Material Data for Moldex3D Simulation. Jeff Chen Account Manager EMEA

Material Data for Moldex3D Simulation Jeff Chen Account Manager EMEA

Outline > Material characteristics Essential characteristics needed for Moldex3D simulation Viscosity PVT Thermal conductivity Heat capacity Viscoelasticity Crystallinity Mechanical properties Young s modulus Poisson s ratio Coefficient of linear thermal expansion Testing method and equipment in Moldex3D material lab > Moldex3D material lab 2

Material Characteristics

Required Data for Moldex3D Simulation > Viscosity data > PVT data > Thermal conductivity (k-value) data > Heat capacity (Cp) data > Viscoelasticity data > Crystallinity > Mechanical properties data 4

Required Data for Moldex3D Simulation > Viscosity data > PVT data > Thermal conductivity (k-value) data > Heat capacity (Cp) data > Viscoelasticity data > Crystallinity > Mechanical properties data 5

Viscosity > Viscosity is critical in predicting filling pattern, filling pressure and related characteristics. 6

Viscosity > Viscosity depends primarily on temperature and shear rate. 7

Viscosity Measurement > Rheological test apparatus capillary rheometer applied to high shear rates (10 to 10,000 1/s) rotational rheometer applied to low shear rates (0.01 to 100 1/s) and low viscosity material (for example: wax) 8

Equipment for Viscosity (from medium to high shear rate) Measurement > Equipment: GOTECH CR6000 & GOTTFERT RG-25 > Procedure: ASTM D3835 Pressure drop across the die is measured for each flow rate at 3 different temperatures, and viscosity-shear rate data are calculated. > Shear rates: 10~10,000 1/sec > Max Temperature: 400 o C > Shear viscosity Model : Cross-WLF model, etc. 9

Equipment for Viscosity (low shear rate) Measurement > Equipment: Anton Paar MCR 502 > Procedure: ASTM D4440 A disk sample (diameter=25mm) is placed between the parallel plates (or cone and plate) at constant temperature environment. Small amplitude oscillated shear deformation is performed, and then the complex viscosity is acquired. > Frequency: 1~ 628 rad/sec > Shear viscosity Model : Cross-WLF model, etc. 10

11 Equipment for Viscosity (low shear rate) Measurement

12 Viscosity

Melt Flow Index (MFI) > What is MFI? Melt flow index is a simple measurement of plastic flow property. The plastic is passed through a small pore ( 2.0mm) at certain temperature and pressure for 10 mins. Melt flow index is grams/10 mins. Tested according to ASTM D1238 testing standard 13

Melt Flow Index (MFI) MFI=8 MFI=10 h g. MFI is for reference only 14

Required Data for Moldex3D Simulation > Viscosity data > PVT data > Thermal conductivity (k-value) data > Heat capacity (Cp) data > Viscoelasticity data > Crystallinity > Mechanical properties data 15

PVT > Polymer is a compressible material > The specific volume increases when being heated up, but reduces when being compressed by high processing pressure. > PVT is critical in predicting volumetric shrinkage, density and related characteristics 16

17 PVT

PVT Measurement > Two measuring principles are generally adopted Confining fluid Advantage- the ability to apply a true hydrostatic pressure to the polymer, both in melt and solid state. Disadvantage- the volumetric changes measured are not that of the polymeric sample only. Mercury can t fast cooling Confined compression (Used at Moldex3D) The polymer is enclosed in a rigid cylinder. A piston, closely fitting into the cylinder, is used both to pressurize the polymer and to measure volumetric changes. Advantage- Hg free (safety) can fast cooling Disadvantage- Friction with cylinder wall 18

Equipment for PVT Measurement > Equipment: GOTECH PVT-6000 > Procedure: ISO 17744 The material is heated to the processing temperature, keeping in fixed pressure, then cooling to 40 o C at constant rate of 5 o C/min. Measure the volume change at no less than 3 different pressures. > Temperature range: 40-300+ o C > Pressure range: 10~150 MPa > pvt Model : modified Tait model 19

Thermal Conductivity > Thermal conductivity is critical in estimating material cooling during filling, packing and cooling phases. 21

Thermal Conductivity > Thermal conductivity depends on temperature. > Tabulated thermal conductivity data at different temperature are needed. > It also can be provided a conductivity value at room temp., if a material dose not test at a wider range of test temperature. Temp. ( ) Conductivity ( W/m- ) 260 0.316 240 0.307 220 0.303 140 0.304 120 0.294 100 0.290 22

Equipment for Thermal Conductivity Measurement > Equipment: GOTTFERT RG-25 > Procedure: ASTM D 5930 A line source probe is inserted into the molten polymer, and then the temperature gradient is measured after an applied voltage to the probe at each acquisition temperature. > Temperature range : RT~350 o C > Information provided : 6~8 data points 23

Heat Capacity > Heat capacity is also critical in estimating material cooling during filling, packing and cooling phases. > Heat capacity depends on temperature. 25

Equipment for Heat Capacity Measurement > Equipment: PerkinElmer DSC 8500 > Procedure: ASTM E1269 The material is heated to its molten state and then cooled down to 40 o C at a constant rate of 20 o C/min. > Information provided : Heat capacity (Cp) 26

Tm, Tc, Tg Measurement > Equipment: PerkinElmer DSC 8500 > Procedure: ASTM D3417 The material is heated at a constant rate of 10 o C/min, and cooled to 40 o C at a constant rate of 20 o C/min. > Information provided : Tm, Tg, Tc Crystalline material Amorphous material Tm Tc Tg Source: Material Testing Lab CoreTech System Co., Ltd 27

Jet Buckling Effect > Viscoelastic free-surface effects Die swell Jetting Bucking Time-series animation of melt front time Simulation result from Literature Die swell Jetting Buckling Ref. : J. L. Favero, Viscoelatic fluid analysis in internal and in free surface using the software OpenFOAM 29

Melt Front of Injection Molded Part > Viscoelasticity might change melt front a lot, in addition to well known factors, such as geometry, material viscosity, and temperature effect VE Couple (Weak Elasticity) VE Couple (Medium Elasticity ) VE Couple (Strong Elasticity) 30

Dynamic Measurement Method for Viscoelasticity > Structure VE Dynamic mechanical analysis, DMA (1) Glassy region (2) Glass transition region (3) Rubbery region DMA > Fluid VE Rotational rheometer (3) Rubbery region (4) viscoelastic fluid (5) viscous fluid Rotational rheometer E Structure VE Fluid VE 35

Measurement Method for Viscoelasticity Dynamic measurement Structure VE Flow VE 36

Equipment for Fluid VE Measurment > Equipment: Anton Paar MCR 502 > Procedure: ASTM D4065 Storage and Loss modulus are acquired by Small Amplitude Oscillatory Shear test isothermally. > Frequency : 0.1~400 rad/s 39

Equipment for Structure VE Measurment > Equipment: TA DMA 2690 > Procedure: ASTM D5023 Storage and Loss modulus are acquired by Small Amplitude Oscillation flexure test isothermally. > Frequency : 0.1~100 Hz 40

Crystallinity > Equipment: PerkinElmer DSC 8500 > Procedure: The material is heated to its molten state and followed by quench process for 4 different constant cooling rates. > Max cooling rate: 600 o C/min > Crystallization Model: Nakamura model 42

Mechanical Properties Coefficient of Linear Thermal Expansion (CLTE) Perkin Elmer TMA4000 ASTM E831 Tensile Modulus, Poisson s ratio Instron 5966 ASTM D638 44

Moldex3D Material Lab

46 Moldex3D Material Research Center

Moldex3D Material Research Center > The Material Research Center of CoreTech System Co., Ltd. (Moldex3D) successfully passed ISO/IEC 17025 Certification at the end of 2017. http://www.moldex3d.com/en/news/20180109-2/ 47

Laboratory Equipment Line-up Rheograph RG25 Capillary viscosity and thermal conductivity with counter pressure Equipped Flow pattern Filling Pressure 48 pvt-6000 pvt change at different temperature and pressure Compressible Shrinkage MCR 502 Rotation and oscillation tests for viscoelastic properties Low shear Flow VE Reactive GMT/SMC DSC 8500 Transition temperatures and crystallization kinetics Tg, Tm Crystallization TMA 4000 CLTE Anisotropic shrinkage Instron- 8966 Mechanical properties Structural Shrinkage

2017 New comers: expanding our capability PVT for thermoset Dynamic Mechanical Rheometer for rubber Foam Qualification System 49 PT-6800 Specific volume with curing Curing shrinkage DMA 242 E Artemis Dynamics mechanism analysis for relaxation modulus Solid VE (Warp, Annealing) MDR-A1 Scorch curve Rubber reaction kinetics, viscosity FOAMAT 285 Foaming and Curing Kinetics

Summary

Summary > If only want to have the qualitative analysis, seeing flow behavior, warpage tendency, but there is no correct material data available, the substitute material is acceptable. > Material properties are critical for simulation in Moldex3D. If we are going to have the quantitative analysis, and are going to see the warpage result (tendency and displacement value), the correct material data is preferred. > Moldex3D material lab provide characterization service for all the data needed of thermoplastic material for Moldex3D simulation. 51