Hogy Számol A Külföldi Extrudert

Extrusion and Injection Molding Analysis
ver. 1
ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2011
Overview
Extrusion and Injection molding
Flow in screw
Flow in cavity or die
Injection molding
Clamp force
Cooling time
Ejection force

Extrusion schematic

Injection molding schematic

Schematic
pellets
clamp
nozzle
hopper
barrel
throat
mold
cavity
screw
heaters

motor /
drive
Flow in screw Extrusion and Injection molding

Understood through simple fluid
analysis
Unroll barrel from screw
rectangular trough and lid
v=pDN
vx
q vz
w/cosq
w is like normal pitch

w/cosq is like axial pitch

Flow analysis
Barrel slides across channel at the helix
angle
vz = pumping
vx = stirring
v=pDN
vx
q vz
w/cosq
w is like normal pitch

w/cosq is like axial pitch

Flow rate
vz shows viscous traction work against
exit pressure
flow rate = f(exit pressure, vbarrel, m, d, w, l)

Flow analysis
Simplify by using Newtonian fluid
Separate into drag and pressure flows

Add solutions (superposition)

Drag flow in rectangular channel (QD)

Simple viscous flow between parallel
plates, end effects negligible
y
v v0
H
1
QD v A v0 wH
2
vo
y

10
Pressure flow in rectangular channel

t
y
hopper
2y
exit
p + dp
Assumptions
no slip at walls
dz
melt is incompressible
steady, laminar flow
end and side wall effects are negligible
11

t
y
hopper
2y
exit
p + dp
z
t
dz
Equilibrium
p p dp 2 y 2t dz 0
12
p p dp 2 y 2t dz 0
dp
t y
dz
Newtonian fluid
dv
m m
dy
13

Eliminating t
1 dp
dv
y dy
m dz
Integrating and noting
@ y = +/- H/2, v = 0
1 dp H
y
v

m dz 8
2
2

14
Total pressure flow (Qp)

H
Qp w
wH dp
v dy
12 m dz

15
Total flow (Q)

vz H H dp
Q QD Q p w

12 m dz
2
3
f(screw speed)
f(pressure drop)
dp/dz set by
back pressure on reciprocating screw (injection
molding)
die resistance (extrusion)
16
Nomenclature
dz = helical length = axial length/sinq
vz = helix velocity = vbarrel*cosq

17
Flow rate
flow
rate
2w
output pressure

18
Schematics
Extrusion
Injection molding

19
Flow in round die or runner

Same assumptions as above
t + dt
r
dr
dz
p + dp
p
t
Equilibrium
p [r dr r 2 ] dp 2p r dr t dt rt dz
2

20

p [r dr 2 r 2 ] dp 2p r dr t dt rt dz
Neglecting HOT
2pr dr dp 2p t dr r dt dz
dp t dr r dt d tr
dz
r dr
r dr
21

dp p
d tr
C
dz
L
r dr
d tr Cr dr
d tr Cr dr
22

2
r
tr C
2
C
p
t r
r
2
2L

23

At center, t = 0
At edge of tube (R), t = max
t max
p R
2L
Newtonian fluid
du
t m
dr
24

du p r

dr
2 Lm
finally
p 2
2
u
r R
4 mL
25
p 2
2
u
r R
4mL
p R p
Q p 2pr u dr
8m
L
0
R

26
Flow in rectangular die or runner

as above
wH p
Qp
12 m L
3

27
Extrusion
Pressure generated by screw rotation
flow rate through screw =
flow rate through die
Q(extruder) = Q(die)
pressure rise in screw = pressure drop in
die
dp(extruder) = p(die)

28
Extrusion - Ex. 1-1

Extrude a polymer through a die with
dimensions diameter 5 mm, length 40
mm at rate 10 cm/s
Screw is fixed, barrel rotates
More data on next page
Calculate barrel RPM

29
Extrusion - Ex. 1-2
polymer density (r = 980 kg/m3

polymer viscosity (m) = 103 N-s/m2
barrel diameter (D) = 28 mm
channel width (w) = 21 mm
channel height (H) = 4 mm
helix angle (q) = 15 degrees
length of screw (L) = 1.25 m
30
Extrusion - Ex. 1-3

First, calculate flow rate
Q product v A 0.1
Qscrew
p 0.0052
4
1.96 106 m3 / s
v z H H 3 dp
w

12 m dz
2
p R 4 p
Qdie
8m L
dp p
31
Extrusion - Ex. 1-4

Substituting, equating, solving
Q product Qdie
4
0.005
p
2 p
6
1.96 10
8 103 0.04
p 5.1 MPa
32
Extrusion - Ex. 1-5

Substituting, equating using p, solving
Q product Qscrew
3
6
0
.
004
0
.
004
5
.
1
10
6
z
1.96 10 0.021
3
2
12
10
4
.
83
l
1.25
dz
4.83m
sinq sin15
solving
v z 49.5 mm / s
33
Extrusion - Ex. 1-6

Solving for RPM
vbarrel
vz
49.5
51.2 mm / s
cosq cos15
60 vbarrel 60 51.2
N
35 RPM
p D
p 28

34
Injection molding cycle

1. To make a shot: use screw (extruder)
equation for flow rate (Q) to produce a
shot volume (vol = Q*t).
back pressure gives dp term
time (t) bounded by cycle time (upper)
and degradation of material (lower)

35
Injection molding cycle

2. To inject the plastic: use pressure flow
equations and injection pressure (p)
or injection time (t) and volume to be
filled (shot volume) to determine flow
rate (Q) and hence time (t) or injection
pressure (p) required to fill mold
injection time (t) will be limited by freezing
of plastic and degradation of material
36
Injection Molding - Ex. 2-1

Injection mold a polymer in a steel tool
Model the sprue, runner and part as a
cylinder of diameter 10 mm, length 150
mm
Determine the screw RPM to make a
shot in less than 3 seconds (screw
rotates)
Determine the injection pressure to
make the part in 2 seconds
37
polymer density (r = 980 kg/m3

polymer viscosity (m) = 103 N-s/m2
barrel diameter (D) = 28 mm
channel width (w) = 21 mm
channel height (H) = 4 mm
helix angle (q) = 15 degrees
length of screw (L) = 1.25 m
38
Screw RPM calculation

Back pressure = 15 MPa
Assume 3 seconds to make shot
Calculate Q
vol pr 2l p 5 150
Q
3,927 mm3 / s
time time
3
2

39

Screw RPM calculation
Qscrew
v z H H 3 dp
w

12 m dz
2
l
dz
sinq
vz vscrew cosq
pDN
vscrew
D 28 2 4 20 mm
60
D barrel diameter 2 channelheight

40

Substituting values, solving
N
p 20 60 cos 15 4
43
15 106
3,927 21
3
1,250
2
12
10
sin 15
N = 101 RPM

41

Injection pressure calculation
Part injection is pressure driven
vol p 5 150
Q
5,891mm3 / s
time
2
2
Qmold
pR 4 p
8m L
42

Substituting, equating, solving
p 5 p
4
5,891
8 10 150
3
p 3.6 MPa 522 psi

43
Power law viscosity
t m k
log m
m k
n 1
log mo
n-1
log
k, n are consistency and

power law index

44
Non-Newtonian, pressure driven flow

in rectangular channel
NB: drag flow analysis is similar to the following
n1
2y n
v v0 1
H
H
2
n 1
n
2y
Q 2wv0 1 dy
H
0

45
Non-Newtonian, pressure driven flow

in rectangular channel
2 n1
n
1
n
2n H
p
Q w

k L 2n 1 2
vave
1
n
n 1
n
Q
n H
p

wH k L 2n 1 2

46
Non-Newtonian, pressure driven flow in

round channel
1
n1
n1
n p n
r n
n
u
1
R
n 1 2k L
R
1
n
n p
Q p
3n 1 2k L
vave
3n1
R n
1
n
n p
p R 2 3n 1 2k L
Q
n 1
R n

47
Example 3-1
Compare Newtonian and NonNewtonian, pressure driven fluid flow in
a rectangular channel
Given
H = 2 mm, w = 15 mm, L = 50 mm
Q = 60 cm3/s= 6 x 10-5 m3/s
m = 100 Pa-s @ d/dt = 3000/s (Newtonian
viscosity)
k = 12198, n = 0.4

48
Example 3-2
First, determine the Newtonian flow properties
vave
Q
6 10 5
m
2
wH 0.015 0.002
s
12mLQ 12 100 0.05 6 10

p
30 MPa
3
3
wH
0.015 0.002
5

49
Example 3-3
2
2
1 p H
y
v

m L 8
2
p H 2 30 106 0.002
m
3
8mL
8 100 0.05
s
2
vmax v y 0
(max at y=0 because this gives the greatest value)

50
Example 3-4
For non-Newtonian flow, determine the
p needed for Q = 6 x 10-5 m3/s and vave
= 2 m/s.
vave
1
n
n 1
n
1
0.4
0.41
0.002 0.4
Q
n H
p

wH k L 2n 1 2
m
p
2
s 12198 0.05
0.4
2 0.4 1

51
Example 3-5
solving
p 23.3 MPa
and
pnon Newtonian 23.3
0.78
pNewtonian
30
52
Example 3-6
For non-Newtonian flow, determine Q
for p = 30 MPa.
30 10

12198 0.05
6
vave
1
0.4
0.4
0.002
2 0.4 1 2
0.41
0.4
m
3.77
s
3
m
Q vave w H 3.77 0.015 0.002 11.3 105
s
Qnon Newtonian 11.3 10 5
1.88
5
QNewtonian
6 10
53
Example 3-7
One can see the effect of shear-thinning
reduction in pressure needed to maintain a
flow
increase in flow with a constant pressure

54
Clamp force
Typically 50 tons/oz of injected material
Can be approximated by
injection pressure x projected area of part
at parting line

55
Cooling in a mold
Assume 1-D heat conduction
Assume mold conducts much better than
plastic (Biot > 1)
Center temperature important
T
T
2
t
x
2
T = temperature
t = time
= thermal diffusivity
=k/rc

56
Cooling in a mold
Fo
hx
Bi
k
x2
TE TW
TM TW
TE = ejection temp
TM = injection temp
TW = mold wall temp
2l = thickness of part
Fo
2

57
Cooling in a mold
Solution
must be approximated or solved numerically
np 2
n
p
, Fo exp
Fo sin

p n ,odd n
2
2

58
Minimum cooling time - tc

Approximation for time taken (tc) for
center of flat sheet (thickness, 2l) to
reach ejection temperature (TE)
4 TM TW
tc 2 ln
p TE TW
p
4l

59
Minimum cooling time - Ex. 4-1
= thermal diffusivity ~ 10-7 m2/s

2l = plate thickness ~ 3 x 10-3 m
TW = mold wall temperature ~ 50oC
TM = melt temperature ~ 250oC
TE = ejection temperature ~ 100oC
Minimum cooling time for the center line to
reach TE
tc~ 15 sec.

60
Minimum cooling time - tc

Approximation for cylinder (radius = r), solved
similarly to the plate
Fo
t
r
TM TW
tc 2 ln 1.7
p
TE TW
1.7 r

61
Non-isothermal flow
Flow rate characteristic time constant:
t = 1/t ~ V/Lx
Heat transfer rate characteristic time constant:

t = 1/t ~ /Lz2
Flow rate
V L2z V Lz Lz
~
Heat transferrate Lx
Lx
Small numbers give short shots
thick runners needed
ratio should be greater than one for filling

62
Non-isothermal flow
Z
3 mm
X
Y
10 cm
1 cm/s
Flow rate
0.01m / s 0.0015m 0.0015m
~
2.25
7 2
Heat transferrate
10 m / s
0.1m
So, the mold should fill.

63
Limits on ejection temperature

Plastic must be cool enough to
withstand ejection force from ejection
pins without breaking
Plastic must be cool enough so that
upon further cooling will not warp

64
Ejection force
Ejection pins force the part out of the
mold after the part has cooled and
solidified enough.
The part will shrink onto any cores,
leading to an interference fit.
Model as a thin walled cylinder with
closed ends (plastic part) on a rigid core
(metal mold).
65
Thin-walled cylinder with closed ends

pd
t
1
2t
pd
a
2
4t
r 0 3

66
Biaxial strain
1 2
pd pd
1
E
E
2tE 4tE
p d d
1
E 2t 4t
1 T
67
Ejection force
E T
p
d d

2t 4t
Fejection
Fejection m p A
m E A T
d d

2t 4t
68
Nomenclature
A = area
d = core diameter
E = Youngs
modulus
p = pressure
t = part thickness
= thermal
expansion
coefficient
T = temperature
differential
= Poissons ratio
m = friction
coefficient

69
Summary
Extrusion and Injection molding
Flow in screw
Flow in cavity or die
Injection molding
Clamp force
Cooling time
Ejection force

70

71

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Extrusion and Injection Molding Analysis

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Injection molding schematic

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Flow in screw Extrusion and Injection molding

w is like normal pitch

ME 6222: Manufacturing Processes and Systems

w is like normal pitch

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Separate into drag and pressure flows

ME 6222: Manufacturing Processes and Systems

Drag flow in rectangular channel (QD)

ME 6222: Manufacturing Processes and Systems

Pressure flow in rectangular channel

Pressure flow in rectangular channel

Pressure flow in rectangular channel

Pressure flow in rectangular channel

ME 6222: Manufacturing Processes and Systems

Total pressure flow (Qp)

ME 6222: Manufacturing Processes and Systems

Total flow (Q)

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Flow in round die or runner

ME 6222: Manufacturing Processes and Systems

Flow in round die or runner

Flow in round die or runner

Flow in round die or runner

ME 6222: Manufacturing Processes and Systems

Flow in round die or runner

Flow in round die or runner

Flow in round die or runner

ME 6222: Manufacturing Processes and Systems

Flow in rectangular die or runner

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

Extrusion - Ex. 1-1

ME 6222: Manufacturing Processes and Systems

Extrusion - Ex. 1-2

polymer density (r = 980 kg/m3

Extrusion - Ex. 1-3

Extrusion - Ex. 1-4

Extrusion - Ex. 1-5

Extrusion - Ex. 1-6

ME 6222: Manufacturing Processes and Systems

Injection molding cycle

ME 6222: Manufacturing Processes and Systems

Injection molding cycle

Injection Molding - Ex. 2-1

Injection Molding - Ex. 2-2

polymer density (r = 980 kg/m3

Injection Molding - Ex. 2-3

Screw RPM calculation

ME 6222: Manufacturing Processes and Systems

Injection Molding - Ex. 2-4

D barrel diameter 2 channelheight

Injection Molding - Ex. 2-5

ME 6222: Manufacturing Processes and Systems