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SEMINAR REPORT

REACTION INJECTION MOLDING

Submitted by

ASHWIN VARKEY

REG. NO.:160909372

MECHANICAL SECTION B

ROLL NO: 49

EMAIL ID:ashwinvarkey9@gmail.com

CONTACT NO: +91 8921987193


Reaction Injection Molding

CONTENTS
Pg.no
1. INTRODUCTION 3
1.1 Types
1.2 Raw Materials

2. REACTION INJECTION MOLDING 5


2.1 RIM Cycle in stages
2.2 Rheological changes

3. TOOLING 8
3.1 Mold materials
3.2 Mold design parameters

4. REACTION INJECTION MOLDING SYSTEM 10


4.1 Parameters
4.2 Advantages
4.3 Disadvantages
4.4 Applications

5. RECENT DEVELOPMENTS 14
5.1 Taguchi method
5.2 Artificial Neural Networks (ANN)
5.3 Finite Element Method (FEM)
5.4 Linear Regression model

6. REFERENCES 19

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Reaction Injection Molding

LIST OF FIGURES

1: RIM Molding Process

2: Industry RIM process

3: Rheological changes during RIM cycle


4: Cavity Mold with Sheet Metal Inserts

5 (a): Filling pressure vs Viscosity graph

5 (b): Filling pressure vs Injection flow graph

5 (c): Pressure drop vs Cavity height

5 (d): Pressure drop vs Gate radius

6: Cause-and-effect diagram shown in fishbone schematics

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Reaction Injection Molding

1. INTRODUCTION

The Reaction Injection Molding process (RIM) was conceived in the laboratories of

Bayer AG, Leverkusen, West Germany, about 1964. The Reaction Injection Molding

process is a structural foam molding process. This process is most suited for

moderate-volume production of medium-to-large structural parts. Polymerization

process finishes in a few seconds (5-30 seconds).

1.1 Types

A modification of reaction injection moulding is structural reaction injection moulding.

In this process, instead of utilising chopped and short fibres, continuous woven fibre

mat or CSM (chopped strand mat) can be applied. But if the reinforcing agents are

combined with the mixture, then the process is known as reinforced reaction injection

moulding (RRIM) [1].

Fig.1 RIM Molding Process [1]

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Reaction Injection Molding

1.2 Raw Materials

The reaction injection molding (RIM) method employs low-viscosity liquid polymers.

These polymers grow and thicken through a number of chemical reactions. After the

polymers have been introduced into the heated mold, they harden. Through the RIM

design process, raw materials and molding techniques can be chosen and

customized, deliver the desired weight, strength, density and hardness characteristics

that are required. The following raw materials are generally used in RIM,

i. Matrix Thermosetting: Epoxy resin, polyester, polyvinyl ester, phenol resin,

unsaturated polyester, polyurethane resin, dicyclopentadiene (dcpd-t)

ii. Matrix Thermoplastic: polypropylene, polyethylene, nylon, polycarbonate,

polyvinyl chloride (PVC), cellulose acetate, polyether ether ketone (PEEK),

Acrylonitrile-butadiene-styrene (ABS), polystyrene biopolymers such as poly

lactic acid, poly vinyl alcohol, and soy based plastic, starch polymers etc.

iii. Reinforcement: Glass fiber, carbon fiber, aramid fiber, mica, plant fibers like

banana, nettle, hemp, flax (all these fibers are used in the form of short fibers,

chopped fibers and fillers) [3].

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Reaction Injection Molding

2. REACTION INJECTION MOLDING PROCESS

Reaction injection molding is a multistage process requiring methods distinct from

standard injection molding. RIM is one of the advanced processing techniques for

composite manufacturing. In this process, two reacting components mixed by

impingement and injected into the mold cavity. The biochemical reaction starts

immediately after incorporating the substances and polymerization starts.

2.1 RIM Cycle in stages

Fig.2 Industry RIM process [2]

The mixing tool applies pressures typically between 1,400 and 3,000 psi to mix the

plastics through impingement. After the reactants incorporate, they are injected into

the mold at high speed. The mixing head stops releasing reactants when the mold is

filled to limit.

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Reaction Injection Molding

Turbulence is created by stream impingement at high pressure (1,500 - 3,000 psi)

Mixhead is designed to develop turbulence in the mix chamber to carefully mix the two

components. Mix chamber is a small cylinder having components come from opposite

sides of chamber. Streams should have equal energy momentum at the time they

meet. Metered shot is removed from mixing chamber by a tightly fitting ram and flows

directly into mold .Mold is normally filled from underneath so air can easily push out

ahead of flow. Shot fills mold to about 90% and expansion during chemical reaction

of the polyol and isocyanate completes the fill. An exothermic chemical reaction

occurs inside the mold, resulting in plastic polymerization.

After the polymer solidifies, it is ejected from the mold in the shape of the component

required. Components react and gel within a range of 2 - 10 secs from the beginning

of injection. Mold remains closed for the time period to allow sufficient cure so part

can be removed and handled preventing damage (30 - 90 secs). Knockout pins,

automatic slides, or pneumatic devices in the mold used to help with demolding. RIM

machines accomplish this process using comparatively lower temperatures. Rather

than thermal energy, RIM produces chemical energy caused due to polymerization

reactions [3].

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Reaction Injection Molding

2.2 Rheological changes in RIM cycle

Fig.3 Rheological changes during RIM cycle [2]

The intimate mixing of isocyanate and polyol streams is important to a successful RIM

operation. Upon entering the mold cavity the materials follow a series of events, during

which the viscosity of the flowing mixture increases during mold filling due to chemical

reaction, the modulus of the material in the mold cavity increases as curing continues

after the mold cavity is filled, and finally the product is ejected from the mold after a

sufficient degree of cure is attained. In other words, when the mold cavity is filled in a

reasonable short time, cure reactions take place to form a three-dimensional network.

Then while chemical reactions continue to yield large molecules with network

structure, the mixed stream fills mold cavity and subsequently solidifies. Therefore,

RIM can be regarded as a process where fluid flow, heat transfer, and chemical

reaction are involved simultaneously [4].

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Reaction Injection Molding

3. TOOLING

The molds used with the RIM process can be made from a variety of materials: cast

and machined aluminium, composites, sprayed metal, epoxy, nickel shell and steel.

The choice is determined by the number of parts to be made, dimensions, shapes and

tolerances, surface texture, mold life, mold cost and part performance.

3.1 Mold materials

Silicone rubbers are used in making reaction injection moulds as it is equipped with

very low quantities of dimensionally no critical parts. Resin mold are used for

components requiring more detail and better physical properties. Spray metal molds

offer better control of surface quality and enhanced moldability. A composite system

with an epoxy and aluminium chip mixture acts as the backup structure for the thin

metal surface. Aluminium frames are cast to act as a mould base for mounting ejector

systems, mix head, side pulls, and to ultimately mount to a production press because

it has maximum physical properties of the urethane material system.

3.2 Mold Design Parameters

RIM products have uniform shrink and dimensional stability. Low mold temperatures

of 120 to 160F help reduce part shrinking. Wall thicknesses from 3/16" to 1/4" are

preferred. Molded thicknesses can be ranged to well over 1/2" without sink marks in

the molded surfaces. Densities are from 37 to 41 pounds per cubic foot. Screw threads

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Reaction Injection Molding

are used by inserting brass screw inserts into molded gaps after the part is molded.

The following parameters are considered.

 Mold Clamping Pressure which is determined by the amount of material and

the type of RIM system injected inside the mold. Generally, clamping pressure

can be upwards of 200 tons, but typical molding pressure is around 100 psi.

Fig.4 Cavity Mold with Sheet Metal Inserts [2]

 Mold Cost – RIM molds can cost 70% less than injection molding. Lower in-

mold pressures allow molds to be created from cheaper materials, usually

machined aluminum.

 Part shrinkage – all plastics, including RIM materials, shrink during molding.

The percentage of shrinkage characteristic of the particular RIM system is

factored into the tool’s design [3].

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Reaction Injection Molding

4. REACTION INJECTION MOLDING SYSTEM

Due to its low processing temperatures and decreased injection pressures, RIM is

well-suited for molding significant components with shifting wall thickness and smooth

surface finishes. Manufacturers can also profit from its relatively high turnover rate,

which makes it proficient in managing low- to mid-volume projects.

4.1 Parameters

The main process parameters in the process of injection, study, temperature and

pressure, viscosity, flow injection, effect of cavity size and gate size and other factors

on the different degree of injection molding the process of both. In the design and use

of rubber injection machine, should fully consider the impact of various factors.

4.1.1 Effect of Viscosity

Fig.5 (a) Filling pressure vs Viscosity [5]

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Reaction Injection Molding

It can be seen from the figure 5 (a) that with the increase of the viscosity, the filling

pressure is generally a linear upward trend. When the viscosity is increased, the

friction force in the rubber material increases, the flow property becomes worse. The

energy consumed by the process is large. When the viscosity reaches a certain value,

the injection molding process is difficult to complete [5].

4.1.2 Effect of Injection flow

Injection flow is larger, the shorter filling time, injection pressure is bigger. Figure 5(b)

shows that injection pressure with flow injection increased increases to a lesser extent.

In mold filling process, when the flow rate is increased, viscous shear stress increases

as well, injection pressure will increase. This, in turn, will reduce the viscosity of the

sizing, so that injection pressure decreases [5].

Fig.5 (b) Filling pressure vs Injection flow [5]

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Reaction Injection Molding

4.1.3 Effect of Cavity height

Fig.5 (c) Pressure drop vs Cavity height [5]

Figure 5 (c) shows that in a certain range of cavity height, pressure drop in a certain

range of the greatest impact. When the cavity height is less than a certain value,

pressure drop sharply; otherwise, the change of pressure drop in smaller. This is

mainly because when the thickness of the product is small, viscous shear stress is

very high; at this time if the thickness is reduced shear force will rise rapidly, causing

the pressure surge [5].

4.1.4 Effect of Gate radius

Fig.5 (d) Pressure drop vs Gate radius [5]

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Reaction Injection Molding

Figure 5 (d) shows the relationship between the gate size and the entrance pressure

drop. From the figure visible, when the gate size is very small, pressure drop versus

gate size expansion decreased quickly. This is because the gate is bigger, at the

entrance of the average velocity becomes smaller, and is filling the shear rate, so as

to reduce the pressure drop [5].

4.2 Advantages

All types of polymers can be processed with RIM process and placed well to optimize

directional properties. In reaction injection molding, no heat energy is required and

mold cost is less. Small to large complex geometries of composite parts can be

manufactured with this technique.

4.3 Disadvantages

The initial capital investment is enormous. Parts & tooling comparatively high and

expensive raw materials. Due to significant shearing action into the barrel and nozzle,

extensive damage to the fibers may take place. Due to increased tooling cost and

operation cost, it is not preferred for small production run.

4.4 Applications

Automotive companies manufacture RIM-produced steering wheels, side panels,

instrument gauges, dashboard consoles, armrests, body frames, and bumpers. The

advent of controllable reactivity resins such as polyuria/amide has introduced a trend

toward larger machines, larger clamps and larger parts. It is used in manufacturing

office supplies, audio equipments, computer cases, and furniture [6].


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Reaction Injection Molding

5. RECENT DEVELOPMENTS

The leading causes of the defect in injection moulding can be because of mould

design, process parameters, machine, operator or material. The details are shown in

the fishbone diagram.

Fig.6 Cause-and-effect diagram shown in fishbone schematics [7]

One of the main goals in injection moulding is the improvement of quality of molded

parts besides the decrease of cycle time, and lower production cost. Optimizing

process parameter problems are routinely performed in the manufacturing industry,

particularly in setting final optimal process parameters. Previously, engineers used

trial-and-error processes which depend on the engineers’ experience and intuition to

determine initial process parameter settings. However, the trial-and-error method is

costly and time-consuming; thus it is not suitable for complex manufacturing


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processes Factors that affect the quality of a molded part can be classified into four

categories: part design, mould design, machine performance and processing

conditions. Determining optimal process parameter settings critically influences

productivity, quality, and cost of production in the plastic injection moulding (PIM)

industry.

5.1 Taguchi method

Taguchi’s method is a tool for the design of high-quality manufacturing system. Dr

Genichi Taguchi, a Japanese quality consultant, has produced a method based on

orthogonal array experiments, which presents decreased variance for the test with an

optimum number of method control parameters. Thus the integration of design of

experiments (DOE) with parametric optimisation of the method to obtain useful

outcomes is achieved in the Taguchi method. The Taguchi method attempts to

optimise a product design and is based upon three stages, as follows:

1. Concept Design: Design at a conceptual level, involving creativity and innovation.

2. Parameter Design: The initial values of the various dimensions and design

parameters need to be set, the detail design phase of conventional engineering.

3. Tolerance Design: With a properly completed parameter design, and an

understanding of the effect that the different parameters have on performance,

resources can be focused on reducing and controlling variation in the critical few

dimensions [7].

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Reaction Injection Molding

5.2 Artificial Neural Networks (ANN)

Artificial neural networks (ANNs) are characterized as mathematical models which

describe the biological process of a human brain. There are three main elements in

the ANNs; neurons or processing elements (PE), interconnections, and training rules.

A neuron is a segment that processes data. It receives and prepares input signals and

continually transfers its output to the next level neurons. A single neuron may hold

more than one input but only one output. The production of a neuron depends upon

the input signals, weights of links, threshold value and activation purposes.

The specimens were made under different injection moulding conditions by changing

melting temperatures, injection speeds and injection pressures of three computer-

controlled progressive strokes. Minimizing the contour distortions was the purpose of

this study. Sixteen experimental runs based on a Taguchi orthogonal array table were

employed for training the RBN, and the SQP method was applied to search for an

optimal solution. In this study, the proposed algorithm yielded better performance than

the design of experiments (DOE) approach. Besides, the analysis of variance

(ANOVA) was conducted to identify the significant factors for the contour distortions

of the specimens [7].

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Reaction Injection Molding

5.3 Finite Element Method (FEM)

FEM allows precise visualization of where structures bend or twist, and indicates the

arrangement of stresses and displacements. FEM software provides a broad range of

simulation options for managing the complexity of both modelling and analysis of a

system. Likewise, the desired level of accuracy needed and associated computational

time specifications can be achieved concurrently to address most design applications.

FEM enables entire designs to be constructed, improved, and optimized before the

design is created. In general, the finite element method is characterized by the

following processes.

Lee et al. [2006] illustrated finite element and abductive neural network methods to

the study of a multi-cavity injection mould. To choose the optimal runner system

parameters to decrease the warp of an injection mould, FEM, Taguchi’s method and

an abductive network were applied. These methods were employed to train the

abductive neural network. Once the runner and gate system parameters were

generated, this network was used to predict the twist of the multi-injection mould

accurately. A simulated annealing (SA) optimization algorithm including a

performance index is then used to the neural network to search the gate and runner

system parameters [7].

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Reaction Injection Molding

5.4 Linear Regression model

Linear regression is a standard statistical technique for solving optimization problems.

Linear regression designs are compelling and can ease complicated relationships

among variables. They help to explain the relationship between the dependent

variable, usually denoted y, with observed values of one or more independent

variables, often indicated x1,x2,...,xn. A vital focus of all regression models is the error

term, which is included to obtain sources of error not achieved by other variables.

Protyusha Das Neogi and Elizabeth A. Cudney (2009) used regression analysis to

compare the actual and the forecasted data estimate of the real value of the output

for each signal member. Linear regression analysis is then performed on the data set.

The composition of this analysis is a linear equation which defines the change of the

independent variable concerning changes in the dependent variables. The strength of

the relationship is then assessed using R-squared value and adjusted R-squared

value. Time series analysis is also performed to predict future values. The predicted

values obtained from the resulting equation are then compared to the values obtained

by the T-Method [7].

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Reaction Injection Molding

6. REFERENCES

[1] Rheology of thermosets: the use of chemorheology to characterise and model

thermoset flow behavior, P.J.Halley

[2]Polyurethanes and Polyisocyanurates, J.A. Brydson, in Plastics Materials (Seventh

Edition), 1999

[3] https://nptel.ac.in/courses/112107085/module5/lecture8/lecture8.pdf

[4] Rheology and Processing of Polymeric Materials, Volume 2 by Chang Dae Han,

page 500-504

[5] Research on Injection Molding Method and Process Control of Polymer Rubber

Zhang Di*,

[6] P.S. Liu, G.F. Chen, in Porous Materials, 2014

[7] Recent Methods for Optimization of Plastic Injection Molding Process - A Literature

Review Rashi A.Yadav, Principal S.V.Joshi, N.K.Kamble Production Engineering

Department D.Y.Patil College of Engineering

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