molding 2020 - tzero · 2020-01-25 · decoupled molding ® workshop. 3. x. x. systematic molding...
TRANSCRIPT
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TZERO®
The Next Level of Systematic Molding: The Influence of Plastic Behavior on Part Design
Doug EspinozaRJG, Inc. TZERO® Manager
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Doug Espinoza is a TZER0® Manager at the corporate office of RJG, Inc. His varied career includes service in the United States Marine Corps, engineering, management, business, development, and strategic planning. Doug has spent more than 21 years in the plastics industry, practicing the RJG methods of scientific molding and implementation while working for injection molding companies.
Doug holds a Bachelor of Science in Plastics Engineering Technology from Ferris State University and a Master of Business Administration degree with an emphasis in International Business from Loyola University Chicago.
Doug is a regular contributor to professional organizations committed to the ongoing development of the plastics industry.
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Where Does the Influence of Plastic Behavior on Part Design Start?
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A Story…2. Dimensions Specified
QC: “Airflow” out of spec.
Molder’s tool shut down for a year for a spec. not given!
3. Part Concept
4. Part Design
5. Economics: # Cavities, etc.
6. Tool Concept
7. Detailed Tool Design
8. Tool Construction
9. First Article
10. Molding Process Developed
11. Parts to Specification
12. Designed Experiment and Validation
13. Production
14. Fix Problems During Production:
1. Performance Spec.
+ PANIC
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Source: 2016 NORTH AMERICAN PLASTICS INDUSTRY STUDY Plante Moran
What Drives Profitable Growth?
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Efficient Program Launches
Successful companies know that launches can become money pits if not managed with formal processes and effective teams.
Source: 2016 NORTH AMERICAN PLASTICS INDUSTRY STUDY Plante Moran
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RJG Global OfficesRJG USA Traverse City, MI(RJG, Inc. Headquarters)
Woodstock, GA(Regional Training Center)
Gibsonville, NC(Regional Training Center)
RJG MexicoChihuahua, Mexico
RJG FranceArinthod, France
RJG GermanyKarlstein, Germany
RJG Ireland / UKCo Tipperary, Ireland
RJG Italy Next Innovation SrlMilano, Italy
RJG (S.E.A.) PTE LTDRepublic of Singapore
RJG ChinaChengdu, China
RJG KoreaCAEProSeoul, Korea
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Helping Molders and Their Customers Succeed- RJG’s Mission & Core Competence
Think Like Plastic!
Heat
Flow
Pressure
Cooling
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Title of chapter will be displayed here/Contents
Part Design• Design affects processing.
Material• All materials do not flow or pack the
same way.• Additives change the way material flows
and packs, including color.
Mold Design & Construction• Fill balance from PPV• Changing waterline locations can
change how a mold processes.
The Process• Two identical machines may perform
differently.• Converting pellets into parts using a
systematic approach yields success.
Successful DFM is based on an understanding of the entire process - from design to the end user
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Cardinal Rule
• Nominal Wall Thickness• Effects Mold Design and Construction• Influences 3 of 4 Plastic Variables
• Plastic Flow Rate• Plastic Pressure Gradient• Plastic Cooling Rate & Time
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Wall Thickness Change 4 mm to 3 mm
Pressure also depends on ____________________Wall Thickness
5,455 psi @97% full
4 mm Nominal Wall 3 mm Nominal Wall, same flow rate
8,950 psi @97% full
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Wall Thickness and Cooling
Fountain Flow
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Wall Thickness and Cooling - Continued
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Wall Thickness and Cooling - Continued
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Another Example
Temp. 52 sec.
316 °F
200 °F
88 °F
Freeze293 °F
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Wall Thickness and Packing
Cavity metal
Flow: Thin section stretches and freezes molecules in alignment
“Living” hinge
Blue = Frozen:no flow => no pack
Frozen about .4 seconds after left edge fills
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Wall Thickness and Packing - Continued
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What if the wall gets so stiff that it can’t bend
inward and sink?
Plastic Cooling Behavior at Rib Junctions
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Filling the Mold: Pressure and Flow
High Pressure
Pressure to push plastic into a part depends on…
LowerPressure
? ____________________Distance (Length of Flow)
High Pressure Lower
Pressure
? __________________Width (of flow front)
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The tighter the radius, the higher the stress and BTU content due to shear. This will add risk to your part design.
What About Corners?
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Cooling Time & Part Design
Poor Design Better Design
Can be further improved
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Material
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How Will the Material be Used?
Thermoplastic Morphology
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Material Viscosity (“thickness”) Varies Over Time
78000
79000
80000
81000
82000
83000
84000
85000
86000
18000
18200
18400
18600
18800
19000
19200
19400
19600
Material viscosityincreasing over time
(new lot?)
Material gets thicker => harder to pack so end of
cavity pressure drops
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Change in Material Viscosity => Change in Plastic Pressure
Ineos Lustran 248 ABSDay 1 Lot
(D1 = 7309)
Ineos Lustran 248 ABSDay 2 Lot
(D1 = 12,742)
13,300
15,800
4,120 Pack
3,170 Pack
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Mold
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Volumetric ShrinkageGating Thick to Thin
Source: “Moldflow Design Guide” from Hanser
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Mold Cooling Evaluation
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Heat Flow Restriction in Narrow Core
Temperature at ejection over 170 °F
max eject Temp.
Length
Width, thickness
Thermal resistance
(1/conductivity)
ThicknessWidthResistance ThermalLengthFlow HeatTemp
×××
∝∆
ΔT
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Collaborate FEASIBLE Design Scenarios
Lifters in MoldMax
Both Halves in MoldMax
Cavity and inserts are cut in half to save calculation time.
Core Half in MoldMax + baffles
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Mold TemperatureLifters in MoldMax Core Half in
MoldMax + baffles
Both Halves in MoldMax
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“Close the Loop”- Validate!
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Machine
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Machine Performance
Machine A can fill the part in 1 sec Machine B can only fill the part in 3 sec
Requirement is Specified to your Process Windows and Quality RequirementsReal example: Fill speed
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Systematic Molding From “the plastic’s point of view”
The Process
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Title of chapter will be displayed here/
• What are common processmistakes made as a result of lack of knowledge?
• Is there one technique that can be used by everyone?
Systematic Molding
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Need Mold PressureSensors
Non-Scientific
Decoupled II
Decoupled III
Typical Process Variation
Viscosity on Process Settings
Trended stability over time
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Forecasting a Process SheetRisk the Process BEFORE Cutting Steel
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UNIVERSAL PROCESS SHEETDecoupled II
Press# IMM-10 (Nissei PNX40)Part Number Puzzle Piece Part Description Puzzle Piece
Mold Number 1809 Cavities 4Material Toyolac 100 322
Hot Runner:Zone1 Zone2 Zone3 Zone4 Zone5 Zone6 Zone7 Zone8N/A N/A N/A N/A N/A N/A N/A N/A
Zone 9 Zone 10 Zone 11 Zone 12 Zone 13 Zone 14 Zone 15 Zone 16N/A N/A N/A N/A N/A N/A N/A N/A
Man1 Man2 Man3 Man4 Man5 Man6 Man7 Man8N/A N/A N/A N/A N/A N/A N/A N/A
Plastic TemperatureCharge
Delay 0.5 sec
Screw Rec 6 secBack 350 ppsiPart
Volume 0.65 cu.inch
Nozzle Zone 1 Zone 2 Zone 3 Zone4 Melt:
Setpoints: 410 410 410 410 410 °F 405 °F
Profile: Flat Screw Type: General Purpose RPM: 50
Plastic Flow
Fill TimeFill Only
Part WeightPeak ppsi in
Mold Peak ppsi in Air0.31 sec 11.1 grms 10016 ppsi 9967 ppsi
Plastic Pressure
Hold TimeHold
PressureFinal Part Shot
Weight Gate Sealed? 17.5 sec 5655 ppsi 12.34 Grams
1Plastic Cooling
Cooling Time 12 sec 24.5 secPRESSURE
MTCU Supply Return Flow Supply Return Delta Δ1 113 113 ºF 1 GPM2 113 113 ºF 1.5 GPM3 ºF GPM4 ºF GPM
Clamp
Clamp Type Hydraulic Tonnage Used 20 tons
Part Out 4.2 sec
FORECASTING THE PROCESSBEFORE CUTTING STEEL
Consider the following:• Press performance• Least Capable Machine Information
• Screw Diameter• Volumetric Flow rate• Max Tonnage• Max Screw Recovery at
recommended back pressure• Nozzle Pressure Loss• Mold open and close time on a
“like Part”• Sample Press Information (Listed Above)• Part Volume• Material Data
• Recommended Melt• Max Shear Rate • Data for Simulated Molding
Software• Part Characteristic's/ Concerns
• Defect Concerns• Dimensional
Cycle Time
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Half the Battle is Knowing What is Happening in the Mold
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DFM Analysis of Complete Product Assembly
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Each Part and Mold Design is Reviewed
Odor filterHousing
Front CoverRear Cover
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RJG Now Offers a “Part Design” Class After Successful Launch with Brand Owners
• Private Workshops• Simulation Services• TZER0® end-to-end
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RJG, Inc. Classes# of Days Online Public In-House
Injection Molding Essentials 2 x x x
Math for Molders 1 x x
Systematic Molding 3 x x
Successful Strategies for Tool Launch 3 x x
Master Molder I 10 x
Master Molder II 10 x
Advanced eDART® Training 3 x x
Part Design for Injection Molding 3 x x
DECOUPLED MOLDING® Workshop 3 x x
Systematic Molding for LSR (Liquid Silicone Rubber) 3 x x
Mold Design for Injection Molding 3 x x
Template Match (Process Match & Troubleshooting) 3 x
Alarms Setting Workshop (eDART® / Optional) 1 x
DOE for Injection Molding Workshop 3 x
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Summary The Next Level of Systematic Molding:
Influence of Plastic Behavior on Part Design• Collaboration with key parties (OEM, material, hot runners…etc )
at early product development phase• Education for enhanced collaboration
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TZERO®
The Next Level of Systematic Molding: The Influence of Plastic Behavior on Part Design
Doug EspinozaRJG, Inc. TZERO® Manager
For more information on RJG’s TZERO® services, visit the RJG, Inc. web pagehttps://www.rjginc.com/consulting/tzero