Beruflich Dokumente
Kultur Dokumente
Prof. Dr.-Ing. Ch. Hopmann, Dipl.-Ing. Andreas Neu Institute of Plastics Processing (IKV) in Industry and the Skilled Crafts at RWTH Aachen University Kunststoffen 2012 Eindhoven, September 27th 2012
Staff of IKV :
80 scientific employees 50 employees in laboratories, workshops and administration 223 student workers
IKV-Locations in Aachen
Pontstrae 49-55 Management and Executive Board Injection Moulding PUR-Technology Training/Skilled Crafts
Seffenter Weg 201 Composites Extrusion and Further Processing Part Design/Materials Technology Centre for Analysis and Testing of Plastics
PRODUCT REQUIREMENTS
material selection
production layout of analysis of moulds, dies complex and machines interconnected processes mould or die / machine prototype, CAM measuring, controlling, adjusting and optimisation of process values
quality assurance
PRODUCT
material innovations
product prototyp
Simulation
process simulation inner part properties integrative simulation special IM processes
Mould Technology
temp. control concepts process control special IM processes Rapid Prototyping/Tooling
Company Organisation
benchmarking intercompany comparison technical consulting process analysis
Machine Technology
drive concepts IM of micro parts IM of foamed parts water injection technique
Crosslinking Materials
processing of polyurethane elastomer injection moulding mould/systems engineering
Outline
Introduction trends in injection moulding New injection moulding technologies for increasing process and function integration Surface functionalisation using variothermal injection moulding Lightweight parts for automotive applications
Projectile injection technique Back foaming of metal sheets Hybrid light-weight construction parts
Hybrid multi-component injection moulding for electronic applications Conclusions and outlook
Fact
The standards of parts in terms of design and functionality as well as demands for economical, resource efficient productions often cannot be fulfilled by conventional materials and manufacturing methods. Limits between different material classes and manufacturing methods have been shifted increasingly.
frontend
[Innolite, KraussMaffei Technologies GmbH, LANXESS Deutschland GmbH, Ford Motor Company, SPE]
Outline
Introduction trends in injection moulding New injection moulding technologies for increasing process and function integration Surface functionalisation using variothermal injection moulding Lightweight parts for automotive applications
Projectile injection technique Back foaming of metal sheets Hybrid light-weight construction parts
Hybrid multi-component injection moulding for electronic applications Conclusions and outlook
Aim Aim
stretched micro structures to create superhydrophobic surfaces
Hybrid production in order to integrate process steps Further development of dynamic mould heating techniques Replication of functional micro structures (e.g. superhydrophobic surfaces)
Results Approach
Use of variothermal injection moulding
variothermal temperature control by mould integrated diode laser
Formation of the frozen outer layer influence of the cavity wall temperature
Injection moulding conventional low cavity wall temperature frozen outer layer polymer melt (fountain flow) Injection moulding variothermal high cavity wall temperature completely filled micro structure
cavity wall
time
time
x500
50 m
x2000
10 m
x5000
5 m
[Fraunhofer ILT]
SEM-Picture and contact angle measurement injection moulding conventional and variothermal (PP)
x100 x750 30 m 200 m
conventional injection moulding incomplete moulding contact angle = 115 (slightly hydrophobic) variothermal injection moulding complete moulding and drawing of the structure contact angle = 166 (superhydrophobic)
x100
200 m
20 m production of high-gloss surfaces in one step thin-wall parts with high flow length
Outline
Introduction trends in injection moulding New injection moulding technologies for increasing process and function integration Surface functionalisation using variothermal injection moulding Lightweight parts for automotive applications
Projectile injection technique Back foaming of metal sheets Hybrid light-weight construction parts
Hybrid multi-component injection moulding for electronic applications Conclusions and outlook
Sucess factors
Reduced wall thicknesses compared to conventional FIT Reduction of material costs Reduction of cycle time Only constant cross sections are feasible, but increased freedom of design regarding shape and size of cross sections Simplified cheap injector technology is applicable
Observations: stable flow of the projectile characteristic melt flow in front of the projectile residual wall defined by projectile cross section 30 mm
Comparison of the hollow space formation within the WIT and the W-PIT
material: Ultramid PA6.6 GF30
WIT
W-PIT
30 mm
Comparison of the hollow space formation within the WIT and the W-PIT
material: Ultramid PA6.6 GF30
WIT
W-PIT
30 mm
Comparison of the residual wall thickness (RWT) and the hollow space eccentricity for WIT and W-PIT
6 residual wall thickness / eccentricity [mm] 5 4 3 2 1 0 1 2 3 measuring position [-] 4
1
WIT average RWT WIT eccentricity W-PIT average RWT W-PIT eccentricity
2
test part
measuring positions
30 mm
Continuous fiber-reinforced media pipes produced with water assisted projectile injection technique
Context Current situation
The focus on energy saving in the automotive industry leads to engine-downsizing and constantly increasing requirements for media pipes regarding pressure peaks and part weight.
Approach Approach
A new process for the production of continuous fiber-reinforced media pipes using the projectile injection technique (PIT) is developed.
Modular designed injection-mould with a fixation device for continuous fiber fabrics
fixed mould half movable mould half
changeable insert
fiber fixation
axial injector
Process sequence for the production of continuous fiber-reinforced media pipes using the PIT
placement and fixation of the reinforcement fabric fixation continuous fiber melt injection projectile
fluid injection
Continuous fiber-reinforced media pipes produced with water assisted projectile injection technique
Potential of the new process technology
Economic advantages: + Cycle time < 30 s + 35 % weight reduction compared to WIT parts with identical mechanical properties (e.g. bursting strength) + Adjustable wall thicknesses independent of rheological material properties due to projectile geometry Technical advantages: + All thermoplastics applicable (no FIT modifcation of the materials required) + Alternative matrix materials applicable (PU, LSR, rubber) + Load-oriented alignment of the continuous fibers + Combination of same materials for fiber and matrix possible + Geometric freedom e.g. through integration of connecting parts + No breaking at the cold impact test (-40 C)
Approach
Development of the complete manufacturing chain Investigations on different bonding agents Simulation development
sheet metal
Mould insertion
Injection moulding
Integrated part
Solution Approach
Use of a conventional injection moulding machine Dosing of the blowing agent using an airlock between feed hopper and plasticising unit
The ProFoam-process
valve gas connector airlock chamber material hopper blowing agent vent blowing agent inlet
accumulator chamber
Simple process set-up of the ProFoam-process as the gas pressure is the only additional parameter Stable, robust foaming process, because the propellant is always dissolved completely Required additional equipment is less complex and thus more flexible in comparison to other foaming processes
CO2 30 bar
N2 30 bar
CO2 50 bar
N2 50 bar
Insert and back-inject the metal sheet integrated forming of the metal sheet in the mould by the melt pressure The melt is loaded a with physical blowing agent using the Profoam-process Mould temperature above 100 C for activation of the adhesive agent and to improve the formability of the metal For foaming the cavity volume is increased using a breathing mould The foam structure is adjustable in a wide range by setting the cavity extension
IKV-test part Enhancement of bending stiffness through weight neutral increase of thickness Increase of design freedom, as the gas pressure in the melt avoids sink marks Homogenous foam structure throughout the whole part with breathing mould Metal optic and metal haptic (cool-touch effect) Premium surface quality for injection moulded foam parts
Outline
Introduction trends in injection moulding New injection moulding technologies for increasing process and function integration Surface functionalisation using variothermal injection moulding Lightweight parts for automotive applications
Projectile injection technique Back foaming of metal sheets Hybrid light-weight construction parts
Hybrid multi-component injection moulding for electronic applications Conclusions and outlook
Aim Aim
Production of electronic parts through the combination of the primary forming processes injection moulding and die casting Manufacture of a thermoplastic carrier with integrated conductor tracks made of low melting metal alloys on one machine and within one mould
Dissipating heat has an antifogging effect on the lenses Hybrid 3-component-application Complex three dimensional course of the conductor track Directly contacted connector pins Finishing free production
Mould and machine technique for the hybrid multi-component injection moulding
Development of a metal injection unit which combines elements of metal die casting and micro injection moulding Fully automated production of the heatable sports glasses using a 3-station index plate mould integrated in a complex production cell
Station 1 Production of the optical glasses and moulding around the metal pins Station 2 Injection of the low melting metal alloy and direct contacting of the metal pins Station 3 Manufacture of the frame and demoulding Monitoring of the hybrid multi-component injection moulding process using pressure and temperature sensors
Outline
Introduction trends in injection moulding New injection moulding technologies for increasing process and function integration Surface functionalisation using variothermal injection moulding Lightweight parts for automotive applications
Projectile injection technique Back foaming of metal sheets Hybrid light-weight construction parts
Hybrid multi-component injection moulding for electronic applications Conclusions and outlook