Polymer fluidity influenced by type and amount of filler

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. DOI: 10.1051/ 02020 (2016) ma eccon /2016 MATEC Web o Con e ences 7602020 7 2016 , 6 CSCC © 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. DOI: 10.1051/ 02020 (2016) ma eccon /2016 MATEC Web o Con e ences 7602020 7 2016 , 6 CSCC 2 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] DOI: 10.1051/ 02020 (2016) ma eccon /2016 MATEC Web o Con e ences 7602020 7 2016 , 6 CSCC 3 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] DOI: 10.1051/ 02020 (2016) ma eccon /2016 MATEC Web o Con e ences 7602020 7 2016 , 6 CSCC 4 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. Re e ences 1. D. Manas, M. S anek, M. Manas, V. Pa a, J. Ja o ik, KGK – Kau schukGummiKuns s o e, 62. Jah gang, (2009) 2. M. O sik, D. Manas, M. Manas, M. S anek, M. H ibo a, K. Kocman, D. Samek, Chemicke lis y 106, (2012) 3. M. S anek, M. Manas, D. Manas, V. Pa a, S. Sanda, V. Senke ik, A. Sk obak, Chemicke lis y, (2011) 4. V. Pa a, M. Manas, D. Manas, M. S anek, Chemicke lis y 105, (2011) 5. M. S anek, D. Manas, M. Manas, O. Suba, In l. J. o Ma h. and Compu e s in Simul., (2011) 6. J. Ja o ik, M. S anek, In l. J. o Ma h. and Compu e s in Simul., (2011) 7. M. S anek, D. Manas, M. Manas, J. 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Da a, In e na ional Jou nal o Plas ics Technology, 19 (1), 1-18, (2015) DOI: 10.1051/ 02020 (2016) ma eccon /2016 MATEC Web o Con e ences 7602020 7 2016 , 6 CSCC 5