Abstract: In order to reduce fuel consumption, the weight of automobiles has to be reduced. Fiber reinforced polymers offer the potential to reach this aim because of their high stiffness to weight ratio. Additionally, the use of fiber reinforced polymers in automotive applications has to allow for an economic large-scale production. In this regard, long fiber reinforced thermoplastics made by direct processing offer both mechanical performance and processability in injection moulding and compression moulding. The work presented in this contribution deals with long glass fiber reinforced polypropylene directly processed in compression moulding (D-LFT). For the use in automotive applications both the temperature and the time dependency of the materials properties have to be investigated to fulfill performance requirements during crash or the demands of service temperatures ranging from -40 °C to 80 °C. To consider both the influence of temperature and time, quasistatic tensile tests have been carried out at different temperatures. These tests have been complemented by high speed tensile tests at different strain rates. As expected, the increase in strain rate results in an increase of the elastic modulus which correlates to an increase of the stiffness with decreasing service temperature. The results are in good accordance with results determined by dynamic mechanical analysis within the range of 0.1 to 100 Hz. The experimental results from different testing methods were grouped and interpreted by using different time temperature shift approaches. In this regard, Williams-Landel-Ferry and Arrhenius approach based on kinetics have been used. As the theoretical shift factor follows an arctan function, an empirical approach was also taken into consideration. It could be shown that this approach describes best the time and temperature superposition for glass fiber reinforced polypropylene manufactured by D-LFT processing.
Abstract: Within Rapid Prototyping technologies are used many
types of materials. Many of them are recyclable but there are still as
plastic like, so practically they do not degrade in the landfill.
Polylactic acid (PLA) is one of the special plastic materials, which
are biodegradable and available for 3D printing within Fused
Deposition Modeling (FDM) technology. The question is, if the
mechanical properties of produced models are comparable to similar
technical plastic materials which are usual for prototype production.
Presented paper shows the experiments results for tensile strength
measurements for specimens prepared with different 3D printer
settings and model orientation. Paper contains also the comparison of
tensile strength values with values measured on specimens produced
by conventional technologies as injection moulding.
Abstract: The plastic industry plays very important role in the
economy of any country. It is generally among the leading share of
the economy of the country. Since metals and their alloys are very
rarely available on the earth. Therefore, to produce plastic products
and components, which finds application in many industrial as well
as household consumer products is beneficial. Since 50% plastic
products are manufactured by injection moulding process. For
production of better quality product, we have to control quality
characteristics and performance of the product. The process
parameters plays a significant role in production of plastic, hence the
control of process parameter is essential. In this paper the effect of
the parameters selection on injection moulding process has been
described. It is to define suitable parameters in producing plastic
product. Selecting the process parameter by trial and error is neither
desirable nor acceptable, as it is often tends to increase the cost and
time. Hence, optimization of processing parameter of injection
moulding process is essential. The experiments were designed with
Taguchi’s orthogonal array to achieve the result with least number of
experiments. Plastic material polypropylene is studied. Tensile
strength test of material is done on universal testing machine, which
is produced by injection moulding machine. By using Taguchi
technique with the help of MiniTab-14 software the best value of
injection pressure, melt temperature, packing pressure and packing
time is obtained. We found that process parameter packing pressure
contribute more in production of good tensile plastic product.
Abstract: Polymeric micro-cantilevers (Cs) are rapidly
becoming popular for MEMS applications such as chemo- and biosensing
as well as purely electromechanical applications such as
microrelays. Polymer materials present suitable physical and
chemical properties combined with low-cost mass production. Hence,
micro-cantilevers made of polymers indicate much more
biocompatibility and adaptability of rapid prototyping along with
mechanical properties. This research studies the effects of three
process and one size factors on the filling behaviour in micro cavity,
and the role of each in the replication of micro parts using different
polymer materials i.e. polypropylene (PP) SABIC 56M10 and
acrylonitrile butadiene styrene (ABS) Magnum 8434 . In particular,
the following factors are considered: barrel temperature, mould
temperature, injection speed and the thickness of micro features. The
study revealed that the barrel temperature and the injection speed are
the key factors affecting the flow length of micro features replicated
in PP and ABS. For both materials, an increase of feature sizes
improves the melt flow. However, the melt fill of micro features does
not increase linearly with the increase of their thickness.
Abstract: In this study, composites were fabricated from oil
palm empty fruit bunch fiber and poly(lactic) acid by extrusion
followed by injection moulding. Surface of the fiber was pre-treated
by ultrasound in an alkali medium and treatment efficiency was
investigated by scanning electron microscopy (SEM) analysis and
Fourier transforms infrared spectrometer (FTIR). Effect of fiber
treatment on composite was characterized by tensile strength (TS),
tensile modulus (TM) and impact strength (IS). Furthermore,
biostrong impact modifier was incorporated into the treated fiber
composite to improve its impact properties. Mechanical testing
showed an improvement of up to 23.5% and 33.6% respectively for
TS and TM of treated fiber composite above untreated fiber
composite. On the other hand incorporation of impact modifier led to
enhancement of about 20% above the initial IS of the treated fiber
composite.
Abstract: In this study, tapioca starch, which acts as natural polymer, was added in the blend in order to produce biodegradable product. Low density polyethylene (LDPE) and tapioca starch blends were prepared by extrusion and the test sample by injection moulding process. Ethylene vinyl acetate (EVA) acts as compatibilizer while glycerol as processing aid was added in the blend. The blends were characterized by using melt flow index (MFI), fourier transform infrared (FTIR) and the effects of water absorption to the sample. As the starch content increased, MFI of the blend was decreased. Tensile testing were conducted shows the tensile strength and elongation at break decreased while the modulus increased as the starch increased. For the biodegradation, soil burial test was conducted and the loss in weight was studied as the starch content increased. Morphology studies were conducted in order to show the distribution between LDPE and starch.
Abstract: Moulded parts contribute to more than 70% of
components in products. However, common defects particularly in
plastic injection moulding exist such as: warpage, shrinkage, sink
marks, and weld lines. In this paper Taguchi experimental design
methods are applied to reduce the warpage defect of thin plate
Acrylonitrile Butadiene Styrene (ABS) and are demonstrated in two
levels; namely, orthogonal arrays of Taguchi and the Analysis of
Variance (ANOVA). Eight trials have been run in which the optimal
parameters that can minimize the warpage defect in factorial
experiment are obtained. The results obtained from ANOVA
approach analysis with respect to those derived from MINITAB
illustrate the most significant factors which may cause warpage in
injection moulding process. Moreover, ANOVA approach in
comparison with other approaches like S/N ratio is more accurate and
with the interaction of factors it is possible to achieve higher and the
better outcomes.
Abstract: In this paper, the influencing parameters of a novel
purely mechanical wireless in-mould injection moulding sensor
were investigated. The sensor is capable of detecting the melt
front at predefined locations inside the mould. The sensor comprises
a movable pin which acts as the sensor element generating
structure-borne sound triggered by the passing melt front. Due to
the sensor design, melt pressure is the driving force. For pressure
level measurement during pin movement a pressure transducer
located at the same position as the movable pin. By deriving
a mathematical model for the mechanical movement, dominant
process parameters could be investigated towards their impact
on the melt front detection characteristic. It was found that the
sensor is not affected by the investigated parameters enabling it
for reliable melt front detection. In addition, it could be proved
that the novel sensor is in comparable range to conventional melt
front detection sensors.