HYBRID MOULDS - THERMAL ASPECTS

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2 DEPARTMENT OF MATERIALS, TEXTILES AND CHEMICAL ENGINEERING HYBRID MOULDS - THERMAL ASPECTS Prof. Ludwig Cardon 2017 October

3 DEPARTMENT OF MATERIALS, TEXTILES AND CHEMICAL ENGINEERING POLYMER, FIBER AND COMPOSITE GHENT UNIVERSITY October 2017

4 GENERAL STRUCTURE Ghent University Faculty of Engineering and Architecture MaTCh Department of Materials, Textiles and Chemical Engineering Research groups (CPMT, LCT, MMS, CTSE, ) Research topics: Polymer, Fibre and Composite Materials Prof. Ludwig Cardon Prof. Karen De Clerck Prof. Dagmar D hooge Prof. Kim Ragaert Prof. Wim Van Paepegem 4

5 RESEARCH Advanced materials Polymeric material Embedded as a multidisciplinary research field Chemicals Polymer processing Polymerisation Polymer granules 5

6 RESEARCH Composites Artificial turf Filtration Sensors Advanced materials 3D-Printing materials Biomedical Recycled materials

7 Thermal Differential Scanning Calorimetry (DSC) ThermoGravimetric Analysis (TGA) Dynamic-Mechanical Thermal analysis (DTMA) Dynamic Vapour Sorption (DVS) Tg, Tm Curing of resins Polymer blends. Characterizatio n, testing, and monitoring Mechanical Favimat (small-scale: single fibres, ribbons, ) Statimat (medium-scale: yarns, films, ) Instron (large-scale: composites, bulk, ) Performed in climatised conditions (elevated temperatures possible) Creep/relaxation Static, cyclic Optical & Stereo-microscopes Scanning electron microscopy FT-IR and FT-Raman spectroscopy UV-VIS spectroscopy Microscopy & Spectroscopy During testing, production and lifetime of the part Fiber Bragg Gratings Digital Image Correlation Cure monitoring Ultrasonics Local defect resonance Monitoring & NDT 7

8 Industrial Polymer Synthesis Dry fabrics Simulation of tension, shear, twist, Draping simulations Multi-scale modeling Experimental and Numerical flow analysis Polymer processing Simulation at micro- and meso-scale Fracture mechanics simulations Structural simulations (static, impact, fatigue) Composites 8

9 Single & twin screw Reactive extrusion Blow film and plate Filament extrusion Extrusion 3D-Printing Processing Extrusion based 3DP 22 up to 80 T injection machines Injection moulding Electrospinning 9

10 Mechanical Recycling Microfibrillar composites composites Recycling Upcycling Chemical recycling 10

11 POLYMER UGENT-CPMT 11

12 CPMT GROUP MATCH DEPARTMENT OF MATERIALS, TEXTILES AND CHEMICAL ENGINEERING CENTRE FOR POLYMER AND MATERIAL TECHNOLOGIES 2 professors 1 bussiness developer 3 postdocs 15 PhD s 3 technicians 20 master students

13 Prof. Cardon - 3D Printing Prof. Cardon - Advanced Polymer Processing Prof. Ragaert - Recycling and Sustainable Use RESEARCH CPMT Extrusion based 3D Printing 3D Printing of composites Printhead development Development of new materials for 3D Printing 3D Printing build strategies Fablab UGent Injection Mould Engineering Conductive polymers Hybrid Moulds Process simulation Mechanical recycling Mixed polymer waste Multilayer packaging WEEE recycling Compounding Microfibrillar composites Design for & from Recycling Degradation effects

14 HYBRID MOULDS THERMAL ASPECTS

15 WHAT ARE HYBRID MOULDS? Who will use this? Product designers new design methods Mould designers more freedom of design Mould makers adapted machining parameters Polymer processors adapted processing parameters 15

16 WHAT ARE HYBRID MOULDS? Actual status of mould development hybrid moulds conventional production technologies AM technologies Mould cooling related to cycle time and product quality optimal cooling channel layout conformal cooling mould material selection Product quality improvement e.g. sink marks degree of crystallisation tribology aspects (e.g. wearing) 16

17 WHAT ARE HYBRID MOULDS? MOULD MATERIAL SELECTION Thermal characteristics of mould materials are very important Related to the core/cavity design strategy new part & mould design strategy Unknown material characteristics heat capacity C p (DSC analysis) specific density r thermal conduction l a Cp l r thermal diffusivity a 17

18 a [10-8 m²/sec] Mould material selection method The metal groups: Thermal diffusivity a [10-8 m²/sec] T [ C] Conventional mould materials Selective Laser Sinter materials Selective Laser Melting materials Copper Protherm Alumec Moldmax XL LaserForm 100 Steel 1730 DirectMetal 20 sinter Holdax Impax Supreme DirectSteel 50 sinter Ramax Prometal Stavax ESR DirectSteel H20 DirectSteel 20 sinter CL 50 (LaserCusing) CL 80 (LaserCusing)

19 a [10-8 m²/sec] Mould material selection method The metal groups: Conventional mould materials Selective Laser Sinter materials Selective Laser Thermal diffusivity a [10-8 m²/sec] (without Copper, Alumec en Protherm) Melting materials T [ C] Moldmax XL LaserForm 100 Steel 1730 DirectMetal 20 sinter Holdax Impax Supreme DirectSteel 50 sinter Ramax Prometal Stavax ESR DirectSteel H20 DirectSteel 20 sinter CL 50 (LaserCusing) CL 80 (LaserCusing)

20 Example of a hybrid mould

21 IR analysis of Prometal and Aluminium mould ProMetal 55 C ProMetal & Aluminium 50 C

22 IR analysis of Prometal and Aluminium mould ProMetal 55 C ProMetal & Aluminium 50 C

23 IR analysis of Prometal and Aluminium mould 23 ProMetal 55 C ProMetal & Aluminium 50 C

24 INTEGRATION OF KNOWLEDGE INTO A BUSINESS CARD BOX Combination of: multi materials in the same mould conventional mould making AM technologies conventional conformal cooling AM conformal cooling With final result : optimal cooling chanel layout No warpage Faster cycle time Beter product quality and material properties 24

25 OPTIMIZED MOULD AM insert for living hinge as for better rheological characteristics and conformal cooling a new cooling has been designed Optimal cooling of living hinge Better rheology at location of living hinge verification via Kistler sensors & IR analyses Heated injection nozzle Integration of DME Quick Strip ejection system extra degree of freedom as for cooling channel design conventional conformal cooling freeform design method related to ejectors 25

26 OPTIMIZED MOULD 26

27 OPTIMIZED MOULD conformal cooling insert in maraging steel via EOS SLM technology 27

28 OPTIMIZED MOULD conventional conformal cooling insert 28

29 OTHER APPLICATIONS? Packaging Heat control for mould making Extrusion and stretch blow moulding Thermoforming Micro injection moulding... 29

30 Conventional cycle time: 38s Estimated cycle time (conformal cooling HM): 19s Real HM cycle time: 32s Conformal cooling for HM shell is not accurate in calculating cycle time 16% of cycle time reduction Annual total profit of ( parts/year) packaging

31 BLOW MOULDING

32 BLOW MOULDING

33 BLOW MOULDING Blow/cooling air simulation

34 MICRO MOULDING 34

35 MICRO MOULDING 35

36 THERMOFORMING Hybrid mould made from PLA Mould via Necuron milling

37 THERMOFORMING - REAL

38 THERMOFORMING - SIMULATION

39 CONTACT INFORMATION CPMT Technologiepark Zwijnaarde, BE prof. dr. Kim Ragaert Sustainable Use and Recycling of Polymers & Composites kim.ragaert@ugent.be Member of prof. dr. Ludwig Cardon Head of CPMT ludwig.cardon@ugent.be

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