Extrusion and Injection Molding -

Analysis

ver. 1

ME 6222: Manufacturing Processes and Systems 1

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

ME 6222: Manufacturing Processes and Systems 2

Prof. J.S. Colton GIT 2011
Extrusion schematic

ME 6222: Manufacturing Processes and Systems 3

Prof. J.S. Colton GIT 2011
Injection molding schematic

ME 6222: Manufacturing Processes and Systems 4

Prof. J.S. Colton GIT 2011
 Schematic
pellets hopper
clamp nozzle barrel
throat

mold

cavity screw heaters motor /

drive

ME 6222: Manufacturing Processes and Systems 5

Prof. J.S. Colton GIT 2011
 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

H w/cosq
w is like normal pitch
w/cosq is like axial pitch

ME 6222: Manufacturing Processes and Systems 6

Prof. J.S. Colton GIT 2011
 Flow analysis
Barrel slides across channel at the helix
angle
vz = pumping
vx = stirring
v=pDN

vx q vz

H w/cosq
w is like normal pitch
w/cosq is like axial pitch

ME 6222: Manufacturing Processes and Systems 7

Prof. J.S. Colton GIT 2011
 Flow rate

vz shows viscous traction work against

exit pressure

flow rate = f(exit pressure, vbarrel, m, d, w, l)

ME 6222: Manufacturing Processes and Systems 8

Prof. J.S. Colton GIT 2011
 Flow analysis

Simplify by using Newtonian fluid

Separate into drag and pressure flows

Add solutions (superposition)

ME 6222: Manufacturing Processes and Systems 9

Prof. J.S. Colton GIT 2011
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 H

ME 6222: Manufacturing Processes and Systems 10

Prof. J.S. Colton GIT 2011
 Pressure flow in rectangular channel
t
hopper exit
y
p p + dp
2y
z
Assumptions t
no slip at walls dz
melt is incompressible
steady, laminar flow
end and side wall effects are negligible
ME 6222: Manufacturing Processes and Systems 11
Prof. J.S. Colton GIT 2011
Pressure flow in rectangular channel
t
hopper exit
y
p p + dp
2y
z
t
dz
Equilibrium

p p dp 2 y 2t dz 0
ME 6222: Manufacturing Processes and Systems 12
Prof. J.S. Colton GIT 2011
Pressure flow in rectangular channel

p p dp 2 y 2t dz 0
dp
t y
dz
Newtonian fluid

dv
m m
dy

ME 6222: Manufacturing Processes and Systems 13

Prof. J.S. Colton GIT 2011
Pressure flow in rectangular channel
Eliminating t
1 dp
dv y dy
m dz
Integrating and noting
@ y = +/- H/2, v = 0

1 dp H y 2 2
v
m dz 8 2
ME 6222: Manufacturing Processes and Systems 14
Prof. J.S. Colton GIT 2011
 Total pressure flow (Qp)

H
2 3
wH dp
Qp w
H
v dy
12 m dz
2

ME 6222: Manufacturing Processes and Systems 15

Prof. J.S. Colton GIT 2011
 Total flow (Q)

vz H H dp 3
Q QD Q p w
2 12 m dz

f(screw speed) f(pressure drop)

dp/dz set by
back pressure on reciprocating screw (injection
molding)
die resistance (extrusion)
ME 6222: Manufacturing Processes and Systems 16
Prof. J.S. Colton GIT 2011
 Nomenclature

dz = helical length = axial length/sinq

vz = helix velocity = vbarrel*cosq

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Prof. J.S. Colton GIT 2011
 Flow rate

2w
flow
rate w

output pressure

ME 6222: Manufacturing Processes and Systems 18

Prof. J.S. Colton GIT 2011
 Schematics

Extrusion

Injection molding

ME 6222: Manufacturing Processes and Systems 19

Prof. J.S. Colton GIT 2011
 Flow in round die or runner
Same assumptions as above

t + dt
r dr
z dz p + dp p

t
Equilibrium

p [r dr r 2 ] dp 2p r dr t dt rt dz
2

ME 6222: Manufacturing Processes and Systems 20

Prof. J.S. Colton GIT 2011
 Flow in round die or runner

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
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Prof. J.S. Colton GIT 2011
 Flow in round die or runner

dp p d tr
C
dz L r dr

d tr Cr dr

d tr Cr dr

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Prof. J.S. Colton GIT 2011
Flow in round die or runner

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

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Prof. J.S. Colton GIT 2011
 Flow in round die or runner

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

du
t m
dr
ME 6222: Manufacturing Processes and Systems 24
Prof. J.S. Colton GIT 2011
 Flow in round die or runner

du p r

dr 2 Lm
finally

p 2
u
4 mL
r R
2

ME 6222: Manufacturing Processes and Systems 25

Prof. J.S. Colton GIT 2011
Flow in round die or runner

u
p 2
4mL
r R2

R
p R p 4
Q p 2pr u dr
0
8m L

ME 6222: Manufacturing Processes and Systems 26

Prof. J.S. Colton GIT 2011
 Flow in rectangular die or runner

as above

wH p 3
Qp
12 m L

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Prof. J.S. Colton GIT 2011
 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)

ME 6222: Manufacturing Processes and Systems 28

Prof. J.S. Colton GIT 2011
 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

ME 6222: Manufacturing Processes and Systems 29

Prof. J.S. Colton GIT 2011
 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

ME 6222: Manufacturing Processes and Systems 30

Prof. J.S. Colton GIT 2011
 Extrusion - Ex. 1-3
First, calculate flow rate

p 0.0052
Q product v A 0.1 1.96 106 m3 / s
4

v z H H 3 dp
Qscrew w
2 12 m dz

p R 4 p
Qdie dp p
8m L

ME 6222: Manufacturing Processes and Systems 31

Prof. J.S. Colton GIT 2011
 Extrusion - Ex. 1-4
Substituting, equating, solving

Q product Qdie
4
0.005
p
6 2 p
1.96 10
8 103 0.04
p 5.1 MPa

ME 6222: Manufacturing Processes and Systems 32

Prof. J.S. Colton GIT 2011
 Extrusion - Ex. 1-5
Substituting, equating using p, solving

Q product Qscrew

6
1.96 10 0.021
v z 0.004

0.004 3
5.1 106


2 12 10 3
4.83
l 1.25
dz 4.83m
sinq sin15
solving
v z 49.5 mm / s
ME 6222: Manufacturing Processes and Systems 33
Prof. J.S. Colton GIT 2011
 Extrusion - Ex. 1-6
Solving for RPM

vz 49.5
vbarrel 51.2 mm / s
cosq cos15

60 vbarrel 60 51.2
N 35 RPM
p D p 28

ME 6222: Manufacturing Processes and Systems 34

Prof. J.S. Colton GIT 2011
 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)

ME 6222: Manufacturing Processes and Systems 35

Prof. J.S. Colton GIT 2011
 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

ME 6222: Manufacturing Processes and Systems 36

Prof. J.S. Colton GIT 2011
 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
ME 6222: Manufacturing Processes and Systems 37
Prof. J.S. Colton GIT 2011
 Injection Molding - Ex. 2-2

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

ME 6222: Manufacturing Processes and Systems 38

Prof. J.S. Colton GIT 2011
 Injection Molding - Ex. 2-3

Screw RPM calculation

Back pressure = 15 MPa
Assume 3 seconds to make shot
Calculate Q

vol pr 2l p 5 150
2
Q 3,927 mm3 / s
time time 3

ME 6222: Manufacturing Processes and Systems 39

Prof. J.S. Colton GIT 2011
 Injection Molding - Ex. 2-4
Screw RPM calculation

v z H H 3 dp
Qscrew w
2 12 m dz

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

ME 6222: Manufacturing Processes and Systems 40

Prof. J.S. Colton GIT 2011
 Injection Molding - Ex. 2-5

Substituting values, solving

N
p 20 60 cos 15 4 43 15 106
3,927 21
2 12 10 3 1,250

sin 15

N = 101 RPM

ME 6222: Manufacturing Processes and Systems 41

Prof. J.S. Colton GIT 2011
 Injection Molding - Ex. 2-6
Injection pressure calculation
Part injection is pressure driven

vol p 5 150
2
Q 5,891mm3 / s
time 2

pR 4 p
Qmold
8m L

ME 6222: Manufacturing Processes and Systems 42

Prof. J.S. Colton GIT 2011
 Injection Molding - Ex. 2-7
Substituting, equating, solving

p 5 p 4
5,891
8 10 1503

p 3.6 MPa 522 psi

ME 6222: Manufacturing Processes and Systems 43

Prof. J.S. Colton GIT 2011
 Power law viscosity

m k n 1 log mo

log m
n-1
1

log
t m k n

k, n are consistency and

power law index

ME 6222: Manufacturing Processes and Systems 44

Prof. J.S. Colton GIT 2011
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
n 1

2y
2

n
Q 2wv0 1 dy
H
0

ME 6222: Manufacturing Processes and Systems 45

Prof. J.S. Colton GIT 2011
Non-Newtonian, pressure driven flow
in rectangular channel
1 2 n1
p n
2n H n
Q w
k L 2n 1 2
1 n 1
Q p n
n H n
vave
wH k L 2n 1 2

ME 6222: Manufacturing Processes and Systems 46

Prof. J.S. Colton GIT 2011
Non-Newtonian, pressure driven flow in
round channel
1 n1 n1
n p n r n
u R n 1
n 1 2k L R

1 3n1
n p n
Q p R n
3n 1 2k L
1 n 1
Q n p n
vave R n
p R 2 3n 1 2k L
ME 6222: Manufacturing Processes and Systems 47
Prof. J.S. Colton GIT 2011
 Example 3-1
Compare Newtonian and Non-
Newtonian, 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

ME 6222: Manufacturing Processes and Systems 48

Prof. J.S. Colton GIT 2011
 Example 3-2
First, determine the Newtonian flow properties

Q 6 10 5 m
vave 2
wH 0.015 0.002 s

12mLQ 12 100 0.05 6 10 5

p 30 MPa
0.015 0.002
3 3
wH

ME 6222: Manufacturing Processes and Systems 49

Prof. J.S. Colton GIT 2011
 Example 3-3

1 p H 2
y
2
v
m L 8 2

p H 2 30 106 0.002
2
m
vmax v y 0 3
8mL 8 100 0.05 s

(max at y=0 because this gives the greatest value)

ME 6222: Manufacturing Processes and Systems 50

Prof. J.S. Colton GIT 2011
 Example 3-4
For non-Newtonian flow, determine the
p needed for Q = 6 x 10-5 m3/s and vave
= 2 m/s.
1 n 1
Q p n
n H n
vave
wH k L 2n 1 2
1 0.41
m p 0.4 0.4 0.002 0.4
2
s 12198 0.05 2 0.4 1 2

ME 6222: Manufacturing Processes and Systems 51

Prof. J.S. Colton GIT 2011
 Example 3-5
solving

p 23.3 MPa
and

pnon Newtonian 23.3

0.78
pNewtonian 30

ME 6222: Manufacturing Processes and Systems 52

Prof. J.S. Colton GIT 2011
 Example 3-6
For non-Newtonian flow, determine Q
for p = 30 MPa.
1 0.41
30 10 6 0.4 0.4 0.002 0.4 m
vave 3.77
12198 0.05 2 0.4 1 2 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
QNewtonian 6 10 5

ME 6222: Manufacturing Processes and Systems 53

Prof. J.S. Colton GIT 2011
 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

ME 6222: Manufacturing Processes and Systems 54

Prof. J.S. Colton GIT 2011
 Clamp force
Typically 50 tons/oz of injected material
Can be approximated by
injection pressure x projected area of part
at parting line

ME 6222: Manufacturing Processes and Systems 55

Prof. J.S. Colton GIT 2011
 Cooling in a mold
Assume 1-D heat conduction
Assume mold conducts much better than
plastic (Biot > 1)
Center temperature important

T = temperature
T T 2
2 t = time
t x = thermal diffusivity
=k/rc

ME 6222: Manufacturing Processes and Systems 56

Prof. J.S. Colton GIT 2011
 Cooling in a mold
t hx x
Fo Bi
x2 k l
TE = ejection temp
TE TW
TM = injection temp
TM TW TW = mold wall temp
2l = thickness of part

2

2
Fo
ME 6222: Manufacturing Processes and Systems 57
Prof. J.S. Colton GIT 2011
 Cooling in a mold
Solution
must be approximated or solved numerically

1 np 2 p
, Fo exp
4 n
Fo sin
p n ,odd n
2 2

ME 6222: Manufacturing Processes and Systems 58

Prof. J.S. Colton GIT 2011
 Minimum cooling time - tc
Approximation for time taken (tc) for
center of flat sheet (thickness, 2l) to
reach ejection temperature (TE)

4l 2
4 TM TW
tc 2 ln

p p TE TW

ME 6222: Manufacturing Processes and Systems 59

Prof. J.S. Colton GIT 2011
 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.

ME 6222: Manufacturing Processes and Systems 60

Prof. J.S. Colton GIT 2011
 Minimum cooling time - tc
Approximation for cylinder (radius = r), solved
similarly to the plate
t
Fo 2
r

1.7 r 2 TM TW
tc 2 ln 1.7

p TE TW

ME 6222: Manufacturing Processes and Systems 61

Prof. J.S. Colton GIT 2011
 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

ME 6222: Manufacturing Processes and Systems 62

Prof. J.S. Colton GIT 2011
 Non-isothermal flow
Z

X
3 mm Y 1 cm/s
10 cm
Flow rate 0.01m / s 0.0015m 0.0015m
~ 7 2
2.25
Heat transferrate 10 m / s 0.1m

So, the mold should fill.

ME 6222: Manufacturing Processes and Systems 63

Prof. J.S. Colton GIT 2011
 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

ME 6222: Manufacturing Processes and Systems 64

Prof. J.S. Colton GIT 2011
 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).
ME 6222: Manufacturing Processes and Systems 65
Prof. J.S. Colton GIT 2011
Thin-walled cylinder with closed ends

pd
t 1
2t
pd
a 2
4t

r 0 3

ME 6222: Manufacturing Processes and Systems 66

Prof. J.S. Colton GIT 2011
 Biaxial strain

1 2
pd pd
1
E E 2tE 4tE

p d d
1
E 2t 4t

1 T

ME 6222: Manufacturing Processes and Systems 67

Prof. J.S. Colton GIT 2011
 Ejection force

E T
p
d d

2t 4t
Fejection m p A

m E A T
Fejection
d d

2t 4t

ME 6222: Manufacturing Processes and Systems 68

Prof. J.S. Colton GIT 2011
 Nomenclature

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

ME 6222: Manufacturing Processes and Systems 69

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

ME 6222: Manufacturing Processes and Systems 70

Prof. J.S. Colton GIT 2011
ME 6222: Manufacturing Processes and Systems 71
Prof. J.S. Colton GIT 2011