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HYBRID MOULDS - THERMAL
ASPECTS
Prof. Ludwig Cardon October 2017
DEPARTMENT OF MATERIALS, TEXTILES AND CHEMICAL ENGINEERING
POLYMER, FIBER AND COMPOSITE MATERIALS
@ GHENT UNIVERSITY
October 2017
DEPARTMENT OF MATERIALS, TEXTILES AND CHEMICAL ENGINEERING
GENERAL STRUCTURE
4
Ghent University
Faculty of Engineering and Architecture
MaTChDepartment of Materials, Textiles and Chemical Engineering
Research groups (CPMT, LCT, MMS, CTSE, …)
Research topics: Polymer, Fibre and Composite Materials
Prof. Ludwig Cardon
Prof. Karen De Clerck
Prof. Dagmar D’hooge
Prof. Kim Ragaert
Prof. Wim Van Paepegem
Advanced materials
Chemicals
Polymerisation
Polymergranules
Polymerprocessing
Polymericmaterial
Embedded as a multidisciplinary
research field
RESEARCH
5
Composites
Filtration
3D-Printing
materials
Recycled materialsBio-
medical
Sensors
Artificial turf
Advancedmaterials
RESEARCH
7
ThermalDifferential Scanning Calorimetry (DSC)
ThermoGravimetric Analysis (TGA)
Dynamic-Mechanical Thermal analysis (DTMA)
Dynamic Vapour Sorption (DVS)
Tg, Tm
Curing of resins
Polymer blends
….
MechanicalFavimat (small-scale: single fibres, ribbons, …)
Statimat (medium-scale: yarns, films, …)
Instron (large-scale: composites, bulk, …)
Performed in climatised conditions
(elevated temperatures possible)
Creep/relaxation
Static, cyclic
…
Characterization, testing, and
monitoring
Microscopy & Spectroscopy
Optical & Stereo-microscopesScanning electron microscopy
FT-IR and FT-Raman spectroscopy UV-VIS spectroscopy
Monitoring & NDT
During testing, production and lifetime of the part
Fiber Bragg GratingsDigital Image Correlation
Cure monitoring Ultrasonics
Local defect resonance
8
Industrial Polymer Synthesis
Experimental and Numerical flow analysis
Multi-scalemodeling
Polymer processing
Simulation at micro- and meso-scaleFracture mechanics simulations
Structural simulations (static, impact, fatigue)
Composites
Dry fabricsSimulation of tension, shear, twist, …
Draping simulations
9
ExtrusionSingle & twin screw
Reactive extrusion
Blow film and plate
Filament extrusion
3D-Printing
Extrusion based 3DP
22 up to 80 T injection machines
Processing
Injection moulding Electrospinning
10
Mechanical Recycling Microfibrillar composites composites
Recycling
Upcycling Chemical recycling
POLYMER RESEARCH @ UGENT-CPMT
11
CPMT GROUP
MATCHDEPARTMENT OF MATERIALS, TEXTILES
AND CHEMICAL ENGINEERING
CENTRE FOR POLYMER AND
MATERIAL TECHNOLOGIES
2 professors
1 bussiness
developer
3 postdocs
15 PhD’s
3 technicians
20 master students
RESEARCH LINES @ CPMTP
rof.
Car
do
n-
3D
Pri
nti
ng • Extrusion based
3D Printing
• 3D Printing of composites
• Printhead development
• Development of new materials for 3D Printing
• 3D Printing build strategies
• Fablab UGent Pro
f. C
ard
on
-A
dva
nce
d P
oly
mer
Pro
cess
ing • Injection Mould
Engineering
• Conductive polymers
• Hybrid Moulds
• Process simulation
Pro
f. R
agae
rt -
Rec
yclin
g an
dSu
stai
nab
leU
se• Mechanical recycling
• Mixed polymerwaste
• Multilayer packaging
• WEEE recycling
• Compounding
• Microfibrillar composites
• Design for & from Recycling
• Degradation effects
HYBRID MOULDSTHERMAL ASPECTS
15
WHAT ARE HYBRID MOULDS?
Who will use this?
Product designers new design methods Mould designersmore freedom of design Mould makers adapted machining parameters Polymer processors adapted processing parameters
16
WHAT ARE HYBRID MOULDS?
Actual status of mould developmenthybrid moulds conventional production technologies AM technologies
Mould cooling related to cycle time and product quality optimal cooling channel layout conformal cooling mould material selection
Product quality improvement e.g. sink marks degree of crystallisation tribology aspects (e.g. wearing)
17
WHAT ARE HYBRID MOULDS?
MOULD MATERIAL SELECTION
Thermal characteristics of mould materials are very important
Related to the core/cavity design strategynew part & mould design strategy
“Unknown” material characteristics
heat capacity Cp (DSC analysis) specific density r thermal conduction l
thermal diffusivity a
r
l
Cpa
Thermal diffusivity a [10-8 m²/sec]
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375
T [°C]
a [
10
-8 m
²/se
c]
Copper
Protherm
Alumec
Moldmax XL
LaserForm 100
Steel 1730
DirectMetal 20 sinter
Holdax
Impax Supreme
DirectSteel 50 sinter
Ramax
Prometal
Stavax ESR
DirectSteel H20
DirectSteel 20 sinter
CL 50 (LaserCusing)
CL 80 (LaserCusing)
The metal groups: Conventional mould materials
Selective Laser Sintermaterials
Selective Laser Melting materials
Mould material selection method
The metal groups: Conventional mould materials
Selective Laser Sintermaterials
Selective Laser Melting materials
Mould material selection method
Thermal diffusivity a [10-8 m²/sec] (without Copper, Alumec en Protherm)
200
325
450
575
700
825
950
1075
1200
1325
1450
1575
1700
0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375
T [°C]
a [
10
-8 m
²/se
c]
Moldmax XL
LaserForm 100
Steel 1730
DirectMetal 20 sinter
Holdax
Impax Supreme
DirectSteel 50 sinter
Ramax
Prometal
Stavax ESR
DirectSteel H20
DirectSteel 20 sinter
CL 50 (LaserCusing)
CL 80 (LaserCusing)
Example of ahybrid mould
ProMetal 55 °C ProMetal & Aluminium 50 °C
IR analysis of Prometal and Aluminium mould
ProMetal & Aluminium 50 °CProMetal 55 °C
IR analysis of Prometal and Aluminium mould
23
ProMetal 55 °C ProMetal & Aluminium 50 °C
IR analysis of Prometal and Aluminium mould
24
Combination of:➢multi materials in the same mould➢conventional mould making➢AM technologies➢“conventional” conformal cooling➢“AM” conformal cooling
With final result :➢optimal cooling chanel layout➢No “warpage”➢Faster cycle time➢Beter product quality and material properties
INTEGRATION OF KNOWLEDGE INTO A BUSINESS CARD BOX
25
• AM insert for living hinge
as for better rheological characteristics and “conformal cooling”
a new cooling has been designed
❖ Optimal “cooling” of living hinge
❖ Better rheology at location of living hinge
verification via Kistler sensors & IR analyses
• Heated injection nozzle
• Integration of DME “Quick Strip” ejection system
extra degree of freedom as for cooling channel design
“conventional” “conformal cooling”
• “freeform” design method related to ejectors
OPTIMIZED MOULD
26
OPTIMIZED MOULD
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conformal cooling insert in “maraging” steelvia EOS SLM technology
OPTIMIZED MOULD
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“conventional”conformal cooling insert
OPTIMIZED MOULD
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• Packaging
• Heat control for mould making
• Extrusion and stretch blow moulding
• Thermoforming
• Micro injection moulding
• ...
OTHER APPLICATIONS?
• Conventional cycle time: 38s
• Estimated cycle time (conformal cooling HM): 19s
• Real HM cycle time: 32s
• HM shell is not accurate in calculating cycle time
• 16% of cycle time reduction
• Annual total profit of 222.000 €(6.000.000 parts/year)
Conformal cooling for packaging
BLOW MOULDING
BLOW MOULDING
Blow/cooling air simulation
BLOW MOULDING
34
MICRO MOULDING
35
MICRO MOULDING
THERMOFORMING
Hybrid mould made from PLA Mould via Necuron milling
THERMOFORMING - REAL
THERMOFORMING - SIMULATION
prof. dr. Ludwig Cardon
Head of CPMT
+32 478 224 335
39
CPMT
Technologiepark 915
9052 Zwijnaarde, BE
+32 9 331 03 91
www.match.ugent.be
Member of
prof. dr. Kim Ragaert
Sustainable Use and Recycling of
Polymers & Composites
+32 476 322 700
CONTACT INFORMATION
