. These samples were sintered at different temperatures for various times. Samples sintered under the condition that gave way to the highest relative density (3 h at 1290 °C) were solution treated and aged respectively. Sintered, solution treated and aged samples were separately subjected to microstructural and mechanical characterization. Microstructural characterization operations such as X-ray diffraction, optical microscope (OM), scanning electron microscope (SEM), transmission electron microscope (TEM) and elemental analysis showed that using polymeric binder system led to plentiful carbide precipitates to be occurred in the injection molded samples. It is also observed that the volume fractions of the intermetallic phases (γ′ and γ″) obtained by aging treatment were decreased due to the plentiful carbide precipitation in the samples. Mechanical characterization was performed by hardness measurements and tensile tests.

Development of magnesium semi-solid injection molding; Magnesium han`yoyu shashutsu seikei gijutsu no kaihatsu

Energy Technology Data Exchange (ETDEWEB)

Sakamoto, K; Sakate, N; Ishida, K; Yamamoto, Y; Nishimura, K [Mazda Motor Corp., Hiroshima (Japan)

1997-10-01

Magnesium semi-solid injection molding is safety and clean process. We have investigated influence of molding conditions on mechanical properties and dimension accuracy of products by semi-solid injection molding. As a result it was proved that the accuracy of products by this process is superior to die casting. This advantage as well as better mechanical properties can be utilized for net shape molding of some automobile parts. 4 refs., 8 figs., 3 tabs.

Evaluation by nanoindentation of technological products manufactured by pulse injection molding process

Directory of Open Access Journals (Sweden)

Natova Margarita

2018-01-01

Full Text Available During conventional polymer injection molding, flow- and weld lines can arise at the molded parts caused by disturbed polymer melt flow when it crosses different parts of the equipment. Such processed plastic goods have discrete zones of inhomogeneities of very small dimensions. In order to stabilize the melt flow and to equalize dimensions of such defective products, an approach for pulse injection molding is applied during production of polymer packagings. Testing methods used for evaluation of macromechanical performance of processed polymer products are not readily applicable to estimate the changes in visual surface obtained during pulse injecting. To overcome this testing inconvenience the performance of processed packagings is evaluated by nanoindentation. Using this method, a quantitative assessment of the polymer properties is obtained from different parts of technological products.

Pressureless sintering behavior of injection molded alumina ceramics

Directory of Open Access Journals (Sweden)

Liu W.

2014-01-01

Full Text Available The pressureless sintering behaviors of two widely used submicron alumina (MgOdoped and undoped with different solid loadings produced by injection molding have been studied systematically. Regardless of the sinterability of different powders depending on their inherent properties, solid loading plays a critical role on the sintering behavior of injection molded alumina, which greatly determines the densification and grain size, and leads to its full densification at low temperatures. As compared to the MgO-doped alumina powder, the undoped specimens exhibit a higher sinterability for its smaller particle size and larger surface area. While full densification could be achieved for MgO-doped powders with only a lower solid loading, due to the fact that MgO addition can reduce the detrimental effect of the large pore space on the pore-boundary separation.

Evolution of Additively Manufactured Injection Molding Inserts Investigated by Thermal Simulations

DEFF Research Database (Denmark)

Hofstätter, Thomas; Pedersen, David B.; Tosello, Guido

Injection molding using inserts from vat polymerization, an additive manufacturing technology, has been investigated for pilot production and rapid prototyping purposes throughout the past years. A standard mold is equipped with additively manufactured inserts in a rectangular shape of (20 x 20 x 2...

Neodymium: YAG laser damage threshold. A comparison of injection-molded and lathe-cut polymethylmethacrylate intraocular lenses.

Science.gov (United States)

Wilson, S E; Brubaker, R F

1987-01-01

The possibility that injection-molded intraocular lenses (IOLs) with imperfections called iridescent clefts could have a decreased threshold to neodymium: YAG (Nd:YAG) laser-induced damage was investigated. Thresholds for Nd:YAG laser-induced damage were determined for injection-molded and lathe-cut polymethylmethacrylate lenses. When aimed at a membrane in contact with a posterior convex surface, the average thresholds were 0.96 +/- 0.18 mJ (Standard deviation [SD]) and 1.80 +/- 0.55 mJ, respectively. The difference was significant at P = 0.001. When injection-molding polymethylmethacrylate was used to make lathe-cut IOLs, very few iridescent clefts were present, and the threshold to Nd:YAG laser-induced damage was 0.94 +/- 0.25 mJ. Iridescent clefts are therefore produced during the injection-molding process but they do not lower the threshold to Nd:YAG laser-induced damage. Rather, the reduced threshold in injection-molded lenses is most probably a result of the polymethylmethacrylate used in their manufacture. Clinically, iridescent clefts in a lens suggest that it has been manufactured by an injection-molding process and that Nd:YAG laser posterior capsulotomy must be performed at the lowest possible energy level to avoid damage.

Analysis of Cavity Pressure and Warpage of Polyoxymethylene Thin Walled Injection Molded Parts: Experiments and Simulations

DEFF Research Database (Denmark)

Guerrier, Patrick; Tosello, Guido; Hattel, Jesper Henri

2014-01-01

Process analysis and simulations on molding experiments of 3D thin shell parts have been conducted. Moldings were carried out with polyoxymethylene (POM). The moldings were performed with cavity pressure sensors in order to compare experimental process results with simulations. The warpage...... was characterized by measuring distances using a tactile coordinate measuring machine (CMM). Molding simulations have been executed taking into account actual processing conditions. Various aspects have been considered in the simulation: machine barrel geometry, injection speed profiles, cavity injection pressure......, melt and mold temperatures, material rheological and pvT characterization. Factors investigated for comparisons were: injection pressure profile, short shots length, flow pattern, and warpage. A reliable molding experimental database was obtained, accurate simulations were conducted and a number...

Results on powder injection molding of Ni[sub 3]Al and application to other intermetallic compositions

Energy Technology Data Exchange (ETDEWEB)

Cooper, R.M.

1992-01-01

Net forming processes are under development to allow affordable production of intermetallic components. Powder injection molding (PIM) mav be employed for the production of complex-shaped intermetallic geometries. Proper choice of powder parameters and processing conditions can lead to the formation of fullv dense structures through pressure-less sintering. In this study, Ni[sub 3]Al with 0.04 wt.-% boron has been successfully injection molded and sintered to full density. A yield strength of 340 MPa, ultimate tensile strength (UTS) of 591 MPa, and 8% elongation were attained for injection molded and sintered tensile bars. Powder characteristics and sintering behavior are given for the nickel aluminide employed in this study to highlight the powder attributes needed for injection molding. Molding parameters, debinding and sintering schedules, along, with mechanical properties are presented to indicate the viability of PIM for intermetallics. This approach based on the understanding of key powder characteristics and use of the reactive synthesis powder process mav be extended to the successful injection molding of other intermetallic systems.

Results on powder injection molding of Ni{sub 3}Al and application to other intermetallic compositions

Energy Technology Data Exchange (ETDEWEB)

Cooper, R.M.

1992-12-31

Net forming processes are under development to allow affordable production of intermetallic components. Powder injection molding (PIM) mav be employed for the production of complex-shaped intermetallic geometries. Proper choice of powder parameters and processing conditions can lead to the formation of fullv dense structures through pressure-less sintering. In this study, Ni{sub 3}Al with 0.04 wt.-% boron has been successfully injection molded and sintered to full density. A yield strength of 340 MPa, ultimate tensile strength (UTS) of 591 MPa, and 8% elongation were attained for injection molded and sintered tensile bars. Powder characteristics and sintering behavior are given for the nickel aluminide employed in this study to highlight the powder attributes needed for injection molding. Molding parameters, debinding and sintering schedules, along, with mechanical properties are presented to indicate the viability of PIM for intermetallics. This approach based on the understanding of key powder characteristics and use of the reactive synthesis powder process mav be extended to the successful injection molding of other intermetallic systems.

Evaluation of stability for monolayer injection molding tools coating

DEFF Research Database (Denmark)

Cech, Jiri; Taboryski, Rafael J.

2012-01-01

We tested and characterized molecular coating of Aluminium and Nickel prototype molds and mold inserts for polymer replication via injection molding (IM). X-Ray photoelectron spectroscopy (XPS) data, sessile drop contact angles with multiple fluids, surface energy and roughness data have been...... collected and used to predict coating lifetimes. Samples have been characterized immediately after coating, after 500+ IM cycles to test durability and after 7 months to test temporal stability. Sessile drop contact angle was measured for multiple fluids, namely water, di-iodomethane and benzylacohol....... Detectable coating presence was indicated by an increased angle on all post IM samples. To conclude, we present mold coating evaluation method, which is well suited for ultrathin, controlable, covalently bonded coating, that is reasonably durable, affordable, scalable to production, detectable on surface...

Production and Mechanical Characterization of Ballistic Thermoplastic Composite Materials

OpenAIRE

D. Korsacilar; C. Atas

2014-01-01

In this study, first thermoplastic composite materials /plates that have high ballistic impact resistance were produced. For this purpose, the thermoplastic prepreg and the vacuum bagging technique were used to produce a composite material. Thermoplastic prepregs (resin-impregnated fiber) that are supplied ready to be used, namely high-density polyethylene (HDPE) was chosen as matrix and unidirectional glass fiber was used as reinforcement. In order to compare the fiber c...

Production and evaluation of recycled polymers from açaí fibers

Directory of Open Access Journals (Sweden)

Clívia Danúbia Pinho da Costa Castro

2010-06-01

Full Text Available The possibility of recycling and the favorable mechanical properties of the products have encouraged the study and production of thermoplastic composites from natural fibrous waste. Açaí (cabbage palm fiber, which is removed from the seed, has been slightly investigated, as compared to what is already known about the fruit pulp. In this study, the influence of açaí fiber as an element of reinforcement in recycled everyday usage thermoplastics using simple, low cost methodology was evaluated. Recycled matrixes of high impact polystyrene and polypropylene were molded by hot compression from which the fiber composites were obtained. The FTIR technique showed that the process was efficient in preventing degradation of the açaí fibers. The influence of the fiber on the mechanical behavior of the recycled matrixes was investigated by microscopic images of compression and impact tests. The results showed better impact performance for the fiber combined with the polymeric matrixes.

Design and thermal analysis of a mold used in the injection of elastomers

Science.gov (United States)

Fekiri, Nasser; Canto, Cécile; Madec, Yannick; Mousseau, Pierre; Plot, Christophe; Sarda, Alain

2017-10-01

In the process of injection molding of elastomers, improving the energy efficiency of the tools is a current challenge for industry in terms of energy consumption, productivity and product quality. In the rubber industry, 20% of the energy consumed by capital goods comes from heating processes; more than 50% of heat losses are linked to insufficient control and thermal insulation of Molds. The design of the tooling evolves in particular towards the reduction of the heated mass and the thermal insulation of the molds. In this paper, we present a complex tool composed, on one hand, of a multi-cavity mold designed by reducing the heated mass and equipped with independent control zones placed closest to each molding cavity and, on the other hand, of a regulated channel block (RCB) which makes it possible to limit the waste of rubber during the injection. The originality of this tool lies in thermally isolating the regulated channel block from the mold and the cavities between them in order to better control the temperature field in the material which is transformed. We present the design and the instrumentation of the experimental set-up. Experimental measurements allow us to understand the thermal of the tool and to show the thermal heterogeneities on the surface of the mold and in the various cavities. Tests of injection molding of the rubber and a thermal balance on the energy consumption of the tool are carried out.

Coaxial Thermoplastic Elastomer-Wrapped Carbon Nanotube Fibers for Deformable and Wearable Strain Sensors

KAUST Repository

Zhou, Jian

2018-01-22

Highly conductive and stretchable fibers are crucial components of wearable electronics systems. Excellent electrical conductivity, stretchability, and wearability are required from such fibers. Existing technologies still display limited performances in these design requirements. Here, achieving highly stretchable and sensitive strain sensors by using a coaxial structure, prepared via coaxial wet spinning of thermoplastic elastomer-wrapped carbon nanotube fibers, is proposed. The sensors attain high sensitivity (with a gauge factor of 425 at 100% strain), high stretchability, and high linearity. They are also reproducible and durable. Their use as safe sensing components on deformable cable, expandable surfaces, and wearable textiles is demonstrated.

Micro Machining of Injection Mold Inserts for Fluidic Channel of Polymeric Biochips

Directory of Open Access Journals (Sweden)

Myeong-Woo Cho

2007-08-01

Full Text Available Recently, the polymeric micro-fluidic biochip, often called LOC (lab-on-a-chip, has been focused as a cheap, rapid and simplified method to replace the existing biochemical laboratory works. It becomes possible to form miniaturized lab functionalities on a chip with the development of MEMS technologies. The micro-fluidic chips contain many micro-channels for the flow of sample and reagents, mixing, and detection tasks. Typical substrate materials for the chip are glass and polymers. Typical techniques for micro-fluidic chip fabrication are utilizing various micro pattern forming methods, such as wet-etching, micro-contact printing, and hot-embossing, micro injection molding, LIGA, and micro powder blasting processes, etc. In this study, to establish the basis of the micro pattern fabrication and mass production of polymeric micro-fluidic chips using injection molding process, micro machining method was applied to form micro-channels on the LOC molds. In the research, a series of machining experiments using micro end-mills were performed to determine optimum machining conditions to improve surface roughness and shape accuracy of designed simplified micro-channels. Obtained conditions were used to machine required mold inserts for micro-channels using micro end-mills. Test injection processes using machined molds and COC polymer were performed, and then the results were investigated.

Real-time parameter optimization based on neural network for smart injection molding

Science.gov (United States)

Lee, H.; Liau, Y.; Ryu, K.

2018-03-01

The manufacturing industry has been facing several challenges, including sustainability, performance and quality of production. Manufacturers attempt to enhance the competitiveness of companies by implementing CPS (Cyber-Physical Systems) through the convergence of IoT(Internet of Things) and ICT(Information & Communication Technology) in the manufacturing process level. Injection molding process has a short cycle time and high productivity. This features have been making it suitable for mass production. In addition, this process is used to produce precise parts in various industry fields such as automobiles, optics and medical devices. Injection molding process has a mixture of discrete and continuous variables. In order to optimized the quality, variables that is generated in the injection molding process must be considered. Furthermore, Optimal parameter setting is time-consuming work to predict the optimum quality of the product. Since the process parameter cannot be easily corrected during the process execution. In this research, we propose a neural network based real-time process parameter optimization methodology that sets optimal process parameters by using mold data, molding machine data, and response data. This paper is expected to have academic contribution as a novel study of parameter optimization during production compare with pre - production parameter optimization in typical studies.

A Review of Metal Injection Molding- Process, Optimization, Defects and Microwave Sintering on WC-Co Cemented Carbide

Science.gov (United States)

Shahbudin, S. N. A.; Othman, M. H.; Amin, Sri Yulis M.; Ibrahim, M. H. I.

2017-08-01

This article is about a review of optimization of metal injection molding and microwave sintering process on tungsten cemented carbide produce by metal injection molding process. In this study, the process parameters for the metal injection molding were optimized using Taguchi method. Taguchi methods have been used widely in engineering analysis to optimize the performance characteristics through the setting of design parameters. Microwave sintering is a process generally being used in powder metallurgy over the conventional method. It has typical characteristics such as accelerated heating rate, shortened processing cycle, high energy efficiency, fine and homogeneous microstructure, and enhanced mechanical performance, which is beneficial to prepare nanostructured cemented carbides in metal injection molding. Besides that, with an advanced and promising technology, metal injection molding has proven that can produce cemented carbides. Cemented tungsten carbide hard metal has been used widely in various applications due to its desirable combination of mechanical, physical, and chemical properties. Moreover, areas of study include common defects in metal injection molding and application of microwave sintering itself has been discussed in this paper.

Process control and product evaluation in micro molding using a screwless/two-plunger injection unit

DEFF Research Database (Denmark)

Tosello, Guido; Hansen, Hans Nørgaard; Dormann, B.

2010-01-01

A newly developed μ-injection molding machine equipped with a screwless/two-plunger injection unit has been employed to mould miniaturized dog-bone shaped specimens on polyoxymethylene and its process capability and robustness have been analyzed. The influence of process parameters on μ-injection......A newly developed μ-injection molding machine equipped with a screwless/two-plunger injection unit has been employed to mould miniaturized dog-bone shaped specimens on polyoxymethylene and its process capability and robustness have been analyzed. The influence of process parameters on μ......-injection molding was investigated using the Design of Experiments technique. Injection pressure and piston stroke speed as well as part weight and dimensions were considered as quality factors over a wide range of process parameters. Experimental results obtained under different processing conditions were...

Adaptive temporal refinement in injection molding

Science.gov (United States)

Karyofylli, Violeta; Schmitz, Mauritius; Hopmann, Christian; Behr, Marek

2018-05-01

Mold filling is an injection molding stage of great significance, because many defects of the plastic components (e.g. weld lines, burrs or insufficient filling) can occur during this process step. Therefore, it plays an important role in determining the quality of the produced parts. Our goal is the temporal refinement in the vicinity of the evolving melt front, in the context of 4D simplex-type space-time grids [1, 2]. This novel discretization method has an inherent flexibility to employ completely unstructured meshes with varying levels of resolution both in spatial dimensions and in the time dimension, thus allowing the use of local time-stepping during the simulations. This can lead to a higher simulation precision, while preserving calculation efficiency. A 3D benchmark case, which concerns the filling of a plate-shaped geometry, is used for verifying our numerical approach [3]. The simulation results obtained with the fully unstructured space-time discretization are compared to those obtained with the standard space-time method and to Moldflow simulation results. This example also serves for providing reliable timing measurements and the efficiency aspects of the filling simulation of complex 3D molds while applying adaptive temporal refinement.

Microcellular injection-molding of polylactide with chain-extender

International Nuclear Information System (INIS)

Pilla, Srikanth; Kramschuster, Adam; Yang Liqiang; Lee, Junghoo; Gong Shaoqin; Turng, Lih-Sheng

2009-01-01

The effects of adding an epoxy-based chain-extender (CE) on the properties of injection-molded solid and microcellular polylactide (PLA) were studied. PLA and PLA with 8 wt.% CE (PLA-CE) were melt-compounded using a twin-screw extruder. Solid and microcellular specimens were produced via a conventional and microcellular injection-molding process, respectively. Various characterization techniques including gel permeation chromatography, tensile testing and dynamic mechanical analysis, scanning electron microscopy and differential scanning calorimetry were applied to study the molecular weight, static and dynamic mechanical properties, cell morphology, and crystallization behavior, respectively. The addition of CE enhanced the molecular weight but decreased the crystallinity of PLA. The addition of CE also reduced the cell size and increased the cell density. Furthermore, the decomposition temperatures and several tensile properties, including specific strength, specific toughness, and strain-at-break of both solid and microcellular PLA specimens, increased with the addition of CE.

Multiobjective Design of Turbo Injection Mode for Axial Flux Motor in Plastic Injection Molding Machine by Particle Swarm Optimization

Directory of Open Access Journals (Sweden)

Jian-Long Kuo

2015-01-01

Full Text Available This paper proposes a turbo injection mode (TIM for an axial flux motor to apply onto injection molding machine. Since the injection molding machine requires different speed and force parameters setting when finishing a complete injection process. The interleaved winding structure in the motor provides two different injection levels to provide enough injection forces. Two wye-wye windings are designed to switch two control modes conveniently. Wye-wye configuration is used to switch two force levels for the motor. When only one set of wye-winding is energized, field weakening function is achieved. Both of the torque and speed increase under field weakening operation. To achieve two control objectives for torque and speed of the motor, fuzzy based multiple performance characteristics index (MPCI with particle swarm optimization (PSO is used to find out the multiobjective optimal design solution. Both of the torque and speed are expected to be maximal at the same time. Three control factors are selected as studied factors: winding diameter, winding type, and air-gap. Experimental results show that both of the torque and speed increase under the optimal condition. This will provide enough large torque and speed to perform the turbo injection mode in injection process for the injection molding machine.

Mechanical behavior of recycled polyethylene/piassava fiber composites

Energy Technology Data Exchange (ETDEWEB)

Elzubair, Amal, E-mail: amal@metalmat.ufrj.br [Universidade Federal de Rio de Janeiro, Departamento de Engenharia Metalurgica e de Materiais, Ilha do Fundao, Bloco F, 21941-972 Rio de Janeiro, RJ (Brazil); Praca General Tiburcio, 80, Urca, 22290-270 Rio de Janeiro, RJ (Brazil); Miguez Suarez, Joao Carlos, E-mail: jmiguez@ime.eb.br [Instituto Militar de Engenharia, Secao de Engenharia Mecanica e de Materiais, Praca General Tiburcio, 80, Urca, 22290-270, Rio de Janeiro, RJ (Brazil); Praca General Tiburcio, 80, Urca, 22290-270 Rio de Janeiro, RJ (Brazil)

2012-11-15

The use of natural fibers for reinforcement of thermoplastics (which are found in domestic waste) is desirable since it is based on abundant and renewable resources and can be ecologically correct. Leopoldinia piassaba Wallace (commonly known as piassava), a palm tree native of Amazon-Brazil, is cheap, easily found in Brazilian markets and the main component of home appliances and decorative goods. The subject of the present work is a study of mechanical properties of composites of recycled high density polyethylene (HDPE-r) reinforced with untreated, and treated (silane and NaOH) piassava fibers, in proportions varying from 0% to 20% and injection molded under fixed processing conditions. The influence of increasing amounts of piassava fibers and of surface treatment on the mechanical behavior of the composites was investigated by thermogravimetric analysis (TGA), mechanical testing (tensile and flexure) and scanning electron microscopy (SEM). The topography of the fractured surfaces of tested tensile specimens of unfilled and filled recycled HDPE was also observed by SEM and correlated with the mechanical behavior. As the fiber content increases, the composites show a gradual change in the mechanical properties and in the fracture mechanisms. Composites with 15% and 20% of piassava fibers were found to exhibit the best mechanical performance.

Smart plastic functionalization by nanoimprint and injection molding

DEFF Research Database (Denmark)

Zalkovskij, Maksim; Thamdrup, Lasse Højlund; Smistrup, Kristian

2015-01-01

In this paper, we present a route for making smart functionalized plastic parts by injection molding with sub-micrometer surface structures. The method is based on combining planar processes well known and established within silicon micro and sub-micro fabrication with proven high resolution...

Mechanical properties of the weld line defect in micro injection molding for various nano filled polypropylene composites

International Nuclear Information System (INIS)

Xie Lei; Ziegmann, Gerhard

2011-01-01

is increased to 30%, the E modulus and tensile strength of micro weld line were increased again compared with the low loading level. → Finally, an empirical prediction equation for micro injection molded weld line strength of nano PP composites was proposed for higher nano filler loading fraction than 10 wt%. - Abstract: The nano filled functional polymer materials have been widely processed with micro injection molding technology for micro electromechanical systems (MEMS) fabrication. As the unfavorable defect in micro injection molding parts, weld line brings reduced mechanical and physical properties, especially for nano filled composites. In this study, polypropylene (PP) was compounded respectively with carbon nano fibers (CNFs) and TiO 2 nano particles at various weight fractions (10, 20, 30, 35 wt%) through co-screws internal mixing. The morphological, thermal and rheological properties of nano composites were characterized by wider angle X-ray diffraction (WXRD), different scanning calorimeter (DSC) and high pressure capillary rheometer. Additionally, under the constant setting of injection molding process parameters in injection molding machine, micro tensile samples with weld lines for each nano filled PP composite were produced. The tensile tests were served as the characterizing method for weld line mechanical properties. The results show that when the CNFs is filled higher than 10 wt%, the tensile strength of samples with weld lines made of nano composites become lower than neat PP. While the raising CNFs content contributes to the improved E modulus of micro injection molded weld lines. Additionally, with the increasing fraction of CNFs in PP, the weld line area's elongation percent is decreased. Whereas for case of TiO 2 , the 10 wt% is the threshold for micro injection molded weld line tensile strength turning from decrease trend to increase. The same as CNFs, elongation of micro weld line samples were in general lower than neat PP as well, due to

LCI Databases Sensitivity Analysis of the Environmental Impact of the Injection Molding Process

Directory of Open Access Journals (Sweden)

Ana Elduque

2015-03-01

Full Text Available During the last decades, society’s concern for the environment has increased. Specific tools like the Life Cycle Assessment (LCA, and software and databases to apply this method have been developed to calculate the environmental burden of products or processes. Calculating the environmental impact of plastic products is relevant as the global plastics production rose to 288 million tons in 2012. Among the different ways of processing plastics, the injection molding process is one of the most used in the industry worldwide. In this paper, a sensitivity analysis of the environmental impact of the injection molding process has been carried out. In order to perform this study, the EcoInvent database inventory for injection molding, and the data from which this database is created, have been studied. Generally, when an LCA of a product is carried out, databases such as EcoInvent, where materials, processes and transports are characterized providing average values, are used to quantify the environmental impact. This approach can be good enough in some cases but in order to assess a specific production process, like injection molding, a further level of detail is needed. This study shows how the final results of environmental impact differ for injection molding when using the PVC’s, PP’s or PET’s data. This aspect suggests the necessity of studying, in a more precise way, this process, to correctly evaluate its environmental burden. This also allows us to identify priority areas and thereby actions to develop a more sustainable way of manufacturing plastics.

Characterizing the influence of matrix ductility on damage phenomenology in continuous fiber-reinforced thermoplastic laminates undergoing quasi-static indentation

KAUST Repository

Yudhanto, Arief

2017-12-12

The use of thermoplastic matrix was known to improve the impact properties of laminated composites. However, different ductility levels can exist in a single family of thermoplastic matrix, and this may consequently modify the damage phenomenology of thermoplastic composites. This paper focuses on the effect of matrix ductility on the out-of-plane properties of thermoplastic composites, which was studied through quasi-static indentation (QSI) test that may represent impact problem albeit the speed difference. We evaluated continuous glass-fiber reinforced polypropylene thermoplastic composites (GFPP), and selected homopolymer PP and copolymer PP that represent ductile and less ductile matrices, respectively. Several cross-ply laminates were selected to study the influence of ply thicknesses and relative orientation of interfaces on QSI properties of GFPP. It is expected that GFPP with ductile matrix improves energy absorption of GFPP. However, the damage mechanism is completely different between GFPP with ductile and GFPP with less ductile matrices. GFPP with ductile matrix exhibits smaller damage zone in comparison to the one with less ductile matrix. Higher matrix ductility inhibits the growth of ply cracking along the fiber, and this causes the limited size of delamination. The stacking sequence poses more influence on less ductile composites rather than the ductile one.

The Effect of Masterbatch Recipes on the Homogenization Properties of Injection Molded Parts

OpenAIRE

Zsíros, László; Török, Dániel; Kovács, József Gábor

2017-01-01

Appearance is a key factor in most injection molding applications. Unfortunately, there is no widespread method to objectively test visual appearance, such as color inhomogeneity of the parts or other surface defects. We developed an evaluation method to characterize the color inhomogeneity of injection molded parts. First, we examined manufacturing conditions and masterbatch recipes and then the individual effects of the components and their interactions on homogeneity.

Injection molding of micro pillars on vertical side walls using polyether-ether-ketone (PEEK)

DEFF Research Database (Denmark)

Zhang, Yang; Hansen, Hans Nørgaard; Sørensen, Søren

2016-01-01

This paper investigates the replication of microstructures on a vertical wall by PEEK injection molding. A 4-cavity insert was used in the injection molding. Pre-fabricated nickel plates with ø 4 μm micro holes on the surface were glued on vertical walls in the cavities. 3 cavities were coated by...

Powder injection molding of Stellite 6 powder: Sintering, microstructural and mechanical properties

International Nuclear Information System (INIS)

Gülsoy, H. Özkan; Özgün, Özgür; Bilketay, Sezer

2016-01-01

The purpose of this study was to produce Co-based Stellite 6 superalloy components by using the method of Powder Injection Molding (PIM) and to characterize the microstructural and mechanical properties of the produced components. The experimental studies were started through the formation of feedstock by mixing Stellite 6 powder with a multicomponent binder system. Prepared feedstock was formed by utilizing powder injection molding technique. Then the molded samples were subjected to the solvent and thermal debinding processes. Different sintering cycles were applied to the raw components for the purpose of determining the optimum sintering conditions. The densities of the sintered components were determined in accordance with the Archimedes' principle. The microstructural characterization was performed through scanning electron microscope (SEM) analysis, energy dispersive spectrometry (EDS) analyses, and X-ray diffraction (XRD) analysis. Hardness measurement and tensile test were conducted in order to determine the mechanical properties. The results illustrated that the injection molded Stellite 6 components were composed of fine and equiaxed grains, plenty of carbide precipitates exhibiting homogenous distribution throughout the microstructure formed at the grain boundaries and thus the mechanical properties were considerably high.

Tensile strength of ramie yarn (spinning by machine)/HDPE thermoplastic matrix composites

International Nuclear Information System (INIS)

Banowati, Lies; Hadi, Bambang K.; Suratman, Rochim; Faza, Aulia

2016-01-01

Technological developments should be trooped to prevent a gap between technology and environmental sustainability, then it needs to be developed “Green technology”. In this research is making of green composites which use natural fiber ramie as reinforcement. Whereas the matrix used was HDPE (High Density Polyethylene) thermoplastic polymer which could be recycled and had a good formability and flexibility. The ramie yarns and fibers for unidirectional (0°) direction respectively were mixed with HDPE powder and processed using hot compression molding. The surface morphology was observed by SEM (Scanning Electrone Microscopy). Results showed that both tensile strength of the ramie fiber/HDPE composites increased in comparison with the ramie yarn (spinning by machine)/HDPE composites. However, the ramie yarn (spinning by machine)/HDPE composites have a good producibility for wider application. Analysis of the test results using the Weibull distribution as approaches to modeling the reliability of the specimens.

Tensile strength of ramie yarn (spinning by machine)/HDPE thermoplastic matrix composites

Energy Technology Data Exchange (ETDEWEB)

Banowati, Lies, E-mail: liesbano@gmail.com; Hadi, Bambang K., E-mail: bkhadi@ae.itb.ac.id; Suratman, Rochim, E-mail: rochim@material.itb.ac.id; Faza, Aulia [Faculty of Mechanical and Aerospace Engineering, Bandung Institute of Technology, Indonesia Jl. Ganesha 10, Bandung (Indonesia)

2016-03-29

Technological developments should be trooped to prevent a gap between technology and environmental sustainability, then it needs to be developed “Green technology”. In this research is making of green composites which use natural fiber ramie as reinforcement. Whereas the matrix used was HDPE (High Density Polyethylene) thermoplastic polymer which could be recycled and had a good formability and flexibility. The ramie yarns and fibers for unidirectional (0°) direction respectively were mixed with HDPE powder and processed using hot compression molding. The surface morphology was observed by SEM (Scanning Electrone Microscopy). Results showed that both tensile strength of the ramie fiber/HDPE composites increased in comparison with the ramie yarn (spinning by machine)/HDPE composites. However, the ramie yarn (spinning by machine)/HDPE composites have a good producibility for wider application. Analysis of the test results using the Weibull distribution as approaches to modeling the reliability of the specimens.

Intelligent methods for the process parameter determination of plastic injection molding

Science.gov (United States)

Gao, Huang; Zhang, Yun; Zhou, Xundao; Li, Dequn

2018-03-01

Injection molding is one of the most widely used material processing methods in producing plastic products with complex geometries and high precision. The determination of process parameters is important in obtaining qualified products and maintaining product quality. This article reviews the recent studies and developments of the intelligent methods applied in the process parameter determination of injection molding. These intelligent methods are classified into three categories: Case-based reasoning methods, expert system- based methods, and data fitting and optimization methods. A framework of process parameter determination is proposed after comprehensive discussions. Finally, the conclusions and future research topics are discussed.

The Effect of Masterbatch Recipes on the Homogenization Properties of Injection Molded Parts

Directory of Open Access Journals (Sweden)

László Zsíros

2017-01-01

Full Text Available Appearance is a key factor in most injection molding applications. Unfortunately, there is no widespread method to objectively test visual appearance, such as color inhomogeneity of the parts or other surface defects. We developed an evaluation method to characterize the color inhomogeneity of injection molded parts. First, we examined manufacturing conditions and masterbatch recipes and then the individual effects of the components and their interactions on homogeneity.

The influence of technological parameters on the dynamic behavior of "liquid wood" samples obtained by injection molding

Science.gov (United States)

Plavanescu Mazurchevici, Simona; Carausu, Constantin; Comaneci, Radu; Nedelcu, Dumitru

2017-10-01

The plastic products contribute to environmental pollution. Replacing the plastic materials with biodegradable materials with superior properties is an absolute necessity and important research direction for the near future. The first steps in this regard were the creation of composite materials containing natural fibers with positive effects on the environment that have penetrated in different fields. The bioplastics and biocomposites made from natural fibers is a topical solution. The next step was made towards obtaining biodegradable and recyclable materials based on cellulose, lignin and no carcinogens. In this category fall the "liquid wood" with a use up to five times without affecting the mechanical properties. "Liquid wood" is a high quality thermoplastic biocomposite. "Liquid wood" is a biopolymer composite divided in three categories, ARBOFORM®, ARBOBLEND® and ARBOFILL®, which have differed composition in terms of lignin percentage, being delivered by Tecnaro, as granules, [1]. The paper's research was focus on Arboform L V3 Nature and Arboform L V3 Nature reinforced with aramid fiber. In the experimental plan were taken into account six parameters (Dinj - direction of injection [°]; Ttop - melting temperature [°C]; Pinj - injection pressure [MPa] Ss - speed [m/min]; tinj - injection time [s] and tc - cooling time [s]) each with two levels, research carried on by Taguchi methodology. Processing Taguchi method allowed both Taguchi setting work parameters influence on storage modulus and damping as the size and influence their ranking. Experimental research concerning the influence technological parameters on storage modulus of samples obtained by injection from Arboform L V3 Nature yielded an average of 6055MPa and descending order as follows: Trac, Ss, Pinj, Dinj and Ttop. The average of model for reinforced material was 6419MPa and descending order of parameters influence such as: Dinj, Trac, Ttop, tinj, Ss and Pinj.

Injection molded nanofluidic chips: Fabrication method and functional tests using single-molecule DNA experiments

DEFF Research Database (Denmark)

Utko, Pawel; Persson, Karl Fredrik; Kristensen, Anders

2011-01-01

We demonstrate that fabrication of nanofluidic systems can be greatly simplified by injection molding of polymers. We functionally test our devices by single-molecule DNA experiments in nanochannels.......We demonstrate that fabrication of nanofluidic systems can be greatly simplified by injection molding of polymers. We functionally test our devices by single-molecule DNA experiments in nanochannels....

INJECTION MOLDING AND STRUCTURAL ANALYSIS IN METAL TO PLASTIC CONVERSION OF BOLTED FLANGE JOINT BY CAE

Directory of Open Access Journals (Sweden)

Marian Blaško

2014-12-01

Full Text Available Many metal parts in various applications are being replaced by plastic parts. There are several reasons for that depending on actual application - minimize part cost, enhance corrosion resistance, integrating more components into one part etc. Most important steps of metal to plastic conversion are material selection and design of plastic part. Plastic part has to withstand the same load as metal part. To fulfill this requirement fiber reinforced engineering plastics are often used. Also it is convenient to substitute heavy wall sections with ribbed structure to increase load-carrying ability of part and decrease cycle time, eliminate voids, sink marks etc. Mechanical properties of such part could be highly affected by fiber orientation. Results of fiber orientation from injection molding filling analysis can be used in stress analysis for better prediction of part response to mechanical load. Such coupled analysis is performed here in this case study on bolted flange joint.

Serial corneal endothelial cell loss with lathe-cut and injection-molded posterior chamber intraocular lenses.

Science.gov (United States)

Kraff, M C; Sanders, D R; Lieberman, H L

1983-01-01

We compared endothelial cell loss of patients implanted with lathe-cut posterior chamber lenses and those implanted with injection-molded lenses over a three-year postoperative period. Results were based on more than 2,500 measurements of corneal endothelial density. Although the technique of cataract extraction (anterior chamber phacoemulsification, posterior chamber phacoemulsification, or planned extracapsular extraction) significantly affected cell loss (P less than .01), the type of implant (lathe-cut or injection-molded) did not. Significant continuing endothelial cell loss did not occur during the first three postoperative years with injection-molded lenses. There was, however, a statistically significant 7% to 15% additional cell loss after surgery over the first two to three postoperative years with lathe-cut implants. There have been no cases of corneal endothelial decompensation developing after implantation of injection-molded or lathe-cut lenses. Because a standard field clinical specular microscope was used in this study, cell counting errors cannot be ruled out as a cause of these findings.

Superconducting YBa2Cu3O7-x fibers from the thermoplastic gel method

International Nuclear Information System (INIS)

Uchikawa, F.; Mackenzie, J.D.

1989-01-01

The successful fabrication of ceramic superconducting YBa 2 Cu 3 O 7-x fibers has been investigated. A new method was proposed for synthesis of the fibers through a solution route. The thermoplastic gels were synthesized using Y, Ba, Cu, ethoxides, and diethylenetriamine. The fibers were drawn from the reheated gels. The fibers were characterized by x-ray diffraction, SEM, and shrinkage ratio measurements. The fired and then annealed fiber is shown to have a superconducting transition temperature of 91 K (onset) and zero resistance temperature of 84 K. With regard to the fired fibers, it is found that the surface area increased and superconducting transition temperature decreased with increasing organic content in the initial gel. The usefulness of this method is shown and the structure of the synthesized gel is discussed

Moldes de ABS construídos pelo processo de modelagem por fusão e deposição para injeção de PP e PEBD PP and LDPE injection in ABS molds built with fused deposition modeling

Directory of Open Access Journals (Sweden)

José A. Foggiatto

2004-12-01

Full Text Available Os processos de prototipagem rápida (Rapid Prototyping - RP e ferramental rápido (Rapid Tooling - RT surgiram para reduzir os tempos de desenvolvimento de produtos na fase de projeto diminuindo a necessidade de retrabalhos e, conseqüentemente, antecipando a entrada de novos produtos no mercado. Neste trabalho foi utilizada uma das tecnologias de prototipagem rápida, denominada Modelagem por Fusão e Deposição (FDM, na construção de moldes em ABS com o objetivo de investigar sua aplicação na moldagem por injeção de termoplásticos. Amostras das peças injetadas foram submetidas a ensaios de difração de raios X, dureza Shore D e tração. Os resultados mostraram a viabilidade de fabricar pequenos lotes de peças em PEBD e PP com propriedades mecânicas bastante similares às encontradas em peças moldadas em moldes metálicos.Rapid Prototyping and Rapid Tooling are aimed at reducing the development time of products in the design phase by minimizing re-workings and, consequently, reducing the time to launch new products. In this work one of the technologies of rapid prototyping, called Fused Deposition Modeling (FDM, was used in the construction of ABS molds with the objective of investigating its application in the injection molding of thermoplastics. Specimens of the molded parts were characterized with X-ray diffraction, Shore D hardness and tensile tests. The results demonstrated the viability to manufacture small batches of LDPE and PP parts with mechanical properties similar to those molded parts in metallic molds.

A wide variety of injection molding technologies is now applicable to small series and mass production

International Nuclear Information System (INIS)

Bloß, P.; Jüttner, G.; Jacob, S.; Löser, C.; Michaelis, J.; Krajewsky, P.

2014-01-01

Micro plastic parts open new fields for application, e. g., to electronics, sensor technologies, optics, and medical engineering. Before micro parts can go to mass production, there is a strong need of having the possibility for testing different designs and materials including material combinations. Hence, flexible individual technical and technological solutions for processing are necessary. To manufacture high quality micro parts, a micro injection moulding machine named formicaPlast based on a two-step plunger injection technology was developed. Resulting from its design, the residence time and the accuracy problems for managing small shot volumes with reproducible high accuracy are uncompromisingly solved. Due to their simple geometry possessing smooth transitions and non adherent inner surfaces, the plunger units allow to process 'all' thermoplastics from polyolefines to high performance polymers, optical clear polymers, thermally sensitive bioresorbables, highly filled systems (the so-called powder injection molding PIM), and liquid silicon rubber (LSR, here with a special kit). The applied platform strategy in the 1K and 2K version allows integrating automation for assembling, handling and packaging. A perpendicular arrangement allows encapsulation of inserts, also partially, and integration of this machine into process chains. Considering a wide variety of different parts consisting of different materials, the high potential of the technology is demonstrated. Based on challenging industrial parts from electronic applications (2K micro MID and bump mat, where both are highly structured parts), the technological solutions are presented in more detail

A feasible injection molding technique for the manufacturing of large diameter aspheric plastic lenses

Science.gov (United States)

Shieh, Jen-Yu; Wang, Luke K.; Ke, Shih-Ying

2010-07-01

A computer aided engineering (CAE) tool-assisted technique, using Moldex3D and aspheric analysis utility (AAU) software in a polycarbonate injection molding design, is proposed to manufacture large diameter aspheric plastic lenses. An experiment is conducted to verify the applicability/feasibility of the proposed technique. Using the preceding two software tools, these crucial process parameters associated with the surface profile errors and birefringence of a molded lens can be attainable. The strategy adopted here is to use the actual quantity of shrinkage after an injection molding trial of an aspherical plastic lens as a reference to perform the core shaping job while keeping the coefficients of aspheric surface, radius, and conic constant unchanged. The design philosophy is characterized by using the CAE tool as a guideline to pursue the best symmetry condition, followed by injection molding trials, to accelerate a product’s developmental time. The advantages are less design complexity and shorter developmental time for a product.

Characterization of curing behavior of UV-curable LSR for LED embedded injection mold

Science.gov (United States)

Tae, Joon-Sung; Yim, Kyung-Gyu; Rhee, Byung-Ohk; Kwak, Jae B.

2016-11-01

For many applications, liquid silicone rubber (LSR) injection molding is widely used for their great design flexibility and high productivity. In particular, a sealing part for a mobile device such as smartphone and watch has been produced by injection molding. While thermally curable LSR causes deformation problem due to a high mold temperature, UV-curable LSR can be molded at room temperature, which has advantages for over-molding with inserts of temperature-sensitive materials. Ultraviolet light-emitting diodes (UV LEDs) have advantages such as a longer service life, a lower heat dissipation, and smaller size to equip into the mold than conventional halogen or mercury UV lamps. In this work, rheological behavior of UV-curable LSR during curing process was analyzed by UV LEDs available in the market. UV-LEDs of various wave lengths and intensities were tested. The steady shear test was applied to find the starting time of curing and the SAOS was applied to find the ending time of curing to estimate processing time. In addition, the hardness change with irradiation energy was compared with the rheological data to confirm the reliability of the rheological test.

Mechanical performance of injection molded polypropylene : characterization and modeling

NARCIS (Netherlands)

Erp, van T.B.; Govaert, L.E.; Peters, G.W.M.

2013-01-01

It is shown that predictions of local mechanical properties in a product can be made from the orientation only using an anisotropic viscoplastic model. Due to processing-induced crystalline orientations, the mechanical properties of injection-molded polymer products are anisotropic and exhibit

Comparison of glare in YAG-damaged intraocular lenses: injection-molded versus lathe-cut.

Science.gov (United States)

Bath, P E; Dang, Y; Martin, W H

1986-11-01

A comparative analysis of YAG laser intraocular lens (IOL) damage was undertaken on injection-molded and lathe-cut IOLs. Damage sites were evaluated with polarized light. A consistent positive polarization was observed in the damage sites of lathe-cut IOLs. A consistent negative polarization was observed in the damage sites of injection-molded IOLs. The presence of positive polarization in IOL damage sites may be correlated with increased potential for glare. Results and clinical implications are discussed.

Ion channel recordings on an injection-molded polymer chip.

Science.gov (United States)

Tanzi, Simone; Matteucci, Marco; Christiansen, Thomas Lehrmann; Friis, Søren; Christensen, Mette Thylstrup; Garnaes, Joergen; Wilson, Sandra; Kutchinsky, Jonatan; Taboryski, Rafael

2013-12-21

In this paper, we demonstrate recordings of the ion channel activity across the cell membrane in a biological cell by employing the so-called patch clamping technique on an injection-molded polymer microfluidic device. The findings will allow direct recordings of ion channel activity to be made using the cheapest materials and production platform to date and with the potential for very high throughput. The employment of cornered apertures for cell capture allowed the fabrication of devices without through holes and via a scheme comprising master origination by dry etching in a silicon substrate, electroplating in nickel and injection molding of the final part. The most critical device parameters were identified as the length of the patching capillary and the very low surface roughness on the inside of the capillary. The cross-sectional shape of the orifice was found to be less critical, as both rectangular and semicircular profiles seemed to have almost the same ability to form tight seals with cells with negligible leak currents. The devices were functionally tested using human embryonic kidney cells expressing voltage-gated sodium channels (Nav1.7) and benchmarked against a commercial state-of-the-art system for automated ion channel recordings. These experiments considered current-voltage (IV) relationships for activation and inactivation of the Nav1.7 channels and their sensitivity to a local anesthetic, lidocaine. Both IVs and lidocaine dose-response curves obtained from the injection-molded polymer device were in good agreement with data obtained from the commercial system.

Metamodel-based design optimization of injection molding process variables and gates of an automotive glove box for enhancing its quality

International Nuclear Information System (INIS)

Kang, Gyung Ju; Park, Chang Hyun; Choi, Dong Hoon

2016-01-01

Injection molding process variables and gates of an automotive glove box were optimally determined to enhance its injection molding quality. We minimized warpage with satisfying constraints on clamp force, weldline, and profiles of filling and packing. Design variables concerning the injection molding process are temperatures of the mold and the resin, ram speeds, and packing pressures and durations; design variables concerning the gates are the shape of the center gate and locations of two side gates. To optimally determine the design variables in an efficient way, we adopted metamodel-based design optimization, sequentially using an optimal Latin hypercube design as a design of experiment, Kriging models as metamodels that replace time-consuming injection molding simulations, and a micro genetic algorithm as an optimization algorithm. In the optimization process, a commercial injection molding analysis software, MoldflowTM, was employed to evaluate the injection molding quality at design points specified. Using the proposed design approach, the warpage was found reduced by 20.5% compared to the initial warpage, while all the design constraints were satisfied, which clearly shows the validity of the proposed design approach

Metamodel-based design optimization of injection molding process variables and gates of an automotive glove box for enhancing its quality

Energy Technology Data Exchange (ETDEWEB)

Kang, Gyung Ju [Pusan National University, Busan (Korea, Republic of); Park, Chang Hyun; Choi, Dong Hoon [Hanyang University, Seoul (Korea, Republic of)

2016-04-15

Injection molding process variables and gates of an automotive glove box were optimally determined to enhance its injection molding quality. We minimized warpage with satisfying constraints on clamp force, weldline, and profiles of filling and packing. Design variables concerning the injection molding process are temperatures of the mold and the resin, ram speeds, and packing pressures and durations; design variables concerning the gates are the shape of the center gate and locations of two side gates. To optimally determine the design variables in an efficient way, we adopted metamodel-based design optimization, sequentially using an optimal Latin hypercube design as a design of experiment, Kriging models as metamodels that replace time-consuming injection molding simulations, and a micro genetic algorithm as an optimization algorithm. In the optimization process, a commercial injection molding analysis software, MoldflowTM, was employed to evaluate the injection molding quality at design points specified. Using the proposed design approach, the warpage was found reduced by 20.5% compared to the initial warpage, while all the design constraints were satisfied, which clearly shows the validity of the proposed design approach.

Effect of fiber loading on mechanical and morphological properties of cocoa pod husk fibers reinforced thermoplastic polyurethane composites

International Nuclear Information System (INIS)

El-Shekeil, Y.A.; Sapuan, S.M.; Algrafi, M.W.

2014-01-01

Highlights: • Increase in fiber loading increased tensile strength and modulus of the composites. • Tensile strain was decreasing with increase in fiber loading. • Flexural strength and modulus increased with increase in fiber content. • Impact strength was deteriorated with increasing fiber loading. • Morphology observations shown a good adhesion between fibers and matrix. - Abstract: In this study, cocoa (Theobroma cacao) pod husk (CPH) fiber reinforced thermoplastic polyurethane (TPU) was prepared by melt compounding method using Haake Polydrive R600 internal mixer. The composites were prepared with different fiber loading: 20%, 30% and 40% (by weight), with the optimum processing parameters: 190 °C, 11 min, and 40 rpm for temperature, time and speed, respectively. Five samples were cut from the composite sheet. Mean value was taken for each composite according to ASTM standards. Effect of fiber loading on mechanical (i.e. tensile, flexural properties and impact strength) and morphological properties was studied. TPU/CPH composites showed increase in tensile strength and modulus with increase in fiber loading, while tensile strain was decreasing with increase in fiber loading. The composite also showed increase in flexural strength and modulus with increase in fiber content. Impact strength was deteriorated with increase in fiber loading. Morphology observations using Scanning Electron Microscope (SEM) showed fiber/matrix good adhesion

Investigation of compression behavior of PE/EVA foam injection molded parts

Science.gov (United States)

Spina, Roberto

2017-10-01

The main objective of the presented work is to evaluate the compression behavior of a polymeric foam blend by using a robust framework for the testing sequence of foaming injection molded parts, with the aim of establishing a standard testing cycle for the evaluation of new matrix material. The research purpose is to assess parameters influencing compression behavior and give useful suggestions for the implementation of a finite element analysis. The polymeric blend consisted of a mixture of low density polyethylenes (LDPEs), a high-density polyethylene (HDPE), an ethylene-vinyl acetate (EVA) and an azodicarbonamide (ADC). The thermal, rheological and compression properties of the blend are fully described, as well as the injection molding process for two specimen types.

Influence of electron beam Irradiation on PP/Piassava fiber composite prepared by melt extrusion process

International Nuclear Information System (INIS)

Gomes, Michelle G.; Ferreira, Maiara S.; Oliveira, Rene R.; Silva, Valquiria A.; Teixeira, Jaciele G.; Moura, Esperidiana A.B.

2013-01-01

In the latest years, the interest for the use of natural fibers in materials composites polymeric has increased significantly due to their environmental and technological advantages. Piassava fibers (Attalea funifera) have been used as reinforcement in the matrix of thermoplastic and thermoset polymers. In the present work (20%, in mass), piassava fibers with particle sizes equal or smaller than 250 μm were incorporated in the polypropylene matrix (PP) no irradiated and polypropylene matrix containing 10 % and 30 % of polypropylene treated by electron-beam radiation at 40 kGy (PP/PPi/Piassava). The composites PP/Piassava and PP/PPi/Piassava were prepared by using a twin screw extruder, followed by injection molding. The composite material samples obtained were treated by electron-beam radiation at 40 kGy, using a 1.5 MeV electron beam accelerator, at room temperature, in presence of air. After irradiation treatment, the irradiated and non-irradiated specimens tests samples were submitted to thermo-mechanical tests, melt flow index (MFI), sol-gel analysis, X-Ray diffraction (XRD) and scanning electron microscopy (SEM). (author)

Simulation of Injection Molding Process Including Mold Filling and Compound Curing

Directory of Open Access Journals (Sweden)

Mohamad Reza Erfanian

2012-12-01

Full Text Available The present work reports and discusses the results of a 3D simulation of the injection molding process of a rubber compound that includes the mold flling stage and  material curing, using the computer code is developed in “UDF” part of the Fluent 6.3 CAE software. The data obtained from a rheometer (MDR 2000 is used to characterize the rubber material in order to fnd the cure model parameters which exist in curing model. Because of non-newtonian behavior of rubber, in this work the non-newtonian model for viscosity was used and viscosity parameters were computed by mean of viscometry test by RPA. After calculation of the physical and curing properties, vulcanization process was simulated for a complex rubber article with non-uniform thickness by solving the continuity, momentum, energy and curing process equations. Predicted flling and curing time in a complex and 3D rubber part is compared with experimentally measured data which confrmed  the accuracy and applicability of the method.

Influence of melt mixer on injection molding of thermoset elastomers

Science.gov (United States)

Rochman, Arif; Zahra, Keith

2016-10-01

One of the drawbacks in injection molding is that the plasticizing screw is short such that polymers having high concentrations of additives, such as thermoset elastomers, might not mix homogeneously within the short period of time during the plasticizing stage. In this study, various melt mixers inside the nozzle chamber, together forming a mixing nozzle, were developed. Three different materials were investigated, namely nitrile butadiene rubber (NBR), ethylene propylene-diene monomer (EPDM) and fluorocarbon (FKM). The use of these melt mixers resulted in better homogeneity and properties of the molded parts despite a curing time reduction of 10 s. This was due to the increase in mixing and shearing introduced a higher rate of crosslinking formation in the molded parts.

Thermoplastic starch materials prepared from rice starch

International Nuclear Information System (INIS)

Pontes, Barbara R.B.; Curvelo, Antonio A.S.

2009-01-01

Rice starch is a source still little studied for the preparation of thermoplastic materials. However, its characteristics, such as the presence of proteins, fats and fibers may turn into thermoplastics with a better performance. The present study intends the evaluation of the viability of making starch thermoplastic from rice starch and glycerol as plasticizer. The results of X-ray diffraction and scanning electronic microscopy demonstrate the thermoplastic acquisition. The increase of plasticizer content brings on more hydrophilic thermoplastics with less resistance to tension and elongation at break. (author)

Determination of tensile forces to enhance the supply stability of reinforced fiber

Energy Technology Data Exchange (ETDEWEB)

Kim, Kun Woo; Lee, Jae Wook; Jang, Jin Seok; Jeong, Myeong Sik; Oh, Joo Young; Kang, Hoon; Kang, Ji Heon [Daegyeong Regional Division, Korea Institute of Industrial Technology, Daegu (Korea, Republic of); Kim, Hyung Ryul [Agency for Defense Development, Changwon (Korea, Republic of); Yoo, Wan Suk [School of Mechanical Engineering, Pusan National University, Busan (Korea, Republic of)

2016-12-15

The manufacturing process of long fiber thermoplastic is initiated by supplying reinforced fiber wound in a spool dispenser. If problems such as tangling or kinking occur in the apparatus used for supplying the reinforced fiber in the long-fiber thermoplastic direct process, the productivity of the long-fiber thermoplastic decreases. Therefore, it is important to enhance the supply stability of reinforced fiber. In general, the increase in supply stability can be achieved by maintaining a steady balloon shape that is controlled by the unwinding velocity or tensile force of the reinforced fiber. In this research, the range of suitable tensile force was determined under the assumption that the unwinding velocity remained constant. The reinforced fiber was assumed to be inextensible, homogeneous, and isotropic and to have uniform density. The transient-state unwinding equation of motion to analyze the unwinding motion of reinforced fiber can be derived by using Hamilton’s principle for an open system in which mass can change within a control volume. In the process of solving the transient-state unwinding equation of motion, the exact two-point boundary conditions are adopted for each time step.

Analysis of the Influence of Microcellular Injection Molding on the Environmental Impact of an Industrial Component

Directory of Open Access Journals (Sweden)

Daniel Elduque

2014-09-01

Full Text Available Microcellular injection molding is a process that offers numerous benefits due to the internal structure generated; thus, many applications are currently being developed in different fields, especially home appliances. In spite of the advantages, when changing the manufacturing process from conventional to microcellular injection molding, it is necessary to analyze its new mechanical properties and the environmental impact of the component. This paper presents a deep study of the environmental behavior of a manufactured component by both conventional and microcellular injection molding. Environmental impact will be evaluated performing a life cycle assessment. Functionality of the component will be also evaluated with samples obtained from manufactured components, to make sure that the mechanical requirements are fulfilled when using microcellular injection molding. For this purpose a special device has been developed to measure the flexural modulus. With a 16% weight reduction, the variation of flexural properties in the microcellular injected components is only 6.8%. Although the energy consumption of the microcellular injection process slightly increases, there is an overall reduction of the environmental burden of 14.9% in ReCiPe and 15% in carbon footprint. Therefore, MuCell technology can be considered as a green manufacturing technology for components working mainly under flexural load.

Improved compression molding technology for continuous fiber reinforced composite laminates. Part 2: AS-4/Polyimidesulfone prepreg system

Science.gov (United States)

Baucom, Robert M.; Hou, Tan-Hung; Kidder, Paul W.; Reddy, Rakasi M.

1991-01-01

AS-4/polyimidesulfone (PISO2) composite prepreg was utilized for the improved compression molding technology investigation. This improved technique employed molding stops which advantageously facilitate the escape of volatile by-products during the B-stage curing step, and effectively minimize the neutralization of the consolidating pressure by intimate interply fiber-fiber contact within the laminate in the subsequent molding cycle. Without the modifying the resin matrix properties, composite panels with both unidirectional and angled plies with outstanding C-scans and mechanical properties were successfully molded using moderate molding conditions, i.e., 660 F and 500 psi, using this technique. The size of the panels molded were up to 6.00 x 6.00 x 0.07 in. A consolidation theory was proposed for the understanding and advancement of the processing science. Processing parameters such as vacuum, pressure cycle design, prepreg quality, etc. were explored.

Low-pressure injection molding of alumina ceramics using a carnauba wax binder: preliminary results

Energy Technology Data Exchange (ETDEWEB)

Quevedo Nogueira, R.E.F.; Bezerra, A.C.; Santos, F.C. dos [Dept. de Engenharia Mecanica, Centro de Tecnologia-UFC, Fortaleza, CE (Brazil); Sousa, M.R. de; Acchar, W. [Dept. de Engenharia Mecanica, Univ. Federal do Rio Grande do Norte, UFRN-Campus Univ., Natal, RN (Brazil)

2001-07-01

Carnauba wax, a natural product from Northeastern Brazil, has found application in the processing of ceramics. However, the use of pure carnauba wax is not recommended due to its narrow melting range and poor mechanical properties. In the present work carnauba wax based organic vehicles with the addition of low-density polyethylene and stearic acid were developed for use in the low-pressure injection molding of alumina ceramics. Viscosimetric testing was employed for the determination of optimal composition of the organic vehicle. The optimal content of ceramic powder in the mixture was also determined. All the materials used are easily available in the Brazilian market. A simple ceramic part was injected at low pressures (0.6 MPa) using a semi-automatic injection molding machine. For this purpose a double cavity mold was designed and built. Preliminary results demonstrate the technical viability of the process using the organic vehicle developed. (orig.)

The Processing Design of Jute Spun Yarn/PLA Braided Composite by Pultrusion Molding

Directory of Open Access Journals (Sweden)

Anin Memon

2013-01-01

Full Text Available Prevalently, the light has been shed on the green composite from the viewpoint of environmental protection. Jute fibers are natural fibers superior due to light weight, low cost, and being environmentally friendly corresponding to the green composite materials. Meticulously, fibers of polylactic acid (PLA thermoplastic biopolymer were used as the resin fibers. In this study, the fabrication of tubular jute spun yarn/PLA braided composite by pultrusion molding was presented. The intermediate materials were prepared by commingled technique. The braiding technique manufactured preform which had jute fiber diagonally oriented at certain angles with the glass fiber inserted into the braiding yarns along the longitudinal direction. The braided preforms were pulled through a heated die where the consolidation flow took place due to reduced matrix viscosity and pressure. The pultrusion experiments were done with jute/PLA commingled yarns and combined with glass fiber yarns to fabricate the tubular composite. Impregnation quality was evaluated by microscope observation of the pultruded cross-sections. The flexural mechanical properties of the pultruded were measured by four-point bending test.

Development and Characterization of a Metal Injection Molding Bio Sourced Inconel 718 Feedstock Based on Polyhydroxyalkanoates

Directory of Open Access Journals (Sweden)

Alexandre Royer

2016-04-01

Full Text Available The binder plays the most important role in the metal injection molding (MIM process. It provides fluidity of the feedstock mixture and adhesion of the powder to keep the molded shape during injection molding. The binder must provide strength and cohesion for the molded part and must be easy to remove from the molded part. Moreover, it must be recyclable, environmentally friendly and economical. Also, the miscibility between polymers affects the homogeneity of the injected parts. The goal of this study is to develop a feedstock of superalloy Inconel 718 that is environmentally friendly. For these different binders, formulations based on polyethylene glycol (PEG, because of his water solubility property, and bio sourced polymers were studied. Polyhydroxyalkanoates (PHA were investigated as a bio sourced polymer due to its miscibility with the PEG. The result is compared to a standard formulation using polypropylene (PP. The chemical and rheological behavior of the binder formulation during mixing, injection and debinding process were investigated. The feedstock was characterized in the same way as the binders and the interactions between the powder and the binders were also studied. The results show the well adapted formulation of polymer binder to produce a superalloy Inconel 718 feedstock.

Facile Fabrication of Animal-Specific Positioning Molds For Multi-modality Molecular Imaging

International Nuclear Information System (INIS)

Park, Jeong Chan; Oh, Ji Eun; Woo, Seung Tae

2008-01-01

Recently multi-modal imaging system has become widely adopted in molecular imaging. We tried to fabricate animal-specific positioning molds for PET/MR fusion imaging using easily available molding clay and rapid foam. The animal-specific positioning molds provide immobilization and reproducible positioning of small animal. Herein, we have compared fiber-based molding clay with rapid foam in fabricating the molds of experimental animal. The round bottomed-acrylic frame, which fitted into microPET gantry, was prepared at first. The experimental mice was anesthetized and placed on the mold for positioning. Rapid foam and fiber-based clay were used to fabricate the mold. In case of both rapid foam and the clay, the experimental animal needs to be pushed down smoothly into the mold for positioning. However, after the mouse was removed, the fabricated clay needed to be dried completely at 60 .deg. C in oven overnight for hardening. Four sealed pipe tips containing [ 18 F]FDG solution were used as fiduciary markers. After injection of [ 18 F]FDG via tail vein, microPET scanning was performed. Successively, MRI scanning was followed in the same animal. Animal-specific positioning molds were fabricated using rapid foam and fiber-based molding clay for multimodality imaging. Functional and anatomical images were obtained with microPET and MRI, respectively. The fused PET/MR images were obtained using freely available AMIDE program. Animal-specific molds were successfully prepared using easily available rapid foam, molding clay and disposable pipet tips. Thanks to animal-specific molds, fusion images of PET and MR were co-registered with negligible misalignment

Development of Metal Plate with Internal Structure Utilizing the Metal Injection Molding (MIM Process

Directory of Open Access Journals (Sweden)

Kwangho Shin

2013-12-01

Full Text Available In this study, we focus on making a double-sided metal plate with an internal structure, such as honeycomb. The stainless steel powder was used in the metal injection molding (MIM process. The preliminary studies were carried out for the measurement of the viscosity of the stainless steel feedstock and for the prediction of the filling behavior through Computer Aided Engineering (CAE simulation. PE (high density polyethylene (HDPE and low density polyethylene (LDPE and polypropylene (PP resins were used to make the sacrificed insert with a honeycomb structure using a plastic injection molding process. Additionally, these sacrificed insert parts were inserted in the metal injection mold, and the metal injection molding process was carried out to build a green part with rectangular shape. Subsequently, debinding and sintering processes were adopted to remove the sacrificed polymer insert. The insert had a suitable rigidity that was able to endure the filling pressure. The core shift analysis was conducted to predict the deformation of the insert part. The 17-4PH feedstock with a low melting temperature was applied. The glass transition temperature of the sacrificed polymer insert would be of a high grade, and this insert should be maintained during the MIM process. Through these processes, a square metal plate with a honeycomb structure was made.

Packing parameters effect on injection molding of polypropylene nanostructured surfaces

DEFF Research Database (Denmark)

Calaon, Matteo; Tosello, Guido; Hansen, Hans Nørgaard

2012-01-01

having a diameter of 500 nm was employed. The tool insert surface was produced using chemical-based-batch techniques such aluminum anodization and nickel electroplating. During the injection molding process, polypropylene (PP) was employed as material and packing phase parameters (packing time, packing...

Modeling of magnetic particle orientation in magnetic powder injection molding

Science.gov (United States)

Doo Jung, Im; Kang, Tae Gon; Seul Shin, Da; Park, Seong Jin

2018-03-01

The magnetic micro powder orientation under viscous shear flow has been analytically understood and characterized into a new analytical orientation model for a powder injection molding process. The effects of hydrodynamic force from the viscous flow, external magnetic force and internal dipole-dipole interaction were considered to predict the orientation under given process conditions. Comparative studies with a finite element method proved the calculation validity with a partial differential form of the model. The angular motion, agglomeration and magnetic chain formation have been simulated, which shows that the effect of dipole-dipole interaction among powders on the orientation state becomes negligible at a high Mason number condition and at a low λ condition (the ratio of external magnetic field strength and internal magnetic moment of powder). Our developed model can be very usefully employed in the process analysis and design of magnetic powder injection molding.

Influence of fiber length on flexural and impact properties of Zalacca Midrib fiber/HDPE by compression molding

Science.gov (United States)

Pamungkas, Agil Fitri; Ariawan, Dody; Surojo, Eko; Triyono, Joko

2018-02-01

The aim of the research is to investigate the effect of fiber length on the flexural and impact properties of the composite of Zalacca Midrib Fiber (ZMF)/HDPE. The process of making composite was using compression molding method. The variation of fiber length were 1 mm, 3 mm, 5 mm, 7 mm and 9 mm, at 30% fiber volume fraction. The flexural and impact test according to ASTM D790 and ASTM D5941, respectively. Observing fracture surface was examained by using Scanning Electron Microscopy (SEM). The results showed that the flexural and impact strengths would be increase with the increase of fiber length.

Characterization of Injection Molded Structures

DEFF Research Database (Denmark)

Sun, Ling; Søgaard, Emil; Andersen, Nis Korsgaard

for different applications. We show how to correlate the structures of the polymer replicas with respect to their functionalities. Furthermore, we introduce how we coordinate with all partners in the “Nanoplast” project, and how we utilize the existing facilities of each method to understand structure......Microscopy has been widely applied to understand surface structures of solid samples. According to the instrumental methodology, there are different microscopy methods: optical microscopy, electron microscopy, and scanning probe microscopy (SPM). These microscopy methods have individual advantages...... and limitations. Therefore, it would be difficult to characterize complex, especially hierarchical structures by using only one method. Here we present a combined optical microscopy, scanning electron microscopy (SEM), and scanning probe microscopy study on injection molded structures. These structures are used...

Forehead Augmentation with a Methyl Methacrylate Onlay Implant Using an Injection-Molding Technique

Directory of Open Access Journals (Sweden)

Dong Kwon Park

2013-09-01

Full Text Available Background The forehead, which occupies about one third of the face, is one of the majordeterminants of a feminine or masculine look. Various methods have been used for the augmentationof the forehead using autologous fat grafts or alloplastic materials. Methylmethacrylate(MMA is the most appropriate material for augmentation of the forehead, and we have usedan injection-molding technique with MMA to achieve satisfactory results.Methods Under local anesthesia with intravenous (IV sedation, an incision was made onthe scalp and a meticulous and delicate subperiosteal dissection was then performed. MMAmonomers and polymers were mixed, the dough was injected into the space created, andmanual molding was performed along with direct inspection. This surgery was indicated forpatients who wanted to correct an unattractive appearance by forehead augmentation. Everypatient in this study visited our clinics 3 months after surgery to evaluate the results. Wejudged the postoperative results in terms of re-operation rates caused by the dissatisfactionof the patients and complications.Results During a 13-year period, 516 patients underwent forehead augmentation with MMA.With the injection-molding technique, the inner surface of the MMA implant is positionedclose to the underlying frontal bone, which minimizes the gap between the implant and bone.The borders of the implant should be tapered sufficiently until no longer palpable or visible.Only 28 patients (5.4% underwent a re-operation due to an undesirable postoperative appearance.Conclusions The injection-molding technique using MMA is a simple, safe, and ideal methodfor the augmentation of the forehead.

Forehead Augmentation with a Methyl Methacrylate Onlay Implant Using an Injection-Molding Technique

Directory of Open Access Journals (Sweden)

Dong Kwon Park

2013-09-01

Full Text Available BackgroundThe forehead, which occupies about one third of the face, is one of the major determinants of a feminine or masculine look. Various methods have been used for the augmentation of the forehead using autologous fat grafts or alloplastic materials. Methylmethacrylate (MMA is the most appropriate material for augmentation of the forehead, and we have used an injection-molding technique with MMA to achieve satisfactory results.MethodsUnder local anesthesia with intravenous (IV sedation, an incision was made on the scalp and a meticulous and delicate subperiosteal dissection was then performed. MMA monomers and polymers were mixed, the dough was injected into the space created, and manual molding was performed along with direct inspection. This surgery was indicated for patients who wanted to correct an unattractive appearance by forehead augmentation. Every patient in this study visited our clinics 3 months after surgery to evaluate the results. We judged the postoperative results in terms of re-operation rates caused by the dissatisfaction of the patients and complications.ResultsDuring a 13-year period, 516 patients underwent forehead augmentation with MMA. With the injection-molding technique, the inner surface of the MMA implant is positioned close to the underlying frontal bone, which minimizes the gap between the implant and bone. The borders of the implant should be tapered sufficiently until no longer palpable or visible. Only 28 patients (5.4% underwent a re-operation due to an undesirable postoperative appearance.ConclusionsThe injection-molding technique using MMA is a simple, safe, and ideal method for the augmentation of the forehead.

Computational design of mould sprue for injection moulding thermoplastics

Directory of Open Access Journals (Sweden)

Muralidhar Lakkanna

2016-01-01

Full Text Available To injection mould polymers, designing mould is a key task involving several critical decisions with direct implications to yield quality, productivity and frugality. One prominent decision among them is specifying sprue-bush conduit expansion as it significantly influences overall injection moulding; abstruseness anguish in its design criteria deceives direct determination. Intuitively designers decide it wisely and then exasperate by optimising or manipulating processing parameters. To overwhelm that anomaly this research aims at proposing an ideal design criteria holistically for all polymeric materials also tend as a functional assessment metric towards perfection i.e., criteria to specify sprue conduit size before mould development. Accordingly, a priori analytical criterion was deduced quantitatively as expansion ratio from ubiquitous empirical relationships specifically a.k.a an exclusive expansion angle imperatively configured for injectant properties. Its computational intelligence advantage was leveraged to augment functionality of perfectly injecting into an impression gap, while synchronising both injector capacity and desired moulding features. For comprehensiveness, it was continuously sensitised over infinite scale as an explicit factor dependent on in-situ spatio-temporal injectant state perplexity with discrete slope and altitude for each polymeric character. In which congregant ranges of apparent viscosity and shear thinning index were conceived to characteristically assort most thermoplastics. Thereon results accorded aggressive conduit expansion widening for viscous incrust, while a very aggressive narrowing for shear thinning encrust; among them apparent viscosity had relative dominance. This important rationale would certainly form a priori design basis as well diagnose filling issues causing several defects. Like this the proposed generic design criteria, being simple would immensely benefit mould designers besides serve

Synthesis of thermoplastic elastomer using potassium persulfate and ammonium peroxydisulfate initiator

International Nuclear Information System (INIS)

Dewi Sondari; Agus Haryono; M Ghozali; Ahmad Randy; Kuntari Adi Suhardjo; Ariyadi B; Surasno

2010-01-01

Thermoplastic elastomer is polymeric material that has elastomer and thermoplastic properties. This material can be easily molded into finished and recyclable goods, thus environmentally safe for long term application. In this study we synthesize thermoplastic elastomer using two initiator that are potassium persulfate and ammonium peroxydisulfate with natural rubber to monomer (styrene/methyl methacrylate) ratio of 50 : 50 and 60 : 40 (v/v). The process of thermoplastic elastomer synthesis was conducted with emulsion grafting polymerization method for 6 hours at 65 °C. We used sodium dodecyl sulfate as emulsifier. FT-IR analysis result shows that grafting process had already occurred shown by new peaks that were observed in 1743 and 1519 cm"-"1. These peaks was assigned to carbonyl (C=O) group of methyl methacrylate and C=C benzene of styrene respectively. From "1H-NMR new peaks at δ = 7.1 ppm was aromatic proton from phenyl group of styrene, at δ = 3.5 ppm was methoxy proton of grafted methyl methacrylate acrylic group, and at δ = 5.1 ppm that is resonance of isoprene methine proton. This result showed that methyl methacrylate and styrene had already grafted onto natural rubber backbone. Initiator influenced grafting efficiency. Potassium persulfate gave 97.6 % grafting efficiency while ammonium peroxydisulfate gave 90.2 % grafting efficiency. (author)

Interfacial crystalline structures in injection over-molded polypropylene and bond strength.

Science.gov (United States)

Yan, Bowen; Wu, Hong; Jiang, Genjie; Guo, Shaoyun; Huang, Jian

2010-11-01

This paper describes interfacial crystalline structures found in injection overmolded polypropylene components and the relationship of these structures to bond strength between the components. The combined effects of the development of hierarchical gradient structures and the particular thermomechanical environment near the interface on the interfacial crystalline structures were investigated in detail by PLM, SEM, DSC, WAXD, and infrared dichroism spectroscopy. The experimental results showed that during molding there was competitive formation of interfacial crystalline structures consisted of "shish-kebab" layer (SKL) and a transcrystalline layers (TCL). Variation in shear stress (controlled by injection pressure and injection speed) plays an important role in the formation of the SKL. The formation of TCL is influenced by the thermal environment, namely melt temperature and mold temperature. Increasing within certain limits, interfacial temperature and the thermal gradient near the interface promotes β-iPP growth. The relationship between interfacial crystalline structures and interfacial bond strength was established by lap shear measurement. The interfacial bond strength is improved by enhancing the formation of TCL, but reduced if SKL predominates.

New techniques of transformation

International Nuclear Information System (INIS)

Morel, E.

1985-01-01

Among new processes for the fabrication of composite materials with an organic matrix the reinforced reaction injection molding is briefly evoked but polymerization under radiation and thermoplastic matrix composites reinforced with continuous fibers should know an industrial development. Radiation polymerization by microwaves, by gamma sources and particularly by electron beams should increase fabrication rate. Chemical effects of radiations, application to polymerization advantages and prospects are examined [fr

Experimental and Numerical Investigation of the Effect of Process Conditions on Residual Wall Thickness and Cooling and Surface Characteristics of Water-Assisted Injection Molded Hollow Products

Directory of Open Access Journals (Sweden)

Hyungpil Park

2015-01-01

Full Text Available Recently, water-assisted injection molding was employed in the automobile industry to manufacture three-dimensional hollow tube-type products with functionalities. However, process optimization is difficult in the case of water-assisted injection molding because of the various rheological interactions between the injected water and the polymer. In this study, the boiling phenomenon that occurs because of the high melt temperature when injecting water and the molding characteristics of the hollow section during the water-assisted injection process were analyzed by a water-assisted injection molding analysis. In addition, the changes in the residual wall thickness accompanying changes in the process conditions were compared with the analysis results by considering water-assisted injection molding based on gas-assisted injection molding. Furthermore, by comparing the cooling characteristics and inner wall surface qualities corresponding to the formation of the hollow section by gas and water injections, a water-assisted injection molding technique was proposed for manufacturing hollow products with functionality.

Influence of Interleaved Films on the Mechanical Properties of Carbon Fiber Fabric/Polypropylene Thermoplastic Composites

Directory of Open Access Journals (Sweden)

Jong Won Kim

2016-05-01

Full Text Available A laminated composite was produced using a thermoplastic prepreg by inserting an interleaved film with the same type of matrix as the prepreg during the lay-up process to improve the low interlaminar properties, which is a known weakness of laminated composites. Carbon fiber fabric (CFF and polypropylene (PP were used to manufacture the thermoplastic prepregs. Eight prepregs were used to produce the laminated composites. Interleaved films with different thicknesses were inserted into each prepreg. The physical properties of the composite, such as thickness, density, fiber volume fraction (Vf, and void content (Vc, were examined. The tensile strength, flexural strength, interlaminar shear strength (ILSS, impact property, and scanning electron microscopy (SEM were used to characterize the mechanical properties. Compared to the composite without any inserted interleaved film, as the thickness of the inserted interleaved resin film was increased, Vc decreased by 51.45%. At the same time, however, the tensile strength decreased by 8.75%. Flexural strength increased by 3.79% and flexural modulus decreased by 15.02%. Interlaminar shear strength increased by 11.05% and impact strength increased by 15.38%. Fracture toughness of the laminated composite was improved due to insertion of interleaved film.

Influence of Interleaved Films on the Mechanical Properties of Carbon Fiber Fabric/Polypropylene Thermoplastic Composites.

Science.gov (United States)

Kim, Jong Won; Lee, Joon Seok

2016-05-06

A laminated composite was produced using a thermoplastic prepreg by inserting an interleaved film with the same type of matrix as the prepreg during the lay-up process to improve the low interlaminar properties, which is a known weakness of laminated composites. Carbon fiber fabric (CFF) and polypropylene (PP) were used to manufacture the thermoplastic prepregs. Eight prepregs were used to produce the laminated composites. Interleaved films with different thicknesses were inserted into each prepreg. The physical properties of the composite, such as thickness, density, fiber volume fraction ( V f ), and void content ( V c ), were examined. The tensile strength, flexural strength, interlaminar shear strength (ILSS), impact property, and scanning electron microscopy (SEM) were used to characterize the mechanical properties. Compared to the composite without any inserted interleaved film, as the thickness of the inserted interleaved resin film was increased, V c decreased by 51.45%. At the same time, however, the tensile strength decreased by 8.75%. Flexural strength increased by 3.79% and flexural modulus decreased by 15.02%. Interlaminar shear strength increased by 11.05% and impact strength increased by 15.38%. Fracture toughness of the laminated composite was improved due to insertion of interleaved film.

Metal Injection Molding (MIM of Magnesium and Its Alloys

Directory of Open Access Journals (Sweden)

Martin Wolff

2016-05-01

Full Text Available Current research has highlighted that magnesium and its alloys as biodegradable material are highly suitable for biomedical applications. The new material fully degrades into nontoxic elements and offers material properties matching those of human bone tissue. As biomedical implants are rather small and complex in shape, the metal injection molding (MIM technique seems to be well suited for the near net shape mass production of such parts. Furthermore, MIM of Mg-alloys is of high interest in further technical fields. This study focusses on the performance of MIM-processing of magnesium alloy powders. It includes Mg-specific development of powder blending, feedstock preparation, injection molding, solvent and thermal debinding and final sintering. Even though Mg is a highly oxygen-affine material forming a stable oxide layer on each particle surface, the material can be sintered to nearly dense parts, providing mechanical properties matching those of as cast material. An ultimate tensile strength of 142 MPa, yield strength of 67 MPa, elastic modulus of 40 GPa and 8% elongation at fracture could be achieved using novel organic polymer binders for the feedstock preparation. Thus, first implant demonstrator parts could be successfully produced by the MIM technique.

Identifying design parameters controlling damage behaviors of continuous fiber-reinforced thermoplastic composites using micromechanics as a virtual testing tool

KAUST Repository

Pulungan, Ditho Ardiansyah; Lubineau, Gilles; Yudhanto, Arief; Yaldiz, Recep; Schijve, Warden

2017-01-01

In this paper, we propose a micromechanical approach to predict damage mechanisms and their interactions in glass fibers/polypropylene thermoplastic composites. First, a representative volume element (RVE) of such materials was rigorously determined using a geometrical two-point probability function and the eigenvalue stabilization of homogenized elastic tensor obtained by Hill-Mandel kinematic homogenization. Next, the 3D finite element models of the RVE were developed accordingly. The fibers were modeled with an isotropic linear elastic material. The matrix was modeled with an isotropic linear elastic, rate-independent hyperbolic Drucker-Prager plasticity coupled with a ductile damage model that is able to show pressure dependency of the yield and damage behavior often found in a thermoplastic material. In addition, cohesive elements were inserted into the fiber-matrix interfaces to simulate debonding. The RVE faces are imposed with periodical boundary conditions to minimize the edge effect. The RVE was then subjected to transverse tensile loading in accordance with experimental tensile tests on [90]8 laminates. The model prediction was found to be in very good agreement with the experimental results in terms of the global stress-strain curves, including the linear and nonlinear portion of the response and also the failure point, making it a useful virtual testing tool for composite material design. Furthermore, the effect of tailoring the main parameters of thermoplastic composites is investigated to provide guidelines for future improvements of these materials.

Identifying design parameters controlling damage behaviors of continuous fiber-reinforced thermoplastic composites using micromechanics as a virtual testing tool

KAUST Repository

Pulungan, Ditho Ardiansyah

2017-03-31

In this paper, we propose a micromechanical approach to predict damage mechanisms and their interactions in glass fibers/polypropylene thermoplastic composites. First, a representative volume element (RVE) of such materials was rigorously determined using a geometrical two-point probability function and the eigenvalue stabilization of homogenized elastic tensor obtained by Hill-Mandel kinematic homogenization. Next, the 3D finite element models of the RVE were developed accordingly. The fibers were modeled with an isotropic linear elastic material. The matrix was modeled with an isotropic linear elastic, rate-independent hyperbolic Drucker-Prager plasticity coupled with a ductile damage model that is able to show pressure dependency of the yield and damage behavior often found in a thermoplastic material. In addition, cohesive elements were inserted into the fiber-matrix interfaces to simulate debonding. The RVE faces are imposed with periodical boundary conditions to minimize the edge effect. The RVE was then subjected to transverse tensile loading in accordance with experimental tensile tests on [90]8 laminates. The model prediction was found to be in very good agreement with the experimental results in terms of the global stress-strain curves, including the linear and nonlinear portion of the response and also the failure point, making it a useful virtual testing tool for composite material design. Furthermore, the effect of tailoring the main parameters of thermoplastic composites is investigated to provide guidelines for future improvements of these materials.

Study of microcellular injection-molded polypropylene/waste ground rubber tire powder blend

International Nuclear Information System (INIS)

Xin, Zhen Xiang; Zhang, Zhen Xiu; Pal, Kaushik; Byeon, Jong Ung; Lee, Sung Hyo; Kim, Jin Kuk

2010-01-01

Microcellular polypropylene/waste ground rubber tire powder blend processing was performed on an injection-molding machine with a chemical foaming agent. The molded samples produced based on the design of experiments (DOE) matrices were subjected to tensile testing and scanning electron microscope (SEM) analyses. Molding conditions and waste ground rubber tire (WGRT) powder have been found to have profound effects on the cell structures and mechanical properties of polypropylene (PP) and waste ground rubber tire powder composite samples. The result shows that microcellular PP/WGRT blend samples exhibit smaller cell size and higher cell density compare with polypropylene resin. Among the molding parameters studied, chemical foaming agent weight percentage has the most significant effect on cell size, cell density, and tensile strength. The results also suggest that tensile strength of microcellular PP/WGRT composites is sensitive to weight reduction, and skin thickness.

Effect of Injection Molding Melt Temperatures on PLGA Craniofacial Plate Properties during In Vitro Degradation

Directory of Open Access Journals (Sweden)

Liliane Pimenta de Melo

2017-01-01

Full Text Available The purpose of this article is to present mechanical and physicochemical properties during in vitro degradation of PLGA material as craniofacial plates based on different values of injection molded temperatures. Injection molded plates were submitted to in vitro degradation in a thermostat bath at 37 ± 1°C by 16 weeks. The material was removed after 15, 30, 60, and 120 days; then bending stiffness, crystallinity, molecular weights, and viscoelasticity were studied. A significant decrease of molecular weight and mechanical properties over time and a difference in FT-IR after 60 days showed faster degradation of the material in the geometry studied. DSC analysis confirmed that the crystallization occurred, especially in higher melt temperature condition. DMA analysis suggests a greater contribution of the viscous component of higher temperature than lower temperature in thermomechanical behavior. The results suggest that physical-mechanical properties of PLGA plates among degradation differ per injection molding temperatures.

All-in-polymer injection molded device for single cell capture using multilevel silicon master fabrication

DEFF Research Database (Denmark)

Tanzi, S.; Larsen, S.T.; Matteucci, M.

2012-01-01

This work demonstrates a novel all-in-polymer device for single cell capture applicable for biological recordings. The chip is injection molded and comprises a "cornered" (non planar) aperture. It has been demonstrated how cornered apertures are straightforward to mold in PDMS [1,2]. In this stud...

Experimental Analysis for Factors Affecting the Repeatability of Plastics Injection Molding Tests on the Self-developed Apparatus

Directory of Open Access Journals (Sweden)

Yugang Huang

2013-06-01

Full Text Available Normal 0 false false false IN X-NONE X-NONE MicrosoftInternetExplorer4 To improve the repeatability of the injection molding test result, the affecting factors were investigated by means of experiments. Besides the traditional processing parameter, the factors of test conditions were also considered. In order to focus on the molding process rather than the molded part, the curve measurement of the melt pressure at the entrance to the nozzle was used as the output characteristic. Experiments for polypropylene (PP showed that the injected volume was the key processing parameter. Within the test conditions, the injection number is the most important factor. According to the analysis the operating procedure was improved effectively. Normal 0 false false false IN X-NONE X-NONE MicrosoftInternetExplorer4 Doi: 10.12777/ijse.5.1.6-11 [How to cite this article: Huang, Y., Li, D., Liu, Y. (2013. Experimental Analysis for Factors Affecting the Repeatability of Plastics Injection Molding Tests on the Self-developed Apparatus. International Journal of Science and Engineering, 5(1,6-11. Doi: 10.12777/ijse.5.1.6-11]

High quality ion channels recordings on an injection molded polymer chip

DEFF Research Database (Denmark)

Tanzi, Simone

In this thesis we demonstrate high quality recordings of the ion channel activity across the cell membrane in a biological cell by employing the so called patch clamping technique on an injection molded polymer microfluidic device. Such recordings are traditionally made using glass micropipettes,...

Know your fibers : process and properties, or, a material science approach to designing pulp molded products

Science.gov (United States)

John F. Hunt

1998-01-01

The following results are preliminary, but show some basic information that will be used in an attempt to model pulp molded structures so that by measuring several basic fundamental properties of a fiber furnish and specifying process conditions, a molded structure could be designed for a particular performance need.

Energy Absorption in Chopped Carbon Fiber Compression Molded Composites

International Nuclear Information System (INIS)

Starbuck, J.M.

2001-01-01

In passenger vehicles the ability to absorb energy due to impact and be survivable for the occupant is called the ''crashworthiness'' of the structure. To identify and quantify the energy absorbing mechanisms in candidate automotive composite materials, test methodologies were developed for conducting progressive crush tests on composite plate specimens. The test method development and experimental set-up focused on isolating the damage modes associated with the frond formation that occurs in dynamic testing of composite tubes. Quasi-static progressive crush tests were performed on composite plates manufactured from chopped carbon fiber with an epoxy resin system using compression molding techniques. The carbon fiber was Toray T700 and the epoxy resin was YLA RS-35. The effect of various material and test parameters on energy absorption was evaluated by varying the following parameters during testing: fiber volume fraction, fiber length, fiber tow size, specimen width, profile radius, and profile constraint condition. It was demonstrated during testing that the use of a roller constraint directed the crushing process and the load deflection curves were similar to progressive crushing of tubes. Of all the parameters evaluated, the fiber length appeared to be the most critical material parameter, with shorter fibers having a higher specific energy absorption than longer fibers. The combination of material parameters that yielded the highest energy absorbing material was identified

Influence of Kenaf Core Fiber Incorporation on the Mechanical Performance and Dimensional Stability of Oil Palm Fiber Reinforced Poly(lactic acid Hybrid Biocomposites

Directory of Open Access Journals (Sweden)

Abubakar Umar Birnin-Yauri

2016-02-01

Full Text Available This study demonstrated the reinforcing potential of kenaf core fiber (KCF to complement and sustain oil palm fiber supply chain in the production of natural fiber-thermoplastic biocomposites. The lignin-rich KCF was incorporated into cellulose-rich oil palm empty fruit bunch fiber (EFBF- and oil palm mesocarp fiber (OPMF-poly(lactic acid (PLA composites, aimed at achieving synergism. The hybrid biocomposites developed by melt blending and subsequent compression molding were characterized for possible application as an alternative to medium-density fiberboards. The mechanical properties and dimensional stability of both single fiber- and hybrid fiber-PLA biocomposites were evaluated and compared. The test results showed a synergistic improvement as a consequence of fiber hybridization. Also, the findings suggested the best material performance with the incorporation of 5% KCF into 55% EFBF or OPMF and 40% PLA matrix. The OPMF-KCF-PLA hybrid biocomposites gave better results than the EFBF-KCF-PLA hybrid biocomposites.

Wall-slip of highly filled powder injection molding compounds: Effect of flow channel geometry and roughness

Science.gov (United States)

Hausnerova, Berenika; Sanetrnik, Daniel; Paravanova, Gordana

2014-05-01

The paper deals with the rheological behavior of highly filled compounds proceeded via powder injection molding (PIM) and applied in many sectors of industry (automotive, medicine, electronic or military). Online rheometer equipped with slit dies varying in surface roughness and dimensions was applied to investigate the wall-slip as a rheological phenomenon, which can be considered as a parameter indicating the separation of compound components (polymer binder and metallic powder) during high shear rates when injection molded.

Injection molding of Y-TZP powders prepared by colloidal processing

International Nuclear Information System (INIS)

Kimura, Y.; Mineshita, O.; Kaga, T.; Tokinaga, T.; Obitsu, M.

1991-01-01

TZP powders containing 3mol% Y 2 O 3 were prepared from ZrOCl 2 solution via an aqueous colloidal suspension of ZrO 2 . Processing variables were optimized to obtain powders suitable for injection molding. Wettability of powders with binders, fluidity of melting compound, removal of binder from green body, and properties of sintered body were investigated

Durability Characteristics Analysis of Plastic Worm Wheel with Glass Fiber Reinforced Polyamide.

Science.gov (United States)

Kim, Gun-Hee; Lee, Jeong-Won; Seo, Tae-Il

2013-05-10

Plastic worm wheel is widely used in the vehicle manufacturing field because it is favorable for weight lightening, vibration and noise reduction, as well as corrosion resistance. However, it is very difficult for general plastics to secure the mechanical properties that are required for vehicle gears. If the plastic resin is reinforced by glass fiber in the fabrication process of plastic worm wheel, it is possible to achieve the mechanical properties of metallic material levels. In this study, the mechanical characteristic analysis of the glass-reinforced plastic worm wheel, according to the contents of glass fiber, is performed by analytic and experimental methods. In the case of the glass fiber-reinforced resin, the orientation and contents of glass fibers can influence the mechanical properties. For the characteristic prediction of plastic worm wheel, computer-aided engineering (CAE) analysis processes such as structural and injection molding analysis were executed with the polyamide resin reinforcement glass fiber (25 wt %, 50 wt %). The injection mold for fabricating the prototype plastic worm wheel was designed and made to reflect the CAE analysis results. Finally, the durability of prototype plastic worm wheel fabricated by the injection molding process was evaluated by the experimental method and the characteristics according to the glass fiber contents.

Effects of KMnO4 Treatment on the Flexural, Impact, and Thermal Properties of Sugar Palm Fiber-Reinforced Thermoplastic Polyurethane Composites

Science.gov (United States)

Mohammed, A. A.; Bachtiar, D.; Rejab, M. R. M.; Jiang, X. X.; Abas, Falak O.; Abass, Raghad U.; Hasany, S. F.; Siregar, Januar P.

2018-05-01

Global warming has had a great impact on environmental changes since the last decade. Eco-friendly industrial products are of great importance to sustain life on earth, including using natural composites. Natural fibers used as fillers are also environmentally valuable because of their biodegradable nature. However, compatibility issues between the fiber and its respective matrix is a major concern. The present work focused on the study of the flexural, impact, and thermal behaviors of environmentally friendly sugar palm fibers (SPF) incorporated into a composite with thermoplastic polyurethane (TPU). Two techniques (extrusion and compression molding) were used to prepare these composites. The fiber size and dosage were kept constant at 250 µm and 30 wt.% SPF, respectively. The effects of potassium permanganate (KMnO4) treatment on the flexural, impact, and thermal behaviors of the treated SPF with 6% NaOH-reinforced TPU composites were investigated. Three different concentrations of KMnO4 (0.033%, 0.066%, and 0.125%) were studied for this purpose. The characterization of the flexural and impact properties of the new TPU/SPF composites was studied as per American Society for Testing Materials ASTM standards. Thermogravimetric analysis was employed for thermal behavior analysis of the TPU/SPF composites. The best flexural strength, impact strength, and modulus properties (8.118 MPa, 55.185 kJ/m2, and 262.102 MPa, respectively) were obtained with a 0.033% KMnO4-treated sample. However, all flexural strength, impact strength, and modulus properties for the KMnO4-treated samples were lower than the sample treated only with 6% NaOH. The highest thermal stability was also shown by the sample treated with 0.033% KMnO4. Therefore, this method enhanced the thermal properties of the TPU/SPF composites with clear deterioration of the flexural and impact properties.

Evolution of Additively Manufactured Injection Molding Inserts Investigated by Thermal Simulations

DEFF Research Database (Denmark)

Hofstätter, Thomas; Pedersen, David B.; Tosello, Guido

.7) mm3 and (60 x 80 x 10) mm3 produced with vat photo polymerization. This contribution discusses the heat transportation within the inserts made from a thermoset material, brass, steel, and ceramic material. It therefore elaborates on the possibilities of injection molding as well as the thermal...

Portable Device Slices Thermoplastic Prepregs

Science.gov (United States)

Taylor, Beverly A.; Boston, Morton W.; Wilson, Maywood L.

1993-01-01

Prepreg slitter designed to slit various widths rapidly by use of slicing bar holding several blades, each capable of slicing strip of preset width in single pass. Produces material evenly sliced and does not contain jagged edges. Used for various applications in such batch processes involving composite materials as press molding and autoclaving, and in such continuous processes as pultrusion. Useful to all manufacturers of thermoplastic composites, and in slicing B-staged thermoset composites.

Gate design in injection molding of microfluidic components using process simulations

DEFF Research Database (Denmark)

Marhöfer, David Maximilian; Tosello, Guido; Islam, Aminul

2015-01-01

to moulding process window, polymer flow, and part quality. This finally led to an optimization of the design and the realization as actual steel mold. Additionally, the simulation results were critically discussed and possible improvements and limitations of the gained results and the deployed software......Process simulations are an effective design and optimization tool in conventional as well as micro injection molding (μIM). They can be applied to optimize and assist the design of the micro part, the mold, the micro cavity and the μIM process. Available simulation software is however developed...... for macroscopic plastic parts. By using the correct implementation and careful modelling though, it can also be applied to micro parts. In the present work, process simulations were applied to a microfluidic distributor and a microfluidic mixer of which features were in the 100 μm dimensional range. The meshing...

Minimization of variation in volumetric shrinkage and deflection on injection molding of Bi-aspheric lens using numerical simulation

Energy Technology Data Exchange (ETDEWEB)

Bensingh, R. Joseph [Central Institute of Plastics Engineering and Technology, Chennai (India); Boopathy, S. Rajendra [College of Engineering, Anna University, Chennai (India); Jebaraj, C. [Vellore Institutes of Technology, Chennai (India)

2016-11-15

The profile of a bi-aspheric lens is such a way that the thickness narrows down from center to periphery (convex). Injection molding of these profiles has high shrinkage in localized areas, which results in internal voids or sink marks when the part gets cool down to room temperature. This paper deals with the influence of injection molding process parameters such as mold surface temperature, melt temperature, injection time, V/P Switch over by percentage volume filled, packing pressure, and packing duration on the volumetric shrinkage and deflection. The optimal molding parameters for minimum variation in volumetric shrinkage and deflection of bi-aspheric lens have been determined with the application of computer numerical simulation integrated with optimization. The real experimental work carried out with optimal molding parameters and found to have a shallow and steep surface profile accuracy of 0.14 and 1.57 mm, 21.38-45.66 and 12.28-26.90 μm, 41.56-157.33 and 41.56-157.33 nm towards Radii of curvatures (RoC), surface roughness (Ra) and waviness of the surface profiles (profile error Pt), respectively.

The Influence of runner system on production of injection molds

Directory of Open Access Journals (Sweden)

Janostik Vaclav

2016-01-01

Full Text Available This experimental study describes the influence of runner system on rheological properties during the injection molding process. Economic effects on the amount of production are discussed as well. Autodesk Moldflow Synergy 2016 (Moldflow was used for the study of the injection process. Three suggestions of the runner system, cold runner system, hot runner system and the combination of cold–hot runner system have been promoted. These three variants underwent the rheological and economic analysis. As a result, recommendations for the application of the runner system for the required amount of production have been suggested

Reduction of the Adhesive Friction of Elastomers through Laser Texturing of Injection Molds

Directory of Open Access Journals (Sweden)

Joel Voyer

2017-11-01

Full Text Available It is well known that elastomers usually possess poor dry sliding friction properties due to their highly adhesive character. In order to overcome this problematic behavior in industrial applications, interfacial materials such as oils, greases, coatings, or lacks are normally used in order to separate or to functionalize the contact surfaces of elastomers. Alternatively, the high adhesion tendency of elastomers may be explicitly reduced by modifying the elastomer composition itself or by enabling a reduction of its effective contact area through, for example, surface laser texturing. This second approach, i.e., the reduction of the adhesive character of elastomers through laser structuring, will be the main topic of the present study. For this purpose, different micro-sized grooved structures were produced on flat injection molds using an ultra-short pulsed laser. The micro-structured molds were then used to produce injection molded micro-ridged Liquid Silicone Rubber (LSR sample pads. The investigations consisted firstly of determining the degree of replication of the mold micro-structures onto the surface of the LSR pads and secondly, to ascertain the degree of reduction of the friction force (or coefficient of friction of these micro-ridged LSR pads in comparison to the benchmark (unstructured LSR pads when tested under dry conditions against Aluminum alloy (Al-6082 or PA6.6-GF30 plates. For this second part of the investigation, the normal force (or contact pressure dependency of the coefficient of friction was determined through stepwise load increasing friction tests. The results of these investigations have shown that the production of micro-ridged surfaces on LSR pads through laser structuring of the injection molds could be successfully achieved and that it enables a significant reduction of the friction force for low normal forces (or contact pressures, where the component of adhesion friction is playing an important and determining

Recycling of ligno-cellulosic and polyethylene wastes from agricultural operations in thermoplastic composites

Science.gov (United States)

In the US, wood plastic composites (WPC) represent one of the successful markets for natural fiber-filled thermoplastic composites. The WPC typically use virgin or recycled thermoplastic as the substrate and wood fiber as the filler. A major application of the WPC is in non-structural building appli...

Long-Term Effects of Botulinum Toxin Complex Type A Injection on Mechano- and Metabo-Sensitive Afferent Fibers Originating from Gastrocnemius Muscle.

Directory of Open Access Journals (Sweden)

Guillaume Caron

Full Text Available The aim of the present study was to investigate long term effects of motor denervation by botulinum toxin complex type A (BoNT/A from Clostridium Botulinum, on the afferent fibers originating from the gastrocnemius muscle of rats. Animals were divided in 2 experimental groups: 1 untreated animals acting as control and 2 treated animals in which the toxin was injected in the left muscle, the latter being itself divided into 3 subgroups according to their locomotor recovery with the help of a test based on footprint measurements of walking rats: i no recovery (B0, ii 50% recovery (B50 and iii full recovery (B100. Then, muscle properties, metabosensitive afferent fiber responses to potassium chloride (KCl and lactic acid injections and Electrically-Induced Fatigue (EIF, and mechanosensitive responses to tendon vibrations were measured. At the end of the experiment, rats were killed and the toxin injected muscles were weighted. After toxin injection, we observed a complete paralysis associated to a loss of force to muscle stimulation and a significant muscle atrophy, and a return to baseline when the animals recover. The response to fatigue was only decreased in the B0 group. The responses to KCl injections were only altered in the B100 groups while responses to lactic acid were altered in the 3 injected groups. Finally, our results indicated that neurotoxin altered the biphasic pattern of response of the mechanosensitive fiber to tendon vibrations in the B0 and B50 groups. These results indicated that neurotoxin injection induces muscle afferent activity alterations that persist and even worsen when the muscle has recovered his motor activity.

Long-Term Effects of Botulinum Toxin Complex Type A Injection on Mechano- and Metabo-Sensitive Afferent Fibers Originating from Gastrocnemius Muscle.

Science.gov (United States)

Caron, Guillaume; Marqueste, Tanguy; Decherchi, Patrick

2015-01-01

The aim of the present study was to investigate long term effects of motor denervation by botulinum toxin complex type A (BoNT/A) from Clostridium Botulinum, on the afferent fibers originating from the gastrocnemius muscle of rats. Animals were divided in 2 experimental groups: 1) untreated animals acting as control and 2) treated animals in which the toxin was injected in the left muscle, the latter being itself divided into 3 subgroups according to their locomotor recovery with the help of a test based on footprint measurements of walking rats: i) no recovery (B0), ii) 50% recovery (B50) and iii) full recovery (B100). Then, muscle properties, metabosensitive afferent fiber responses to potassium chloride (KCl) and lactic acid injections and Electrically-Induced Fatigue (EIF), and mechanosensitive responses to tendon vibrations were measured. At the end of the experiment, rats were killed and the toxin injected muscles were weighted. After toxin injection, we observed a complete paralysis associated to a loss of force to muscle stimulation and a significant muscle atrophy, and a return to baseline when the animals recover. The response to fatigue was only decreased in the B0 group. The responses to KCl injections were only altered in the B100 groups while responses to lactic acid were altered in the 3 injected groups. Finally, our results indicated that neurotoxin altered the biphasic pattern of response of the mechanosensitive fiber to tendon vibrations in the B0 and B50 groups. These results indicated that neurotoxin injection induces muscle afferent activity alterations that persist and even worsen when the muscle has recovered his motor activity.

Injection molded chips with integrated conducting polymer electrodes for electroporation of cells

DEFF Research Database (Denmark)

Andresen, Kristian; Hansen, Morten; Matschuk, Maria

2010-01-01

We present the design-concept for an all polymer injection molded single use microfluidic device. The fabricated devices comprise integrated conducting polymer electrodes and Luer fitting ports to allow for liquid and electrical access. A case study of low voltage electroporation of biological...

Effect of fiber orientation on tensile and impact properties of Zalacca Midrib fiber-HDPE composites by compression molding

Science.gov (United States)

Lasikun, Ariawan, Dody; Surojo, Eko; Triyono, Joko

2018-02-01

The research aims to investigate the fiber orientation effect on the tensile and impact properties of zalacca midrib fiber /HDPE composites. The composites were produced by compression molding with pressing temperature at 150°C, pressing pressure at 50 bar, and holding time of 25 minutes. The fiber orientations applied in composites were 0°, 15°, 30°, 45°, 60°, 75°, and 90°, at 10% fiber volume fraction. The samples were evaluated by using: Tensile test and Izod impact test according to ASTM D638 and ASTM D5941, respectively. The result of experiments indicate that the orientation of zalacca midrib fiber influences the characteristics of HDPE composite-zalacca midrib fiber. The composite mechanical strength decline with the increase of orientation fibers from 0° to 90°. The composite failure mode of composites are observed by Scanning Electron Microscope (SEM).

Assessment Of Mold-Design Dependent Textures In CIM-Components By Polarized Light Optical Texture Analysis (PLOTA)

International Nuclear Information System (INIS)

Kern, Frank; Rauch, Johannes; Gadow, Rainer

2007-01-01

By thermoplastic ceramic injection moulding (CIM) ceramic components of high complexity can be produced in a large number of items at low dimensional tolerances. The cost advantage by the high degree of automation leads to an economical mass-production. The structure of injection-moulded components is determined by the form filling behaviour and viscosity of the feedstock, the machine parameters, the design of the mold and the gate design. With an adapted mold- and gate-design CIM-components without textures are possible. The ''Polarized Light Optical Texture analysis'' (PLOTA) makes it possible to inspect the components and detect and quantify the textures produced by a new mold. Based on the work of R. Fischer (2004) the PLOTA procedure was improved by including the possibility to measure the inclination angle and thus describe the orientation of the grains in three dimensions. Sampled thin sections of ceramic components are analysed under the polarization microscope and are brought in diagonal position. Pictures are taken with a digital camera. The pictures are converted in the L*a*b*- colour space and the crystals color values a* and b* in the picture are measured. The color values are compared with the values of a quartz wedge, which serves as universal standard. From the received values the inclination angle can be calculated relative to the microscope axis. It is possible to use the received data quantitatively e.g. for the FEM supported simulation of texture-conditioned divergences of mechanical values. Thus the injection molding parameters can be optimized to obtain improved mechanical properties

Two component tungsten powder injection molding – An effective mass production process

International Nuclear Information System (INIS)

Antusch, Steffen; Commin, Lorelei; Mueller, Marcus; Piotter, Volker; Weingaertner, Tobias

2014-01-01

Tungsten and tungsten-alloys are presently considered to be the most promising materials for plasma facing components for future fusion power plants. The Karlsruhe Institute of Technology (KIT) divertor design concept for the future DEMO power plant is based on modular He-cooled finger units and the development of suitable mass production methods for such parts was needed. A time and cost effective near-net-shape forming process with the advantage of shape complexity, material utilization and high final density is Powder Injection Molding (PIM). This process allows also the joining of two different materials e.g. tungsten with a doped tungsten alloy, without brazing. The complete technological process of 2-Component powder injection molding for tungsten materials and its application on producing real DEMO divertor parts, characterization results of the finished parts e.g. microstructure, hardness, density and joining zone quality are discussed in this contribution

Molding Properties of Inconel 718 Feedstocks Used in Low-Pressure Powder Injection Molding

Directory of Open Access Journals (Sweden)

Fouad Fareh

2016-01-01

Full Text Available The impact of binders and temperature on the rheological properties of feedstocks used in low-pressure powder injection molding was investigated. Experiments were conducted on different feedstock formulations obtained by mixing Inconel 718 powder with wax-based binder systems. The shear rate sensitivity index and the activation energy were used to study the degree of dependence of shear rate and temperature on the viscosity of the feedstocks. The injection performance of feedstocks was then evaluated using an analytical moldability model. The results indicated that the viscosity profiles of feedstocks depend significantly on the binder constituents, and the secondary binder constituents play an important role in the rheological behavior (pseudoplastic or near-Newtonian exhibited by the feedstock formulations. Viscosity values as low as 0.06 to 2.9 Pa·s were measured at high shear rates and high temperatures. The results indicate that a feedstock containing a surfactant agent exhibits the best moldability characteristics.

Influence of injection temperatures and fiberglass compositions on mechanical properties of polypropylene

Science.gov (United States)

Keey, Tony Tiew Chun; Azuddin, M.

2017-06-01

Injection molding process appears to be one of the most suitable mass and cost efficiency manufacturing processes for polymeric parts nowadays due to its high efficiency of large scale production. When down-scaling the products and components, the limits of conventional injection molding process are reached. These constraints had initiated the development of conventional injection molding process into a new era of micro injection molding technology. In this study, fiberglass reinforced polypropylenes (PP) with various glass fiber percentage materials were used. The study start with fabrication of micro tensile specimens at three different injection temperature, 260°C, 270°C and 280°C for different percentage by weight of fiberglass reinforced PP. Then evaluate the effects of various injection temperatures on the tensile properties of micro tensile specimens. Different percentage by weight of fiberglass reinforced PP were tested as well and it was found that 20% fiberglass reinforced PP possessed the greatest percentage increase of tensile strength with increasing temperatures.

Fabrication and characterization of injection molded multi level nano and microfluidic systems

DEFF Research Database (Denmark)

Matteucci, Marco; Christiansen, Thomas Lehrmann; Tanzi, Simone

2013-01-01

We here present a method for fabrication of multi-level all-polymer chips by means of silicon dry etching, electroplating and injection molding. This method was used for successful fabrication of microfluidic chips for applications in the fields of electrochemistry, cell trapping and DNA elongati...

Experimental validation of viscous and viscoelastic simulations of micro injection molding process

DEFF Research Database (Denmark)

Gava, Alberto; Tosello, Guido; Lucchetta, Giovanni

2009-01-01

The effects of two different rheological models used in the simulation of the micro injection molding (µIM) process are investigated. The Cross-WLF viscous model and the Giesekus viscoelastic model are selected and their performance evaluated using 3D models implemented on two different...

Transcription of Small Surface Structures in Injection Molding - an Experimental Study

DEFF Research Database (Denmark)

Arlø, Uffe Rolf; Kjær, Erik Michael

2001-01-01

The ability to replicate the surface roughness from mold wall to the plastic part in injection moldning has many functional and cosmetic important implications from medical use to designer products. Generally the understanding of surface transcription i.e the the replication of the surface...... structure from the mould to plastic part, also relates to micro injection moulding and moulding of parts with specific micro structures on the surface such as optical parts. The present study concerns transcription of surface roughness as a function of process parameters. The study is carried out...

Friction behavior of ceramic injection-molded (CIM) brackets.

Science.gov (United States)

Reimann, Susanne; Bourauel, Christoph; Weber, Anna; Dirk, Cornelius; Lietz, Thomas

2016-07-01

Bracket material, bracket design, archwire material, and ligature type are critical modifiers of friction behavior during archwire-guided movement of teeth. We designed this in vitro study to compare the friction losses of ceramic injection-molded (CIM) versus pressed-ceramic (PC) and metal injection-molded (MIM) brackets-used with different ligatures and archwires-during archwire-guided retraction of a canine. Nine bracket systems were compared, including five CIM (Clarity™ and Clarity™ ADVANCED, both by 3M Unitek; discovery(®) pearl by Dentaurum; Glam by Forestadent; InVu by TP Orthodontics), two PC (Inspire Ice by Ormco; Mystique by DENTSPLY GAC), and two MIM (discovery(®) and discovery(®) smart, both by Dentaurum) systems. All of these were combined with archwires made of either stainless steel or fiberglass-reinforced resin (remanium(®) ideal arch or Translucent pearl ideal arch, both by Dentaurum) and with elastic ligatures or uncoated or coated stainless steel (all by Dentaurum). Archwire-guided retraction of a canine was simulated with a force of 0.5 N in the orthodontic measurement and simulation system (OMSS). Friction loss was determined by subtracting the effective orthodontic forces from the applied forces. Based on five repeated measurements performed on five brackets each, weighted means were calculated and evaluated by analysis of variance and a Bonferroni post hoc test with a significance level of 0.05. Friction losses were significantly (p brackets used with a stainless-steel ligature and the resin archwire. No critical difference to friction behavior was apparent between the various manufacturing technologies behind the bracket systems.

Injection molding simulation to improve the efficiency and quality of metal molding designs. Kanagata no sekkei koritsu ka to hinshitsu kojo wo hakaru shashutsu seikei simulation

Energy Technology Data Exchange (ETDEWEB)

Ito, Y. (Sony Corp., Tokyo (Japan))

1992-01-01

In order to improve the efficiency and quality of metal molding designs, Sony Corp. has adopted an injection molding simulation system since the first half of 1980s. Since, however, molding materials are thermal fluids, which transit their phase from liquid into solid, and boundary conditions will be changed in the middle of their cycles, their analyzing works are very difficult. Therefore, softwares in this field are still on the way to be developed. Since this corporation has joined to the Cornell Injection Molding Program (CIMP) project in Cornell University, they have added improvements on their programs to be supplied, and have used them with their own programs developed additionally based on transformation processes. They have carried out minimizing of shape of boss root and examining holding pressure control by this simulation system. Since actually input works for CAD process have been carried out by hand now, it takes a time a little, though, they have also considered to make it easy by automating for applications of the full model. 4 refs., 7 figs.

Injection molded superhydrophobic surfaces based on microlithography and black silicon processing

DEFF Research Database (Denmark)

Søgaard, Emil; Andersen, Nis Korsgaard; Taboryski, Rafael

2012-01-01

in detail with an engineering perspective on choice of materials and manufacturability by injection molding. Microscope slides with superhydrophobic properties were succesfully fabricated. Preliminary results indicate a contact angle increase from 95° for the unstructured polymer to a maximum 150......°. The lowest drop roll off angles observed were in the range 1° to 5°....

A Soft Tooling process chain employing Additive Manufacturing for injection molding of a 3D component with micro pillars

DEFF Research Database (Denmark)

Zhang, Yang; Pedersen, David Bue; Segebrecht Gøtje, Asger

2017-01-01

The purpose of the research presented in this paper is to investigate the capability of a soft tooling process chain employing Additive Manufacturing (AM) for preproduction of an insert with micro features by injection molding. The Soft Tooling insert was manufactured in a high temperature...... photopolymer by Digital Light Processing (vat photopolymerization). The mold cavity was formed by two insert halves, by design; both inserts have four angled tines, with micro holes (Ø200 μm, 200 μm deep) on the surface. Injection molding with polyethylene was used with the soft tool inserts to manufacture...

SAXS studies of the injection molding effects on the nanostructure of polyesters. II: polytrimetylene terephthalate (PTT)

International Nuclear Information System (INIS)

Marinelli, Alessandra L.; Plivelic, Tomas; Torriani, Iris; Bretas, Rosario E.S.

2005-01-01

In this work, the nanoperiodicity of some PTT samples, injection molded at different conditions, was evaluated as a function of the thickness of the samples. From the small angle X-ray scattering (SAXS) results, it was possible to observe that, as expected, there is a gradient of the L and lc values found through the thickness of the PTT samples. It was also found that at the center of the PTT sample injection molded at low injection temperature, Ti, the crystallinity degree evaluated previously by wide angle X-ray diffraction (WAXD) is high and the orientation in this region must be also high, because smaller values of L and l C were found at this region of the sample. The opposite trend was found to PBT.(author)

Effect of Alumina Nanoparticles on the Rheological Behavior of Aluminum-Binder Mixtures for Powder Injection Molding

Directory of Open Access Journals (Sweden)

Hassan Abdoos

2014-10-01

Full Text Available Preparation of appropriate powder-binder mixtures is the crucial step of powder injection molding process. Hence, the rheological properties of powder-binder mixture are important factors in production of sound parts using powder injection molding. Nowadays, the use of nanoparticles in powder injection molding is increasing due to the improved properties and dimensional precision of the final parts. On the other hand, nanoparticles can initiate problems such as agglomeration and loss of rheological properties and homogeneity. In the present study, the rheological behavior of aluminum mixtures containing nanoalumina particles was investigated. Two powder loadings of aluminum powder (54 vol% and 60 vol%, in which 0, 3, 6 and 9 wt% of aluminum was replaced with nanoalumina, were used. The powder systems were blended with the molten binder system in a banbury internal mixer and the rheological properties of the resulting mixtures were evaluated. All feedstocks showed pseudo-plastic behavior. The presence of nanoparticles increased the viscosity of feedstocks. Due to overwhelming particles cohesion by hydrodynamic forces, the viscosity of the mixtures decreased at high shear rates. Tap density results confirmed an improvement in packing compressibility of the mentioned powders. Shear rate sensitivity decreased with incorporation of nanoparticles into the mixtures. This phenomenon improved the injection capability through further reduction in viscosity.

Crosslinking of thermoplastic composites using electron beam radiation

International Nuclear Information System (INIS)

Strong, A.B.; Black, S.R.; Bryce, G.R.; Olcott, D.D.

1991-01-01

The crosslinking of thermoset materials has been clearly demonstrated to improve many desirable physical and chemical properties for composite applications. While thermoplastic resins also offer many advantages for composite applications, they are not crosslinked and, therefore, may not meet the same property criteria as crosslinked thermosets. Electron beams have been used successfully for crosslinking non-reinforced thermoplastic materials. Electron beams have also been used for curing composite thermoset materials. This research utilizes electron beams to crosslink high performance thermoplastic composite materials (PEEK and PPS with glass and carbon fibers). The tensile strength and tensile modulus are compared under various crosslinking conditions. The method is found to have some advantages in potentially improving physical properties of thermoplastic composite materials

Color measurement of plastics - From compounding via pelletizing, up to injection molding and extrusion

Science.gov (United States)

Botos, J.; Murail, N.; Heidemeyer, P.; Kretschmer, K.; Ulmer, B.; Zentgraf, T.; Bastian, M.; Hochrein, T.

2014-05-01

The typical offline color measurement on injection molded or pressed specimens is a very expensive and time-consuming process. In order to optimize the productivity and quality, it is desirable to measure the color already during the production. Therefore several systems have been developed to monitor the color e.g. on melts, strands, pellets, the extrudate or injection molded part already during the process. Different kinds of inline, online and atline methods with their respective advantages and disadvantages will be compared. The criteria are e.g. the testing time, which ranges from real-time to some minutes, the required calibration procedure, the spectral resolution and the final measuring precision. The latter ranges between 0.05 to 0.5 in the CIE L*a*b* system depending on the particular measurement system. Due to the high temperatures in typical plastics processes thermochromism of polymers and dyes has to be taken into account. This effect can influence the color value in the magnitude of some 10% and is barely understood so far. Different suitable methods to compensate thermochromic effects during compounding or injection molding by using calibration curves or artificial neural networks are presented. Furthermore it is even possible to control the color during extrusion and compounding almost in real-time. The goal is a specific developed software for adjusting the color recipe automatically with the final objective of a closed-loop control.

Metal Injection Molding (MIM) of NdFeB Magnets

OpenAIRE

Hartwig T.; Lopes L.; Wendhausen P.; Ünal N.

2014-01-01

Due to the increased and unstable prices for Rare Earth elements there are activities to develop alternative hard magnetic materials. Reducing the amount of material necessary to produce complex sintered NdFeB magnets can also help to reduce some of the supply problem. Metal Injection Molding (MIM) is able to produce near net shape parts and can reduce the amount of finishing to achieve final geometry. Although MIM of NdFeB has been patented and published fairly soon after the development of ...

An anisotropic elasto-viscoplastic model for short-fiber reinforced polymers

NARCIS (Netherlands)

Amiri Rad, A.; Govaert, L.E.; van Dommelen, J.A.W.

2017-01-01

The influence of flow on the fiber orientation in injection molding of short-fiber composites leads to both anisotropy and inhomogeneity of the mechanical response. An anisotropic elasto-viscoplastic constitutive model is developed to capture the anisotropic and time-dependent behavior and

An Anisotropic Elasto-Viscoplastic Model for Short-Fiber Reinforced Polymers

NARCIS (Netherlands)

Amiri Rad, A.; Govaert, L.E.; van Dommelen, J.A.W.

2018-01-01

The influence of flow on the fiber orientation in injection molding of short-fiber composites leads to both anisotropy and inhomogeneity of the mechanical response. An anisotropic elasto-viscoplastic constitutive model is developed to capture the anisotropic and time-dependent behavior and

Hydrogen silsesquioxane mold coatings for improved replication of nanopatterns by injection molding

DEFF Research Database (Denmark)

Hobæk, Thor Christian; Matschuk, Maria; Kafka, Jan

2015-01-01

of replication, thus allowing more time to fill the nanoscale cavities compared to standard metal molds. A monolayer of a fluorinated silane (heptadecafluorotrichlorosilane) deposited on the mold surface reduces the mold/polymer interfacial energy to support demolding of the polymer replica. The mechanical...

Strength of cellulosic fiber/starch acetate composites with variable fiber and plasticizer content

DEFF Research Database (Denmark)

Joffe, Roberts; Madsen, Bo; Nättinen, Kalle

2015-01-01

In this experimental study, the performance of injection-molded short flax and hemp fibers in plasticized starch acetate were analyzed in terms of strength. Parameters involved in the analysis are a variable fiber and plasticizer content. The measured strength of the composites varies in the range...... of 12–51 MPa for flax fibers and 11–42 MPa for hemp fibers, which is significantly higher than the properties of the unreinforced starch acetate matrix. The micro-structural parameters used in modeling of composite strength were obtained from optical observations and indirect measurements. Some...

Improvement Performance of the Filling Step in Injection Mold through Vibration

Directory of Open Access Journals (Sweden)

Trejo-Hernández M.

2012-10-01

Full Text Available This paper shows the flow improvement in the filling step of the polymer injection process due to the polymer excitation though vibration. This process can be split up into three main steps: filling, pocking and cooling. Several mechanical and aesthetic properties of the finished product can be changed in the filling step. The objective of this investigation is to demonstrate the improvement in the filling mold under vibration without adding chemical products. To reach this result, an experimental mold was designed and manufactured in which a vibration device was coupled; it was possible to demonstrate the vibration advantage through this process. Moreover, a heuristic methodology was proposed for the experiment which shows an improvement in the filling process with frequencies close to 3 Hz.

All polymer, injection molded nanoslits, fabricated through two-level UV-LIGA processes

DEFF Research Database (Denmark)

Østergaard, Peter Friis; Matteucci, Marco; Marie, Rodolphe

2012-01-01

in the micro- and nanoregime is required. To obtain this, injection molding is included in the research process for making several chips (100-1000) with the same layout. The time it takes for the individual chip to be fabricated in this way is much shorter than with conventional cleanroom methods...

Fire safety improvement of para-aramid fiber in thermoplastic polyurethane elastomer

International Nuclear Information System (INIS)

Chen, Xilei; Wang, Wenduo; Li, Shaoxiang; Jiao, Chuanmei

2017-01-01

Highlights: • Fire safety of para-aramid fiber on TPU has been investigated. • Para-aramid fiber has excellent flame retardant abilities and smoke suppression properties on TPU. • A new technique to improve the fire safety polymer is provided in this article. - Abstract: This article mainly studied fire safety effects of para-aramid fiber (AF) in thermoplastic polyurethane (TPU). The TPU/AF composites were prepared by molten blending method, and then the fire safety effects of all TPU composites were tested using cone calorimeter test (CCT), microscale combustion colorimeter test (MCC), smoke density test (SDT), and thermogravimetric/fourier transform infrared spectroscopy (TG-IR). The CCT test showed that AF could improve the fire safety of TPU. Remarkably, the peak value of heat release rate (pHRR) and the peak value of smoke production rate (pSPR) for the sample with 1.0 wt% content of AF were decreased by 52.0% and 40.5% compared with pure TPU, respectively. The MCC test showed that the HRR value of AF-2 decreased by 27.6% compared with pure TPU. TG test showed that AF promoted the char formation in the degradation process of TPU; as a result the residual carbon was increased. The TG-IR test revealed that AF had increased the thermal stability of TPU at the beginning and reduced the release of CO_2 with the decomposition going on. Through the analysis of the results of this experiment, it will make a great influence on the study of the para-aramid fiber in the aspect of fire safety of polymer.

Fire safety improvement of para-aramid fiber in thermoplastic polyurethane elastomer

Energy Technology Data Exchange (ETDEWEB)

Chen, Xilei; Wang, Wenduo; Li, Shaoxiang; Jiao, Chuanmei, E-mail: jiaochm@qust.edu.cn

2017-02-15

Highlights: • Fire safety of para-aramid fiber on TPU has been investigated. • Para-aramid fiber has excellent flame retardant abilities and smoke suppression properties on TPU. • A new technique to improve the fire safety polymer is provided in this article. - Abstract: This article mainly studied fire safety effects of para-aramid fiber (AF) in thermoplastic polyurethane (TPU). The TPU/AF composites were prepared by molten blending method, and then the fire safety effects of all TPU composites were tested using cone calorimeter test (CCT), microscale combustion colorimeter test (MCC), smoke density test (SDT), and thermogravimetric/fourier transform infrared spectroscopy (TG-IR). The CCT test showed that AF could improve the fire safety of TPU. Remarkably, the peak value of heat release rate (pHRR) and the peak value of smoke production rate (pSPR) for the sample with 1.0 wt% content of AF were decreased by 52.0% and 40.5% compared with pure TPU, respectively. The MCC test showed that the HRR value of AF-2 decreased by 27.6% compared with pure TPU. TG test showed that AF promoted the char formation in the degradation process of TPU; as a result the residual carbon was increased. The TG-IR test revealed that AF had increased the thermal stability of TPU at the beginning and reduced the release of CO{sub 2} with the decomposition going on. Through the analysis of the results of this experiment, it will make a great influence on the study of the para-aramid fiber in the aspect of fire safety of polymer.

Carbon fiber reinforced thermoplastic composites from acrylic polymer matrices: Interfacial adhesion and physical properties

Directory of Open Access Journals (Sweden)

H. Kishi

2017-04-01

Full Text Available Acrylic polymers have high potential as matrix polymers for carbon fiber reinforced thermoplastic polymers (CFRTP due to their superior mechanical properties and the fact that they can be fabricated at relatively low temperatures. We focused on improving the interfacial adhesion between carbon fibers (CFs and acrylic polymers using several functional monomers for co-polymerization with methyl methacrylate (MMA. The copolymerized acrylic matrices showed good adhesion to the CF surfaces. In particular, an acrylic copolymer with acrylamide (AAm showed high interfacial adhesive strength with CFs compared to pure PMMA, and a hydroxyethyl acrylamide (HEAA copolymer containing both amide and hydroxyl groups showed high flexural strength of the CFRTP. A 3 mol% HEAA-copolymerized CFRTP achieved a flexural strength almost twice that of pure PMMA matrix CFRTP, and equivalent to that of an epoxy matrix CFRP.

Transferability of glass lens molding

Science.gov (United States)

Katsuki, Masahide

2006-02-01

Sphere lenses have been used for long time. But it is well known that sphere lenses theoretically have spherical aberration, coma and so on. And, aspheric lenses attract attention recently. Plastic lenses are molded easily with injection machines, and are relatively low cost. They are suitable for mass production. On the other hand, glass lenses have several excellent features such as high refractive index, heat resistance and so on. Many aspheric glass lenses came to be used for the latest digital camera and mobile phone camera module. It is very difficult to produce aspheric glass lenses by conventional process of curve generating and polishing. For the solution of this problem, Glass Molding Machine was developed and is spreading through the market. High precision mold is necessary to mold glass lenses with Glass Molding Machine. The mold core is ground or turned by high precision NC aspheric generator. To obtain higher transferability of the mold core, the function of the molding machine and the conditions of molding are very important. But because of high molding temperature, there are factors of thermal expansion and contraction of the mold and glass material. And it is hard to avoid the factors. In this session, I introduce following items. [1] Technology of glass molding and the machine is introduced. [2] The transferability of glass molding is analyzed with some data of glass lenses molded. [3] Compensation of molding shape error is discussed with examples.

Influence of Injection-Molding Process Parameters on Part Replication of Microstructures with Additively-Manufactured Soft Tooling Inserts WCMNM 2017 No

DEFF Research Database (Denmark)

Mischkot, Michael; Zhang, Yang; Segebrecht Gøtje, Asger

The objective of this research is to investigate the influence of injection molding parameters on the dimensional replication of microstructure surfaces in injection molding with additively manufactured soft tooling inserts in a photopolymer material. The replication degree of micropillars...... diameter and decreases the replication degree of the pillar height. A high melt temperature increases the pillar diameter independently from the pillar height. A higher injection speed affects both pillar diameter and height negatively. In addition, the study showed a significant difference...

Thermoplastic starch/ethylene vinyl alcohol/forsterite nanocomposite as a candidate material for bone tissue engineering

Energy Technology Data Exchange (ETDEWEB)

Mahdieh, Zahra [Polymeric Materials Research Group (PMRG), Department of Materials Science and Engineering, Sharif University of Technology, Tehran, P.O. Box 11155-9466 (Iran, Islamic Republic of); Bagheri, Reza, E-mail: rezabagh@sharif.edu [Polymeric Materials Research Group (PMRG), Department of Materials Science and Engineering, Sharif University of Technology, Tehran, P.O. Box 11155-9466 (Iran, Islamic Republic of); Eslami, Masoud; Amiri, Mohammad [Polymeric Materials Research Group (PMRG), Department of Materials Science and Engineering, Sharif University of Technology, Tehran, P.O. Box 11155-9466 (Iran, Islamic Republic of); Shokrgozar, Mohammad Ali; Mehrjoo, Morteza [National Cell Bank of Iran, Pasteur Institute of Iran, Tehran (Iran, Islamic Republic of)

2016-12-01

Recently, biodegradable polymers such as starch based blends have been well renowned in the biomedical field. Studies have considered them suitable for bone scaffolds, bone cements, tissue engineering scaffolds, drug delivery systems and hydrogels. The aim of this study was to synthesize nanocomposite biomaterial consisting a blend of thermoplastic starch and ethylene vinyl alcohol as the polymer matrix, and nano-structured forsterite as the ceramic reinforcing phase for bone tissue engineering applications. Furthermore, vitamin E was applied as a thermal stabilizer during melt compounding. Extrusion and injection molding were incorporated for melt blending and shaping of samples, respectively. With blending thermoplastic starch and ethylene vinyl alcohol, some properties of thermoplastic starch such as degradation rate and water absorption were modified. In addition, using nanoforsterite as the ceramic reinforcing phase resulted in the improvement of mechanical and biological traits. The addition of nanoforsterite decreased the weight loss of the thermoplastic starch and ethylene vinyl alcohol blend in simulated body fluid. Moreover, this addition modified the pH in the MTT (methyl thiazolyl tetrazolium) assay and stimulated the cell proliferation. Cell adhesion assays indicated a favorable interaction between cells and the biomaterial. The proposed nanocomposite has appropriate biocompatibility, as well as mechanical properties in order to be used in bone tissue engineering. - Highlights: • A biodegradable nanocomposite is proposed for orthopedic applications. • Vitamin E is used as an antioxidant to prevent the thermomechanical degradations. • Nanoforsterite reduced the composite degradation rate in the simulated body fluid. • Nanoforsterite modified pH in MTT assay and stimulated cell proliferation.

Thermoplastic starch/ethylene vinyl alcohol/forsterite nanocomposite as a candidate material for bone tissue engineering

International Nuclear Information System (INIS)

Mahdieh, Zahra; Bagheri, Reza; Eslami, Masoud; Amiri, Mohammad; Shokrgozar, Mohammad Ali; Mehrjoo, Morteza

2016-01-01

Recently, biodegradable polymers such as starch based blends have been well renowned in the biomedical field. Studies have considered them suitable for bone scaffolds, bone cements, tissue engineering scaffolds, drug delivery systems and hydrogels. The aim of this study was to synthesize nanocomposite biomaterial consisting a blend of thermoplastic starch and ethylene vinyl alcohol as the polymer matrix, and nano-structured forsterite as the ceramic reinforcing phase for bone tissue engineering applications. Furthermore, vitamin E was applied as a thermal stabilizer during melt compounding. Extrusion and injection molding were incorporated for melt blending and shaping of samples, respectively. With blending thermoplastic starch and ethylene vinyl alcohol, some properties of thermoplastic starch such as degradation rate and water absorption were modified. In addition, using nanoforsterite as the ceramic reinforcing phase resulted in the improvement of mechanical and biological traits. The addition of nanoforsterite decreased the weight loss of the thermoplastic starch and ethylene vinyl alcohol blend in simulated body fluid. Moreover, this addition modified the pH in the MTT (methyl thiazolyl tetrazolium) assay and stimulated the cell proliferation. Cell adhesion assays indicated a favorable interaction between cells and the biomaterial. The proposed nanocomposite has appropriate biocompatibility, as well as mechanical properties in order to be used in bone tissue engineering. - Highlights: • A biodegradable nanocomposite is proposed for orthopedic applications. • Vitamin E is used as an antioxidant to prevent the thermomechanical degradations. • Nanoforsterite reduced the composite degradation rate in the simulated body fluid. • Nanoforsterite modified pH in MTT assay and stimulated cell proliferation.

Effect of compatibilizing agents on the interface and mechanical behaviour of polypropylene/hemp bast fiber biocomposites

Science.gov (United States)

Boruvka, M.; Lenfeld, P.; Brdlik, P.; Behalek, L.

2015-07-01

During the last years automotive industry has given a lot of attention to the biobased polymers that are sustainable and eco-friendly. Nevertheless fully green composites are currently too expensive for most applications. A viable solution and logical starting point at this material revolution lies in reinforced synthetic thermoplastics based on plant derived biodegradable fibers. Plant fibers (PF's) have potential to reduce weight of composite vehicle parts up to 40% compared with the main automotive composites filler, glass fibers (GF's). Production of GF's composites is much more energy intensive and polluting compared with growing, harvesting and preparing of PF's. The main disadvantage of PF's lies in combination of non-polar hydrophobic polymer matrix and polar hydrophilic fibers. This combination creates poor interface with low adhesion of both components. That implies poor wettability of fibres by polymer matrix and low mechanical properties of biocomposites. Therefore specific compatibilizing agents (Struktol SA1012, Fusabond P353, Smart + Luperox) were used in order to enhance compatibility between reinforcement and matrix. In this paper sets of biocomposite compounds were prepared by twin screw extrusion considering different type and weight percentage (wt. %) of compatibilizing agents, hemp bast fibres (HBF's) within ratio 20 (wt. %) and polypropylene (PP) THERMOFIL PP E020M matrix. Resulting compounds were than injection molded and tested samples were characterized by means of scanning electron microscopy (SEM) and mechanical testing.

Investigation on the micro injection molding process of an overmolded multi-material micro component

DEFF Research Database (Denmark)

Baruffi, Federico; Calaon, Matteo; Tosello, Guido

and difficult assembly steps, being the plastic molded directly on a metal substrate. In this scenario, an investigation on the fully automated micro overmolding manufacturing technology of a three-material micro component for acoustic applications has been carried out. Preliminary experiments allowed......Micro injection molding (μIM) is one of the few technologies capable of meeting the increasing demand of complex shaped micro plastic parts. This process, combined with the overmolding technique, allows a fast and cost-efficient production of multi-material micro components, saving numerous...

Resin Viscosity Influence on Fiber Compaction in Tapered Resin Injection Pultrusion Manufacturing

Science.gov (United States)

Masuram, N. B.; Roux, J. A.; Jeswani, A. L.

2018-06-01

Viscosity of the liquid resin effects the chemical and mechanical properties of the pultruded composite. In resin injection pultrusion manufacturing the liquid resin is injected into a specially designed tapered injection chamber through the injection slots present on top and bottom of the chamber. The resin is injected at a pressure so as to completely wetout the fiber reinforcements inside the tapered injection chamber. As the resin penetrates through the fibers, the resin also pushes the fibers away from the wall towards the center of chamber causing compaction of the fiber reinforcements. The fibers are squeezed together due to compaction, making resin penetration more difficult; thus higher resin injection pressures are required to efficaciously penetrate through the compacted fibers and achieve complete wetout. The impact of resin viscosity on resin flow, fiber compaction, wetout and on the final product is further discussed. Injection chamber design predominantly effects the resin flow inside the chamber and the minimum injection pressure required to completely wet the fibers. Therefore, a desirable injection chamber design is such that wetout occurs at lower injection pressures and at low internal pressures inside the injection chamber.

Estudo de caso de peça moldada pelo processo de injeção-compressão para termoplásticos utilizando análise computacional Study of injection-compression molded part using CAE analysis

Directory of Open Access Journals (Sweden)

Thyago M. Kiam

2007-03-01

Full Text Available O processamento de termoplásticos através do processo de injeção representa o principal método de fabricação de peças plásticas. Limitações do processo de injeção convencional, principalmente quanto à matéria-prima e configuração e funcionamento das máquinas disponíveis, tornam inviável a produção de produtos com grande área projetada e pequena espessura, como janelas automotivas e alguns tipos de lentes. Paralelamente, o processo de injeção evolui continuamente e há uma série de novas tecnologias geradas a partir do processo original, dentre elas o processo de injeção-compressão. No presente trabalho, utilizando análise computacional, estudou-se a produção de lentes de policarbonato através de dois processos distintos: injeção convencional e processo de injeção-compressão. A seqüência de estudos envolveu basicamente os seguintes pontos: estudo do padrão de preenchimento com conseqüente otimização do processo de injeção-compressão quanto à formação de linha de emenda; estudo da janela de processo para ambos os casos e comparação de alguns parâmetros principalmente tensão de cisalhamento e força de fechamento, por se tratarem de fatores limitantes na produção de peças com grande área projetada. Os resultados para o caso estudado comprovam grande vantagem na utilização do processo de injeção-compressão.The injection-molding of thermoplastics is the main process used in the production of plastics parts. There are some limitations in the conventional injection process, specially related to raw materials, machines configuration and operation, which hamper fabrication of thin parts with large areas such as car windows and lenses. On the other hand, the process has been improved continuously with several new technologies, going beyond the conventional injection molding process, including the "injection-compression" process. In this paper, using CAE (computer aided engineering technology

Rheological and thermal performance of newly developed binder systems for ceramic injection molding

Science.gov (United States)

Hausnerova, Berenika; Kasparkova, Vera; Hnatkova, Eva

2016-05-01

In a novel binder system, carnauba wax was considered to replace the synthetic backbone polymers (polyolefins) enhancing the environmental sustainability of Ceramic Injection Molding (CIM) technology. The paper presents comparison of the rheological performance and thermal behavior of the aluminum oxide CIM feedstocks based on a binder containing carnauba wax with those consisting of a commercial binder. Further, acrawax (N, N'-Ethylene Bis-stearamide) has been considered as another possible substitute of polyolefins. For both proposed substitutes there is a significant reduction in viscosity, and in case of carnauba wax based feedstock also in processing temperature, which is essential for injection molding of reactive powders. Thermal characterization comprised analyses of single neat binders, their mixtures and mixtures with aluminum oxide. The presence of powder lowered melting temperatures of all tested binders except of polyolefin. Further depression in melting point of poly(ethylene glycol) is observed in combination with polyolefin in the presence of powder, and it is related to changes in size of the crystalline domains.

An axisymmetrical non-linear finite element model for induction heating in injection molding tools

DEFF Research Database (Denmark)

Guerrier, Patrick; Nielsen, Kaspar Kirstein; Menotti, Stefano

2016-01-01

To analyze the heating and cooling phase of an induction heated injection molding tool accurately, the temperature dependent magnetic properties, namely the non-linear B-H curves, need to be accounted for in an induction heating simulation. Hence, a finite element model has been developed......, including the non-linear temperature dependent magnetic data described by a three-parameter modified Frohlich equation fitted to the magnetic saturation curve, and solved with an iterative procedure. The numerical calculations are compared with experiments conducted with two types of induction coils, built...... in to the injection molding tool. The model shows very good agreement with the experimental temperature measurements. It is also shown that the non-linearity can be used without the temperature dependency in some cases, and a proposed method is presented of how to estimate an effective linear permeability to use...

Micro injection moulding process validation for high precision manufacture of thermoplastic elastomer micro suspension rings

DEFF Research Database (Denmark)

Calaon, M.; Tosello, G.; Elsborg Hansen, R.

Micro injection moulding (μIM) is one of the most suitable micro manufacturing processes for flexible mass-production of multi-material functional micro components. The technology was employed in this research used to produce thermoplastic elastomer (TPE) micro suspension rings identified...... main μIM process parameters (melt temperature, injection speed, packing pressure) using the Design of Experiment statistical technique. Measurements results demonstrated the importance of calibrating mould´s master geometries to ensure correct part production and effective quality conformance...... on the frequency in order to improve the signal quality and assure acoustic reproduction fidelity. Production quality of the TPE rings drastically influence the product functionality. In the present study, a procedure for μIM TPE micro rings production optimization has been established. The procedure entail using...

Implementation of Molding Constraints in Topology Optimization

DEFF Research Database (Denmark)

Marx, S.; Kristensen, Anders Schmidt

2009-01-01

In many cases the topology optimization method yield inadmissible solutions in respect to a particular manufacturing process, e.g. injection molding. In the present work it is chosen to focus on the most common injection molding parameters/factors determining the quality of the mold geometry, i.......e. uniform thickness, filling of the die and ejection of the molded item, i.e. extrusion. The mentioned injection mold parameters/factors are introduced in the topology optimization by defining a centerline of the initial domain and then penalize elements in respect to the distance to the defined centerline...

Effect of injection molding parameters on nanofillers dispersion in masterbatch based PP-clay nanocomposites

OpenAIRE

J. Soulestin; J. J. Rajesh; M. F. Lacrampe; P. Krawczak

2012-01-01

The effect of injection molding parameters (screw rotational speed, back pressure, injec-tion flow rate and holding pressure) on the nanofiller dispersion of melt-mixed PP/clay nanocomposites was investigated. The nanocomposites containing 4 wt% clay were obtained by dilution of a PP/clay masterbatch into a PP matrix. The evaluation of the dispersion degree was obtained from dynamic rheological measurements. The storage modulus and complex viscosity exhibit significant dependence on the injec...

Long-fibre reinforced thermoplastics. Applications and limitations of a new type of material

Energy Technology Data Exchange (ETDEWEB)

Neise, E.

1986-06-01

New processing possibilities are offered by long-fibre reinforced thermoplastics, because - contrary to thermoset processing - no chemical reaction occurs and thermoforming and welding of prepregs is possible. Processing techniques like filament winding, tape laying or pultrusion are in development at different institutes.

Self-sorting of guests and hard blocks in bisurea-based thermoplastic elastomers

NARCIS (Netherlands)

Botterhuis, N.E.; Karthikeyan, S.; Spiering, A.J.H.; Sijbesma, R.P.

2010-01-01

Self-sorting in thermoplastic elastomers was studied using bisurea-based thermoplastic elastomers (TPEs) which are known to form hard blocks via hierarchical aggregation of bisurea segments into ribbons and of ribbons into fibers. Self-sorting of different bisurea hard blocks in mixtures of polymers

Mechanical characterization and structural analysis of recycled fiber-reinforced-polymer resin-transfer-molded beams

Science.gov (United States)

Tan, Eugene Wie Loon

1999-09-01

The present investigation was focussed on the mechanical characterization and structural analysis of resin-transfer-molded beams containing recycled fiber-reinforced polymers. The beams were structurally reinforced with continuous unidirectional glass fibers. The reinforcing filler materials consisted entirely of recycled fiber-reinforced polymer wastes (trim and overspray). The principal resin was a 100-percent dicyclo-pentadiene unsaturated polyester specially formulated with very low viscosity for resin transfer molding. Variations of the resin transfer molding technique were employed to produce specimens for material characterization. The basic materials that constituted the structural beams, continuous-glass-fiber-reinforced, recycled-trim-filled and recycled-overspray-filled unsaturated polyesters, were fully characterized in axial and transverse compression and tension, and inplane and interlaminar shear, to ascertain their strengths, ultimate strains, elastic moduli and Poisson's ratios. Experimentally determined mechanical properties of the recycled-trim-filled and recycled-overspray-filled materials from the present investigation were superior to those of unsaturated polyester polymer concretes and Portland cement concretes. Mechanical testing and finite element analyses of flexure (1 x 1 x 20 in) and beam (2 x 4 x 40 in) specimens were conducted. These structurally-reinforced specimens were tested and analyzed in four-point, third-point flexure to determine their ultimate loads, maximum fiber stresses and mid-span deflections. The experimentally determined load capacities of these specimens were compared to those of equivalent steel-reinforced Portland cement concrete beams computed using reinforced concrete theory. Mechanics of materials beam theory was utilized to predict the ultimate loads and mid-span deflections of the flexure and beam specimens. However, these predictions proved to be severely inadequate. Finite element (fracture propagation

Fabrication and Evaluation of Graphite Fiber-Reinforced Polyimide Composite Tube Forms Using Modified Resin Transfer Molding

Science.gov (United States)

Exum, Daniel B.; Ilias, S.; Avva, V. S.; Sadler, Bob

1997-01-01

The techniques necessary for the fabrication of a complex three-dimensional tubular form using a PMR-type resin have been developed to allow for the construction of several tubes with good physical and mechanical properties. Employing established resin transfer molding practices, the relatively non-hazardous AMB-21 in acetone formulation was used to successfully impregnate four layers of AS4 braided graphite fiber preform previously loaded around an aluminum cylindrical core in an enclosed mold cavity. Using heat and vacuum, the solvent was evaporated to form a prepreg followed by a partial imidization and removal of condensation products. The aluminum core was replaced by a silicone rubber bladder and the cure cycle continued to the final stage of 550 F with a bladder internal pressure of 200 lbs/sq in while simultaneously applying a strong vacuum to the prepreg for removal of any additional imidization products. A combination of several modifications to the standard resin transfer molding methodology enabled the mold to 'breathe', allowing the imidization products a pathway for escape. AMB-21 resin was chosen because of the carcinogenic nature of the primary commercial polyimide PMR-15. The AMB-21 resin was formulated using commercially available monomers or monomer precursors and dissolved in a mixture of methyl alcohol and acetone. The viscosity of the resulting monomer solution was checked by use of a Brookfield rheometer and adjusted by adding acetone to an easily pumpable viscosity of about 600 cP. In addition, several types of chromatographic and thermal analyses were of the braids, and excess handling of the preforms broke some of the microscopic fibers, needlessly decreasing the strength of the finished part. In addition, three dimensional braided preforms with fibers along the length of the tube will be significantly stronger in tension than the braided preforms used in this study.

Constitutive modelling of creep in a long fiber random glass mat thermoplastic composite

Science.gov (United States)

Dasappa, Prasad

The primary objective of this proposed research is to characterize and model the creep behaviour of Glass Mat Thermoplastic (GMT) composites under thermo-mechanical loads. In addition, tensile testing has been performed to study the variability in mechanical properties. The thermo-physical properties of the polypropylene matrix including crystallinity level, transitions and the variation of the stiffness with temperature have also been determined. In this work, the creep of a long fibre GMT composite has been investigated for a relatively wide range of stresses from 5 to 80 MPa and temperatures from 25 to 90°C. The higher limit for stress is approximately 90% of the nominal tensile strength of the material. A Design of Experiments (ANOVA) statistical method was applied to determine the effects of stress and temperature in the random mat material which is known for wild experimental scatter. Two sets of creep tests were conducted. First, preliminary short-term creep tests consisting of 30 minutes creep followed by recovery were carried out over a wide range of stresses and temperatures. These tests were carried out to determine the linear viscoelastic region of the material. From these tests, the material was found to be linear viscoelastic up-to 20 MPa at room temperature and considerable non-linearities were observed with both stress and temperature. Using Time-Temperature superposition (TTS) a long term master curve for creep compliance for up-to 185 years at room temperature has been obtained. Further, viscoplastic strains were developed in these tests indicating the need for a non-linear viscoelastic viscoplastic constitutive model. The second set of creep tests was performed to develop a general non-linear viscoelastic viscoplastic constitutive model. Long term creep-recovery tests consisting of 1 day creep followed by recovery has been conducted over the stress range between 20 and 70 MPa at four temperatures: 25°C, 40°C, 60°C and 80°C. Findley's model

Recycling C/PPS laminates into long fibre thermoplastic composites by low shear mixing

NARCIS (Netherlands)

de Bruijn, Thomas A.; Vincent, Guillaume Almire; van Hattum, Ferrie

2017-01-01

The increasing interest in continuous fibre reinforced thermoplastic composites has resulted in a rise of industrial waste. The recycling of the waste is topic of this study, aiming at high mechanical properties by retaining both a long fibre length and the matrix material. Consolidated continuous

Stability of FDTS monolayer coating on aluminum injection molding tools

DEFF Research Database (Denmark)

Cech, Jiri; Taboryski, Rafael J.

2012-01-01

microns can obliterate small features. The nanoimprint lithography community extensively uses functional monolayer coatings on silicon/SiO2 lithographic stamps [7–11]. This treatment dramatically reduces stiction, and improves yield and quality of replicated nanostructures. Here we report on a fluorinated...... trichloro-silane based coating deposited on aluminum or its alloys by molecular vapor deposition. We have tested the stability of this coating in challenging conditions of injection molding, an environment with high shear stress from the molten polymer, pressures up to 200 MPa, temperatures up to 250 ◦C...

Research on mechanical properties of carbon fiber /polyamide reinforced PP composites

Science.gov (United States)

Chen, Xinghui; Yu, Qiang; Liu, Lixia; Ji, Wenhua; Yang, Li; Fan, Dongli

2017-10-01

The polyamide composites reinforced by carbon fiber/polypropylene are produced by injection molding processing. The flow abilities and mechanical properties of the CF/PA/PP composite materials are studied by the fusion index instrument and the universal testing machine. The results show that with the content of carbon fiber/polyamide increase, the impact breaking strength and the tensile property of the composite materials increase, which is instructive to the actual injection production of polypropylene products.

Development of polylactide (PLA) and PLA nanocomposite foams in injection molding for automotive applications

Science.gov (United States)

Najafi Chaloupli, Naqi

Plastic materials are extensively used in automotive structures since they make cars more energy efficient. Recently, the automotive industry is searching for bio-based and renewable alternatives to petroleum-based plastics to reduce the dependence on fossil fuels. Among polymers originating from renewable sources, polylactide (PLA) has attracted significant interest. The use of this polymer in durable industries is promising. Fuel-efficient automobiles are nowadays demanded due to the increasing concerns about environmental and fuel issues. The automobile fuel efficiency can be improved by using a lightweight material and, thereby, reducing the automobile weight. A potential method to achieve this objective is the use of the foaming technology. Foam is a material where a gas phase is encapsulated by a solid phase. Foaming technology helps to manufacture lightweight parts with superior properties in comparison with their solid counterparts. The basic mechanisms of foaming process normally consists of gas implementation, formation of uniform polymer-gas solution, cell nucleation, cell growth and, finally, cell stabilization. PLA foaming has, however, proved to be difficult mainly due to poor rheological properties, small processing window, and slow crystallization kinetics. The ultimate purpose of this work is to reduce by 30 % the weight of polylactide (PLA)-clay based nanocomposites by manufacturing injection-molded foamed parts. To use standard processing equipment, a chemical blowing agent (CBA) was employed. The injection molding technique was utilized in this project because it is the most widely used fabrication process in industry that can produce complex shaped articles. This process, however, is more challenging than other foaming processes since it deals with many additional controlling parameters. In the first part of this project, we illustrated how long chain branching (LCB) and molecular structure impact the melt rheology, crystallization and batch

Nonlinear core deflection in injection molding

Science.gov (United States)

Poungthong, P.; Giacomin, A. J.; Saengow, C.; Kolitawong, C.; Liao, H.-C.; Tseng, S.-C.

2018-05-01

Injection molding of thin slender parts is often complicated by core deflection. This deflection is caused by molten plastics race tracking through the slit between the core and the rigid cavity wall. The pressure of this liquid exerts a lateral force of the slender core causing the core to bend, and this bending is governed by a nonlinear fifth order ordinary differential equation for the deflection that is not directly in the position along the core. Here we subject this differential equation to 6 sets of boundary conditions, corresponding to 6 commercial core constraints. For each such set of boundary conditions, we develop an explicit approximate analytical solution, including both a linear term and a nonlinear term. By comparison with finite difference solutions, we find our new analytical solutions to be accurate. We then use these solutions to derive explicit analytical approximations for maximum deflections and for the core position of these maximum deflections. Our experiments on the base-gated free-tip boundary condition agree closely with our new explicit approximate analytical solution.

Fabrication and characterization of injection molded poly (ε-caprolactone) and poly (ε-caprolactone)/hydroxyapatite scaffolds for tissue engineering

International Nuclear Information System (INIS)

Cui Zhixiang; Nelson, Brenton; Peng, YiYan; Li Ke; Pilla, Srikanth; Li Wanju; Turng, Lih-Sheng; Shen Changyu

2012-01-01

In this study, poly(ε-caprolactone) (PCL)/sodium chloride (NaCl), PCL/poly(ethylene oxide) (PEO)/NaCl and PCL/PEO/NaCl/hydroxyapatite (HA) composites were injection molded and characterized. The water soluble and sacrificial polymer, PEO, and NaCl particulates in the composites were leached by deionized water to produce porous and interconnected microstructures. The effect of leaching time on porosity, and residual contents of NaCl and NaCl/HA, as well as the effect of HA addition on mechanical properties was investigated. In addition, the biocompatibility was observed via seeding human mesenchymal stem cells (hMSCs) on PCL and PCL/HA scaffolds. The results showed that the leaching time depends on the spatial distribution of sacrificial PEO phase and NaCl particulates. The addition of HA has significantly improved the elastic (E′) and loss moduli (E″) of PCL/HA scaffolds. Human MSCs were observed to have attached and proliferated on both PCL and PCL/HA scaffolds. Taken together, the molded PCL and PCL/HA scaffolds could be good candidates as tissue engineering scaffolds. Additionally, injection molding would be a potential and high throughput technology to fabricate tissue scaffolds. - Highlights: ►PCL/NaCl, PCL/PEO/NaCl and PCL/PEO/NaCl/HA composites were injection molded. ►Leaching time depends on the distribution of PEO phase and NaCl particulates. ►The elastic and loss moduli of PCL/HA scaffolds have significantly improved. ►Human hMSCs have attached, survived and proliferated well on PCL and PCL/HA scaffolds. ►Molded PCL and PCL/HA scaffolds could be good candidates for tissue engineering.

Liquid crystal polyester-carbon fiber composites

Science.gov (United States)

Chung, T. S.

1984-01-01

Liquid crystal polymers (LCP) have been developed as a thermoplastic matrix for high performance composites. A successful melt impregnation method has been developed which results in the production of continuous carbon fiber (CF) reinforced LCP prepreg tape. Subsequent layup and molding of prepreg into laminates has yielded composites of good quality. Tensile and flexural properties of LCP/CF composites are comparable to those of epoxy/CF composites. The LCP/CF composites have better impact resistance than the latter, although epoxy/CF composites possess superior compression and shear strength. The LCP/CF composites have good property retention until 200 F (67 % of room temperature value). Above 200 F, mechanical properties decrease significantly. Experimental results indicate that the poor compression and shear strength may be due to the poor interfacial adhesion between the matrix and carbon fiber as adequate toughness of the LCP matrix. Low mechanical property retention at high temperatures may be attributable to the low beta-transition temperature (around 80 C) of the LCP matrix material.

Pyrolysis characteristics of typical biomass thermoplastic composites

Directory of Open Access Journals (Sweden)

Hongzhen Cai

Full Text Available The biomass thermoplastic composites were prepared by extrusion molding method with poplar flour, rice husk, cotton stalk and corn stalk. The thermo gravimetric analyzer (TGA has also been used for evaluating the pyrolysis process of the composites. The results showed that the pyrolysis process mainly consists of two stages: biomass pyrolysis and the plastic pyrolysis. The increase of biomass content in the composite raised the first stage pyrolysis peak temperature. However, the carbon residue was reduced and the pyrolysis efficiency was better because of synergistic effect of biomass and plastic. The composite with different kinds of biomass have similar pyrolysis process, and the pyrolysis efficiency of the composite with corn stalk was best. The calcium carbonate could inhibit pyrolysis process and increase the first stage pyrolysis peak temperature and carbon residue as a filling material of the composite. Keywords: Biomass thermoplastic composite, Calcium carbonate, Pyrolysis characteristic

Fast Mold Temperature Evolution on Micro Features Replication Quality during Injection Molding

DEFF Research Database (Denmark)

Liparoti, S.; Calaon, Matteo; Speranza, V.

2016-01-01

lithography and subsequent nickel electroplating. The mold temperature was controlled by a thin heating device (composed by polyimide as insulating layer and polyimide carbon black loaded aselectrical conductive layer) able to increase the temperature on mold surface in a few seconds (40°C/s) by Joule effect...

Mechanical properties of green composites based on thermoplastic starch

Science.gov (United States)

Fornes, F.; Sánchez-Nácher, L.; Fenollar, O.; Boronat, T.; Garcia-Sanoguera, D.

2010-06-01

The present work is focused on study of "green composites" elaborated from thermoplastic starch (TPS) as polymer matrix and a fiber from natural origin (rush) as reinforced fiber. The effect of the fiber content has been studied by means of the mechanical properties. The composite resulting presents a lack of interaction between matrix and fiber that represents a performance decrease. However the biodegradability behavior of the resulting composite raise this composite as useful an industrial level.

Frequency and amplitude dependences of molding accuracy in ultrasonic nanoimprint technology

International Nuclear Information System (INIS)

Mekaru, Harutaka; Takahashi, Masaharu

2009-01-01

We use neither a heater nor ultraviolet lights, and are researching and developing an ultrasonic nanoimprint as a new nano-patterning technology. In our ultrasonic nanoimprint technology, ultrasonic vibration is not used as a heat generator instead of the heater. A mold is connected with an ultrasonic generator, and mold patterns are pushed down and pulled up at a high speed into a thermoplastic. Frictional heat is generated by ultrasonic vibration between mold patterns and thermoplastic patterns formed by an initial contact force. However, because frictional heat occurs locally, the whole mold is not heated. Therefore, a molding material can be comprehensively processed at room temperature. A magnetostriction actuator was built into our ultrasonic nanoimprint system as an ultrasonic generator, and the frequency and amplitude can be changed between dc–10 kHz and 0–4 µm, respectively. First, the ultrasonic nanoimprint was experimented by using this system on polyethylene terephthalate (PET, T g = 69 °C), whose the glass transition temperature (T g ) is comparatively low in engineering plastics, and it was ascertained that the most suitable elastic material for this technique was an ethyl urethane rubber. In addition, we used a changeable frequency of the magnetostriction actuator, and nano-patterns in an electroformed-Ni mold were transferred to a 0.5 mm thick sheet of PET, polymethylmethacrylate (PMMA) and polycarbonate (PC), which are typical engineering plastics, under variable molding conditions. The frequency and amplitude dependence of ultrasonic vibration to the molding accuracy were investigated by measuring depth and width of imprinted patterns. As a result, regardless of the molding material, the imprinted depth was changed drastically when the frequency exceeded 5 kHz. On the other hand, when the amplitude of ultrasonic vibration grew, the imprinted depth gradually deepened. Influence of the frequency and amplitude of ultrasonic vibration was not

High performance thermoplastics: A review of neat resin and composite properties

Science.gov (United States)

Johnston, Norman J.; Hergenrother, Paul M.

1987-01-01

A review was made of the principal thermoplastics used to fabricate high performance composites. Neat resin tensile and fracture toughness properties, glass transition temperatures (Tg), crystalline melt temperatures (Tm) and approximate processing conditions are presented. Mechanical properties of carbon fiber composites made from many of these thermoplastics are given, including flexural, longitudinal tensile, transverse tensile and in-plane shear properties as well as short beam shear and compressive strengths and interlaminar fracture toughness. Attractive features and problems involved in the use of thermo-plastics as matrices for high performance composites are discussed.

Compact surface plasmon resonance biosensor utilizing an injection-molded prism

Science.gov (United States)

Chen, How-Foo; Chen, Chih-Han; Chang, Yun-Hsiang; Chuang, Hsin-Yuan

2016-05-01

Targeting at a low cost and accessible diagnostic device in clinical practice, a compact surface plasmon resonance (SPR) biosensor with a large dynamic range in high sensitivity is designed to satisfy commercial needs in food safety, environmental bio-pollution monitoring, and fast clinical diagnosis. The core component integrates an optical coupler, a sample-loading plate, and angle-tuning reflectors is injection-molded as a free-from prism made of plastic optics. This design makes a matching-oil-free operation during operation. The disposability of this low-cost component ensures testing or diagnosis without cross contamination in bio-samples.

The Place for Thermoplastic Composites in Structural Components

Science.gov (United States)

1987-12-01

hydroforming of thermoplastics is so attractive is that it takes advantage of sheet-metal forming technology that has been in development for many years. High ...interfacial bond strength and fracture energies (Table D-1). Note the high bond strength of treated type I fibers and a correspondingly low fracture energy ...value, indicating little energy dissipated in the pull-out of fractured fibers. The untreated type I fibers have a low bond strength and a high pull-out

Bending behavior of thermoplastic composite sheets viscoelasticity and temperature dependency in the draping process

CERN Document Server

Ropers, Steffen

2017-01-01

Within the scope of this work, Steffen Ropers evaluates the viscoelastic and temperature-dependent nature of the bending behavior of thermoplastic composite sheets in order to further enhance the predictability of the draping simulation. This simulation is a useful tool for the development of robust large scale processes for continuously fiber-reinforced polymers (CFRP). The bending behavior thereby largely influences the size and position of wrinkles, which are one of the most common processing defects for continuously fiber-reinforced parts. Thus, a better understanding of the bending behavior of thermoplastic composite sheets as well as an appropriate testing method along with corresponding material models contribute to a wide-spread application of CFRPs in large scale production. Contents Thermoplastic Prepregs Draping Simulation of Thermoplastic Prepregs Bending Characterization of Textile Composites Modeling of Bending Behavior Target Groups Researchers and students in the field of polymer, lightweight,...

Fabrication and characterization of injection molded poly ({epsilon}-caprolactone) and poly ({epsilon}-caprolactone)/hydroxyapatite scaffolds for tissue engineering

Energy Technology Data Exchange (ETDEWEB)

Cui Zhixiang [Zhengzhou University, Henan (China); Nelson, Brenton; Peng, YiYan [University of Wisconsin-Madison, Wisconsin (United States); Li Ke [South China University of Technology, Guangzhou (China); Pilla, Srikanth; Li Wanju [University of Wisconsin-Madison, Wisconsin (United States); Turng, Lih-Sheng, E-mail: turng@engr.wisc.edu [University of Wisconsin-Madison, Wisconsin (United States); South China University of Technology, Guangzhou (China); Huazhong University of Science of Technology, Wuhan (China); Shen Changyu, E-mail: shency@zzu.edu.cn [Zhengzhou University, Henan (China)

2012-08-01

In this study, poly({epsilon}-caprolactone) (PCL)/sodium chloride (NaCl), PCL/poly(ethylene oxide) (PEO)/NaCl and PCL/PEO/NaCl/hydroxyapatite (HA) composites were injection molded and characterized. The water soluble and sacrificial polymer, PEO, and NaCl particulates in the composites were leached by deionized water to produce porous and interconnected microstructures. The effect of leaching time on porosity, and residual contents of NaCl and NaCl/HA, as well as the effect of HA addition on mechanical properties was investigated. In addition, the biocompatibility was observed via seeding human mesenchymal stem cells (hMSCs) on PCL and PCL/HA scaffolds. The results showed that the leaching time depends on the spatial distribution of sacrificial PEO phase and NaCl particulates. The addition of HA has significantly improved the elastic (E Prime ) and loss moduli (E Double-Prime ) of PCL/HA scaffolds. Human MSCs were observed to have attached and proliferated on both PCL and PCL/HA scaffolds. Taken together, the molded PCL and PCL/HA scaffolds could be good candidates as tissue engineering scaffolds. Additionally, injection molding would be a potential and high throughput technology to fabricate tissue scaffolds. - Highlights: Black-Right-Pointing-Pointer PCL/NaCl, PCL/PEO/NaCl and PCL/PEO/NaCl/HA composites were injection molded. Black-Right-Pointing-Pointer Leaching time depends on the distribution of PEO phase and NaCl particulates. Black-Right-Pointing-Pointer The elastic and loss moduli of PCL/HA scaffolds have significantly improved. Black-Right-Pointing-Pointer Human hMSCs have attached, survived and proliferated well on PCL and PCL/HA scaffolds. Black-Right-Pointing-Pointer Molded PCL and PCL/HA scaffolds could be good candidates for tissue engineering.

Performance Simulation and Verification of Vat Photopolymerization Based, Additively Manufactured Injection Molding Inserts with Micro-Features

DEFF Research Database (Denmark)

Mischkot, Michael; Hofstätter, Thomas; Michailidou, Ifigeneia

2017-01-01

Injection molding soft tooling inserts manufactured additively with vat photopolymerization represent a valid technology for prototyping and pilot production of polymer parts. However, a significant drawback is the low heat conductivity of photopolymers influencing cycletime and part quality...

Thermal and curl properties of PET/PP blend fibers compatibilized ...

Indian Academy of Sciences (India)

67

blend fibers were prepared using a melt-spinning system, and their curl properties were investigated. ... by extrusion and injection molding processes. ..... Inuwa I M, Hassan A, Samsudin S A, Kassim M H M and Jawaid M 2014. Polym.

Demineralized bone matrix fibers formable as general and custom 3D printed mold-based implants for promoting bone regeneration.

Science.gov (United States)

Rodriguez, Rudy U; Kemper, Nathan; Breathwaite, Erick; Dutta, Sucharita M; Hsu, Erin L; Hsu, Wellington K; Francis, Michael P

2016-07-26

Bone repair frequently requires time-consuming implant construction, particularly when using un-formed implants with poor handling properties. We therefore developed osteoinductive, micro-fibrous surface patterned demineralized bone matrix (DBM) fibers for engineering both defect-matched and general three-dimensional implants. Implant molds were filled with demineralized human cortical bone fibers there were compressed and lyophilized, forming mechanically strong shaped DBM scaffolds. Enzyme linked immunosorbent assays and mass spectrometry confirmed that DBM fibers contained abundant osteogenic growth factors (bone morphogenetic proteins, insulin-like growth factor-I) and extracellular matrix proteins. Mercury porosimetry and mechanical testing showed interconnected pores within the mechanically stable, custom DBM fiber scaffolds. Mesenchymal stem cells readily attached to the DBM and showed increasing metabolic activity over time. DBM fibers further increased alkaline phosphatase activity in C2C12 cells. In vivo, DBM implants elicited osteoinductive potential in a mouse muscle pouch, and also promoted spine fusion in a rat arthrodesis model. DBM fibers can be engineered into custom-shaped, osteoinductive and osteoconductive implants with potential for repairing osseous defects with precise fitment, potentially reducing operating time. By providing pre-formed and custom implants, this regenerative allograft may improve patient outcomes following surgical bone repair, while further advancing personalized orthopedic and craniomaxillofacial medicine using three-dimensional-printed tissue molds.

Process monitoring of glass reinforced polypropylene laminates using fiber Bragg gratings

KAUST Repository

Mulle, Matthieu

2015-12-29

Hot-press molding of glass-fiber-reinforced polypropylene (GFPP) laminates was monitored using longitudinally and transversely embedded fiber Bragg gratings (FBGs) at different locations in unidirectional laminates. The optical sensors proved to efficiently characterize some material properties; for example, strain variations could be related physical change of the laminate, revealing key transition points such as the onset of melt or solidification. These results were confirmed through some comparison with traditional techniques such as differential scanning calorimetry. After the GFPP plate was released from the mold, residual strains were estimated. Because cooling rate is an important process parameter in thermoplastics, affecting crystallinity and ultimately residual strain, two different conditions (22 and 3 °C/min) were investigated. In the longitudinal direction, results were nearly identical while in the transverse direction results showed a 20% discrepancy. Coefficients of thermal expansion (CTE) were also identified during a post-process heating procedure using the embedded FBGs and compared to the results of a thermo-mechanical analysis. Again, dissimilarities were observed for the transverse direction. With regards to through the thickness properties, no differences were observed for residual strains or for CTEs.

Pressure transmission area and maximum pressure transmission of different thermoplastic resin denture base materials under impact load.

Science.gov (United States)

Nasution, Hubban; Kamonkhantikul, Krid; Arksornnukit, Mansuang; Takahashi, Hidekazu

2018-01-01

The purposes of the present study were to examine the pressure transmission area and maximum pressure transmission of thermoplastic resin denture base materials under an impact load, and to evaluate the modulus of elasticity and nanohardness of thermoplastic resin denture base. Three injection-molded thermoplastic resin denture base materials [polycarbonate (Basis PC), ethylene propylene (Duraflex), and polyamide (Valplast)] and one conventional heat-polymerized acrylic resin (PMMA, SR Triplex Hot) denture base, all with a mandibular first molar acrylic resin denture tooth set in were evaluated (n=6). Pressure transmission area and maximum pressure transmission of the specimens under an impact load were observed by using pressure-sensitive sheets. The modulus of elasticity and nanohardness of each denture base (n=10) were measured on 15×15×15×3mm 3 specimen by using an ultramicroindentation system. The pressure transmission area, modulus of elasticity, and nanohardness data were statistically analyzed with 1-way ANOVA, followed by Tamhane or Tukey HSD post hoc test (α=.05). The maximum pressure transmission data were statistically analyzed with Kruskal-Wallis H test, followed by Mann-Whitney U test (α=.05). Polymethyl methacrylate showed significantly larger pressure transmission area and higher maximum pressure transmission than the other groups (Pelasticity and nanohardness among the four types of denture bases (Pelasticity and nanohardness of each type of denture base were demonstrated. Copyright © 2017 Japan Prosthodontic Society. Published by Elsevier Ltd. All rights reserved.

A validation of the fibre orientation and fibre length attrition prediction for long fibre-reinforced thermoplastics

Science.gov (United States)

Hopmann, Ch.; Weber, M.; van Haag, J.; Schöngart, M.

2015-05-01

To improve the mechanical performance of polymeric parts, fibre reinforcement has established in industrial applications during the last decades. Next to the widely used Short Fibre-reinforced Thermoplastics (SFT) the use of Long Fibre-reinforced Thermoplastics (LFT) is increasingly growing. Especially for non-polar polymeric matrices like polypropylene (PP), longer fibres can significantly improve the mechanical performance. As with every kind of discontinuous fibre reinforcement the fibre orientations (FO) show a high impact on the mechanical properties. On the contrary to SFT where the local fibre length distribution (FLD) can be often neglected, for LFT the FLD show a high impact on the material's properties and has to be taken into account in equal measure to the FOD. Recently numerical models are available in commercial filling simulation software and allow predicting both the local FOD and FLD in LFT parts. The aim of this paper is to compare i.) the FOD results and ii) the FLD results from available orientation- and fibre length attrition-models to those obtained from experimental data. The investigations are conducted by the use of different injection moulded specimens made from long glass fibre reinforced PP. In order to determine the FOD, selected part sections are examined by means of Computed Tomographic (CT) analyses. The fully three dimensional measurement of the FOD is then performed by digital image processing using grey scale correlation. The FLD results are also obtained by using digital image processing after a thermal pyrolytic separation of the polymeric matrix from the fibres. Further the FOD and the FLD are predicted by using a reduced strain closure (RSC) as well as an anisotropic rotary diffusion - reduced strain closure model (ARD-RSC) and Phelps-Tucker fibre length attrition model implemented in the commercial filling software Moldflow, Autodesk Inc., San Rafael, CA, USA.

A validation of the fibre orientation and fibre length attrition prediction for long fibre-reinforced thermoplastics

International Nuclear Information System (INIS)

Hopmann, Ch.; Weber, M.; Haag, J. van; Schöngart, M.

2015-01-01

To improve the mechanical performance of polymeric parts, fibre reinforcement has established in industrial applications during the last decades. Next to the widely used Short Fibre-reinforced Thermoplastics (SFT) the use of Long Fibre-reinforced Thermoplastics (LFT) is increasingly growing. Especially for non-polar polymeric matrices like polypropylene (PP), longer fibres can significantly improve the mechanical performance. As with every kind of discontinuous fibre reinforcement the fibre orientations (FO) show a high impact on the mechanical properties. On the contrary to SFT where the local fibre length distribution (FLD) can be often neglected, for LFT the FLD show a high impact on the material’s properties and has to be taken into account in equal measure to the FOD. Recently numerical models are available in commercial filling simulation software and allow predicting both the local FOD and FLD in LFT parts. The aim of this paper is to compare i.) the FOD results and ii) the FLD results from available orientation- and fibre length attrition-models to those obtained from experimental data. The investigations are conducted by the use of different injection moulded specimens made from long glass fibre reinforced PP. In order to determine the FOD, selected part sections are examined by means of Computed Tomographic (CT) analyses. The fully three dimensional measurement of the FOD is then performed by digital image processing using grey scale correlation. The FLD results are also obtained by using digital image processing after a thermal pyrolytic separation of the polymeric matrix from the fibres. Further the FOD and the FLD are predicted by using a reduced strain closure (RSC) as well as an anisotropic rotary diffusion - reduced strain closure model (ARD-RSC) and Phelps-Tucker fibre length attrition model implemented in the commercial filling software Moldflow, Autodesk Inc., San Rafael, CA, USA

A validation of the fibre orientation and fibre length attrition prediction for long fibre-reinforced thermoplastics

Energy Technology Data Exchange (ETDEWEB)

Hopmann, Ch.; Weber, M.; Haag, J. van; Schöngart, M. [Institute of Plastics Processing (IKV) at RWTH Aachen University, Pontstr. 49, 52062 Aachen (Germany)

2015-05-22

To improve the mechanical performance of polymeric parts, fibre reinforcement has established in industrial applications during the last decades. Next to the widely used Short Fibre-reinforced Thermoplastics (SFT) the use of Long Fibre-reinforced Thermoplastics (LFT) is increasingly growing. Especially for non-polar polymeric matrices like polypropylene (PP), longer fibres can significantly improve the mechanical performance. As with every kind of discontinuous fibre reinforcement the fibre orientations (FO) show a high impact on the mechanical properties. On the contrary to SFT where the local fibre length distribution (FLD) can be often neglected, for LFT the FLD show a high impact on the material’s properties and has to be taken into account in equal measure to the FOD. Recently numerical models are available in commercial filling simulation software and allow predicting both the local FOD and FLD in LFT parts. The aim of this paper is to compare i.) the FOD results and ii) the FLD results from available orientation- and fibre length attrition-models to those obtained from experimental data. The investigations are conducted by the use of different injection moulded specimens made from long glass fibre reinforced PP. In order to determine the FOD, selected part sections are examined by means of Computed Tomographic (CT) analyses. The fully three dimensional measurement of the FOD is then performed by digital image processing using grey scale correlation. The FLD results are also obtained by using digital image processing after a thermal pyrolytic separation of the polymeric matrix from the fibres. Further the FOD and the FLD are predicted by using a reduced strain closure (RSC) as well as an anisotropic rotary diffusion - reduced strain closure model (ARD-RSC) and Phelps-Tucker fibre length attrition model implemented in the commercial filling software Moldflow, Autodesk Inc., San Rafael, CA, USA.

Effect of rheological parameters on curing rate during NBR injection molding

Science.gov (United States)

Kyas, Kamil; Stanek, Michal; Manas, David; Skrobak, Adam

2013-04-01

In this work, non-isothermal injection molding process for NBR rubber mixture considering Isayev-Deng curing kinetic model, generalized Newtonian model with Carreau-WLF viscosity was modeled by using finite element method in order to understand the effect of volume flow rate, index of non-Newtonian behavior and relaxation time on the temperature profile and curing rate. It was found that for specific geometry and processing conditions, increase in relaxation time or in the index of non-Newtonian behavior increases the curing rate due to viscous dissipation taking place at the flow domain walls.

Biodegradable plastics derived from micro-fibrillated cellulose fiber and chitosan

Energy Technology Data Exchange (ETDEWEB)

Nishiyama, M.; Hosokawa, J.; Yoshihara, K.; Kubo, T.; Kabeya, H.; Endo, T. [Shikoku National Industrial Research Inst., Kagawa (Japan)

1995-12-25

We have been carrying out studies to develop biodegradable plastics from natural polysaccharides. We have found that a combination of micro-fibrillated cellulose fiber and chitosan produces a useful material that can be used to form biodegradable film and moldings. Cellulose-chitosan composite film demonstrate higher strength than general purpose plastic films, and wet strength peaks when chitosan content is 10-20%. The relatively small amount of chitosan needed is economically convenient because chitosan is more expensive than cellulose. This film biodegrade well in soil, completely dissolving and disappearing in two months. Biodegradability is influenced by the temperature used in thermal treatment the film, the quantity of acid groups in the cellulose, and other factors. These characteristics will be used to control decomposition. Since cellulose-chitosan-plastics are not thermoplastics, we have been working on joint research with companies to produce films, nonwoven fabrics and foams. We discuss here the properties and application of these composite moldings. 4 refs., 3 figs., 3 tabs.

Methods for integrating a functional component into a microfluidic device

Science.gov (United States)

Simmons, Blake; Domeier, Linda; Woo, Noble; Shepodd, Timothy; Renzi, Ronald F.

2014-08-19

Injection molding is used to form microfluidic devices with integrated functional components. One or more functional components are placed in a mold cavity, which is then closed. Molten thermoplastic resin is injected into the mold and then cooled, thereby forming a solid substrate including the functional component(s). The solid substrate including the functional component(s) is then bonded to a second substrate, which may include microchannels or other features.

Potassium methyl siliconate-treated pulp fibers and their effects on wood plastic composites: Water sorption and dimensional stability

Science.gov (United States)

Cheng Piao; Zhiyong Cai; Nicole M. Stark; Charles J. Monlezun

2013-01-01

Potassium methyl siliconate (PMS) was investigated as a new nano modifier of wood fiber and wood flour to improve the compatibility between the fiber/flour and the plastic matrix in fiber reinforced plastic composites. Before injection molding, bleached and brown pulp fibers and mixed species wood flour were pretreated in PMS solutions. The morphology of the treated...

Efecto de fibras micro y nanométricas de carbono en el comportamiento dinámicomecánico y tribológico de la poliéter-éter cetona

Directory of Open Access Journals (Sweden)

Bladimir Ramón Valencia

2011-07-01

Full Text Available In this work, the effect ofcarbon nano- and microfibers on the dynamic mechanical and tribological properties of the thermoplastic polymer polyether ether ketone (PEEK was studied. The compound materials were obtained by blending PEEK and carbon nano- and microfibers in different proportions (0.6, 1, 3 and 5 wt% of fibers using melt extrusion and injection molding. The samples were injected into a mold and cooled with water. Thereby different degrees of crystallinity of the polymer were obtained. Therefore, all samples were heat treated after the cooling process in order to homogenize the crystalline structure of PEEK. The characterization of the dynamic mechanical properties of the reinforced samples showed an increase in the stiffness below the glass transition temperature compared to pristine PEEK. The performance could be further improved by increasing the amount of carbon fibers where blends with 5 wt% of fibers exhibited the highest stiffness values. Furthermore, tribological tests were conducted under oscillation at high frequency in reciprocal-linear motion in a SRV tribometer to determine the friction and wear coefficient of the samples. The pristine PEEK provided the worst performance revealing the highest friction and wear coefficient of all samples. The addition of carbon fibers reduced the friction and wear coefficient and the best results were obtained with high loads of carbon fibers.

Effect of additives on the orientation of magnetic Sr-ferrite powders in powder injection molded compacts

Energy Technology Data Exchange (ETDEWEB)

Cho, T.S. [Sangju National Unviersity, Sangju (Korea); Jeung, W.Y. [Korea Institute of Science and Technology, Seoul (Korea)

2001-03-01

The effect of additives on the orientation of magnetic Sr-ferrite powders has been studied during powder injection molding under applied magnetic field for fabricating multi=pole anisotropic sintered Sr-ferrite magnets. The orientation of the Sr-ferrite powders depends sensitively on the fluidity of powder-binder mixture, related to the binder additives and the injection molding temperature, and the magnetic field intensity. The orientation of Sr-ferrite powders is good for the compacts with stearic acid added in the binder system of paraffin wax/ carnauba wax/HDPE, but it is poor of the compacts with silane coupling agent added. The orientation of sr-ferrites higher than 80% is achieved at the following useful conditions; apparent viscosity lower than 2500 poise in 1000 sec {sup -1} shear rate and applied magnetic field higher than 4 kOe. (author). 15 refs., 1 tab., 6 figs.

Integrated hot-melt extrusion - injection molding continuous tablet manufacturing platform: Effects of critical process parameters and formulation attributes on product robustness and dimensional stability.

Science.gov (United States)

Desai, Parind M; Hogan, Rachael C; Brancazio, David; Puri, Vibha; Jensen, Keith D; Chun, Jung-Hoon; Myerson, Allan S; Trout, Bernhardt L

2017-10-05

This study provides a framework for robust tablet development using an integrated hot-melt extrusion-injection molding (IM) continuous manufacturing platform. Griseofulvin, maltodextrin, xylitol and lactose were employed as drug, carrier, plasticizer and reinforcing agent respectively. A pre-blended drug-excipient mixture was fed from a loss-in-weight feeder to a twin-screw extruder. The extrudate was subsequently injected directly into the integrated IM unit and molded into tablets. Tablets were stored in different storage conditions up to 20 weeks to monitor physical stability and were evaluated by polarized light microscopy, DSC, SEM, XRD and dissolution analysis. Optimized injection pressure provided robust tablet formulations. Tablets manufactured at low and high injection pressures exhibited the flaws of sink marks and flashing respectively. Higher solidification temperature during IM process reduced the thermal induced residual stress and prevented chipping and cracking issues. Polarized light microscopy revealed a homogeneous dispersion of crystalline griseofulvin in an amorphous matrix. DSC underpinned the effect of high tablet residual moisture on maltodextrin-xylitol phase separation that resulted in dimensional instability. Tablets with low residual moisture demonstrated long term dimensional stability. This study serves as a model for IM tablet formulations for mechanistic understanding of critical process parameters and formulation attributes required for optimal product performance. Copyright © 2017 Elsevier B.V. All rights reserved.

Nanoimprint technology nanotransfer for thermoplastic and photocurable polymers

CERN Document Server

Taniguchi, Jun; Mizuno, Jun; Saito, Takushi

2013-01-01

Nanoscale pattern transfer technology using molds is a rapidly advancing area and one that has seen much recent attention due to its potential for use in nanotechnology industries and applications. However, because of these rapid advances, it can be difficult to keep up with the technological trends and the latest cutting-edge methods. In order to fully understand these pioneering technologies, a comprehensive understanding of the basic science and an overview of the techniques are required. Nanoimprint Technology: Nanotransfer for Thermoplastic and Photocurable Polymers covers

Thermoplastic polyolefins as formaldehyde free binders in highly filled lignocellulosic panel boards: using glycerine as a processing aid in kenaf fiber polypropylene boards

Directory of Open Access Journals (Sweden)

Anand Ramesh Sanadi

2008-12-01

Full Text Available A new technique was developed to make highly loaded (up to 95% formaldehyde free natural fiber boards. The purpose of the paper is to report a broad study on 85% kenaf boards using linear thermoplastic polymers as the binder in preparing the boards to determine if these materials have potential in commercial applications by comparing them to other commercial materials. In these materials, linear thermoplastic polymer chains act as an adhesive and the product resembles a typical wood based panel (e.g., phenol formaldehyde fiber board. The process involved the use of small amount of glycerine in the fiber to enhance processibility in a thermo-kinetic mixer followed by hot pressing. In this paper, we report the properties of 85% by weight kenaf fiber boards using polypropylene as the adhesive. A maleated polypropylene was used to improve the adhesion and stress transfer between the adhesive and kenaf fiber. The addition of 2% by weight of glycerine based on the dry weight of kenaf fiber resulted in the best properties of the boards. Differential scanning calorimetric studies suggested that the glycerine had a little effect on the percent crystallinity of the matrix. Dynamic mechanical tests of the 85% boards showed some differences compared to conventional 60% by weight kenaf-PP composites. The 85% kenaf boards had a flexural strength of 75 MPa and a flexural modulus of 6.8 GPa with a specific gravity of 1.24. These properties are comparable to standard formaldehyde free high density hardboards with flexural strengths of 48.3 MPa and flexural modulus of 5.5 GPa, and a specific gravity of 1.28. This paper gives a broad overview of an initial study of these new materials.

Molding 4.0 - The Economics of an Injection Molding As-a-Service Business Model

DEFF Research Database (Denmark)

Charalambis, Alessandro; Tonetti, Marco Alessandro; Tosello, Guido

involved contributes to a hazy definition of the phenomenon. In this work, Industry 4.0 is analyzed by analyzing into its influence on the plastics industry, with a focus on the injection molding technology. A new business model for the plastic industry is proposed, which fosters closer cooperation......During the last few years, the term Industry 4.0 or The Fourth Industrial Revolution, made its appearance and spread across industries. While it is accepted that the term broadly refers to a set of recent innovations with potential to disrupt value and process chains, the heterogeneity of actors...... the paradigm of Industry 4.0 is able to disrupt the industry by decreasing machine downtime and offering remarkable improvements in machine up-time. The present research aims to highlighting some of the opportunities for the plastic industry enabled by the implementation of an Internet of Things architecture....

An investigation of flow properties of metal matrix composites suspensions for injection molding

International Nuclear Information System (INIS)

Ahmad, F.; Bevis, M.J.

1997-01-01

Flow properties of metal matrix composites suspensions have significant effects on the fibre orientation during mould filling. The results presented in this paper relate to the flow properties of aluminium powder and glass fibres compounded into a sacrificial thermoplastics binder. For this purpose, a range of aluminium compounds and aluminium composite suspensions were investigated over a wide shear rate range expected to occur during injection mould process. Aluminium composites wee prepared by substituting glass fibres for aluminium in aluminium compound. Aluminium composite containing a maximum critical volume fraction of fibres which did not exhibit an increase n viscosity was determined. The effect of temperature on the flow behaviour of aluminium composite was also investigated. (author)

Using injection molding and reversible bonding for easy fabrication of magnetic cell trapping and sorting devices

Energy Technology Data Exchange (ETDEWEB)

Royet, David; Hériveaux, Yoann; Marchalot, Julien; Scorretti, Riccardo [Univ Lyon, ECL, UCB Lyon1, CNRS, Ampere, F-69134 Ecully (France); Dias, André; Dempsey, Nora M. [Univ. Grenoble Alpes - CNRS, Inst Neel, F-38042 Grenoble (France); Bonfim, Marlio [Universidade Federal do Paraná, DELT, Curitiba (Brazil); Simonet, Pascal; Frénéa-Robin, Marie [Univ Lyon, ECL, UCB Lyon1, CNRS, Ampere, F-69134 Ecully (France)

2017-04-01

Magnetism and microfluidics are two key elements for the development of inexpensive and reliable tools dedicated to high-throughput biological analysis and providing a large panel of applications in domains ranging from fundamental biology to medical diagnostics. In this work, we introduce a simple protocol, relying on injection molding and reversible bonding for fabrication of magnetic cell trapping and sorting devices using only standard soft-lithography equipment. Magnetic strips or grids made of Polydimethylsiloxane (PDMS) doped with hard (NdFeB) or soft (carbonyl iron) magnetic powders were integrated at the bottom of whole PDMS chips. Preliminary results show the effective deviation/trapping of magnetic beads or magnetically-labeled bacteria as the sample flows through the microchannel, proving the potential of this rapid prototyping approach for easy fabrication of magnetic cell sorters. - Highlights: • Soft and hard magnetic PDMS composites were microstructured by injection molding. • Tunable or autonomous magnetic microdevices can be fabricated using this approach. • Continuous-flow bacterial cell trapping and deviation were demonstrated.

Using injection molding and reversible bonding for easy fabrication of magnetic cell trapping and sorting devices

International Nuclear Information System (INIS)

Royet, David; Hériveaux, Yoann; Marchalot, Julien; Scorretti, Riccardo; Dias, André; Dempsey, Nora M.; Bonfim, Marlio; Simonet, Pascal; Frénéa-Robin, Marie

2017-01-01

Magnetism and microfluidics are two key elements for the development of inexpensive and reliable tools dedicated to high-throughput biological analysis and providing a large panel of applications in domains ranging from fundamental biology to medical diagnostics. In this work, we introduce a simple protocol, relying on injection molding and reversible bonding for fabrication of magnetic cell trapping and sorting devices using only standard soft-lithography equipment. Magnetic strips or grids made of Polydimethylsiloxane (PDMS) doped with hard (NdFeB) or soft (carbonyl iron) magnetic powders were integrated at the bottom of whole PDMS chips. Preliminary results show the effective deviation/trapping of magnetic beads or magnetically-labeled bacteria as the sample flows through the microchannel, proving the potential of this rapid prototyping approach for easy fabrication of magnetic cell sorters. - Highlights: • Soft and hard magnetic PDMS composites were microstructured by injection molding. • Tunable or autonomous magnetic microdevices can be fabricated using this approach. • Continuous-flow bacterial cell trapping and deviation were demonstrated.

Polyurethane elastomer as a matrix material for short carbon fiber reinforced thermoplastic composites

Directory of Open Access Journals (Sweden)

Ümit Tayfun

2017-09-01

Full Text Available Short carbon fibers (CF with different surface sized (epoxy (EP and polyurethane (PU were used as reinforcing agent in thermoplastic polyurethane (TPU based composites. Composites containing 5, 10, 15, and 20 weight % sized and desized CFs were prepared by using melt-mixing method. The surface characteristics of CFs were examined by energy dispersive X-ray spectroscopy (EDX and Fourier transform infrared spectroscopy (FTIR. Tensile testing, shore hardness test, dynamic mechanical analysis (DMA and melt flow index (MFI test were performed for determining final composite properties. The dispersion of CFs in TPU matrix was examined by scanning electron microscopy (SEM. Tensile strength, Youngs’ modulus and Shore hardness of TPU were enhanced by the addition of sized CFs. About two-fold improvement for tensile strength and ten-fold improvement for Youngs’ modulus were observed with the incorporation of 20 wt% EP-CF and PU-CF in TPU. The storage modulus of PU-CF containing composites was higher than those of TPU and other composites. No remarkable change was observed in MFI value of TPU after CF loadings. Processing conditions in this work was suitable for composite production. Sized CFs exhibited better dispersion with regard to desized CF due to the stronger adhesion of TPU matrix to fiber surface.

Visualization of mold filling stages in thermal nanoimprint by using pressure gradients

DEFF Research Database (Denmark)

Schift, H.; Bellini, S.; Mikkelsen, Morten Bo Lindholm

2007-01-01

A method for the visualization of mold filling during a thermoplastic imprint at a microscopic level was developed, which is based on superposition of images of a series of different states of imprint. The animated movie sequence gives an insight into the complex flow of polymer and shows how voids...

High performance thermoplastics - A review of neat resin and composite properties

Science.gov (United States)

Johnston, Norman J.; Hergenrother, Paul M.

1987-01-01

A review was made of the principal thermoplastics used to fabricate high performance composites. Neat resin tensile and fracture toughness properties, glass transition temperatures (Tg), crystalline melt temperatures (Tm) and approximate processing conditions are presented. Mechanical properties of carbon fiber composites made from many of these thermoplastics are given, including flexural, longitudinal tensile, transverse tensile and in-plane shear properties as well as short beam shear and compressive strengths and interlaminar fracture toughness.

High-Performance Stretchable Conductive Composite Fibers from Surface-Modified Silver Nanowires and Thermoplastic Polyurethane by Wet Spinning.

Science.gov (United States)

Lu, Ying; Jiang, Jianwei; Yoon, Sungho; Kim, Kyung-Shik; Kim, Jae-Hyun; Park, Sanghyuk; Kim, Sang-Ho; Piao, Longhai

2018-01-17

Highly stretchable and conductive fibers have attracted great interest as a fundamental building block for the next generation of textile-based electronics. Because of its high conductivity and high aspect ratio, the Ag nanowire (AgNW) has been considered one of the most promising conducting materials for the percolation network-based conductive films and composites. However, the poor dispersibility of AgNWs in hydrophobic polymers has hindered their application to stretchable conductive composite fibers. In this paper, we present a highly stretchable and conductive composite fiber from the co-spinning of surface-modified AgNWs and thermoplastic polyurethane (PU). The surface modification of AgNWs with a polyethylene glycol derivative improved the compatibility of PU and AgNWs, which allowed the NWs to disperse homogeneously in the elastomeric matrix, forming effective percolation networks and causing the composite fiber to show enhanced electrical and mechanical performance. The maximum AgNW mass fraction in the composite fiber was 75.9 wt %, and its initial electrical conductivity was as high as 14 205 S/cm. The composite fibers also exhibited superior stretchability: the maximum rupture strain of the composite fiber with 14.6 wt % AgNW was 786%, and the composite fiber was also conductive even when it was stretched up to 200%. In addition, 2-dimensional (2-D) Ag nanoplates were added to the AgNW/PU composite fibers to increase the stability of the conductive network under repeated stretching and releasing. The Ag nanoplates acted as a bridge to effectively prevent the AgNWs from slippage and greatly improved the stability of the conductive network.

Selective etching of injection molded zirconia-toughened alumina: Towards osseointegrated and antibacterial ceramic implants.

Science.gov (United States)

Flamant, Quentin; Caravaca, Carlos; Meille, Sylvain; Gremillard, Laurent; Chevalier, Jérôme; Biotteau-Deheuvels, Katia; Kuntz, Meinhard; Chandrawati, Rona; Herrmann, Inge K; Spicer, Christopher D; Stevens, Molly M; Anglada, Marc

2016-12-01

Due to their outstanding mechanical properties and excellent biocompatibility, zirconia-toughened alumina (ZTA) ceramics have become the gold standard in orthopedics for the fabrication of ceramic bearing components over the last decade. However, ZTA is bioinert, which hampers its implantation in direct contact with bone. Furthermore, periprosthetic joint infections are now the leading cause of failure for joint arthroplasty prostheses. To address both issues, an improved surface design is required: a controlled micro- and nano-roughness can promote osseointegration and limit bacterial adhesion whereas surface porosity allows loading and delivery of antibacterial compounds. In this work, we developed an integrated strategy aiming to provide both osseointegrative and antibacterial properties to ZTA surfaces. The micro-topography was controlled by injection molding. Meanwhile a novel process involving the selective dissolution of zirconia (selective etching) was used to produce nano-roughness and interconnected nanoporosity. Potential utilization of the porosity for loading and delivery of antibiotic molecules was demonstrated, and the impact of selective etching on mechanical properties and hydrothermal stability was shown to be limited. The combination of injection molding and selective etching thus appears promising for fabricating a new generation of ZTA components implantable in direct contact with bone. Zirconia-toughened alumina (ZTA) is the current gold standard for the fabrication of orthopedic ceramic components. In the present work, we propose an innovative strategy to provide both osseointegrative and antibacterial properties to ZTA surfaces: we demonstrate that injection molding allows a flexible design of surface micro-topography and can be combined with selective etching, a novel process that induces nano-roughness and surface interconnected porosity without the need for coating, avoiding reliability issues. These surface modifications have the

The Development of High Temperature Thermoplastic Composite Materials for Additive Manufactured Autoclave Tooling

Energy Technology Data Exchange (ETDEWEB)

Kunc, Vlastimil [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Duty, Chad E. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Lindahl, John M. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Hassen, Ahmed A. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

2017-08-01

In this work, ORNL and Techmer investigated and screened different high temperature thermoplastic reinforced materials to fabricate composite molds for autoclave processes using Additive Manufacturing (AM) techniques. This project directly led to the development and commercial release of two printable, high temperature composite materials available through Techmer PM. These new materials are targeted for high temperature tooling made via large scale additive manufacturing.

Dimensional stability of wood-plastic composites reinforced with potassium methyl siliconate modified fiber and sawdust made from beetle-killed trees

Science.gov (United States)

Cheng Piao; Zhiyong Cai; Nicole M. Stark; Charles J. Montezun

2014-01-01

Wood fromtwovarieties of beetle-killed trees was used to fabricate wood–plastic composites. Loblolly pine and lodgepole pine beetle-killed trees were defibrated mechanically and thermomechanically, respectively, into fiber. Fiber and sawdust produced from the trees were modified with potassium methyl siliconate (PMS) and injection-molded into fiber/sawdust reinforced...

Conductive films of silver nanoparticles as novel susceptors for induction welding of thermoplastic composites

Science.gov (United States)

Dermanaki Farahani, Rouhollah; Janier, Mathieu; Dubé, Martine

2018-03-01

In the present work, a conductive film of silver nanoparticles (nAg) as a novel heating element type, called susceptor, was developed and tested for induction welding of carbon fiber/polyphenylene sulfide (CF/PPS) thermoplastic composites, i.e., unidirectional pre-impregnated 16 plies of CF/PPS compression-molded in a quasi-isotropic stacking sequence. The nAg were synthesized, dispersed in deionized (DI) water and casted onto a pure PPS film, resulting in a conductive film upon the evaporation of DI water and thermal post-annealing. The thermal annealing at 250 °C significantly (by 7 orders) decreased the film’s electrical resistivity from 9.4 × 103 down to 3.1 × 10-4 Ω cm. The new susceptors led to fast heating rates in induction welding when compared to the standard stainless steel mesh susceptors under similar welding conditions. Lap shear mechanical testing revealed that the apparent lap shear strength (LSS) is sensitive to the susceptors’ resistivity and the input current. A relatively high LSS value was achieved for the specimens welded using the new susceptors which exceeded the value of those welded using stainless steel mesh susceptors (28.3 MPa compared to 20 MPa). The weld interface and specimens’ cross-section observation revealed that the nAg were dispersed and embedded into the resin upon welding. This study contains preliminary results that show high potential of nanoparticles as effective susceptors to further improve the mechanical performance of the joints in welding of thermoplastic composites.

Improvement of the Shock Absorption Ability of a Face Guard by Incorporating a Glass-Fiber-Reinforced Thermoplastic and Buffering Space

OpenAIRE

Wada, Takahiro; Churei, Hiroshi; Takayanagi, Haruka; Iwasaki, Naohiko; Ueno, Toshiaki; Takahashi, Hidekazu; Uo, Motohiro

2018-01-01

This study aimed to evaluate the shock absorption ability of trial face guards (FGs) incorporating a glass-fiber-reinforced thermoplastic (GF) and buffering space. The mechanical properties of 3.2 mm and 1.6 mm thick commercial medical splint materials (Aquaplast, AP) and experimental GF prepared from 1.6 mm thick AP and fiberglass cloth were determined by a three-point bending test. Shock absorption tests were conducted on APs with two different thicknesses and two types of experimental mate...

Deep UV patterning of acrylic masters for molding biomimetic dry adhesives

International Nuclear Information System (INIS)

Sameoto, D; Menon, C

2010-01-01

We present a novel fabrication method for the production of biomimetic dry adhesives that allows enormous variation in fiber shapes and sizes. The technology is based on deep-UV patterning of commercial acrylic with semi-collimated light available from germicidal lamps, and combined careful processing conditions, material selection and novel developer choices to produce relatively high-aspect-ratio fibers with overhanging caps on large areas. These acrylic fibers are used as a master mold for subsequent silicone rubber negative mold casting. Because the bulk acrylic demonstrates little inherent adhesion to silicone rubbers, the master molds created in this process do not require any surface treatments to achieve high-yield demolding of interlocked structures. Multiple polymers can be cast from silicone rubber negative molds and this process could be used to structure smart materials on areas over multiple square feet. Using direct photopatterning of acrylic allows many of the desired structures for biomimetic dry adhesives to be produced with relative ease compared to silicon-based molding processes, including angled fibers and hierarchical structures. Optimized fiber shapes for a variety of polymers can be produced using this process, and adhesion measurements on a well-characterized polyurethane, ST-1060, are used to determine the effect of fiber geometry on adhesion performance

Tablet coating by injection molding technology - Optimization of coating formulation attributes and coating process parameters.

Science.gov (United States)

Desai, Parind M; Puri, Vibha; Brancazio, David; Halkude, Bhakti S; Hartman, Jeremy E; Wahane, Aniket V; Martinez, Alexander R; Jensen, Keith D; Harinath, Eranda; Braatz, Richard D; Chun, Jung-Hoon; Trout, Bernhardt L

2018-01-01

We developed and evaluated a solvent-free injection molding (IM) coating technology that could be suitable for continuous manufacturing via incorporation with IM tableting. Coating formulations (coating polymers and plasticizers) were prepared using hot-melt extrusion and screened via stress-strain analysis employing a universal testing machine. Selected coating formulations were studied for their melt flow characteristics. Tablets were coated using a vertical injection molding unit. Process parameters like softening temperature, injection pressure, and cooling temperature played a very important role in IM coating processing. IM coating employing polyethylene oxide (PEO) based formulations required sufficient room humidity (>30% RH) to avoid immediate cracks, whereas other formulations were insensitive to the room humidity. Tested formulations based on Eudrajit E PO and Kollicoat IR had unsuitable mechanical properties. Three coating formulations based on hydroxypropyl pea starch, PEO 1,000,000 and Opadry had favorable mechanical (35% elongation, >95×10 4 J/m 3 toughness) and melt flow (>0.4g/min) characteristics, that rendered acceptable IM coats. These three formulations increased the dissolution time by 10, 15 and 35min, respectively (75% drug release), compared to the uncoated tablets (15min). Coated tablets stored in several environmental conditions remained stable to cracking for the evaluated 8-week time period. Copyright © 2017 Elsevier B.V. All rights reserved.

Estudio y análisis del moldeo por inyección de materiales poliméricos

Directory of Open Access Journals (Sweden)

David Juárez Varón

2012-11-01

Full Text Available This article aims at analyzing the injection molding of thermoplastic polymeric materials by examining their current situation from the perspective of industrial production, the evolution of technology and modeling of the injection process.

Screening of sorghum lines against long smut and grain mold pathogens

Science.gov (United States)

Long smut infection is severe in the drier regions of Africa and Asia; whereas, grain mold is the most important widespread complex disease where sorghum is grown worldwide. Both fungal diseases cause significant losses in grain yield and quality. Long smut has not yet been observed in the United ...

Effects of fast mold temperature evolution on micro features replication quality during injection molding

DEFF Research Database (Denmark)

Liparoti, S.; Calaon, M.; Speranza, V.

2017-01-01

lithography and subsequent nickel electroplating. The mold temperature was controlled by a thin heating device (composed by polyimide as insulating layer and polyimide carbon black loaded as electrical conductive layer) able to increase the temperature on mold surface in a few seconds (40°C/s) by Joule...

Improving Powder Injection Molding: an Opportunity for the Aerospace Industry

Directory of Open Access Journals (Sweden)

I. Emri

2014-01-01

Full Text Available This work deals with powder injection molding (PIM technology of metal and ceramis powders using polyoximethylene (POM binder. In this study, two ways to decrease the viscosity of PIM feedstock materials with polyoxymethylene were investigated. The first way was to reduce the average molecular weight (AMV of the binder and the second one to select a polydisperse particle size distribution with high maximum packing fraction. It was shown that binder with AMW equal to 24410 g/mol gives required level of viscosity around 10 Pa/s. It was shown that using the low disperse powder with wide size distribution can lead to volumetric loading of approximately 83 %. Moreover, using such a feedstock has viscosity lower than required by PIM technology 1000 Pa/s.

Replication of micro and nano-features on iPP by injection molding with fast cavity surface temperature evolution

DEFF Research Database (Denmark)

Speranzaa, Vito; Liparotia, Sara; Calaon, Matteo

2017-01-01

The production of polymeric components with functional structures in the micrometer and sub-micrometer range is a complex challenge for the injection molding process, since it suffers the use of low cavity surface temperatures that induce the fast formation of a frozen layer, thus preventing...... was sufficient to obtain accurate replication, with adequate surface temperatures. In the case of nano-features, the replication accuracy was affected by the morphology developed on the molding surface, that is aligned along the flow direction with dimensions comparable with the dimension of the nano...

3D printed metal molds for hot embossing plastic microfluidic devices.

Science.gov (United States)

Lin, Tung-Yi; Do, Truong; Kwon, Patrick; Lillehoj, Peter B

2017-01-17

Plastics are one of the most commonly used materials for fabricating microfluidic devices. While various methods exist for fabricating plastic microdevices, hot embossing offers several unique advantages including high throughput, excellent compatibility with most thermoplastics and low start-up costs. However, hot embossing requires metal or silicon molds that are fabricated using CNC milling or microfabrication techniques which are time consuming, expensive and required skilled technicians. Here, we demonstrate for the first time the fabrication of plastic microchannels using 3D printed metal molds. Through optimization of the powder composition and processing parameters, we were able to generate stainless steel molds with superior material properties (density and surface finish) than previously reported 3D printed metal parts. Molds were used to fabricate poly(methyl methacrylate) (PMMA) replicas which exhibited good feature integrity and replication quality. Microchannels fabricated using these replicas exhibited leak-free operation and comparable flow performance as those fabricated from CNC milled molds. The speed and simplicity of this approach can greatly facilitate the development (i.e. prototyping) and manufacture of plastic microfluidic devices for research and commercial applications.

Influence of different process settings conditions on the accuracy of micro injection molding simulations: an experimental validation

DEFF Research Database (Denmark)

Tosello, Guido; Gava, Alberto; Hansen, Hans Nørgaard

2009-01-01

Currently available software packages exhibit poor results accuracy when performing micro injection molding (µIM) simulations. However, with an appropriate set-up of the processing conditions, the quality of results can be improved. The effects on the simulation results of different and alternative...... process conditions are investigated, namely the nominal injection speed, as well as the cavity filling time and the evolution of the cavity injection pressure as experimental data. In addition, the sensitivity of the results to the quality of the rheological data is analyzed. Simulated results...... are compared with experiments in terms of flow front position at part and micro features levels, as well as cavity injection filling time measurements....

Optimization of powder injection molding of feedstock based on aluminum oxide and multicomponent water-soluble polymer binder

Czech Academy of Sciences Publication Activity Database

Hausnerová, B.; Marcaníková, L.; Filip, Petr; Sáha, P.

2011-01-01

Roč. 51, č. 7 (2011), s. 1376-1382 ISSN 0032-3888 R&D Projects: GA ČR GA103/08/1307 Institutional research plan: CEZ:AV0Z20600510 Keywords : powder injection molding * viscosity * thermogravimetric analysis Subject RIV: BK - Fluid Dynamics Impact factor: 1.302, year: 2011

Thermoplastic starch materials prepared from rice starch; Preparacao e caracterizacao de materiais termoplasticos preparados a partir de amido de arroz

Energy Technology Data Exchange (ETDEWEB)

Pontes, Barbara R.B.; Curvelo, Antonio A.S., E-mail: barbarapont@gmail.co [Universidade de Sao Paulo (IQSC/USP), Sao Carlos, SP (Brazil). Inst. de Quimica

2009-07-01

Rice starch is a source still little studied for the preparation of thermoplastic materials. However, its characteristics, such as the presence of proteins, fats and fibers may turn into thermoplastics with a better performance. The present study intends the evaluation of the viability of making starch thermoplastic from rice starch and glycerol as plasticizer. The results of X-ray diffraction and scanning electronic microscopy demonstrate the thermoplastic acquisition. The increase of plasticizer content brings on more hydrophilic thermoplastics with less resistance to tension and elongation at break. (author)

Applying simulation to optimize plastic molded optical parts

Science.gov (United States)

Jaworski, Matthew; Bakharev, Alexander; Costa, Franco; Friedl, Chris

2012-10-01

Optical injection molded parts are used in many different industries including electronics, consumer, medical and automotive due to their cost and performance advantages compared to alternative materials such as glass. The injection molding process, however, induces elastic (residual stress) and viscoelastic (flow orientation stress) deformation into the molded article which alters the material's refractive index to be anisotropic in different directions. Being able to predict and correct optical performance issues associated with birefringence early in the design phase is a huge competitive advantage. This paper reviews how to apply simulation analysis of the entire molding process to optimize manufacturability and part performance.

Fiber optic liquid-level sensor using a long fiber Bragg grating

Science.gov (United States)

Ricchiuti, Amelia L.; Barrera, David; Nonaka, Koji; Sales, Salvador

2013-05-01

A technique for liquid-level sensors based on a long fiber Bragg grating (FBG) is presented and experimentally demonstrated. The measurement system is based on the measurement of the central frequency distribution of the FBG based on time-frequency domain analysis. A short optical pulse is injected into a 10-cm long FBG mounted in a container. The back-reflected pulse is scanned by means of an oscilloscope. When part of the grating is immersed in a liquid having temperature higher than the surrounding ambient, the structure of the uniform grating is distorted and its time-frequency response changes. A spatial resolution of 2 mm, given by the input pulse duration, and a 10-cm long measurement range are achieved. Liquid-temperature sensing has also been implemented by scanning the spectral response of the FBG by means of a CW laser and an OSA.

POWDER INJECTION MOLDING OF SIC FOR THERMAL MANAGEMENT V

Directory of Open Access Journals (Sweden)

Valmikanathan Onbattuvelli

2012-06-01

Full Text Available Silicon carbide (SiC exhibits many functional properties that are relevant to applications in electronics, aerospace, defense and automotive industries. However, the successful translation of these properties into final applications lies in the net-shaping of ceramics into fully dense microstructures. Increasing the packing density of the starting powders is one effective route to achieve high sintered density and dimensional precision. The present paper presents an in-depth study on the effects of nanoparticle addition on the powder injection molding process (PIM of SiC powder-polymer mixtures. In particular, bimodal mixtures of nanoscale and sub-micrometer particles are found to have significantly increased powder packing characteristics (solids loading in the powder-polymer mixtures. The influence of nanoparticle addition on the multi-step PIM process is examined. The above results provide new perspectives which could impact a wide range of materials, powder processing techniques and applications.

Chemorheology of in-mold coating for compression molded SMC applications

Science.gov (United States)

Ko, Seunghyun; Straus, Elliott J.; Castro, Jose M.

2015-05-01

In-mold coating (IMC) is applied to compression molded sheet molding compound (SMC) exterior automotive or truck body panels as an environmentally friendly alternative to make the surface conductive for subsequent electrostatic painting operations. The coating is a thermosetting liquid that when injected onto the surface of the part cures and bonds to provide a smooth conductive surface. In order to optimize the IMC process, it is essential to predict the time available for flow, that is the time before the thermosetting reaction starts (inhibition time) as well as the time when the coating has enough structural integrity so that the mold can be opened without damaging the part surface (cure time). To predict both the inhibition time and the cure time, it is critical to study the chemorheology of IMC. In this paper, we study the chemorheology for a typical commercial IMC system, and show its relevance to both the flow and cure time for the IMC stage during SMC compression molding.

Tool steel quality and surface finishing of plastic molds

Directory of Open Access Journals (Sweden)

Rafael Agnelli Mesquita

2010-01-01

Full Text Available Plastic industry is today in a constant growth, demanding several products from other segments, which includes the plastic molds, mainly used in the injection molding process. Considering all the requirements of plastic molds, the surface finishing is of special interest, as the injected plastic part is able to reproduce any details (and also defects from the mold surface. Therefore, several aspects on mold finishing are important, mainly related to manufacturing conditions - machining, grinding, polishing and texturing, and also related to the tool steel quality, in relation to microstructure homogeneity and non-metallic inclusions (cleanliness. The present paper is then focused on this interrelationship between steel quality and manufacturing process, which are both related to the final quality of plastic mold surfaces. Examples are discussed in terms of surface finishing of plastic molds and the properties or the microstructure of mold steels.

Verification of a three-dimensional resin transfer molding process simulation model

Science.gov (United States)

Fingerson, John C.; Loos, Alfred C.; Dexter, H. Benson

1995-01-01

Experimental evidence was obtained to complete the verification of the parameters needed for input to a three-dimensional finite element model simulating the resin flow and cure through an orthotropic fabric preform. The material characterizations completed include resin kinetics and viscosity models, as well as preform permeability and compaction models. The steady-state and advancing front permeability measurement methods are compared. The results indicate that both methods yield similar permeabilities for a plain weave, bi-axial fiberglass fabric. Also, a method to determine principal directions and permeabilities is discussed and results are shown for a multi-axial warp knit preform. The flow of resin through a blade-stiffened preform was modeled and experiments were completed to verify the results. The predicted inlet pressure was approximately 65% of the measured value. A parametric study was performed to explain differences in measured and predicted flow front advancement and inlet pressures. Furthermore, PR-500 epoxy resin/IM7 8HS carbon fabric flat panels were fabricated by the Resin Transfer Molding process. Tests were completed utilizing both perimeter injection and center-port injection as resin inlet boundary conditions. The mold was instrumented with FDEMS sensors, pressure transducers, and thermocouples to monitor the process conditions. Results include a comparison of predicted and measured inlet pressures and flow front position. For the perimeter injection case, the measured inlet pressure and flow front results compared well to the predicted results. The results of the center-port injection case showed that the predicted inlet pressure was approximately 50% of the measured inlet pressure. Also, measured flow front position data did not agree well with the predicted results. Possible reasons for error include fiber deformation at the resin inlet and a lag in FDEMS sensor wet-out due to low mold pressures.

Structural characterization and mechanical properties of polypropylene reinforced natural fibers

Science.gov (United States)

Karim, M. A. A.; Zaman, I.; Rozlan, S. A. M.; Berhanuddin, N. I. C.; Manshoor, B.; Mustapha, M. S.; Khalid, A.; Chan, S. W.

2017-10-01

Recently the development of natural fiber composite instead of synthetics fiber has lead to eco-friendly product manufacturing to meet various applications in the field of automotive, construction and manufacturing. The use of natural fibers offer an alternative to the reinforcing fibers because of their good mechanical properties, low density, renewability, and biodegradability. In this present research, the effects of maleic anhydride polypropylene (MAPP) on the mechanical properties and material characterization behaviour of kenaf fiber and coir fiber reinforced polypropylene were investigated. Different fractions of composites with 10wt%, 20wt% and 30wt% fiber content were prepared by using brabender mixer at 190°C. The 3wt% MAPP was added during the mixing. The composites were subsequently molded with injection molding to prepare the test specimens. The mechanical properties of the samples were investigated according to ISO 527 to determine the tensile strength and modulus. These results were also confirmed by the SEM machine observations of fracture surface of composites and FTIR analysis of the chemical structure. As the results, the presence of MAPP helps increasing the mechanical properties of both fibers and 30wt% kenaf fiber with 3wt% MAPP gives the best result compare to others.

Effect of boron compounds on physical, mechanical, and fire properties of injection molded wood plastic composites

Science.gov (United States)

Nadir Ayrilmis; Turgay Akbulut; Turker Dundar; Robert H. White; Fatih Mengeloglu; Zeki Candan; Umit Buyuksari; Erkan Avci

2011-01-01

Physical, mechanical, and fire properties of the injection-molded wood flour/polypropylene composites (WPCs) incorporated with different levels of boron compounds, borax/boric acid (BX/BA) (0.5:0.5 wt %) and zinc borate (ZB) (4, 8, or 12 wt %) were investigated. The effect of the coupling agent loading (2, 4, or 6 wt %), maleic anhydride-grafted PP (MAPP), on the...

Comparative analysis of different process simulation settings of a micro injection molded part featuring conformal cooling

DEFF Research Database (Denmark)

Marhöfer, David Maximilian; Tosello, Guido; Islam, Aminul

2015-01-01

. In the reported work, process simulations using Autodesk Moldflow Insight 2015® are applied to a micro mechanical part to be fabricated by micro injection molding and with over-all dimensions of 12.0 × 3.0 × 0.8 mm³ and micro features (micro hole, diameter of 580 μm, and sharp radii down to 100 μm). Three...

Effects of cavity surface temperature on mechanical properties of specimens with and without a weld line in rapid heat cycle molding

International Nuclear Information System (INIS)

Wang, Guilong; Zhao, Guoqun; Wang, Xiaoxin

2013-01-01

Highlights: ► Higher cavity surface temperature reduces tensile strength of non-weldline part. ► Higher cavity surface temperature increases weldline tensile strength for PS and PP. ► Higher cavity surface temperature reduces weldline tensile strength for ABS, ABS/PMMA, ABS/PMMA/nano-C a CO 3 and FRPP. ► Tensile strength is reduced more by the weldline than impact strength. ► FRPP has the lowest weld line factor than other plastics without reinforced fibers. - Abstract: Rapid heat cycle molding (RHCM) is a recently developed injection molding technology to enhance surface esthetic of the parts. By rapid heating and cooling of mold cavity surfaces in molding process, it can greatly alleviate or even eliminate the surface defects such as flow mark, weld line, glass fiber rich surface, silver mark, jetting mark, and swirl mark, and also improve gloss finish and dimensional accuracy without prolonging the molding cycle. Besides surface esthetic, mechanical property is also a very import issue for the molded plastic part. The aim of this study is focusing on the effects of the cavity surface temperature just before filling, T cs , in RHCM on the mechanical strength of the specimen with and without weld line. Six kinds of typical plastics including polystyrene (PS), polypropylene (PP), acrylonitrile butadiene styrene (ABS), acrylonitrile butadiene styrene/polymethylmethacrylate (ABS/PMMA), ABS/PMMA/nano-C a CO 3 and glass fiber reinforced polypropylene (FRPP) are used in experiments. The specimens with and without a weld line are produced with the different T cs on the developed electric-heating RHCM system. Tensile tests and notched Izod impact tests are conducted to characterize the mechanical strength of the specimens molded with different cavity surface temperatures. Simulations, differential scanning calorimetry (DSC), scanning electron microscope (SEM) and optical microscope are implemented to explain the impact mechanism of T cs on mechanical properties

Simulation model for transcervical laryngeal injection providing real-time feedback.

Science.gov (United States)

Ainsworth, Tiffiny A; Kobler, James B; Loan, Gregory J; Burns, James A

2014-12-01

This study aimed to develop and evaluate a model for teaching transcervical laryngeal injections. A 3-dimensional printer was used to create a laryngotracheal framework based on de-identified computed tomography images of a human larynx. The arytenoid cartilages and intrinsic laryngeal musculature were created in silicone from clay casts and thermoplastic molds. The thyroarytenoid (TA) muscle was created with electrically conductive silicone using metallic filaments embedded in silicone. Wires connected TA muscles to an electrical circuit incorporating a cell phone and speaker. A needle electrode completed the circuit when inserted in the TA during simulated injection, providing real-time feedback of successful needle placement by producing an audible sound. Face validation by the senior author confirmed appropriate tactile feedback and anatomical realism. Otolaryngologists pilot tested the model and completed presimulation and postsimulation questionnaires. The high-fidelity simulation model provided tactile and audio feedback during needle placement, simulating transcervical vocal fold injections. Otolaryngology residents demonstrated higher comfort levels with transcervical thyroarytenoid injection on postsimulation questionnaires. This is the first study to describe a simulator for developing transcervical vocal fold injection skills. The model provides real-time tactile and auditory feedback that aids in skill acquisition. Otolaryngologists reported increased confidence with transcervical injection after using the simulator. © The Author(s) 2014.

Influence of sorbitol on mechanical and physico-chemical properties of soy protein-based bioplastics processed by injection molding

Directory of Open Access Journals (Sweden)

Manuel Felix

Full Text Available Abstract Soy Protein Isolate (SPI has been evaluated as useful candidate for the development of protein-based bioplastic materials processed by injection molding. The influence of sorbitol (SB as plasticizer in mechanical properties and water uptake capacity was evaluated in SPI-based bioplastics. A mixing rheometer that allows monitoring torque and temperature during mixing and a small-scale-plunger-type injection molding machine were used to obtain SPI/Plasticizer blends and SPI-based bioplastics, respectively. Dynamic measurements were carried out to obtain mechanical spectra of different bioplastics. Moreover, the mechanical characterization was supplemented with uniaxial tensile tests. Additionally, the influence of SB in water uptake capacity was also evaluated. The introduction of SB leads to increase the rigidity of bioplastics as well as the water uptake capacity after 24h, however it involves a decrease in strain at break. Final bioplastics are plastic materials with both adequate properties for the substitution of conventional petroleum plastics and high biodegradability.

Development of fire resistant, nontoxic aircraft interior materials

Science.gov (United States)

Haley, G.; Silverman, B.; Tajima, Y.

1976-01-01

All available newly developed nonmetallic polymers were examined for possible usage in developing fire resistant, nontoxic nonmetallic parts or assemblies for aircraft interiors. Specifically, feasibility for the development of clear films for new decorative laminates, compression moldings, injection molded parts, thermoformed plastic parts, and flexible foams were given primary considerations. Preliminary data on the flame resistant characteristics of the materials were obtained. Preliminary toxicity data were generated from samples of materials submitted from the contractor. Preliminary data on the physical characteristics of various thermoplastic materials to be considered for either compression molded, injection molded, or thermoformed parts were obtained.

Diode Laser Assisted Filament Winding of Thermoplastic Matrix Composites

Science.gov (United States)

Quadrini, Fabrizio; Squeo, Erica Anna; Prosperi, Claudia

2010-01-01

A new consolidation method for the laser-assisted filament winding of thermoplastic prepregs is discussed: for the first time a diode laser is used, as well as long glass fiber reinforced polypropylene prepregs. A consolidation apparatus was built by means of a CNC motion table, a stepper motor and a simple tensioner. Preliminary tests were performed in a hoop winding configuration: only the winding speed was changed, and all the other process parameters (laser power, distance from the laser focus, consolidation force) were kept constant. Small wound rings with an internal diameter of 25 mm were produced and compression tests were carried out to evaluate the composite agglomeration in dependence of the winding speed. At lower winding speeds, a strong interpenetration of adjacent layers was observed.

Occupational exposure to bisphenol A (BPA) in a plastic injection molding factory in Malaysia

OpenAIRE

Wided Kouidhi; Letchumi Thannimalay; Chen Sau Soon; Mustafa Ali Mohd

2017-01-01

Objectives: The purpose of this study has been to assess ambient bisphenol A (BPA) levels in workplaces and urine levels of workers and to establish a BPA database for different populations in Malaysia. Material and Methods: Urine samples were collected from plastic factory workers and from control subjects after their shift. Air samples were collected using gas analyzers from 5 sampling positions in the injection molding unit work area and from ambient air. The level of BPA in airborne and u...

Experimental evaluation and simulation of volumetric shrinkage and warpage on polymeric composite reinforced with short natural fibers

Science.gov (United States)

Santos, Jonnathan D.; Fajardo, Jorge I.; Cuji, Alvaro R.; García, Jaime A.; Garzón, Luis E.; López, Luis M.

2015-09-01

A polymeric natural fiber-reinforced composite is developed by extrusion and injection molding process. The shrinkage and warpage of high-density polyethylene reinforced with short natural fibers of Guadua angustifolia Kunth are analyzed by experimental measurements and computer simulations. Autodesk Moldflow® and Solid Works® are employed to simulate both volumetric shrinkage and warpage of injected parts at different configurations: 0 wt.%, 20 wt.%, 30 wt.% and 40 wt.% reinforcing on shrinkage and warpage behavior of polymer composite. Become evident the restrictive effect of reinforcing on the volumetric shrinkage and warpage of injected parts. The results indicate that volumetric shrinkage of natural composite is reduced up to 58% with fiber increasing, whereas the warpage shows a reduction form 79% to 86% with major fiber content. These results suggest that it is a highly beneficial use of natural fibers to improve the assembly properties of polymeric natural fiber-reinforced composites.

Acoustic Emission Detection of Macro-Cracks on Engraving Tool Steel Inserts during the Injection Molding Cycle Using PZT Sensors

Directory of Open Access Journals (Sweden)

Aleš Hančič

2013-05-01

Full Text Available This paper presents an improved monitoring system for the failure detection of engraving tool steel inserts during the injection molding cycle. This system uses acoustic emission PZT sensors mounted through acoustic waveguides on the engraving insert. We were thus able to clearly distinguish the defect through measured AE signals. Two engraving tool steel inserts were tested during the production of standard test specimens, each under the same processing conditions. By closely comparing the captured AE signals on both engraving inserts during the filling and packing stages, we were able to detect the presence of macro-cracks on one engraving insert. Gabor wavelet analysis was used for closer examination of the captured AE signals’ peak amplitudes during the filling and packing stages. The obtained results revealed that such a system could be used successfully as an improved tool for monitoring the integrity of an injection molding process.

Effect of injection molded micro-structured polystyrene surfaces on proliferation of MC3T3-E1 cells

Directory of Open Access Journals (Sweden)

G. Lucchetta

2015-04-01

Full Text Available In this work, osteoinductive micro-pillared polystyrene surfaces were mass-produced for bone replacement applications, by means of the micro injection molding process. Firstly, the molding process parameters were optimized with a two-level, three-factor central composite face-centered plan to increase the quality of polystyrene micro pillars replication and to maximize the pillars height uniformity over the molded part. Secondly, osteoblastic MC3T3-E1 cells adhesion and proliferation on the replicated substrates were assessed as a function of micro topography parameters, such as pillars diameter, aspect ratio and spacing. Cell morphology and proliferation were evaluated through MTS test after 1, 3 and 7 days from seeding. The experimental results showed that cells adhesion and proliferation is more positively promoted on micro-pillared surfaces compared to flat surfaces, but no correlations were observed between cell proliferation and pillar diameter and spacing.

Biodegradation of thermoplastic starch/eggshell powder composites.

Science.gov (United States)

Bootklad, Munlika; Kaewtatip, Kaewta

2013-09-12

Thermoplastic starch (TPS) was prepared using compression molding and chicken eggshell was used as a filler. The effect of the eggshell powder (EP) on the properties of TPS was compared with the effect of commercial calcium carbonate (CC). The organic compound on the surface of the eggshell powder acted as a coupling agent that resulted in a strong adhesion between the eggshell powder and the TPS matrix, as confirmed by SEM micrographs. The biodegradation was determined by the soil burial test. The TPS/EP composites were more rapidly degraded than the TPS/CC composites. In addition, the eggshell powder improved the water resistance and thermal stability of the TPS. Copyright © 2013 Elsevier Ltd. All rights reserved.

Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing.

Science.gov (United States)

Villegas, Irene F; Palardy, Genevieve

2016-02-11

This paper presents a novel straightforward method for ultrasonic welding of thermoplastic-composite coupons in optimum processing conditions. The ultrasonic welding process described in this paper is based on three main pillars. Firstly, flat energy directors are used for preferential heat generation at the joining interface during the welding process. A flat energy director is a neat thermoplastic resin film that is placed between the parts to be joined prior to the welding process and heats up preferentially owing to its lower compressive stiffness relative to the composite substrates. Consequently, flat energy directors provide a simple solution that does not require molding of resin protrusions on the surfaces of the composite substrates, as opposed to ultrasonic welding of unreinforced plastics. Secondly, the process data provided by the ultrasonic welder is used to rapidly define the optimum welding parameters for any thermoplastic composite material combination. Thirdly, displacement control is used in the welding process to ensure consistent quality of the welded joints. According to this method, thermoplastic-composite flat coupons are individually welded in a single lap configuration. Mechanical testing of the welded coupons allows determining the apparent lap shear strength of the joints, which is one of the properties most commonly used to quantify the strength of thermoplastic composite welded joints.

Fabrication of Bonding-Type Hollow Microneedle Array by Injection Molding and Evaluation of its Puncture Characteristics

Science.gov (United States)

Ogai, Noriyuki; Sugimura, Ryo; Tamaru, Takuya; Takiguchi, Yoshihiro

A microneedle array which consists from small needles compared to a conventional metal injection needle is expected as a low invasive transdermal medical treatment device, and many fabrication approach have been conducted. In this study, we fabricated plastic hollow microneedle array by a fabrication method based on the combination of injection molding, bonding and assembly techniques. To evaluate puncture characteristics of the fabricated needle, we measured a puncture force to silicone rubber by experimental equipment using loadcell and automatic stage. Furthermore, we propose and demonstrate a new method to measure actual punctured depth from punctured trace on the needle surface modified by O2 plasma treatment.

Thermosetting epoxy resin/thermoplastic system with combined shape memory and self-healing properties

International Nuclear Information System (INIS)

Yao, Yongtao; Wang, Jingjie; Lu, Haibao; Liu, Yanju; Leng, Jinsong; Xu, Ben; Fu, Yongqing

2016-01-01

A novel and facile strategy was proposed to construct a thermosetting/thermoplastic system with both shape memory and self-healing properties based on commercial epoxy resin and poly(ϵ-caprolactone)-PCL. Thermoplastic material is capable of re-structuring and changing the stiffness/modulus when the temperature is above melting temperature. PCL microfiber was used as a plasticizer in epoxy resin–based blends, and served as a ‘hard segment’ to fix a temporary shape of the composites during shape memory cycles. In this study, the electrospun PCL membrane with a porous network structure enabled a homogenous PCL fibrous distribution and optimized interaction between fiber and epoxy resin. The self-healing capability is achieved by phase transition during curing of the composites. The mechanism of the shape memory effect of the thermosetting (rubber)/thermoplastic composite is attributed to the structural design of the thermoplastic network inside the thermosetting resin/rubber matrix. (paper)

Research cooperation project on the development of easy injection molding control technology for engineering plastics; Engineering plastic no seikei joken kan`i settei gijutsu ni kansuru kenkyu kyoryoku jigyo seika hokokusho

Energy Technology Data Exchange (ETDEWEB)

NONE

1997-03-01

In order to enhance the industries which supply assembly parts to Japan`s assembly industries in Thailand, research cooperation project on the plastic parts production technology has started. For the research cooperation, the mold design is effectively conducted using simulation technique of CAE (computer aided engineering), and an international easy injection molding control system is made using the molding support software for injection molding machines. In FY 1996, actual situations of plastic parts and assembly industries in Thailand have been investigated through the cooperation with the counterpart of Thailand. Demand and supply of engineering plastics, receive and inspection of parts, and current circumstances of molding processing makers in Thailand have been grasped. Based on the results of this investigation, proposal of basic plan, time schedule, and delivery plan of molding machines and testing equipment have been discussed, to make the basic plan. 18 refs., 4 figs., 23 tabs.

Influence of capillary die geometry on wall slip of highly filled powder injection molding compounds

Czech Academy of Sciences Publication Activity Database

Sanétrník, D.; Hausnerová, B.; Filip, Petr; Hnátková, E.

2018-01-01

Roč. 325, February (2018), s. 615-619 ISSN 0032-5910 R&D Projects: GA ČR GA17-26808S Grant - others:Ministerstvo školství, mládeže a tělovýchovy (MŠMT)(CZ) LO1504 Institutional support: RVO:67985874 Keywords : powder injection molding * highly filled polymer * wall slip * capillary entrance angle Subject RIV: BK - Fluid Dynamics OBOR OECD: Fluids and plasma physics (including surface physics) Impact factor: 2.942, year: 2016

Diode Laser Assisted Filament Winding of Thermoplastic Matrix Composites

Directory of Open Access Journals (Sweden)

Claudia Prosperi

2010-01-01

Full Text Available A new consolidation method for the laser-assisted filament winding of thermoplastic prepregs is discussed: for the first time a diode laser is used, as well as long glass fiber reinforced polypropylene prepregs. A consolidation apparatus was built by means of a CNC motion table, a stepper motor and a simple tensioner. Preliminary tests were performed in a hoop winding configuration: only the winding speed was changed, and all the other process parameters (laser power, distance from the laser focus, consolidation force were kept constant. Small wound rings with an internal diameter of 25 mm were produced and compression tests were carried out to evaluate the composite agglomeration in dependence of the winding speed. At lower winding speeds, a stronginterpenetration of adjacent layers was observed.

Qualification Methods of Al2O3 Injection Molding Raw Materials

International Nuclear Information System (INIS)

Egész, Á; Gömze, L A

2015-01-01

For producing ceramic arc tube parts (plugs), there are used two different major components for producing injection molding raw material (feedstock): high purity alumina powder as the main component, and an organic paraffin wax as a binder material. It is expressly important to know the material, physical and chemical properties of these components, since mainly these have effect on the homogenity of feedstock, and therefore on the quality of end product. In this research, both of the main components and the moldable raw material was investigated by visual, physical, and thermal methods. As most important and main statement, the researchers found that the dynamic viscosity of raw material depends more on the applied temperature, than on the deformation speed gradient.Applied analitycal methods were laser granulometry, sieve analysis, differential thermal analysis and rheology analysis. (paper)

Metal Injection Molding (MIM of NdFeB Magnets

Directory of Open Access Journals (Sweden)

Hartwig T.

2014-07-01

Full Text Available Due to the increased and unstable prices for Rare Earth elements there are activities to develop alternative hard magnetic materials. Reducing the amount of material necessary to produce complex sintered NdFeB magnets can also help to reduce some of the supply problem. Metal Injection Molding (MIM is able to produce near net shape parts and can reduce the amount of finishing to achieve final geometry. Although MIM of NdFeB has been patented and published fairly soon after the development of the NdFeB magnets there has never been an industrial production. This could be due to the fact that MIM was very young at that time and hardly developed. Thus, the feasibility of the process needs to be revaluated. This paper presents results of our work on determining the process parameters influencing the magnetic properties of the sintered magnets as well as the shrinkage during processing. The role of binder and powder loading on the alignment of the particles as well as on the carbon and oxygen contamination was examined.

Analysis and modeling of simulated residual stress of mold injected plastic parts by using robust correlations

OpenAIRE

Vargas, Carlos; Sierra, Juan; Posada, Juan; Botero-Cadavid, Juan F.

2017-01-01

ABSTRACT The injection molding process is the most widely used processing technique for polymers. The analysis of residual stresses generated during this process is crucial for the part quality assessment. The present study evaluates the residual stresses in a tensile strength specimen using the simulation software Moldex3D for two polymers, polypropylene and polycarbonate. The residual stresses obtained under a simulated design of experiment were modeled using a robust multivariable regressi...

Influence of gamma irradiation in the thermoplastic elastomer (TPE)

International Nuclear Information System (INIS)

Oliveira, Camila B.; Parra, Duclerc F.; Marchini, Leonardo G.

2017-01-01

The TPE is the nomenclature used for the thermoplastic elastomer, which is also known as thermoplastic rubber. It belongs to an under-researched class of engineering plastics, however, in recent years there has been steady growth due to its important and unusual combination of properties. During its use, it behaves like an elastomer, but, unlike traditional elastomers (vulcanized rubbers), it can be processed using conventional technologies and equipment used for thermoplastics, such as extrusion and injection. The processing of polymers, such as TPE by means of radiation, constitutes a technological area dedicated to the study of the physical and chemical effects caused by high energy radiation, such as gamma radiation. Thus the objective of this work is to evaluate the mechanical and thermal properties of TPE irradiated by 60 Co source of gamma radiation in different doses. The thermoplastic elastomer being modified by means of ionizing radiation at doses of 5, 10, 20, 30, 50 and 100 kGy the effects of the radiation on the mechanical and thermal properties of this material are evaluated through the tests of tensile tests, TGA, FTIR and Fluency Index

Particle Dispersibility Improvement of Polyester Fibers with a New Line Injection

International Nuclear Information System (INIS)

Park, Seong Yoon; Kim, Hak Yong; Jin, Fan Long; Park, Soo Jin

2010-01-01

In order to develop a new line injection system for spin draw yarn (FD SDY) fibers, the effect of various parameters in extrusion and melt line conditions on the dispersion and distribution of TiO 2 particles within FD PET fibers was investigated. As a result, the dispersibility of TiO 2 particles in a PET matrix is found to depend on the particle size and its surface characteristics. Surface modification of TiO 2 by dimethyl polysiloxane resulted in the improved dispersibility and affinity of TiO 2 particles in the PET matrix. Especially, residence time, mixing temperature, and mixing shear rate in the new line injection system under the SDY spinning process were very important parameters to minimize the agglomeration of TiO 2 particles. The FD SDY prepared by the new line injection system was superior to those using the polymerization process and the conventional masterbatch chip dosing process in the color-L and color-b values of the fibers