Industrial design I cinque sensi della plastica Parma - 28 Marzo 2014 Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio Andrea Romeo Consorzio Proplast Project Manager and CAE Rensponsible 5-6 December 2013 Turin –Italy Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Proplast was founded in 1998 Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 The Consortium 184 Companies 13 Universities 9 Associations 3 Public Entities and foundations 210 associates Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Goals Technical consultancy and technological tranfer Laboratory services and analysis Training and HR activities Research and development activities for polymer processes Reference point to develop research and development activities between Universities and Companies Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 PROPLAST, Trexel, ENGEL partnership To promote and disseminate the Mucell technology Demo installation At Proplast’s site (Tortona, Italy) IMM: Engel 180 tons, screw: 55 mm Shot weight: 100-500 g Mucell unit - Co2 or Nitrogen Goal Support customers at every stage of the technology implementation and application •Part design for Mucell and simulation •Support to mould design •Mucell moulding trials / mould piloting Technological development Aestethical surfaces on Mucell parts (material design and optimization) Combination with H&C technologies (pressurised water, induction) Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 EUROPEAN FUND FOR REGIONAL DEVELOPMENT P.O.R. 2007 – 2013 Goal Research and experimentation on Microcrellular Injection Moulding Consortium 5 Industrial partners (Mouldmakers, End Users, Compounders) Reference Research and Technical Centre Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Established in 1980, Onni-Stamp is able to balance the most innovative technologies and the expertise and skills of its technologists acquired in over 30 years of activity and production. Its mission is to follow up the customer from the scratch over all the phases of a plastics component development: from part design to maintenance of tools and equipments. Onni-Stamp S.r.l. mainly focuses on: design management production maintenance of plastics injection moulds. Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Concept Combining 2 different innovative technologies: Mucell Heat and cool microcellular injection moulding dynamic mould conditioning Focus on: → Mouldability and process conditions → Aesthetics → Warpage → Materials → Eventual pit falls evaluation Conventional moulding Mucell Heat and cool Mucell + Heat and cool Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 The moulded part Specific features to evaluate, measure, compare Holes to generate welding lines max rib/wall thickness ratio 2:1 Measurement reference points U-shaped part to amplify warpage Ribs Different surface finish (mirror polishing, textures) Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Virtual run Process Material Structure Simulating the process • Conventional moulding • Mucell injection moulding Prevision of the Microstructure Building the material model Structural simulation • Cell dimensions • Accurate Mechanical model sensitive to morphology • Stiffness • Cell density and distribution • Strength • Performance • Heat and cool injection moulding Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Rheological simulations with Mucell Rheology Mucell Process Filling Chance to accurately simulate the Microcellular Moulding Process with Moldex 3D Cells nucleation /growth Cooling (average/transient) Local results Ejection PROCESS - Global part quality QUALITY Cycle time Injection pressure Clamping force STRUCTURAL FEM ANALYSIS - Expansion / weight reduction Volum. shrinkage/sink marks Warpage / residual stresses - Cells density Cells size The Microcellular Injection Moulding Process can be analysed, predict, optimised via simulation softwares Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Rheology The Microcellular Injection Moulding Process can be analysed, predict, optimised via simulation softwares Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Rheology Virtual Mucell Injection moulding Mucell Compact tinj (s) 0,9 0,9 Tmelt (°C) 260 260 Tmould (°C) 40/40 70/70 Gas dosing (%) 0,5 -- Switch over point (%) 99 99 thold (s) -- 7 Phold (bar) -- 1600 tcooling (s) 20 23 Variation (%) tcycle (s) 26 36 -28 Shot weight (g) 92,9 100,3 -7,4 Pinj max (bar) 1428 1768 -19 90 220 -59 Clamping force (ton) Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Rheology Sink marks reduction Compact moulding Mucell Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Rheology Warpage reduction Corner effect prediction Compact Moulding Mucell C D A B nominal compact Mucell simulated measured simulated measured Variation (%) A 110 108,76 109,17 109,22 109,16 - 0,05 B 200 198,10 198,64 198,76 198,72 - 0,02 C 200 198,61 198,92 199,18 198,86 - 0,29 D 110 Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio 109,21 109,30 109,52 – MECSPE, 109,20 I cinque sensi della Plastica Parma 28/3/14 - 0,29 Rheology Warpage reduction Prediction of planarity Compact moulding Mucell Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Rheology Expansion prediction Cells density Global weight reduction: 5.5% Global weight reduction: 7.4% Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Rheology Expansion prediction Cells size Global weight reduction: 5.5% Global weight reduction: 7.4% Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Cells size prediction 1. 2. 3. 1. Reduced cell size High cell density 2. Medium cell size Medium cell density 3. High cell size Low cell density Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio * Global weight reduction: 5.5% I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Cells density prediction 1. 2. 3. 1. Reduced cell size High cell density 2. Medium cell size Medium cell density 3. High cell size Low cell density Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio * Global weight reduction: 5.5% I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Cells size near the gate SEM validation: average cell size 2 µm Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Cells size at a half of flow lenght SEM validation: average cell size 33 µm sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio SEM validation: average cellNuovi size 22 µm I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Cells size at the end of flow SEM validation: average cell size 77 µm SEM validation: average cell size 58 µm Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Cells density near the gate SEM Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Cells density at a half of flow lenght SEM Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Cells density at the end of flow SEM SEM Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Structural simulations on Mucell components Simulation workflow Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Material modeling Central technology for structural engineering Integration of local predicted microstructure – Matrix + fibers + cells – Additional information about material microstructure The result: Material model sensitive to its morphology Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Mesh mapping Mapping software • Exchanges data between dissimilar meshes Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Mesh mapping Density of porosity Size of porosity Volume Fraction of porosity Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Mucell test case 1 Accurate component’s mechanical prediction Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Mucell test case 2 Accurate component’s mechanical prediction Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Mucell test case 3 Accurate component’s mechanical prediction Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Mucell + Heat and Cool Mucell + Heat and cool Thermal analysis Target: heat and cool on the aesthetical surface - Conformal channels design optimization (layout, position, cross sections) Prediction of the temperature uniformity over the cavity Prediction of heating and cooling times Exstimation of total cycle time Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Experimentation Workplace layout Study / simulations / design Moulding trials SCF System (N2 and CO2) controller, MIK gas metering unit, gas nozzle Vicory 220 hydraulic Injection Moulding Machine, Ø55 dedicated screw Dynatemp H&C controller, Standard thermoregulators Mould design and mould manufacturing Mucell Heat and Cool Aprol Enmon system Plant consumptions monitoring and controlling Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 The mould Pressure and Temperature Sensors to efficiently control the process Conformal cooling channels For temperature uniformity and for reducing the mould’s thermal inertia making heat and cool affordable Variable injection system For evaluating different flow lengths and the effect of welding lines Variable injection systems and flow lenghts Kistler pressure and temperature sensors Conformal cooling channels Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Moulding trials Several moulding trials were perfomed at Proplast’s, at different process conditions and on different materials (amorphous and semicrystalline): Injection conditions 1 central gate 2 lateral gates 1 lateral gate Tested materials ABS, ELIX P2 - HAT ABS Thermo-resistant, ABS CILAC TBB PC-ABS, BAYBLEND T85 XF PA6, AQUAMID NAT PA6 from regenerated monomer, ECONYL 6FLH PA6 + nano fillers, PANCH 1015 UCT2 HN Expansion conditions Compact (100% density) Weight reduction: -5% Max achievable weight reduction Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Assessment and metrics Process 600 • Max injection pressure • Holding pressure • Cavity pressure (at 3 sensors positions) • Clamping force • Injection time • Cooling time • Total cycle time • Melt temperature Pressioni [Bar] Evaluating: 500 pressione 1 estremità 400 pressione 2 centrale 300 pressione 3 estremità 200 100 0 0 5 10 Tempo [sec] 15 20 • Mould temperature • Cavity temperature Aesthetics Statistical analysis of defects and rating of gloss Dimensional stability Shrinkage and warpage analysis Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Outcomes (I) Process Shot weight Clamping force Max injection pressure Injection time Cycle time Melt temperature Mould temperature g kN Bar sec sec °C °C Compact Mucell Variation % 100 2200 1770 0,88 36 260 60 92,9 900 1442 0,85 26 260 40 -7,1% -59,1% -18,5% -27,8% Max injection pressure reduced Very uniform packing occurs with Mucell, driven by cells growth pressure 800 800 Compact 725 bar 700 Reduced by -24% 600 600 Pressure pressione at tip 1 1 estremità Pressure 2 pressione at centre centrale Pressure 3 pressione at tip 2 estremità 500 400 300 200 Pressure [bar] Pressure [bar] Mucell 700 Pressure sensors 0 10 20 Pressure1 pressione at tip 1 estremità Pressure2 pressione at centre centrale Pressure3 pressione at tip 2 estremità 500 400 300 200 100 0 548 bar 100 0 30 Nuovi Time [sec]sviluppi nello stampaggio microcellulare: 0 10 20 30 Timeattraverso [sec] analisi dei vantaggi un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Trials performed on thermoresistant ABS CILAC TBB, 1 central gate Outcomes (II) Warpage and shrinkage Mucell trials always provided improvements about warpage and distribution of shrinkage, both as average value and as standard deviation. Values depend on material and condition process, as well. Variation % -45% -43% L central L lateral 2 mm mm mm mm mm [adim] % % % % Mucell 198,80 198,56 218,63 218,65 0,23 0,0012 0,607 0,623 0,615 -0,012 L lateral 1 L central L tips L lateral 1 L lateral 2 Warpage Overall Warpage Shrinkage central Shrinkage lateral 1 Shrinkage lateral 2 ∆ shrinkage Compact 198,96 198,54 218,74 218,75 0,42 0,0021 0,527 0,574 0,568 -0,045 L tips -73% Warpage and shrinkage parameters calculation 𝑤𝑎𝑟𝑝𝑎𝑔𝑒 = 𝐿𝑐𝑒𝑛𝑡𝑟𝑎𝑙 − 𝐿𝑡𝑖𝑝𝑠 𝑜𝑣𝑒𝑟𝑎𝑙𝑙 𝑤𝑎𝑟𝑝𝑎𝑔𝑒 = 𝐿𝑐𝑒𝑛𝑡𝑟𝑎𝑙 − 𝐿𝑡𝑖𝑝𝑠 𝐿𝑚𝑜𝑢𝑙𝑑 𝑠ℎ𝑟𝑖𝑛𝑘𝑎𝑔𝑒 % = 𝐿𝑚𝑜𝑢𝑙𝑑 − 𝐿𝑝𝑎𝑟𝑡 ∙ 100 𝐿𝑚𝑜𝑢𝑙𝑑 ∆𝑠ℎ𝑟𝑖𝑛𝑘𝑎𝑔𝑒% = 𝑠ℎ𝑟𝑖𝑛𝑘% 𝑐𝑒𝑛𝑡𝑟𝑎𝑙 − 𝑠ℎ𝑟𝑖𝑛𝑘% 𝑙𝑎𝑡 1 + 𝑠ℎ𝑟𝑖𝑛𝑘% 𝑙𝑎𝑡 2 2 Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Trials performed on thermoresistant ABS CILAC TBB, 1 central gate Outcomes (III) Aesthetics Mucell prevent sink marks very effectively but generates silver streaks. Heat and cool gives a very high glossy surface but is not able to eliminate sink marks. Mucell and heat and cool combined solve dimensional issues, sink marks and produce a very high gloss surfaces Compact conventional Deep sink marks High gloss Heat and cool (Only) reduced sink marks Very high gloss Mucell No sink marks Silver streaks Mucell + Heat and cool No sink marks No silver streaks Very high gloss Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Trials performed on thermoresistant ABS CILAC TBB, 1 central gate Conclusions Conclusions (I) Process General reduction of clamping force General decrease of max injection pressure General reduction of mould temperature General reduction of cycle time Dimensional stability Mucell trials always provided improvements about warpage and distribution of shrinkage, both as average value and as standard deviation. Values depend on material and condition process, as well. Aesthetics At every condition Mucell removed sink marks The use of combined Heat and cool technology eliminates aesthetical defects, as well. Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Conclusions (II) – Predictive coherence Simulations • Chance to simulate and predict Mucell with Moldex 3D (process, part quality, expansion properties) - Process settings Cycle time Pressures Clamping force Expansion / weight reduction Volumetric shrinkage / sink marks Warpage / residual stress distribution Local cell size - Cell distribution and density - • Chance to interface process results from Moldex to structural simulations of Mucell components - Material model sensitive to Mucell microstructure Stiffness/ strength prediction Prediction of the component’s performance • Chance to design/simulate the Mucell + Heat and Cool process for high aesthetical applications - Design/optimization cooling channels Temperature distribution prediction Heating and cooling time prediction Total cycle time estimation Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14 Thank you for your attention eng. Andrea Romeo Consorzio Proplast Project Manager and CAE Responsible [email protected] +39 01311859743 www.proplast.it Nuovi sviluppi nello stampaggio microcellulare: analisi dei vantaggi attraverso un caso di studio I cinque sensi della Plastica – MECSPE, Parma 28/3/14
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