15 rotational molding
DESCRIPTION
Very good plastic technology presentationsTRANSCRIPT
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Rotational Molding
An Introduction to the Basics
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Rotational Molding Personal Introduction
R. Dru Laws Employed with Mity-Lite Engineering
throughout and after schooling Bachelors in Mechanical Engineering
– From BYU
Masters in Polymer Engineering– From QUB (in Ireland)
Engineering Director for Mity Fence Systems Owner/Founder of RotoScientific
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Rotational Molding Example Product
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Rotational Molding Example Product
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Rotational Molding Example Product
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Rotational Molding Example Product
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Rotational Molding Example Product
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Rotational Molding Example Product
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Rotational Molding Presentation Outline
IntroductionThe MaterialsThe MachinesThe MoldsThe MethodConclusion
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Rotational Molding Introduction
Also known as rotomolding or rotocasting
Process for manufacturing large, hollow, one-piece plastic products
Best know for the manufacture of tanks and toys (Little-Tykes)
Suitable for small & complex shapes
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Rotational Molding Introduction
Historical Development– 1850’s: Patent granted for rotomolding
principle– 1910’s: Method used for chocolate
products– 1940’s: Method used for vinyl plastisols– 1950’s: Invention of PE for the process– 1960’s: Rapid expansion in toy industry– 1970’s: Gradual expansion for technical
products– 1990’s: Significant improvement in
process control (at QUB)
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Rotational Molding Introduction
1500 Rotomolders around the world
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Rotational Molding Introduction
North American Market SegmentsPlayground
2%Industrial
16%
Materials Handling3%
Containers9%
Tanks18%
Others10%
Household2%
Toys40%
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Rotational Molding Introduction – The Process
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Rotational Molding Introduction
Strengths– Small production runs– Large part capability– Low tooling costs– ‘Stress-free” products– Short product development lead times
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Rotational Molding Introduction
Weaknesses– Slow cycle times– Limited material choices– Difficult to automate– Poor image– Low technology culture
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Rotational Molding Presentation Outline
IntroductionThe MaterialsThe MachinesThe MoldsThe MethodConclusion
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Rotational Molding The MaterialsOthers, 2%
LLDPE, 61%HDPE, 11%
XLPE, 8%
MDPE, 3%
LDPE, 2%
PVC, 13%
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Rotational Molding The Materials
Low Zero Shear Viscosity is required to aid in the flow of the polymer within mold
MFI– Lower MFI resins – high strength
products– Higher MFI – good surface finish and
surface detail
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Rotational Molding The Materials
Particle shape and size is crucial to the flow characteristics as the mold is rotating– Standard size is a 35 mesh powder (500
micron, 0.0197 inches)
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Rotational Molding The Materials
Dry-flow/Bulk-density characteristics– Dry-flow is the time it takes 100 grams
of resin powder to pass through a funnel of given dimensions
– Bulk-density is the quantity of undisturbed powder than can fit inside a beaker of specified dimensions
– Inversely proportional to each other
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Rotational Molding The Materials
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Rotational Molding The Materials
Other Material– Foams
• Post-process
• In-process
– Liquid reactive polymers– Micro-pellets– Additives– Ceramics
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Rotational Molding Presentation Outline
IntroductionThe MaterialsThe MachinesThe MoldsThe MethodConclusion
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Rotational Molding The Machines
Rock-and-Roll Clamshell Vertical Shuttle Carousel
– Fixed
– Independent
Electric & Jacket
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Rotational Molding Rock-and-Roll Machines
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Rotational Molding Rock-and-Roll Machines
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Rotational Molding Clamshell Machines
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Rotational Molding Vertical Machines
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Rotational Molding Shuttle Machines
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Rotational Molding Fixed Carousel Machines
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Rotational MoldingIndependent Carousel Machines
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Rotational Molding Electric Machines
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Rotational Molding The Machines
The “ARM” and “PLATE”
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Rotational Molding Presentation Outline
IntroductionThe MaterialsThe MachinesThe MoldsThe MethodConclusion
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Rotational Molding The Molds
Materials– Steel
• Mild
• Stainless
– Aluminum• Cast
• Machined
• Plate
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Rotational Molding The Molds
Anatomy– Frame and Spider– Two or more sections (with draft)– Parting line with alignment features– Clamping hardware and pry-points– Vent (breather) tubes– Texture and other features– Release agents
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Rotational MoldingThe Molds – Frame and Spider
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Rotational Molding The Molds - Mold Sections
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Rotational Molding The Molds - Parting Line
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Rotational Molding The Molds - Parting Lines
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Rotational Molding The Molds - Parting Lines
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Rotational MoldingThe Molds - Clamping Hardware
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Rotational MoldingThe Molds – Pry Points
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Rotational Molding The Molds - Vents
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Rotational Molding The Molds - Vents
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Rotational Molding The Molds – Kiss-Offs
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Rotational Molding The Molds - Threads
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Rotational Molding The Molds - Inserts
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Rotational Molding Presentation Outline
IntroductionThe MaterialsThe MachinesThe MoldsThe MethodConclusion
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Rotational Molding The Method
1. Loading
2. Heating
3. Cooling
4. Unloading
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Rotational Molding
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Rotational Molding The Method - Loading
A predetermined amount of resin is loaded into the mold
The mold is closed after the flanges have been cleared of resin particles
The mold is secured shutRotate the mold to ensure no tools
have been left on the machine
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Rotational Molding The Method - Heating
Rotate the mold in a high-temperature environment
The resin will always sit at the lowest point of the cavity (powder pool)
It will slowly coat the mold interior until all the resin has melted
The resin will then continue to densify as the gap between the particles disappears
Remove the mold from the oven when the powder has completely melted and densified
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Rotational Molding The Method - Cooling
Rotate the mold in a room temperature environment
This allows the layer of resin to cool and solidify
Water can also be used, but care should be exercised
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Rotational Molding The Method - Unloading
Remove the clamping system“Pry” open the moldLift the completed, hollow, one-piece
part from the mold.Repeat the cycle
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Rotational Molding The Method
The concern– How do you really know when it is time
to do the next step?• When is the resin melted?• When is it cooled?
– In the early 90’s, QUB invented an instrument that revolutionized process comprehension and control
• The Rotolog™
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Rotational Molding The Method – Rotolog™
Temperature sensors (4 type-K Thermocouples)
RF TransmitterRF Receiver and Signal ConditionerComputer Software
– Real time monitoring of the temperatures
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Rotational Molding The Method – Rotolog™
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Rotational Molding The Method – Rotolog™
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Rotational MoldingThe Method – Temperature Profiles
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Rotational Molding The Method – IAT Profile
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Rotational Molding The Method – IAT Profile
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Rotational Molding The Method – IAT Profile
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Rotational Molding The Method – IAT Profile
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Rotational Molding The Method – IAT Profile
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Rotational Molding The Method – IAT Profile
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Rotational Molding The Method – IAT Profile
We can thus observe:A. When powder first
sticks to the moldB. When the powder has
been consumedC. When optimal melt
sintering has occurredD. When solidification is
occurringE. When the plastic
separates from the mold
A
B
C
D
E
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Rotational Molding The Method – IAT Profile
• The Peak Internal Air Temperature (PIAT) is the key process control parameter and is independent of all other process variables (point C)
C
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Rotational Molding The Method
Other important (QUB) developments– Pressurization (Dynamic Venting)– Permanent temperature feedback
(K-Kontrol)– RotoSim computer simulation– Worldwide training seminars and
consulting– PPRC – Rotomolding division
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Rotational Molding Presentation Outline
IntroductionThe MaterialsThe MachinesThe MoldsThe MethodConclusion
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Rotational Molding Conclusion
Though in a state of infancy, Rotomolding offers unique advantages over other plastics processes
There are endless opportunities for research and development
Rotomolding has a very promising future, more so than many competing processes
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Rotational Molding Acknowledgements
Thank-you to Dr. Brent Strong for providing me with this opportunity
Thank-you for your attention
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Rotational Molding
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