a Co esponding au ho : s a[email p o ec ed]
mel low on
solidi ying laye
wall
Polyme luidi y in luenced by ype and amoun o ille
Michal S anek1a, Da id Manas1, Mi osla Manas1, Adam Sk obak1, Vacla Janos ik1 and Voj ech Senke ik1
1 Tomas Ba a Uni e si y in Zlin, TGM 5555, 760 01 Zlin, Czech Republic
Abs ac . Deli e y o polyme mel s in o he mold ca i y is he mos impo an s age o he injec ion molding
p ocess. This pape shows he in luence o ca i y su ace oughness and echnological pa ame e s on he low leng h
o polyme s in o mold ca i y. Applica ion o he measu emen esul s may ha e signi ican in luence on he
p oduc ion o shaping pa s o he injec ion molds especially in changing he so a used p ocesses and subs i u ing
hem by less cos ly p oduc ion p ocesses which migh inc ease he compe i i eness o he ool p oduce s and sho en
he ime be ween p oduc plan and i s implemen a ion. This esea ch ocused in o he in luence o echnological
pa ame e s on illing o he injec ion mold ca i y and he low leng h espec i ely.
1 In oduc ion
Injec ion molding is one o he mos ex ended
polyme p ocessing echnologies. I enables he
manu ac u e o inal p oduc s, which do no equi e any
u he ope a ions. The ools used o hei p oduc ion –
he injec ion molds – a e e y complica ed assemblies
ha a e made using se e al echnologies and ma e ials.
Wo king o shaping ca i ies is he majo p oblem
in ol ing no only he ca i y o he mold i sel , gi ing he
shape and dimensions o he u u e p oduc , bu also he
low pa hway ( unne s) leading he polyme mel o he
sepa a e ca i ies. The unne may be e y complex and in
mos cases akes up o 40% olume o he p oduc i sel
(ca i y). In p ac ice, high quali y o unne su ace is s ill
e y o en equi ed. Hence su ace polishing o pe ec
condi ions o mel low is demanded. The s a ed
inishing ope a ions a e e y ime and money consuming
leading o high cos s o he ool p oduc ion.
The luidi y o polyme s is a ec ed by many
pa ame e s (mold design, mel empe a u e, injec ion a e
and p essu es) and by he low p ope ies o polyme s.
Resul s o he expe imen s ca ied ou wi h
polyp opylene con ained di e en amoun o ille p o ed
a minimal in luence o su ace oughness o he unne s
on he polyme mel low. This conside s excluding (i
he condi ions allow i ) he e y complex and expensi e
inishing ope a ions om he echnological p ocess as he
in luence o he su ace oughness on he low
cha ac e is ics does no seem o play as impo an ole as
was p e iously hough .
A plas ic nucleus is o med by his way o lamina
low, which enables he comp ession o he mel in he
mold and consecu i e c eeping. A cons an lowing a e
gi en by he axial mo emen o he sc ew is chosen o
mos o he lows. Du ing illing he mold ca i y he
plas ic ma e ial does no slide along he mold su ace bu
i is olled o e . This ype o lamina low is usually
desc ibed as a “ oun ain low” (Figu e 1).
Figu e 1. Foun ain low.
2 Injec ion molding echnology
The injec ion mold o was designed o he easies
possible manipula ion bo h wi h he mold i sel and
du ing injec ion molding while changing he es ing
pla es, size o he mold ga e, p essu e and empe a u e
senso s e c. The injec ion mold is inse ed in o a uni e sal
ame (Figu e 2) which was designed o use wi h many
di e en injec ion molds ha i he size o he ame.
This makes he change o he sepa a e injec ion molds
easie , because he ame emains clamped o he
injec ion molding machine and only he shaping and
ejec ion pa s o he molds a e changed. A aching igh
and le sides o he ame o ixed and mo ing pla es o
he injec ion molding machine is done using ou
adjus able clamps on each side.
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© The Au ho s, published by EDP Sciences. This is an open access a icle dis ibu ed unde he e ms o he C ea i e
Commons A ibu ion
License 4.0 (h p://c ea i ecommons.o g/licenses/by/4.0/).
Figu e 2. Assembly o injec ion mold.
1– ame, 2 – injec ion mold, 3 – ejec ion sys em.
The shaping pa o he injec ion mold is composed o
igh and le side. The mos impo an pa s o he
injec ion mold conce ning he measu emen s a e: es ing
pla e, ca i y pla e and a special sp ue pulle inse .
Figu e 3. Ca i y pla e –spi al shaping pla e ( op), es ing pla e
(bo om).
The ca i y (Figu e 3) o injec ion mold o is in a
shape o a spi al wi h he maximum leng h o 2000 mm
and dimensions o channel c oss-sec ion: 6x1 mm. The
ca i y is c ea ed when he injec ion mold is closed, i.e.
when shaping pla e seals he es ing pla e.
The su ace o he pla es was machined by ou
di e en echnologies, which a e mos commonly used o
wo k down he ca i ies o molds and unne s in indus ial
p oduc ion. These echnologies a e polishing, g inding,
milling and wo ypes o elec o-spa k e osion – ine and
ough design (Table 1). The es ing pla es a e made om
ool s eel whose a e used o simple and as changing he
su ace o he mold ca i y.
Table 1. Su ace o es ing pla es.
Su ace
Ra [PPm
]
Su ace pho o
Polished pla e
0,102
G ound pla e
0,172
Elec o –
spa k
machined pla e
wi h a ine design
4,055
Milled pla e
4,499
Elec o – spa k
machined pla e
wi h a ough
design
9,566
2.1 Injec ion molding machine
Injec ion molding machine A bu g All ounde 420C –
1000 has been used o es ing sample p epa a ion. Mel
empe a u e o all ma e ials has been se on 240°C and
empe a u e o mold was 30°C.
2.2 Tes ed polyme s
Na u al polyp opylene (Moplen) and polyp opylene
(Hos acom) wi h di e en amoun and ype o ille –
glass ibe s and alc (5%, 10%, 15%, 20%, 25%, 30%,
35%, 40% o sho glass ibe s and alc) has been used o
he expe imen .
3 Resul s
The aim o he measu emen s was o ind ou he
in luence o sepa a e pa ame e s, especially he quali y o
he injec ion mold ca i y su ace, ille ype and ille
amoun , on he low leng h. The main esul s o he
measu emen and es ing a e gi en on he ollowing
pic u es.
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3.1 In luence o ma e ial luidi y on su ace
oughness.
In luence o he low leng h on su ace quali y is shown
on he nex igu es. The su ace quali y was changed by
he es ing pla es wi h di e en su ace oughness.
Rough design pla eMilled pla eFine design pla eG inded pla ePolished pla e
240
235
230
225
Tes ing pla es
Flow le g h [mm]
Rough design pla eMilled pla eFine design pla eG inded pla ePolished pla e
240
235
230
225
Tes ing pla es
Flow le ng h [ mm]
Figu e 4. In luence o he low leng h on su ace quali y
(0% - GF op, alc bo om).
Rough design pla eMilled pla eFine design pla eG inded pla ePolished pla e
207
206
205
204
203
202
201
200
Tes ing pla es
Flow le g h [mm]
Figu e 5. In luence o he low leng h on su ace quali y
(20% - GF op, alc bo om).
The amoun o glass ibe s ille and alc was o he
demons a ion selec ed only wi h 0%, 20% and 40%. The
o he esul s we e simila – he bes luidi y had ough
design pla e and he wo se luidi y had polished pla e.
Rough design pla eMilled pla eFine design pla eG inded pla ePolished pla e
190
185
180
175
170
Tes ing pla es
Flow le g h [mm]
Rough design pla eMilled pla eFine design pla eG inded pla ePolished pla e
210,0
207,5
205,0
202,5
200,0
197,5
195,0
Tes ing pla es
Flow le ng h [mm]
Figu e 6. In luence o he low leng h on su ace quali y
(40% - GF op, alc bo om).
3. 2 In luence o ma e ial luidi y on ille amoun
In luence o he es ing samples leng h on glass ibe s
ille and alc amoun (0, 5, 10, 15, 20, 25, 30, 40%) is
shown on he nex pic u es. The esul s a e displayed
sepa a ely o each es ing pla e because o be e
compa ison.
40%35%30%25%20%15%10%5%0%
230
220
210
200
190
180
170
% o glas s ibe s
Floe leng h [ mm]
Rough design pla eMilled pla eFine design pla eG inded pla ePolished pla e
220
218
216
214
212
210
208
206
Tes ing pla es
Flow leng h [mm]
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40%35%30%25%20%15%10%5%0%
225
220
215
210
205
200
195
% o alc
Flow leng h [mm]
Figu e 7. In luence o he low leng h on ille amoun
(Polished pla e)
40%35%30%25%20%15%10%5%0%
230
220
210
200
190
180
170
% o glas s ibe s
Flow le ng h [mm]
40%35%30%25%20%15%10%5%0%
230
220
210
200
190
% o alc
Flow leg h [mm]
Figu e 8. In luence o he low leng h on ille amoun
(G inded pla e).
40%35%30%25%20%15%10%5%0%
240
230
220
210
200
190
180
170
160
% o glas s ibe s
Flow le g h [mm]
40%35%30%25%20%15%10%5%0%
235
230
225
220
215
210
205
200
195
% o alc
Flow leng h [mm]
Figu e 9. In luence o he low leng h on ille amoun
(Fine design pla e)
40%35%30%25%20%15%10%5%0%
240
230
220
210
200
190
180
170
% o glas s ibe s
Flow leng h [mm]
40%35%30%25%20%15%10%5%0%
240
230
220
210
200
% o alc
Flow leng h [mm]
Figu e 10. In luence o he low leng h on ille amoun
(Milled pla e).
40%35%30%25%20%15%10%5%0%
240
230
220
210
200
190
% o glas s ibe s
Flow le g h [mm]
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40%35%30%25%20%15%10%5%0%
245
240
235
230
225
220
215
210
% o alc
Flow leng h [mm]
Figu e 11. In luence o he low leng h on ille amoun
(Rough design pla e).
The luidi y was be e in all ways wi h smalle amoun o
glass ibe s and alc as well. In case o glass ibe s and
alc used as ille in polyme ma e ials he e is signi ican
in luence on wo se low ma e ial p ope ies. On he o he
hand he inal p oduc o m he illed ma e ial has be e
mechanical p ope ies and o cou se lowe pe cen age o
sh inkage.
Figu e 12. Dependence o he low leng h on su ace quali y
and ille amoun .
4 Conclusion
This esea ch looked in o he in luence o echnological
pa ame e s on illing o he injec ion mold ca i y and he
low leng h espec i ely. The di e ences in low leng hs
a he es ing ca i y pla es wi h di e en su ace
oughness we e e y small, a he highe in case o
oughe su aces. Bu he e is demons able di e ence o
wo se low p ope ies on each es ing pla e wi h
inc easing pe cen age o ille (GF – glass ibe s o alc).
The measu emen shows ha su ace oughness o he
injec ion mold ca i y o unne s ha e no subs an ial
in luence on he leng h o low. This can be di ec ly pu
in o p ac ice. I also sugges s ha inal wo king and
machining (e.g. g inding and polishing) o some pa s o
he mold, especially he lowing pa hways, a e no
necessa y.
Acknowledgemen
This wo k was suppo ed by he Minis y o Educa ion,
You h and Spo s o he Czech Republic wi hin he
Na ional Sus ainabili y P og amme p ojec No. LO1303
(MSMT-7778/2014) and by he Eu opean Regional
De elopmen Fund unde he p ojec CEBIA-Tech No.
CZ.1.05/2.1.00/03.0089 and also by he in e nal g an o
TBU in Zlin No. IGA/FT/2016/010 unded om he
esou ces o speci ic uni e si y esea ch.
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