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'EKNIKAL MALAYSIA MELAKA UNIVERSITI ' I

Analysis of Plastic Flow inside the Three Plate Mould

Thesis submitted in accordance with the partial requirements of the Universiti Telcnikal Malaysia Melaka for the Bachelor of Manufacturing Engineering (Manufacturing Design)

Nurul Syarafina bt Sholahuddin

Faculty of Manufacturing Engineering May 2007

ABSTRACT

The purpose of this project is to analyze the behavior of the plastic flow inside the three plate mould by using Moldex software. This research project was done by calculating the optimum size of feeding systems, including sprue, runner and gate. Besides that, the research focused on identifling the suitable location of gate, runner system and sprue system. Other than that, this research was to understand the parameters involved in flow simulation type of the plastic material, type of mould and type of injection moulding machine. In order to complete this research, hand phone housing for Nokia 2210 model

was chosen as the 3D model. The 3D modeling of hand phone housing was prepared
using Solidwork software. Then, transferred to Rhinocerous software. After the 3D modeling was exported, Rhinocerous software was used to do the meshing process on the part surface and then continue to design the runner, gate and sprue. After that, plastic flow analysis of Nokia 2210 mould was done using Moldex software. As result, various defects have been identified on Nokia 2210 such as short shot, weld line and air trap.

Kajian projek ini bertujuan untuk mengkaji kelakuan aliran plastik di d a l a m acuan tiga plat dengan menggunakan perisian Moldex. Kajian ini dilakukan dengan mengira saiz yang optimum terhadap spru, pelari dan get. Lokasi bagi sistem get, sistem pelari dan sistem spru juga dikenalpasti. Seterusnya, kajian ini diteruskan dengan memahami semua parameter yang terlibat d a l a m simulasi aliran, jenis bahan plastik berkenaan dengan acuan dan jenis pengacuan suntikan. Untuk menyempurnakan kajian ini, perumah telefon bimbit Nokia, siri 2210 dipilih sebagai model 3D. Penyelidikan ini h u l a dengan melukis model 3D perurnah telefon bimbit yang dipilih dengan menggunakan perisian Solidwork. Dari perisian Solidwork, lukisan model dipindahkan ke perisian Rhinocerus untuk proses seterusnya. Dengan menggunakan perisian Rhinocerus, proses penjaringan pada permukaan model dilakukan seterusnya,rekabentuk pelari, get dan spru dihasilkan dengan mengambilkira saiz dan kedudukan yang sesuai dengan acuan tiga plat. Setelah semua proses merekabentuk sistem pada acuan selesai, fail dipindahkan ke perisian yang seterusnya, iaitu perisian Moldex. Dalam perisian Moldex, pemilihan bahan plastik yang sesuai dilakukan clan parameter-parameter yang tertentu ditentukan sehingga mencapai tahap optimum. Setelah analisa dijalankan, keputusan mendapati terdapat beberapa kerosakan dikenalpasti, seperti plastik tidak lengkap, garis kimpal dan air yang terperangkap.

CHAPTER 1
1.0 INTRODUCTION

1.1

Background

Plastic materials are the most important material in the world. The history of plastics goes back more than 100 years. However, compared to other materials, plastics are relatively modern. Their usage over the past century has enabled society to make huge technological advances to take us towards the new Millennium. Plastics are usually used in agriculture, appliances, clothing, construction, electronics, furniture, packaging, transportation and numerous other areas. Almost in every human life activity, directly or indirectly involves in the products that made from plastics materials. [I7] There are many process can be used to produce the plastic product such as injection moulding process, extrusion process, blow moulding process, compression, and rotating process. The most popular process is injection moulding process. In the past, many people do not have any detail information about plastic injection technology. It was known by only a handfbl of expert. This process can produce high mass production and complicated shape of product. Injection moulding is the process of forcing melted plastic in to a mould cavity. Once the plastic has cooled, the part can be ejected. It is usefbl when the parts are too complex or cost prohibitive to machine. With this process, many parts can be made at the same time, out of the same mould. In injection process, mould is needed which it can be attached to the injection machine to produce plastic part. [I6]

Mould is a tool to produce plastic part. To get one mould, involves various stages from design stage where the mould needs to be designed using Computer Aided Design Software and then machine the raw materials to become mould parts and finally, assemble the mould parts to become one complete set of mould. It is very important to get good appearance, such as no welding line, sink mark, accurate dimension, flatness, and the most important capable to assemble to other parts. Some plastic parts are produced using injection machine have various problems such as welding line, sink mark and etc., due to various factors, such as wrong gate location, wrong size of gate, wrong size of runner, wrong length of runner, wrong location of water hole and other factors that effect the quality of plastic parts.[101 In the past few years, many mould makers have used trial and error method to produce mould where they were usually very high skill people to assist on design stages. Sometime to produce one set of mould had taken long time due to the modification and

a r t . repairing at mould to get good plastic p

The defects of plastic part can be reduced by flow analysis on the plastic part at the design stage which plastics parts will be analyzed using flow analysis software. This analysis usually looks at the various parameter such as flow front, flow rate, temperature different, shrinkage distribution, air trap, optimum window condition and etc. [lo]

1.2

Objectives

The objectives of this project are:

1. To analyze the behaviors of plastic flow inside the 3-plate mould. 2. To calculate the optimum size of sprue, runner and gate.
3. To identi@ the suitable location of gate, runner and sprue.

4. To understand the parameters involved in flow simulation.

5. To understand the type of plastics material, mould and injection machine.

1.3

Scope

In this study the type of 3-plate mould is used to analyze the flow behaviors of plastic using Moldex software. The 3D product will be drawn using solid work software. In order to analyze the plastic behavior, the optimum sizes of feeding systems were calculated and the location of the feeding systems was identified. After that the 3D product will be transferred to Rhinoceros software as post processor. Moldex software will be used to analyze the flow of plastic. Data fiom the result will be compiled and study the result.

1.4

Problem Statements

At the present time, mould makers are still using try and error method to locate the location of feeding system such as gate, runner and sprue inside the plastic injection mould. They need experienced people who capable to decide the size and location of feeding system especially in 3 plate mould. With simulation software the behaviors of flow of plastic inside the cavity mould can be predicted. In 3-plate mould the feeding system can be decided using different approach such as centre gate, offcentre gate and multiple gate systems. The size and location of gate, runner and sprue play importance role for producing good quality plastic product. If wrong method used when choose the feeding system size and location, it will affect the product quality such as welding line, air trap and etc. The Moldex software as a simulation software is used to ensure the best choice location and size of feeding system such as gate, runner and sprue. This because of the defect of plastic product can be eliminated before fabrication actual mould.

CHAPTER 2
2.0 LITERATURE REVIEW

2.1

Introduction

This section discussed about analysis plastic flow inside the 3-plate mould. In this chapter, the theory in the field of plastics technology is described. In the area of plastic technology, studies focuses on a few different aspects namely are three-plate mould, plastic materials, injection flow rate and etc.

2.2

Plastic material

A plastic is a material that can change its shape; so many things can be made of plastic.
The head of the Monsanto Plastics Research says that, "Plastics are materials that, while being processed, can be pushed into almost any desired shape and then retain that shape.
(171

There are many types of plastic. Some can be shaped only when they are freshly made; then they become hard afterwards. Others can be changed by heating them up or even by melting them.

Most plastics are man-made; they do not occur in nature. They are often made fiom oil that comes out of the ground. The process of making plastics is usually quite complicated The term "plastics" encompasses organic materials, such as the elements carbon (C), hydrogen (H), nitrogen (N), chlorine (Cl) and sulfur (S), which has properties similar to those naturally grown in organic materials such as wood, horn and rosin. Organic materials are based on polymers, which are produced by the conversion of natural products or by syththesis from primary chemicals coming fiom oil, natural gas or coal.
[I71

It designs in many different formulas for different purpose including for moulding. Approximately 18000 different materials are available for moulding. Majority of available materials are blends of previously developed material. Malaysia exports of plastics and plastics product were valued at RM9.38 (US$ 2.47) billion in 2003, the bulk of which went to the key markets of some country like Singapore, China and Hong

on^.''^]

2.2.1 Thermoplastics
Basically, plastic materials are divided generally into two groups namely thermoplastic and thermoset, based on their characteristic after the processing stage. The behavior of thermoplastics depends on other variables as well as their structure and their composition 18]. Thermoplastic materials is softened by the application of heat, hardened when cooled and fixed the shape of the moulding which may be quite rigid or flexible according to the type of plastic used. It can remould again and can recycle. This is because, there are no chemical changes takes places.

2.2.2 Types of thermoplastic Materials 2.2.2.1 Acrylonitrile Butadiene Styrene - ABS

Tough and good resistance to chemicals, oils etc., and has excellent outdoor properties. Applications are used where are smooth and glossy finish with strength is required, such as piping for chemical and gas installations, safety helmets, typewriter and telephone cases, tables, chairs luggage, torch and vacuum body cases. Trade names are BASFTerluran, Bayer - Novudor, Mosanto - Lustran r201as shown in Figure 2.1.

Figure 2.1 : Characteristics of ABS

2.2.2.2 Polymethyl Methacrylate (acrylic) - PMMA

It has good weather properties and resistance to most acids and oils. Available from through glass clear and full range of translucent (semi-transparent) and opaque colours. Applications such as fish tanks, watch glass, sink and bath tap tops, machine guards, goggles, lighting optical lenses. Trade names are Altulor - Altulite, Du Pont - Lucite, ICI - Diacon, and Rohrn GMBH - Plexiglas. 1201

Resist most chemicals, oil and is touch, with exceptionally good flexing properties. Applications are for milk bottle crates, packing trays and containers, cooling fans and electrical connectors on motorcars, moulded toys, shoe heels, chairs, luggage, and instrument cases. Trade names are BASF - Novolen, ICI - Propathene, Shell - Shell PP
1201 as shown

in Figure 2.2.

Form

acronym

recycle code

characteristics

common uses

hard, flexible, polypropylene PP translucent, dry feel

containers, appliances, toys, plumbing

Figure 2.2: Characteristics of PP

2.2.2.4 Polyethylene - PE
Polyethylenes are divided into two groups, which are Low Density Polyethylene, (LDPE) and High Density Polyethylene (HDPE) 1201as shown in Figure 2.3.

Form

acronym

recycle code

characteristics

common uses

high density

hard to semiHDPE flexible, waxy surface, opaque

fertiliser bags, car petrol tanks, gas pipe, tanks and rope

Figure 2.3: Characteristics of PE

2.2.2.4.1

High Density Polyethylene (HDPE)

HDPE has higher level crystalline than LDPE. These give plastics which have a higher density, rigidity, tensile strength, hardness, heat distortion temperature, chemical resistance, viscosity & resistance to permeability; however the impact strength is lower. The material has a density less than water 0.94g/cm3 - 0.965g/cm3. The shrinkage value up to 0.05 inlin possible for thick sectioned moulding. Application for this material are using for milk-bottle crates, containers used for refrigeration, fish boxes, shipping pails for paint and adhesive. This material is strong and stiff, even at low temperature. For this reasons it is used to produce components which must have reasonable impact strength at low temperature. Trade names are BASF - Lupolen HD, BP - Rigidex, Dow - Dow polyethylene. i201

2.2.2.4.2 Low Density Polypropylene (LDPE)

LDPE is crystalline thermoplastic material and is such it is not available in transparent grades. Its natural colour is a milky white and it has a soft wax-like feel. The material LDPE is an easy flow material and has a density less than water 0.9 g/cm3- 0.925 g..cm3. at 200C a material with a melt flow index (MFI) of 2 will have a higher viscosity than PS. The shrinkage of LDPE is about 2%. The melting point is approximately 105OC. By refer to density and melting point determinations, LDPE can be distinguished from HDPE and PP. injection pressure for injection machine up to 13000 bars equal to 130 h4hJm2equalto 11600 psi. The applications for this materials are using for toys, caps and lids for containers, bowls, beakers, pipe coupling, pots, bins etc. trade names are BASF

- Lupolen, Du Pont-Alathon, ICI-Alkathene and Shell-Cartona. 1201

2.3

Characteristic of Low Density Polyethylene (LDPE)

2.3.1 Common Name

Low Density Polyethylene

2.3.2 Abbreviation
PE

2.3.3 Systematic chemical name

Low density poly (methylene)

2.3.4 Suppliers and trade names

There are some suppliers and trade name listed in Table 2.1.

Table 2.1 : Suppliers and trade names

2.3.5 Material properties

LDPE is a crystalline thermoplastic and as such it is not available in transparent grades.

Its natural colour is a milky white and it has a soft wax-like feel. The material has a density less than water (0.92 g cm"), is tough but only has moderate tensile strength. The chemical resistance and electrical insulation properties (over a wide range of temperatures) are excellent.

2.3.6 Ease flow

LDPE is an easy flow material. Ease of flow is rated by the melt flow index (MFI), the lower the number, the stiffer is the flow. However, low MFI materials have better stresscrack resistance and exhibit higher impact strength (Due to higher molecular weight).

2.3.7 Shrinkage
When the density is 0.910 - 0.925 g cm
-3

the shrinkage is approximately 0.020-0.050

idin (type I-low). When the density is 0.926 - 0.940 g cm % ]! shrinkage. The shrinkage for LDPE is about 2

" (type 11- medium) the

shrinkage is about 0.015 - 0.04idin. For type 111, or HDPE, it can have very high

2.3.8 Resistance to the following

There is no solvent at room temperature. Not chemically attacked by non oxidizing acids, alkalis and many aqueous solutions. Low water absorption even after long immersion times, addition of carbon black (to improve weathering) will increase water absorption. Absorption of other liquid (e.g acetone and benzene) will be greater for LDPE than for HDPE.

2.3.9 Not resistance

LDPE has no resistance to Ultra-violet light, oxygen at elevated temperatures and strong nitric acids. It will dissolve in benzene at 60C. Aromatic and chlorinated hydrocarbons will cause swelling. Certain materials, e.g detergents, may cause stress cracking of grades with a MFI greater than 0.4 HDPE is also more prone stress cracking. ['I

2.3.10 Material detection or identification

LDPE floats in water and cuts easily with a knife. It is insoluble in most common solvents but soluble in hot benzene or toluene. Ignites easily when placed in a flame and bums rapidly. Burning drops usually fall and there is an odour of burning wax or p&in, the flame is blue but tipped with yellow. The melting point is approximately 105C. It can be distinguished from HDPE and PP by density and melting point determinations. LDPE is an inert material which does not dissolve in common chemicals.

2.3.11 Colouring
Dry colouring is used for noncritical applications but master batching is the preferred
system where accurate and consistence colour matching is required. Compounded material is more expensive and is not so widely used as good colouring can be achieved with master batches. Liquid colour is under active development, e.g. to overcome problems such as poor feeding.

2.3.12 Material and component handling

Predrying is not usually necessary unless hygroscopic additives are present. When necessary, 3h at 65OC is usually sufficient. [51

2.3.13 Mould and gate consideration

As the MFI increases the smaller the feed system of the mould needs to be. However, the runner sizes should not be reduced too much as it necessary to supply a reasonable amount of dwell pressure in order to compensate for shrinkage. A wide range of gates types is used. There is now considerable interest in the use of hot runners and insulated hot tip runners, such systems reduce scrap production and components are ejected from the mould already finished.

2.3.14 Flow path

This material is a very easy flow material. At lmm wall thickness, the maximum flow path, wall thickness ratio would be higher.

2.3.15 Projected area

The clamping pressure required is of the order of 1-2 tsi (1 5-30 MN m-2). I'[

2.3.16 Cylinder equipment

To prevent material weeping from the nozzle it is usual to fit a value in the nozzle (e.g spring loaded), to minimize material flowing back down the screw a valve is also fitted to the screw. Decompression (suck-back) is used as an alternative to nozzle valves, e.g in conjunction with hot-runner moulds.

2.3.17 Screw cushion

From 2 to 6 rnrn

2.3.18 Shot capacity

Because of the material's good heat stability as little as 10% of the cylinders rated capacity may be used, the maximum possible will be about 95%.

23.19 Melt temperature-as measured in the nozzle or by an air-shot technique: 180280C as shown in Table 2.2. Table 2.2: Melt temperature Melt temperature 180"-280C(356"-536F) 165"-220C(330"-428F) 205"-260C(400"-500F)

Type Low (Type I) Medium (Type 11) High (Type 111)

2.3.20 Barrel residence time

If the material is overheated oxidation occurs and there is a serious loss of electrical insulation ability, it is therefore necessary to incorporate antioxidants, e.g di-Q-naphthylp-phenyl-enediamine, so as to minimize change. It is good practice not to allow the material to cook in the barrel.

2.3.21 Temperature settings

Table 2.3 shows that the stages of the temperature on the various part of injection moulding machine. Table 2.3: Temperature settings Zone No. 1 2 3
4

Location Barrel rear (near the hopper) Barrel middle Barrel middle Barrel front Nozzle Mould

Temperatures "C From 120 160 180 200 210 10 To 200 230 260 280 270 60

Temperatures "F From 248 320 356 392 410 50 To 392 446 500 536 518 140

2.3.22 Injection speed-mould filling speed

To get fast injection speeds, high pressure are not required.

2.3.23 Injection pressure

The machine should be capable of giving the following: First Stage: up to 1300 bars; 130 MN m'2 ; 18800 psi. Second Stage (dwell or follow-up pressure): up to 800 bars; 80

MN m-2;1 1600 psi. Careful control over both dwell time and pressure is needed in order
to avoid over packing of the mould and yet still be able to compensate for shrinkage.

2.3.24 Screw rotational speed (rpm)

The screw rotational can be very high. High screw speeds can, however, result in melt temperature variations; therefore adjust the speed to suit the cooling time.

2.3.25 Back pressure

Up to 200 bars; 20 MN mm2 ;2900 psi.

2.3.26 Shutting down

No need to purge with another material.

2.3.27 Reprocessing
Up to 100% regrind may be used; ensure that the scrap is kept clean and dry. If the regrind is mixed with virgin polymer, then the material can be re-used more than other plastics.

2.3.28 Finishing
Difficult to deflash because of the flexibility of the material. Hands scalpels, cropping, etc. may be used to remove the feed system. Better to design the mould so that the degating is achieved during mould opening. Decoration of mouldings is not very common.

2.4

Mould

An injection mould normally consists of two basic sets of component.. One is cavities and cores; the second is the base in which the cavities and cores are mounted as shown in Figure 2.4. The combination of these two components is a result of standardization in the mouldmaking industry.

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Figure 2.4: Elements of injection mould

2.4.1 Mould base The exploded view in Figure 2.5 shows parts of a mould base. The locating ring surrounds the sprue bushing and is used for locating the mould in the press-platen concentrically with the machine nozzle. The opening into which the ring fits is made to a tolerance of -0.000 and +0.002. The ring itself is made 0.010 smaller than the opening providing a clearance of 0.005 per side. The sprue bushing on the locating ring end has a spherical radius of L/z or % in. to fit the machine nozzle radius. The sprue bushing goes through the front clamping plate or backup plate and front cavity plate, thus extending to the parting line. The parting line is formed by cavity plates A and B. Cavity plate A, as the name implies, retains the cavity inserts and supports the leader pins, which maintain the alignment of cavity halves during operation. Leader pins are made 0.001 below nominal and to a tolerance of +0.0000 and -0.0005.

Occasionally, there are instances where the core protrudes a considerable amount, thus requiring precise guidance of mould halves before cavity and core touch each other. In such an event, the leader pins must be long enough to perform the job of guiding prior to contact of the mating halves. Mating with A plate is B plate, which holds opposite half of the cavity or the core and contains the leader pin bushings for guiding the leader pins. B plate has its own backup or support plate. It also frequently supported by pillars against the U-shaped structure known as the ejector housing. The U-shaped structure consisting of the rear clamping plate and spacer blocks are bolted to the B plate either as separate parts or as a welded unit. The U-shaped structure provides the space for the moving ejector plate or ejection stroke also known as stripper stroke. The ejector plate, ejector retainer, and pins are supported by the returns pins. The stripper plates provide clearance holes around the supporting pillars. The rear clamping plate of the U-shaped structure usually has openings for stripper rods, which actuate the ejector plate. The ejection plates retain the heads of knockout pins as well as return pins. All the mould plates (excluding the ejector parts) and spacer blocks are ground to a thickness tolerance of +-0.001. A combination of tolerance could conceivability build up to cause an unevenness at the four corners. It is advisable to check the uniformity of all four comers prior to preparing the base to receive cavities.

Figure 2.5: Exploded view of mould base and Cross section of mould base

2.4.2

Cavity and core

Figure 2.6 shows a cross section and top view of the part drawn to actual size. A fieehand outline of cavity core is made using as a guide the fact that the outside of the part will form the cavity and the inside of the part, the core. This establishes the parting line and the gate location. An analysis is made of whether, with this arrangement, the part will stay on the core during mould opening. The depth of the ribs and the binding between them as a result of shrinkage should overcome any tendency of sticking in the cavity. The finish in the slots for the ribs would be smooth as machined or as electricdischarge-machined (EDM) but would not have a directional polish.

Figure 2.6: Parting line, cavity and core outline

The part is designed without the ribs and that the center ring has tapers in the direction of withdrawal as illustrated in Figure 2.7. With this, the part would definitely stick in the wrong side. Ejection pins are placed as indicated in Figure 2.7. Even a slight ring scratch of 0.001 depths in the middle of the flange could aid in the retention of the part. If it were permissible to have the ejection-pin impressions on the outside, then the arrangement in figure 2.6 could prevail, except that the half that was stationary would become the ejection half and would incorporate the ejecting pins. Not all parts lend themselves to this kind of treatment. For example, a '/4 in.-diameter rod, 2 in. long. The part is symmetrical, and there are no means of making it stick to the ejection side. Should the end opposite to the gate tend to adhere to the stationary half, it could be provided with a dummy gate to retain it on the correct side.

Figure 2.7: Parting line, cavity and core outline

2.5

Characteristic of plastic injection moulding

Each types of mould has same characteristic which can be known such as sprue, runner, gate, and air vent as shown in Figure 2.8.

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Figure 2.8: Sprue, runner and gate