mark brown ceo mbrown@burgereng - molding conference 2020 · scale: the silent & sneaky enemy...
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Mark BrownCEO
mbrown@burgereng.com
Precision Machining Engineering Design Custom Injection Molding
Offering Engineered Solutions Through
Humble Beginnings
Intellectual PropertyUS Patents Granted
Thinswitch ®Mold Temperature Regulator™Smartlock®FasTie ®Liquid-Resistant Thinswitch ®Swap® Valve Global Thinswitch SpeedBar ®Dr. Eddy ®Tracer ® FCI Technology
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Scientific Coolingsm
Outcome Based LearningMold Cooling can be 70-80% of cycle time.
Consistent part quality, faster cycle times andincreased profits result from optimized cooling.
We Can Help!
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Unit 1 Objectives1. Learn energy principles and relationship to specific
polymers.
2. Understand Heat Transfer and Energy Flow effects on part quality and cycle time.
3. Create and balance a heat budget using Energy Flow calculations.
4. Participate in “Hands-On” experiments and exercises to reinforce learning objectives.
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There are Several Types of Energy
Potential EnergyKinetic Energy
Electrical EnergyHeat Energy
Other Examples?
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To understand this story we must study:
The nature of energy
Material properties
Heat flow
Associated math
HotStuff!
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Why care about Heat Energy?How much cooling is enough?
Heat energy input is the starting place.
For cooling a single mold
Or an entire plant!
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Introducing The Strange and Interesting Thermal Behavior of
Polymers The basic molecule of a polymer is called a monomer.
Polymers are made up of long chains of monomers.
2 Broad Classes of Polymers:Amorphous and Semi-Crystalline
Specific Heat, Latent Heat, and Polymers
Calculation of Heat Energy in Polymers
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Heat Transfer Basics Energy cannot be created or destroyed.
Energy must be removed from the molded parts and sent somewhere else
This is called heat transfer.
Heat transfer occurs when temperatures are not equal
There are 3 types of heat transfer-conduction, convection, and radiation.
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Unit 2 Objectives1. Understand Reynolds Number and its relationship to
Turbulent Flow.
2. Learn Turbulent Flow impact on mold cooling and sustainable molding practices.
3. Learn how to calculate water cooling requirements.
4. Review coolant delivery and distribution principles.
5. Learn the effects of water chemistry on cooling efficiency.
6. Study the 3R’s of Scientific Coolingsm to develop and maintain efficient cooling setups and processes.
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Turbulence = Process Stability!And Optimum Cooling
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95
100
105
110
115
120
125
130
0.00 0.50 1.00 1.50
Stee
l Tem
p, °F
Cooling Flow Rate, GPM
Steel Temperature vs. Flow3/8” dia. cooling line with 70°F water
UnstableSteel Temp.
Stable & Efficient
WastedCapacity
4000 8000
Reynolds Number
Concept of Water Treatment:Understand and Control Water Chemistry
1. Control pH, 7.0 is neutral, Lower = Acidic, Higher = Alkaline
2. Use inhibitors to control scale and corrosion
3. Control microbiological growth with biocides
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Unit 3 Objectives1. Discuss design elements related to mold cooling &
reinforce mold cooling calculation skills.
2. Discuss mold maintenance techniques related to mold cooling.
3. Survey & discussion of advanced methods--Simulation, Thermal Imaging, & High Temperature Cooling.
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Hierarchy of InfluencePart Design
Mold Design
Processing
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Cooling Leverage
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FlowLength
DiameterTemperature
Long lever - Turbulence
Long lever – Increased Cooling AreaLonger & Larger Diameter Circuit
Multiplies Power of Coolant
Short lever - Coolant temp. changes mold temp, but small effect on heat transfer
Short lever - More flowafter turbulence hasdiminishing benefit
Mold Maintenance Strategies
Scale: The Silent & Sneaky Enemy of Optimum Cooling .05” Thick Scale Can Equal
3 – 5” of Steel in terms of heat transfer resistance
Scale increases roughness & pressure drop & decreases flow through cooling circuits
Scale buildup dramatically increases energy costs for pumping and cooling
k=BTU/hr-Ft-°FBeCu 38.00
P-20 Steel 16.8Calcium Scale .05-.5
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Tools of the Trade Mold Cooling Calculator
www.smartflow-usa.com/scientific-cooling-calculator
Turbulent Flow Calculator www.smartflow-usa.com/turbulent-flow-rate-calculator
Manifold Builderhttp://www.manifoldbuilder.com
Technical Documentshttp://www.smartflow-usa.com/documents.htm
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