2014 Molding Innovation Day

Transcription

1 2014 Molding Innovation Day MuCell Capacità di predizione di Moldex3D Dal processo alla riduzione di peso e di deformazione L esperienza di laboratorio sui processi microcellulari Ing. Andrea Romeo - Proplast 10 Luglio 2014 POINT Polo per Innovazione Tecnologica Dalmine Bergamo Moldex3D Italia srl Corso Promessi Sposi 23/D Lecco (LC)

2 2 Moldex3D: il Processo Microcellulare Gli attori

3 3 Proplast was founded in 1998

4 The Consortium 184 Companies 9 Associations 13 Universities 3 Public Entities and foundations 210 associates 4

5 Goals Technical consultancy and technological tranfer Laboratory services and analysis Training and HR activities Research and development activities for polymer processes Reference point to develop research and development activities between Universities and Companies 5

6 PROPLAST, Trexel, ENGEL partnership To promote and disseminate the Mucell technology Demo installation At Proplast s site (Tortona, Italy) IMM: Engel 180 tons, screw: 55 mm Shot weight: g Mucell unit - Co2 or Nitrogen Goal Support customers at every stage of the technology implementation and application Part design for Mucell Support to mould design Mucell moulding trials / mould piloting Technological development Aestethical surfaces on Mucell parts (material design and optimization) Combination with H&C technologies (pressurised water, induction) 6

7 EUROPEAN FUND FOR REGIONAL DEVELOPMENT P.O.R Goal Research and experimentation on Microcrellular Injection Moulding Consortium 5 Industrial partners (Moldmakers, End Users, Compounders) Reference Research and Technical Centre 7

8 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. Onni-Stamp S.r.l. mainly focuses on: design management production maintenance of plastics injection moulds. 8

9 Concept Combining 2 different innovative technologies: Mucell microcellular injection moulding Heat and cool dynamic mould conditioning Focus on: Mouldability and process conditions Aesthetics Warpage Materials Eventual pit falls evaluation Conventiona l moulding Heat and cool Mucell Mucell + Heat and cool 9

10 The moulded part Specific features to evaluate, measure, compare Holes to generate welding lines Measurement reference points max rib/wall thickness ratio 2:1 U-shaped part to amplify warpage Different surface finish (mirror polishing, textures) Ribs 10

11 Virtual run Process Material Structure Simulating the process Conventional moulding Mucell injection moulding Heat and cool injection moulding Prevision of the Microstructur e Cell dimensions Cell density and distribution Building the material model Accurate Mechanical model sensitive to morphology Structural simulation Stiffness Strength Performance 11

12 12 Rheological simulations with Mucell

13 Rheology Mucell Process Chance to accurately simulate the Microcellular Moulding Process with Moldex 3D Filling Cells nucleation /growth Cooling (average/transien t) Ejection Local results Global part quality PROCESS - Cycle time - Injection pressure - Clamping force STRUCTUR AL FEM ANALYSIS QUALITY - Expansion / weight reduction - Volum. shrinkage/sink marks - Warpage / residual stresses - Cells density - Cells size The Microcellular Injection Moulding Process can be analysed, predict, optimised via simulation softwares 13

14 Rheology Mucell Process Chance to accurately simulate the Microcellular Moulding Process with Moldex 3D Filling Cells nucleation /growth Cooling (average/transien t) Ejection Local results Global part quality PROCESS - Cycle time - Injection pressure - Clamping force - Investiments - Productivity - Production costs - Consumptions ECONOMICAL ANALYSIS COMPARISON STRUCTUR TO AL COMPACT FEM MOULDING ANALYSIS QUALITY - Expansion / weight reduction - PERFORMANCE Volum. shrinkage/sink marks ANALYSIS - Warpage / residual - stresses Moulding - Specs Check - - Cells Working density - Cells size The Microcellular Injection Moulding Process can be analysed, predict, optimised via simulation softwares 14

15 Rheology Virtual Mucell Injection moulding Mucell Compact t inj (s) 0,9 0,9 T melt ( C) T mould ( C) 40/40 70/70 Gas dosing (%) 0,5 -- Switch over point (%) t hold (s) -- 7 P hold (bar) t cooling (s) t cycle (s) Shot weight (g) 92,9 100,3 P inj max (bar) Clamping force (ton) Variation (%) -28-7,

16 Rheology Sink marks reduction Compact moulding Mucell 16

17 Rheology Warpage reduction Compact Moulding Corner effect prediction Mucell C D A B 17 nominal compact Mucell simulate d measured simulated measured A ,76 109,17 109,22 109,16 B ,10 198,64 198,76 198,72 C ,61 198,92 199,18 198,86 D ,21 109,30 109,52 109,20 Variation (%) - 0,05-0,02-0,29-0,29

18 Rheology Warpage reduction Compact moulding Prediction of planarity Mucell 18

19 Rheology Expansion prediction Cells density Global weight reduction: 5.5% Global weight reduction: 7.4% 19

20 Rheology Expansion prediction Cells size Global weight reduction: 5.5% Global weight reduction: 7.4% 20

21 Cells size prediction Reduced cell size High cell density Medium cell size Medium cell density High cell size Low cell density 21 * Global weight reduction: 5.5%

22 Cells density prediction Reduced cell size High cell density Medium cell size Medium cell density High cell size Low cell density 22 * Global weight reduction: 5.5%

23 Cells size near the gate SEM validation: average cell size 2 µm 23

24 Cells size at a half of flow lenght SEM validation: average cell size 33 µm SEM validation: average cell size 22 µm 24

25 Cells size at the end of flow SEM validation: average cell size 77 µm 25 SEM validation: average cell size 58 µm

26 Cells density near the gate SEM 26

27 Cells density at a half of flow lenght SEM 27

28 Cells density at the end of flow SEM SEM 28

29 29 Structural simulations on Mucell components

30 30 Simulation workflow

31 Material modeling Central technology for structural engineering Integration of local predicted microstructure Matrix + fibers + cells Additional information about material microstructure The result: Material model sensitive to its morphology 31

32 Mesh mapping Mapping software Exchanges data between dissimilar meshes 32

33 Mesh mapping Density of porosity Size of porosity Volume Fraction of porosity 33

34 Mucell test case 1 Accurate component s mechanical prediction 34

35 Mucell test case 2 Accurate component s mechanical prediction 35

36 Mucell test case 3 Accurate component s mechanical prediction 36

37 37 Mucell + Heat and Cool

38 Mucell + Heat and cool Thermal analysis 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 38

39 Pressure and Temperature Sensors to efficiently control the process The mould Conformal cooling channels For temperature uniformity and for reducing the mould s thermal inertia making heat and cool affordable Variable injection system For evaluating different flow lengths and the effect of welding lines Variable injection systems and flow lenghts Conformal cooling channels Kistler pressure and temperature sensors 39

40 Moulding trials 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 40

41 Assessment and metrics Process 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 Pressioni [Bar] pressione 1 estremità pressione 2 centrale pressione 3 estremità Tempo [sec] Aesthetics Statistical analysis of defects and rating of gloss Dimensional stability Shrinkage and warpage analysis 41

42 Process Outcomes (I) Compact Mucell Variation% Shot weight g ,9-7,1% Clamping force kn ,1% Max injection pressure Bar ,5% Injection time sec 0,88 0,85 Cycle time sec ,8% Melt temperature C Mould temperature C Max injection pressure reduced Very uniform packing occurs with Mucell, driven by cells growth pressure Pressioni [Bar] bar Tempo [sec] Compact Pressur pressione e at tip 1 estremità 1 pressione Pressur e at 2 centrale centre pressione Pressur e at tip 3 estremità 2 Reduced by - 24% Pressure sensors Trials performed on thermoresistant ABS CILAC TBB, 1 central gate Pressioni [Bar] bar Tempo [sec] Mucell Pressur pressione e at tip 1 estremità 1 pressione Pressur e at 2 centrale centre pressione Pressur 3 e at tip estremità 2

43 Outcomes (II) Warpage and shrinkage 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. 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, % 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% L man lateral 1 L man central L man bracci L man lateral 2 Warpage and shrinkage parameters calculation 43 Trials performed on thermoresistant ABS CILAC TBB, 1 central gate

44 Outcomes (III) Aesthetics Mucell 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 Compact conventional Deep sink marks High gloss Mucell No sink marks Silver streaks Heat and cool (Only) reduced sink marks Very high gloss Mucell + Heat and cool No sink marks No silver streaks Very high gloss 44 Trials performed on thermoresistant ABS CILAC TBB, 1 central gate

45 ABS TermoresistenteABS CILAC TBB Analisi di un caso particolare Compatto Mucell pressione 1 estremità Pressioni [Bar] pressione 1 estremità pressione 2 centrale pressione 3 estremità Pressioni [Bar] pressione 2 centrale pressione 3 estremità Tempo [sec] Tempo [sec] 45

46 46 Conclusions

47 Conclusions (I) Process General reduction of clamping force General decrease of max injection pressure General reduction of mould temperature General reduction of cycle time Dimensional stability 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. Aesthetics At every condition Mucell removed sink marks The use of combined Heat and cool technology eliminates aesthetical defects, as well. 47

48 Conclusions (II) Predictive cohere 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 simulations of Mucell components - Material model sensitive to Mucell microstructure - Stiffness/ strength prediction - Prediction of the component s performance 48 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

49 Moldex3D Italia srl Corso Promessi Sposi 23/D Lecco (LC)