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2K Thermoplast-Thermoset rubber injection molding
Ing. Wim Six
24/06/2016
Content
• KU Leuven - Propolis• Project definition• Thermoset material data• Test product
o Simulation modelo Simulation resultso Simulations VS measurements
• Conclusions
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Founded in 1425Oldest and largest university in Belgium
12 university colleges80,000 students (40% market share)
KU Leuven - Propolis
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KU Leuven - Propolis
• Academic Educationo Master of science:
• Civil engineering • Electronics and ICT Engineering• Energy Engineering• Electromechanical engineering• Polymer Processing engineering
• Scientific and Social Services • Scientific research
o Polymer processing o Lightweight structures
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5/18
• Processing and Characterization of o Short fibre (bio-, glass-) reinforced (bio-)TP
materials (recycled materials)• Optimisation of processes
o Energy, cycle time, temperatures, RTD…• Multiscale Modelling of thermal/mechanical
properties for innovative material combinationso Sandwich structureso Adhesive Bonding Structural adhesiveso Light weight materials (foams,…)
• Development for applications with RPA’s
KULeuven – Propolis: research
KULeuven - Propoliso Labs
• Processing
• Material testing
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KULeuven - Propolis• Simulation softwareSiemens NX 10.0 ASMI 2016
Virtual Extrusion Laboratory 6.8 T-sim 4.81
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Project definition• optimization of 2K Thermoset rubber-Thermoplastic
injection molding
hard-soft combination EPDM, NBR, NR …. prediction of process parameters optimizing mold prediction of properties of final product
Goal: optimal adhesion between TP en TS
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Test product• Simple plate geometry
o TP 150 x 40 x 2 mm o TS 150 x 40 x 2 mm
• 2K injection molding machine @ CEL Kunststoffen, Diepenbeek
Engel ES330/80V/80 HL-2F o Variotherm unito TP injection unito TS rubber injection unito Gas and water assisted injection
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Material parameters viscosity EPDMmeasured by dual bore reometeruncured material
100
1000
10000
10 100 1000
visc
osity
(Pas
]
shr. rate [1/s]
120°C 130C 140°C 150°C 160°C 170°C
( ) ( )( )
( )ααα
α
τ
γη
ηγαη
⋅+
−⋅
−⋅+
=
CC
g
gnT
TT
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*
101
0,,
( )
⋅=
TT bBT exp0η
http://www.azom.com/equipment-details.aspx?EquipID=1125
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Material parameters curing behavior: Kamal-Sourour
Measured by MDR
−=
TEiAiK i exp.
( )( )ααα
−+= 1.21nmKKdt
d
http://www.montechusa.com/rheometer_mdr3000pro.shtml
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2K simulation in Moldflow 2016• No straight forward method for 2K Thermoset rubber-
Thermoplastic injection• Use of reactive solver 3D mesh
o Part insert: HPDE• Thermoplastic proporties
• Cp, λ, ρ
• Initial temperature• 80°C
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2K simulation in Moldflow 2016• No straight forward method for 2K Thermoset rubber-
Thermoplastic injection• Use of reactive solver 3D mesh
o Rubber : EPDM• Tmold=160°C• Tinj=85°C• tcure=1200s• tpack=200s• tinj=0,5s
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2K simulation in Moldflow 2016• No straight forward method for 2K Thermoset rubber-
Thermoplastic injectiono Two cases
• cooling water TP side @ 60 and 100°C• monitoring of curing• melted amount
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Simulation resultsmold wall temperature
138°C115°C
water @ 60°C water @ 100°C
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Simulation resultsMold wall temperature
60
80
100
120
140
160
180
-40 -30 -20 -10 0 10 20 30 40
tem
peat
ure
[°C]
location [mm]
water TP 60°C water TP 100°C
adhesive zone!
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Simulation resultsRemelted amount T>120°C
water @ 60°C water @ 100°C
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Simulation resultsCuring
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1
0 5 10 15 20 25 30 35 40
degr
ee o
f cur
e []
distance [mm]
80s 120s 160s 200s 300s 500s 400s 1100s
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1
0 5 10 15 20 25 30 35 40
deg
ree
of
cure
[]
distance [mm]
80s 120s 160s 200s 300s 400s 500s 1100s
water @ 60°C water @ 100°C
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MeasurementsCuring• #curing ~ hardness
o Shore Ao trelax=15so XY table for location
EPDM HDPE
25 20 15 10 5 2 1 0
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Measurements: exampleEPDM HDPE
25 20 15 10 5 2 1 0
0
10
20
30
40
50
60
0 5 10 15 20 25 30
hard
ness
shor
e A
distance[mm]
Hardness with TP wall temp 60°C
1600s 1400s 1200s
1000s 800s 600s
0
0,2
0,4
0,6
0,8
1
1,2
0 5 10 15 20 25 30de
gree
of c
ure
distance[mm]
vulcansiation with TP wall temp 60°C
1600s 1400s 1200s
1000s 800s 600s
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Measurement VS simulationsEPDM HDPE
25 20 15 10 5 2 1 0
0
0,2
0,4
0,6
0,8
1
1,2
0 5 10 15 20 25 30 35 40
degr
ee o
f cur
e
distance [mm]
simulatie 1200s gemeten 1200ssimulatie 800s gemeten 800s
0
0,2
0,4
0,6
0,8
1
1,2
0 5 10 15 20 25 30 35 40
degr
ee o
f cur
e
distance [mm]
1200s simulation 800s simulation800s measurement 1200s measuremetn
water @ 60°C water @ 100°C
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adhesion
water @ 60°C water @ 100°C
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adhesion
water @ 60°C water @ 100°C
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ConclusionsMODELo Part Insert as 2nd componentCURINGo Good agreement simulations measurementsADHESIONo remelted TP adhesionFUTURE WORKo DOE o determine strength of adhesion vs process parameterso Mechanical properties vs curing time
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