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Moldex3D Italia srlCorso Promessi Sposi 23/D -
23900 Lecco (LC)www.moldex3d.com
2014 Molding Innovation Day
10 Luglio 2014POINT Polo per Innovazione TecnologicaDalmine Bergamo
MuCellCapacità di predizione di Moldex3D
Dal processo alla riduzione di peso e di deformazioneL’esperienza di laboratorio sui processi microcellul ari
Ing. Andrea Romeo - Proplast
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Moldex3D : il Processo Microcellulare – Gli attori
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Proplast was founded in 1998
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210 associates
The Consortium
184 Companies9 Associations
3 Public Entities and foundations13 Universities
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Research and development activities
for polymer processes
Goals
Reference point to develop research
and development activities between
Universities and Companies
Training and HR
activities
Technical consultancy and
technological tranfer
Laboratory services
and analysis
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PROPLAST, Trexel, ENGEL partnershipTo promote and disseminate the Mucell technology
Demo installationAt Proplast’s site (Tortona, Italy) IMM: Engel 180 tons, screw: 55 mm Shot weight: 100-500 gMucell unit - Co2 or Nitrogen
GoalSupport customers at every stage of the technology implementation and application•Part design for Mucell•Support to mould design•Mucell moulding trials / mould piloting
Technological developmentAestethical surfaces on Mucell parts (material design and optimization)Combination with H&C technologies (pressurised water, induction)
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EUROPEAN FUND FOR REGIONAL DEVELOPMENT
P.O.R. 2007 – 2013
GoalResearch and experimentation on Microcrellular Injection Moulding
Consortium5 Industrial partners (Moldmakers, End Users, Compounders)
Reference Research and Technical Centre
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Onni-Stamp S.r.l. mainly focuses on:
� design� management� production� maintenance
of plastics injection moulds.
Established in 1980, Onni-Stamp is able to balance the most innovative technologies and the expertise and skills of its technologists acquired in over 30 years of activity and production.
Its mission is to follow up the customer from the scratch over all the phases of a plastics component development: from part design to maintenance of tools and equipments.
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Conventional moulding
Mucell
Heat and cool
Mucell + Heat and
cool
Combining 2 different innovative technologies:
Mucellmicrocellular injection moulding
Heat and cooldynamic mould conditioning
Focus on:→ Mouldability and process conditions→ Aesthetics→ Warpage→ Materials→ Eventual pit falls evaluation
Concept
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Different surface finish(mirror polishing,
textures)
Ribs
Measurementreference points
U-shaped part toamplify warpage
Holes to generate welding lines
max rib/wallthickness ratio 2:1
Specific features to evaluate , measure , compare
The moulded part
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Simulating the process• Conventional
moulding
• Mucell injectionmoulding
• Heat and cool injection moulding
Prevision of the Microstructure• Cell dimensions
• Cell density and distribution
Building the material model• Accurate
Mechanical model sensitive to morphology
Structural simulation• Stiffness
• Strength
• Performance
Process ↔↔↔↔ Material ↔↔↔↔ Structure
Virtual run
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Rheological simulations with Mucell
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Mucell Process Chance to accurately simulate the Microcellular Moulding Processwith Moldex 3D
The Microcellular Injection Moulding Process can be analysed, predict, optimised via simulation softwares
STRUCTURAL FEM ANALYSIS
FillingCells
nucleation/growth
Ejection
PROCESS QUALITY
Global part quality
Localresults
Cooling(average/transien
t)
- Expansion / weightreduction
- Volum. shrinkage/sinkmarks
- Warpage / residualstresses
- Cells density- Cells size
- Cycle time- Injection pressure- Clamping force
Rheology
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The Microcellular Injection Moulding Process can be analysed, predict, optimised via simulation softwares
Mucell Process Chance to accurately simulate the Microcellular Moulding Processwith Moldex 3D
FillingCells
nucleation/growth
EjectionGlobal part
qualityLocal
results
Cooling(average/transien
t)
STRUCTURAL FEM ANALYSIS
PROCESS QUALITY
- Cycle time- Injection pressure- Clamping force
- Expansion / weightreduction
- Volum. shrinkage/sinkmarks
- Warpage / residualstresses
- Cells density- Cells size
ECONOMICAL ANALYSIS
PERFORMANCE ANALYSIS
- Moulding- Specs Check- Working
- Investiments- Productivity- Production costs- Consumptions
COMPARISON TO COMPACT
MOULDING
Rheology
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Virtual MucellInjection moulding Mucell Compact
tinj (s) 0,9 0,9
Tmelt (°C) 260 260
Tmould (°C) 40/40 70/70
Gas dosing (%) 0,5 --
Switch over point (%) 99 99
thold (s) -- 7
Phold (bar) -- 1600
tcooling (s) 20 23
tcycle (s) 26 36
Shot weight (g) 92,9 100,3
Pinj max (bar) 1428 1768
Clamping force(ton)
90 220
Variation (%)
-28
-7,4
-19
-59
Rheology
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Sink marksreduction
Mucell
Rheology
Compact moulding
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Warpage reduction
Rheology
BA
D
C
MucellCompact Moulding
nominal compact Mucell
simulated
measured simulated measured
A 110 108,76 109,17 109,22 109,16
B 200 198,10 198,64 198,76 198,72
C 200 198,61 198,92 199,18 198,86
D 110 109,21 109,30 109,52 109,20
predictionCorner effect
prediction
Variation (%)
- 0,05
- 0,02
- 0,29
- 0,29
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Warpage reduction
Rheology
MucellCompact moulding
planarityPrediction of
planarity
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RheologyExpansionprediction
Global weight reduction: 5.5% Global weight reduction: 7.4%
Cells density
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RheologyExpansionprediction Cells size
Global weight reduction: 5.5% Global weight reduction: 7.4%
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1.
2.
3.
2. 3.
1.
Reduced cell sizeHigh cell density
Medium cell sizeMedium cell
density
High cell sizeLow cell density
* Global weight reduction: 5.5%
Cells size prediction
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2.
3.
1.
1. 2. 3.
Cells density prediction
Reduced cell sizeHigh cell density
Medium cell sizeMedium cell
density
High cell sizeLow cell density
* Global weight reduction: 5.5%
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SEM validation: average cell size 2 µm
Cells size near the gate
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SEM validation: average cell size 33 µm
SEM validation: average cell size 22 µm
Cells size at a half of flow lenght
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SEM validation: average cell size 77 µm
SEM validation: average cell size 58 µm
Cells size at the end of flow
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SEM
Cells density near the gate
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SEM
Cells density at a half of flow lenght
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SEM
SEM
Cells density at the end offlow
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Structural simulations on Mucell components
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Simulation workflow
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� Central technology for structural engineering� Integration of local predicted microstructure
– Matrix + fibers + cells– Additional information about material microstructure
Material modeling
The result: Material model sensitive to its morphology
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� Mapping software• Exchanges data between dissimilar meshes
Mesh mapping
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Mesh mapping
Density of porosity Size of porosity Volume Fraction of porosity
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Mucell test case 1
Accurate component’s mechanical prediction
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Mucell test case 2
Accurate component’s mechanical prediction
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Mucell test case 3
Accurate component’s mechanical prediction
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Mucell + Heat and Cool
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Thermal analysis
Mucell + Heat and cool
Target: heat and cool on the aesthetical surface- Conformal channels design optimization (layout, position, cross
sections)- Prediction of the temperature uniformity over the cavity- Prediction of heating and cooling times- Exstimation of total cycle time
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The mould
Variable injectionsystems and flow
lenghts
Kistler pressure and temperature
sensors
Conformal coolingchannels
Pressure and TemperatureSensors to efficiently control the process
Conformal cooling channelsFor temperature uniformity and for reducing the mould’s thermal inertia making heat and cool affordable
Variable injection systemFor evaluating different flow lengths and the effect of welding lines
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Several moulding trials were perfomed at Proplast’s, at different process conditions and on different materials (amorphous and semicrystalline):
Tested materials
� ABS, ELIX P2 - HAT � ABS Thermo-resistant, ABS CILAC TBB� PC-ABS, BAYBLEND T85 XF
� PA6, AQUAMID NAT� PA6 da from regenerated monomer, ECONYL 6FLH� PA6 + nano fillers, PANCH 1015 UCT2 HN
Injection conditions
� 1 central gate� 2 lateral gates� 1 lateral gate
Expansion conditions
� Compact (100% density)� Weight reduction: -5%� Max achievable weight reduction
Moulding trials
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0
100
200
300
400
500
600
0 5 10 15 20
Pre
ssio
ni [B
ar]
Tempo [sec]
pressione 1estremità
pressione 2centrale
pressione 3estremità
Evaluating:
• Max injection pressure• Holding pressure• Cavity pressure (at 3 sensors positions)
• Clamping force
• Injection time• Cooling time• Total cycle time• Melt temperature
• Mould temperature• Cavity temperature
Process
Statistical analysis of defects and rating of gloss
Aesthetics
Shrinkage and warpage analysis
Dimensional stability
Assessment and metrics
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Compact Mucell Variation %
Shot weight g 100 92,9 -7,1%
Clamping force kN 2200 900 -59,1%
Max injection pressure Bar 1770 1442 -18,5%
Injection time sec 0,88 0,85
Cycle time sec 36 26 -27,8%
Melt temperature °C 260 260
Mould temperature °C 60 40
Process
0
100
200
300
400
500
600
700
800
0 10 20 30
Pre
ssio
ni [B
ar]
Tempo [sec]
pressione 1estremitàpressione 2centralepressione 3estremità
0
100
200
300
400
500
600
700
800
0 10 20 30
Pre
ssio
ni [B
ar]
Tempo [sec]
pressione 1estremitàpressione 2centralepressione 3estremità
Compact MucellReduced by -24%
725 bar
548 bar
Pressure sensors
Max injection pressure reducedVery uniform packing occurs with Mucell, driven by cells growth pressure
Trials performed on thermoresistant ABS CILAC TBB, 1 central gate
Pressure at tip1Pressure atcentrePressure at tip2
Pressure at tip1Pressure atcentrePressure at tip2
Outcomes (I)
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Lman central
Lman bracci
Lm
anla
tera
l1
Lm
anla
tera
l2
Compatto Mucell Variation %
L centrale mm 198,96 198,80
L bracci mm 198,54 198,56
L lateral 1 mm 218,74 218,63
L lateral 2 mm 218,75 218,65
Warpage mm 0,42 0,23 -45%
Overall Warpage [adim] 0,0021 0,0012 -43%
Ritiro central % 0,527 0,607
Ritiro lateral 1 % 0,574 0,623
Ritiro lateral 2 % 0,568 0,615
∆ shrinkage % -0,045 -0,012 -73%
Warpage and shrinkage
Trials performed on thermoresistant ABS CILAC TBB, 1 central gate
Mucell trials always provided improvements about warpage and distribution of shrinkage, both as average value and as standard deviation.
Values depend on material and condition process, as well.
Warpage and shrinkage parameters calculation
Outcomes (II)
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Compact conventional Mucell
Heat and cool
Mucell + Heat and cool
Deep sink marks� High gloss
� No sink marksSilver streaks
(Only) reduced sink marks� Very high gloss
� No sink marks� No silver streaks� Very high gloss
AestheticsMucell prevent sink marks very effectively but generates silver streaks.
Heat and cool gives a very high glossy surface but is not able to eliminate sink marks.
Mucell and heat and cool combined solve dimensional issues, sink marks and produce a very high gloss surfaces
Outcomes (III)
Trials performed on thermoresistant ABS CILAC TBB, 1 central gate
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ABS TermoresistenteABS CILAC TBB
0
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30
35
40
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0 5 10 15 20 25 30
Pre
ssio
ni [B
ar]
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pressione 1estremità
pressione 2centrale
pressione 3estremità
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0 5 10 15 20 25 30
Pre
ssio
ni [B
ar]
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pressione 2centrale
pressione 3estremità
Compatto Mucell
Analisi di un caso particolare
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Conclusions
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Conclusions (I)
ProcessGeneral reduction of clamping forceGeneral decrease of max injection pressureGeneral reduction of mould temperatureGeneral reduction of cycle time
Dimensional stabilityMucell trials always provided improvements about warpage and distribution of shrinkage, both as average value and as standard deviation.
Values depend on material and condition process, as well.
AestheticsAt every condition Mucell removed sink marksThe use of combined Heat and cool technology eliminates aesthetical defects, as well.
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Simulations
• Chance to simulate and predict Mucell with Moldex 3D (process, part quality, expansion properties)
- Process settings- Cycle time- Pressures- Clamping force
- Expansion / weight reduction- Volumetric shrinkage / sink marks- Warpage / residual stress distribution- Local cell size- Cell distribution and density
• Chance to interface process results from Moldex to structural simulation s of Mucellcomponents
- Material model sensitive to Mucell microstructure- Stiffness/ strength prediction- Prediction of the component’s performance
• Chance to design/simulate the Mucell + Heat and Cool process for high aesthetical applications
- Design/optimization cooling channels- Temperature distribution prediction- Heating and cooling time prediction- Total cycle time estimation
Conclusions (II) – Predictive coherence
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www.moldex3d.it