institute of plastics processing ikv andreas neuss
TRANSCRIPT
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YNew Injection Moulding Technologies for
Tomorrow's Production
Prof. Dr.-Ing. Ch. Hopmann, Dipl.-Ing. Andreas Neuß
Institute of Plastics Processing (IKV)
in Industry and the Skilled Crafts at RWTH Aachen University
Kunststoffen 2012
Eindhoven, September 27th 2012
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Y The Institute of Plastics ProcessingInstitut für Kunststoffverarbeitung (IKV)
Founded in 1950, supported by a Sponsors' Society
Associated with the RWTH Aachen University
Sponsors' Society with 237 members(one third foreign companies )
• raw material producers• machine manufacturers• plastics processors• research institutes• associations
Staff of IKV : • 80 scientific employees• 50 employees in laboratories, workshops and administration• 223 student workers
(As of January 2011)
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Y IKV-Locations in Aachen
Pontstraße 49-55Management and Executive Board
Injection MouldingPUR-Technology
Training/Skilled Crafts
Seffenter Weg 201Composites
Extrusion and Further ProcessingPart Design/Materials Technology
Centre for Analysis and Testing of Plastics
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ENVIRONMENTAL PROTECTION, RECYCLING
PRODUCTION PLANNING, PLANT ORGANISATION
CAD, CAE,
materialinnovations
productprototyp
testingsensor,systems
Key features of the IKV research programme
mould ordie / machineprototype,
CAM
measuring,controlling,
adjusting andoptimisation ofprocess values
THERMOPLASTICS, THERMOSETS, ELASTOMERS, COMPOSITES, SPECIAL MATERIALS
INJECTION MOULDING, EXTRUSION, BLOW MOULDING, COMPRESSION MOULDING, SPECIAL PROCESSES
material data,materialmodels
CAD, CAE,design rules
productionplanning, PPS,
machineselection
SPC,statistic
experimentaldesign
PRODUCTREQUIRE-
MENTS
materialselection
product layout
and design
layout of moulds, diesand machines
production analysis of complex
interconnected processes
quality assurance PRODUCT
design rules
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Y Performance Record 2011
More than 700 participants in conferences
More the 22.000 participants in crafts trainings
More than 190 papers
More than 100 student theses
15 doctor degrees
9 awards in scientific excellence
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Y Injection moulding department
• special IM processes• process combinations• special materials• key technologies
• process simulation• inner part properties• integrative simulation• special IM processes
• temp. control concepts• process control• special IM processes• Rapid Prototyping/Tooling
Mould Technology Company Organisation
Crosslinking Materials• processing of polyurethane• elastomer injection moulding
• mould/systems engineering
• benchmarking• intercompany comparison• technical consulting• process analysis
• drive concepts• IM of micro parts• IM of foamed parts• water injection technique
Machine Technology
Process Technology Simulation
Dipl.-Ing. A. Neuß Tel. +49 241 80-93827
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Y Outline
Introduction – trends in injection moulding
New injection moulding technologies for increasing process and function integration
Surface functionalisation using variothermal injection moulding
Lightweight parts for automotive applications
Projectile injection technique
Back foaming of metal sheets
Hybrid light-weight construction parts
Hybrid multi-component injection moulding for electronic applications
Conclusions and outlook
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Y Current situation in injection moulding
Current Situation • Increasing demands regarding
• adding value,• performance of materials,• lightweight design of assembly groups,• integration of functions,• efficiency of production processes,• saving of resources (e.g. material).
Fact• The standards of parts in terms of design
and functionality as well as demands for economical, resource efficient productions often cannot be fulfilled by conventional materials and manufacturing methods.
• Limits between different material classes and manufacturing methods have been shifted increasingly.
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Y Trends and current developments in injection moulding
Trends and current developments• New technologies for part functionalisation Production of high-value polymer surfaces,
e.g. surface modification using microstructures, …
• Process integration by combining different manufacturing technologies
production of assembly groups with different components under reduction of the process chain,e.g. multi-component injection moulding, SkinForm®, …
• Multi-material mixes in one partcombination of different materials to meet all the
requirements,e.g. automotive front ends made of plastics/metal and/or plastics/”organic sheet” combinations, …
• Material and resource efficiency fluid-assited injection moulding processes for thermoplastics,
new drive concepts for injection moulding machines, …
[Innolite, KraussMaffei Technologies GmbH, LANXESS Deutschland GmbH, Ford Motor Company, SPE]
frontend
door trim panel
dashboard support
rain sensor
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Y Outline
Introduction – trends in injection moulding
New injection moulding technologies for increasing process and function integration
Surface functionalisation using variothermal injection moulding
Lightweight parts for automotive applications
Projectile injection technique
Back foaming of metal sheets
Hybrid light-weight construction parts
Hybrid multi-component injection moulding for electronic applications
Conclusions and outlook
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Y Production of functional, microstructured surfacesusing variothermal injection moulding
Current situation• Functional surfaces are produced in many
steps and long process chains
Aim• Hybrid production in order to integrate
process steps
• Further development of dynamic mould heating techniques
• Replication of functional micro structures(e.g. superhydrophobic surfaces)
Results• Use of variothermal injection moulding
• Development of a laser based mouldheating to realise high heat-up rates
stretched micro structures to create superhydrophobic surfaces
variothermal temperature control by mouldintegrated diode laser
Current situation
Aim
Approach
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Y
cavity wall
completely filled micro structure
polymer melt(fountain flow)
frozen outer layer
Injection moulding – conventional low cavity wall temperature
Injection moulding – variothermalhigh cavity wall temperature
cavity wall
time time
tem
pera
ture
Formation of the frozen outer layer –influence of the cavity wall temperature
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Y Dynamic mould heating using diode laser irradiation
very high power transfer heat-up rates of up to 300 K/s using
mould integrated optics pyrometer based control of the laser
power no modification of the mould required
when an external system is used flexible, specific heating of any geometry simultaneos heating of multiple cavities
possible no limitations regarding heatable mould
material (steel, copper, aluminium)
laser optics
beam wave guide
collimated laser beam Ø 23 mm
transparent mould insert
laser scanner
focused laser beam
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Microstructured mould insert immitatingthe surface of the lotus leaf
[Fraunhofer ILT]
grindinggrooves
superimposedroughness
x500 50 µm x2000 10 µm x5000 5 µm
Ø15 µm
20 µ
m
direct ablation of hardenedtool steel
structuring by means of ultra shortpulse laser (pulse length 10 ps)
no steel melt at the edgeof the structure
roughness on the structures
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SEM-Picture and contact angle measurement –injection moulding conventional and variothermal (PP)
conventionalinjection moulding
incomplete moulding
contact angle = 115°(slightly hydrophobic)
variothermal injectionmoulding
complete moulding anddrawing of the structure
contact angle = 166°(superhydrophobic)
x750 30 µmx100 200 µm
x100 200 µm
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Schematic illustration of the moulding and demoulding behaviour
filling of thecavity
demouldingof the part
moulded part
variothermal processconventional process
direction ofdemoulding
cavity
stretched hair
plasticsmelt
completefilling of thesuperimposednano-structure
moulded part
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Y Potential use of variothermal process control in injection moulding
moulding of functional, micro structured surfaces
20 µm
production of high-gloss surfacesin one step
reduction of visible weld lines
thin-wall parts with high flow length
[IKV, Gigaset, Hofmann, Mitsubishi, Samsung, gwk, Zumtobel]
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Y Outline
Introduction – trends in injection moulding
New injection moulding technologies for increasing process and function integration
Surface functionalisation using variothermal injection moulding
Lightweight parts for automotive applications
Projectile injection technique
Back foaming of metal sheets
Hybrid light-weight construction parts
Hybrid multi-component injection moulding for electronic applications
Conclusions and outlook
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YProcess development of the
projectile injection technique (PIT)
Sucess factors• Reduced wall thicknesses compared to
conventional FIT Reduction of material costs Reduction of cycle time
• Only constant cross sections are feasible, but increased freedom of design regarding shape and size of cross sections
• Simplified cheap injector technology is applicable
Initial Situation• Process was first-time described in Japanese
patents in the middle of the 90s. • Sporadically applied until now, first
application in Europe in 2006• Prospects and limitations are barely known
so far
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Y Visualization of PIT process in sight vision mould
transparent material: PMMA Plexiglas® 7N
process variant: full-shot
Observations:
stable flow of the projectile
characteristic melt flow in front of the projectile
residual wall defined by projectile cross section
30 mm
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Comparison of the hollow space formation within the WIT and the W-PIT
30 mm
WIT
W-PIT
material: Ultramid PA6.6 GF30
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Y Comparison of the hollow space formation within the WIT and the W-PIT
WIT
W-PIT
material: Ultramid PA6.6 GF30
30 mm
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Y Comparison of the residual wall thickness (RWT) and the hollow space eccentricity for WIT and W-PIT
1 2 3 40
1
2
3
4
5
6 WIT average RWT WIT eccentricity W-PIT average RWT W-PIT eccentricity
resi
dual
wal
l thi
ckne
ss/ e
ccen
trici
ty
[mm
]
measuring position [-]
test part
measuringpositions
1
2
43
30 mm
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Y Continuous fiber-reinforced media pipes produced with water assisted projectile injection technique
Context• The focus on energy saving in the automotive
industry leads to engine-downsizing andconstantly increasing requirements for mediapipes regarding pressure peaks and partweight.
Approach• A new process for the production of continuous
fiber-reinforced media pipes using the projectile injection technique (PIT) is developed.
Previous results• A newly designed FIT-injection-mould allows the
integration of continuous-fiber fabrics and theinvestigation of different processing strategies.
[Contitech]
Current situation
Approach
First results
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movable mould halffixed mould half
axial injector
changeable insert
fiber fixation
Modular designed injection-mould with a fixation device for continuous fiber fabrics
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Y Process sequence for the production of continuous fiber-reinforced media pipes using the PIT
melt injection
fluid injection
fluid holding pressure
placement and fixation of the reinforcement fabric
fixation continuous fiber projectile
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Y Continuous fiber-reinforced media pipes produced with water assisted projectile injection technique
Potential of the new process technology
Economic advantages:+ Cycle time < 30 s + 35 % weight reduction compared to WIT parts with identical
mechanical properties (e.g. bursting strength)+ Adjustable wall thicknesses independent of rheological
material properties due to projectile geometry
Technical advantages:+ All thermoplastics applicable (no FIT modifcation of the
materials required)+ Alternative matrix materials applicable (PU, LSR, rubber)+ Load-oriented alignment of the continuous fibers+ Combination of same materials for fiber and matrix possible+ Geometric freedom e.g. through integration of connecting
parts+ No breaking at the cold impact test (-40 °C)
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"Hylight" – Novel design of automotive hybrid-lightweight construction
• Development of the complete manufacturing chain
• Investigations on different bonding agents• Simulation development
Initial situation• Hybrid parts are popular in automotive
industries• Suboptimal material utilisation caused by
missing data for simulations
Approach
• Adhesive bond between metal and plastics using suitable bonding agents
• 20% weight-reduction through new simulation and process knowledge
Objectives
[Ford]
hybrid-frontend
project partners
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Y Hybrid bonding by injection moulding
adhesive bonding on the whole surfacebonding by form closure
state of the art bonding technique adhesive bonding technique
polymer polymer
adhesive agentsheet metalsheet metal
rivetcollar
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Y Hylight – Process chain
Sheet coating with adhesionagent (Coil Coating) Deep drawing of coated sheet
Integrated partInjectionmoulding
Mould insertion
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Y Torsion tests of a hybrid test specimen
0
5
10
15
20
25
PA6-GF30 PA6-GF50 PPA-GF30 PPA-GF50 PP-LGF30
Tors
ions
stei
figke
it [
Nm
/°] unbeschichtet
beschichtet
tors
iona
l rig
idity
uncoatedcoated
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Y ProFoam – New process for foam injection mouldingof thermoplastics
Why foam injection mouldig• Reduction of warpage• Reduction of cycle time• High weight-specific bending-stiffness • Weight reduction
Initial situation• Processing of physical blowing agents
requires a complex systems engineeringso far.
Solution• Use of a conventional injection moulding
machine• Dosing of the blowing agent using an
airlock between feed hopper andplasticising unit
airlock sealing
Door lock cover (PBT-GF30) [Ticona]
compact
foamed
Why foam injection moulding?
Initial situation
Approach
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Y The ProFoam-process
airlock chamber
valvegas connector
accumulator chamberblowing agent inlet
blowing agent vent
material hopper
plasticising cylinder is set underpressure with blowing agent
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Y Advantages of the ProFoam-process
Simple process set-up of the ProFoam-process as the gas pressure is the only additional parameter
Stable, robust foaming process, because the propellant is always dissolved completely
Required additional equipment is less complex and thus more flexible in comparison to other foaming processes
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Y Influence of the blowing agent on the foam structure(PA6GF35, easy flow at 260 °C, 15 % weight reduction)
CO230 bar
CO250 bar
N230 bar
N250 bar
material: Lanxess BKV 35 H2.0 EF
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Y Back foaming of metal sheets with integrated forming
Insert and back-inject the metal sheet – integrated forming of the metal sheet in the mould by the melt pressure
The melt is loaded a with physical blowing agent using the Profoam-process
Mould temperature above 100 °C for activation of the adhesive agent and to improve the formability of the metal
For foaming the cavity volume is increased using a “breathing” mould
The foam structure is adjustable in a wide range by setting the cavity extension
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Y Benefits of back foaming of metal sheets
IKV-test part
Enhancement of bending stiffness through weight neutral increase of thickness
Increase of design freedom, as the gas pressure in the melt avoids sink marks
Homogenous foam structure throughout the whole part with “breathing” mould
Metal optic and metal haptic (cool-touch effect)
Premium surface quality for injection moulded foam parts
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Y Outline
Introduction – trends in injection moulding
New injection moulding technologies for increasing process and function integration
Surface functionalisation using variothermal injection moulding
Lightweight parts for automotive applications
Projectile injection technique
Back foaming of metal sheets
Hybrid light-weight construction parts
Hybrid multi-component injection moulding for electronic applications
Conclusions and outlook
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Y Hybrid multi-component injection mouldingfor electro- and electronic applications
Problemstellung• Production of plastic/metal
hybrids is characterised by many production steps and limitations in the achievable productivity and complexity of the parts.
Aim• Production of electronic parts through the
combination of the primary forming processes injection moulding and die casting
• Manufacture of a thermoplastic carrier with integrated conductor tracks made of low melting metal alloys on one machine and within one mould
Current situation
Aim
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Y Demonstrator part „heatable sports glasses”
Fully automated production cell
Advanced mould technology based on multi-component injection moulding
Demonstrator „heatable sports glasses“ Use of ohmic heating of the conductor track to
produce heat (resistance heating)
Dissipating heat has an antifogging effect on the lenses
Hybrid 3-component-application
Complex three dimensional course of the conductor track
Directly contacted connector pins
Finishing free production
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Y Mould and machine technique for thehybrid multi-component injection moulding
• Development of a metal injection unit which combineselements of metal die casting and micro injection moulding
• Fully automated production of the heatable sports glassesusing a 3-station index plate mould integrated in a complexproduction cell
Station 1• Production of the optical glasses and moulding around the
metal pinsStation 2• Injection of the low melting metal alloy and direct contacting
of the metal pinsStation 3• Manufacture of the frame and demoulding
• Monitoring of the hybrid multi-component injection mouldingprocess using pressure and temperature sensors
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Y Outline
Introduction – trends in injection moulding
New injection moulding technologies for increasing process and function integration
Surface functionalisation using variothermal injection moulding
Lightweight parts for automotive applications
Projectile injection technique
Back foaming of metal sheets
Hybrid light-weight construction parts
Hybrid multi-component injection moulding for electronic applications
Conclusions and outlook
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Y Conclusions and outlook
Global trends in plastics processing as the demand for lightweight design, increasing functional integration and efficiency of the whole production pose a challenge for the injection moulders in Europe.
These demands often cannot be fulfilled by conventional materials and manufacturing methods.
The presented new injection moulding technologies for part functionalisation, combination of different processes and materials as well as saving material and energy have the potential to overcome some current limitations of state of the art processes.
The IKV would be very happy to discuss both our and your ideas for new injection moulding technologies to meet the challenges of tomorrow’s production.
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YNew Injection Moulding Technologies for
Tomorrow's Production
Thank you very much for your attention!
Prof. Dr.-Ing. Ch. Hopmann, Dipl.-Ing. Andreas Neuß
Institute of Plastics Processing (IKV)
in Industry and the Skilled Crafts at RWTH Aachen University