Exact - TPO - ExxonMobil Chemical Company

Kunststoffe international, Absorption of Water by Molded Plastics
...ly in accordance with Annex A.1 of DIN EN ISO 62 as being 1.02 ∙ 10–12 m²/s. This compares with the diffusion coefficient stated in [3] of 0.9 ∙ 10–12 m²/s. The experimental value is not exact, but is of the same order of magnitude and is sufficiently accurate. For a transient diffusion analysis, the density and the degree of water absorption at saturation are still required. The required material properties for a diffusion calculation are illustrated with an example in Table 2. The definition ...

Kunststoffe international, All about Plasticizing Screws
...min, while in plastics with medical ingredients degradation processes may already set in after only 2 min. Reference Value for the Length of the Screw At the stage of developing a specific screw geometry, the exact channel volume is of course not yet known. Here, the volume of the existing standard 3-zone screw can be used for preliminary orientation. In the case of screws operating according to the same principle, the volumes usually deviate only slightly from the standard value. In principle,...

Kunststoffe international, No More Weight Problems
...t that the varying fiberglass content not only leads to fluctuations in the material viscosity but also varies its density. The focus was on the dimensional deviations of the moldings. It was known from preliminary tests that an exact reproduction of the cavity pressure leads to high dimensional stability. Therefore the part weight is not only determined by the filling level of the mold, but by the material density in each case as well. Consequently, the part weight is not directly related to th...

Kunststoffe international, Nozzles Regulate Thickness
...ble nozzle was attached to each outlet. Instead of the complex main distributor, fixed capillaries were placed behind these nozzles, which significantly reduced the computing effort for the simulations. In addition, this structure allows the exact recording of the individual volume flows in a later practical test, so that the results of simulation and test can be directly compared. A spiral mandrel distributor, on the other hand, would prevent a clear allocation by superimposing the individual m...

Kunststoffe international, Plastic in the Service of Medicine
...e required dimensions and the maximum tolerance of ± 0.02 mm at the individual components of the inhaler are not permitted, since otherwise the function is impaired. For example, when operating the inhaler, the blister must be transported exactly to the next medication reservoir, opened, the used conveyor belt wound up and the unused stored. The drug must then be completely pulled out of the opened blister and transported through the mouthpiece by a slight negative pressure, as it arises when in...

Kunststoffe international, Real-Time Process Monitoring in Cleanroom Environments
... continuous process monitoring and process interruption, when significant process parameters are out of tolerance. The efficient Husky ASC controller in combination with a highly dynamic servo motor offers a large variety of advantages. The exact control of up to seven drives (six Servo-axes and one axis for the valve gate UltraSyncE) in combination with the path and force detection by the controller offers extensive possibilities to optimize the process. The Husky system also offers the possib...

Kunststoffe international, Reverse Rotation
...-part consistency and process reliability. Gammaflux hot runner controls (GF Controls GmbH, Wiesbaden, Germany) are used for precise temperature control of the hot runner molds and manifolds. The controller measures the exact temperature at millisecond intervals and a control algorithm makes adjustments if the temperature deviates 0.014 °C (0.03 °F) from the setpoint. A second derivative helps minimize overshoot and undershoot of the setpoint temperature. Higher Production Volume and Lower Unit...

Kunststoffe international, Sophisticated Geometry – and Hermetically Tight
... Joint design with the help of energy directors is required for reliable process management. For injection-molded parts energy directors are weld geometries including spikes or ridges inside the joining area. They focus the ultrasonic and define the exact location of melt formation. In this way, the component transmits the ultrasonic waves to the joining area. Another issue was the contact surface for the weld tool, referred to as sonotrode. The sonotrode makes contact with the grid walls betwee...

Kunststoffe international, 2005-11-21, 30 Years of Playmobil: Investing in the Future
...parts. This is the reason for the long lead time. It is particularly long in the case of filigree and complex multi-cavity moulds for 2,3, or 4-component injection moulding. Each mould costs between EUR 10000 and 200000, with the exact price depending on the size of parts, the number of cavities and the technology employed, such as hot runners and core pullers. "We ourselves make approximately half of the moulds and we have the rest made by mould-making shops, mostly from the surrounding reg...

Kunststoffe international, 2005-11-21, 3D Simulation: Simulation of Foaming Polyurethanes
...omputers (PC cluster). The results are then evaluated and a new calculation with modified initial and boundary conditions may be performed. The model for the interface between the PU foam and ambient air is a special feature of the simulation tool. Exact simulation of this so-called free boundary requires a method that provides an excellent approximation of the boundary and good mass conservation. This is important if the creation and transport of entrained air is to be properly handled. The cal...

Kunststoffe international, 2005-11-21, Adjusted Geometries
...n practice. By contrast, the green wall thickness distribution, which is shown in Fig.3, can easily be manufactured from the machine point of view. It consistently avoids high peaks, which experience has shown to cause problems because of the exact positioning required on the part. The parison, whose initial wall thickness has now been modified, is now used to simulate the inflation process again. In this case, however, it is not simply shaped to the mould wall, but the wall thickness is instead...

Kunststoffe international, 2005-11-21, All-rounders: Industrial Gases in Plastics Processing
...g agents. Successful use of CO2 depends critically on whether several important process parameters can be observed. The DSD 500 high-pressure metering device was developed especially for CO2, which is especially difficult to handle, and even permits exact metering of CO2 or nitrogen into the extruder at high, varying melt pressure (Fig. 5). Foaming of Polyurethane Carbon dioxide is a tried-and-tested alternative for continuous and discontinuous methods of producing low-density polyurethane (PUR...

Kunststoffe international, 2005-11-21, Bank Rating: Leadership – An Important Rating Factor
...ating to the balance sheet analysis, while the soft factors cover management and leadership, which have a considerable influence on corporate success. In many rating procedures, hard and soft factors are weighted more or less equally, although the exact weighting varies from one bank to another. The performance and commitment of the workforce depend very much on the method of leadership. Staff motivation and staff skills affect the corporate result and thus count as "hard" success fact...

Kunststoffe international, 2005-11-21, CAD/FEA Integration: Water Pump with Improved Long-term Performance
...r a sub-contractor. Since the moulding processes for phenolic resin differ from those for metal and thermoplastics, Vyncolit frequently provides consulting services. Analysis with CAD Systems The first step for Vyncolit consists in determining the exact characteristics to be expected from a given product. Wim de Bock, finite element (FE) engineer at Vyncolit, explains: “We find out first how and where a component will be stressed and then design the component with suitable geometry and materia...

Kunststoffe international, 2005-11-21, Calculation Model: Modelling the Solids Feed Section in Grooved-feed Extruders
...ing conditional equation is obtained for the feed angle α0: ((Formula_3)) The pressure transmission coefficients k1, k2 und k3 describe the varying pressure transmission and anisotropic pressure distribution in the screw channel. Since an exact determination is very time-consuming, in practice the following numerical values are normally used [9]: k1 = k3 = 1; k2 = 0.5. μZ is the external friction coefficient at the barrel wall (solid on steel), μi the internal friction coefficient,...

Kunststoffe international, 2005-11-21, Calculation of Snap Beam Forces
...or the deformed snap beam in this way correspond quite well to results from FEM calculations. In contrast, previous methods gave considerable differences. Thus the retaining force could easily be overestimated by around 100 % or more. For still more exact results a second order theory must be used. In the design of the snap beam it is easy to take the deformation into account beginning with the resultant angles α’1 and α’2 and proceeding using (3) and (4) to arrive at the...

Kunststoffe international, 2005-11-21, Coextrusion: Flexible Production of Multi-layer Pipes
...ime-consuming purging of the channels. The centring mechanism is located downstream of the stripe adapter. It can be fitted optionally with dial gauges or hardened inserts. The meters are intended as an aid for the machine operator. They display the exact value by which he has adjusted the die set. The hardened inserts are mounted beneath the centring bolts. They permanently prevent the bolts from being pressed into the centring ring and thus lead to less friction. This facilitates the setting-u...

Kunststoffe international, 2005-11-21, Compounding: Maximising Use of Machine Potential
...s, there was high dissipation, so that the interfacial temperature between the melt and barrel wall differed significantly from the actual barrel wall temperature. This interfacial temperature is, however, required as a boundary condition for an exact simulation calculation but has so far proved difficult to determine by calculation. Conclusion As has been demonstrated by the above comparison between theory and practice, it is now possible to determine the energy consumption of twin-screw extr...

Kunststoffe international, 2005-11-21, Comprehensive Product Range: Advancing into New Dimensions
...s-relevant data and in the case of malfunction permits rapid localisation of the machines and process faults. To produce the clamping forces on the mould and top tables for twin-sheet forming, for example, hydraulic drives are used for this machine. Exact and reproducible settings for presuction, preblowing, vacuum and demoulding of the formed part can then be implemented on an infinitely variable scale. In this way, areas requiring high stretch can be more selectively pre-stretched and shaped. ...

Kunststoffe international, 2005-11-21, Compression Moulding: Highly Precise and Fully Automated
...ally needed to describe the elongational viscosity and the wall slippage factor of the compression moulding compounds can be determined with the aid of the squeeze flow rheometer developed at the IKV. A crucial factor in obtaining an exact simulation result is that the simulation be performed by a trained user who is familiar with both the simulation program and the compression process. In addition, the quality of the material data and the assumed process parameters play an important role. Unfo...

Kunststoffe international, 2005-11-21, Continuous-strand-reinforced composites: Multilayer Knitted Fabrics for Rail Vehicles
...ropic reinforcement and consisting entirely of glass yarns (90°/+45°/0°/-45°/90°) and two stitch yarn systems [2] were made and included in the studies. Weights per unit area were between 780 and 1090g/m² or 1630 and 2170g/m², the exact figure depending on the actual CKF sample. The corresponding figures for glass roving and a continuous-strand glass mat studied for comparison purposes were much lower at 590 and 300g/m². Concurrent with the textile work, a modular drape-forming an...

Kunststoffe international, 2005-11-21, Convertible Top Systems: Convertible Top – Lightweight and Made Easy
...p with regard to the specific installation situation. FEM simulation of the manufacturing suitability of the parts and of the computation of certain load cases – as far as possible and meaningful – is used for designing the systems. However, exact simulation is only possible to a limited extent since several characteristics of many types of plastic are presently only insufficiently available. As a result, prototype production and part testing in interaction with associated parts are still an imp...

Kunststoffe international, 2005-11-21, Cooling Injection Moulds
...bes In testing heat-conducting tubes from three different manufacturers, considerable differences in cooling efficiency were found (Fig. 8). The variations in efficiency are presumably due to different liquids inside the heat-conducting tubes. The exact compositions of the filling media is not disclosed by the manufacturers. An index for the media is the quoted maximum permissible service temperature (150°C for the most effective tube from manufacturer C, 250°C for the tubes from manufac...

Kunststoffe international, 2005-11-21, Crash Simulation: Computer Modelling
...ropic, since the fibres are strongly oriented by flow in the injection moulding process. This results in anisotropic, i.e. directionally dependent, mechanical behaviour of the material in respect of stiffness, yield stress and elongation at break. Exact Numerical Material Description The basic prerequisite for virtual development of intelligent components made from plastics is a numerical material description that can model all the specified effects. This therefore goes well beyond the requirem...

Kunststoffe international, 2005-11-21, Customised Mould Technology: Integrated Rotary Platform for Flexible Two-Component Production
...PP and 15% glass fibres. The soft component, a thermoplastic elastomer, constitutes roughly 10%. Other specifications to be met: ”Numerous modular parts had to be mounted accurately on the console support. It was essential for the clearances to be exact”, explained Helmut Herb, a senior officer at Otto. "Furthermore, the console frame support had to meet anti-squeak and head-impact safety requirements. This latter requirement was accomplished by over-moulding certain areas with the soft comp...

Kunststoffe international, 2005-11-21, Defect-Free Microstructures
...free demoulding of the parts requires that the mould be opened very slowly. In the servoelectric injection moulding machine from Battenfeld, mould opening and closing are accomplished by a toggle that is driven by a planetory roller screw. To assure exact movement of the moving platen, the motion of the crosshead (to which the planetary roller screw spindle is attached) is employed as the control variable for the first few tenths of a millimetre of the opening stroke. This prevents a sudden open...

Kunststoffe international, 2005-11-21, Design of Radial Spiral Dies
...s, with the result that it does not become more complicated, even in the case of many layers. - The modules in a multi-layer die can be separated better thermally and so the materials can be kept at different temperatures until they flow together. Exact Rheological Design is Needed Given the advantages mentioned above, radial and spiral mandrel dies could be expected to benefit many areas. Yet, so far, they have been rarely used. One reason is likely to be the lack of experience of developing ...

Kunststoffe international, 2005-11-21, Desktop Manufacturing and Biofunctional Processing
...wever, these processes are elaborate and require blocks from layer, press-moulded and glass ceramics, and metals and composites for crown and bridge technology. Automation of dental manufacturing techniques has been delayed by such problems as the exact scanning and duplication of the tooth stump - an essential for the quality of fit and aesthetics. CAD, CAM, and CIM technology are now the established techniques in the dental sector. Unlike machining methods, solid free form fabrication (SFF) bu...

Kunststoffe international, 2005-11-21, Dimensioning Parts: Non-linear Viscoelasticity
...ive to simulations based on the standard approach used in FEA. This leads to better exploitation of the material’s potential, and in turn to cost savings with regard to materials. As fewer prototype tests are needed, more exact simulations additionally shorten development times and simultaneously reduce development costs. Acknowledgements The investigations received financial support from the Federal Ministry of Economy and Labour (BMWA) by the Arbeitsgemeinschaft industrieller Forschungsvereini...

Kunststoffe international, 2005-11-21, Direct Colouring: Producing Colour Masterbatches Economically
... in single-screw extruders. Since the pigments are already dispersed, the different mono-components must only be melted and mixed in a single-screw extruder. Because of the identical dispersion quality of laboratory and production raw material exact transferability of the colour value obtained in the laboratory is ensured on the production scale. Economic Considerations The manufacturing costs (machinery costs, energy, labour, cleaning material and waste) of the extrusion depend on the type an...

Kunststoffe international, 2005-11-21, Directions for a New Used Machine Politics: What is the Worth of Your Used Injection Moulding Machine?
...erous other injection moulding machine manufacturers. For determination of the machine residual value and other characteristic values ASK uses its own software. The data on the used machines are usually unsatisfactory. Prices and more exact data for instance on the machine run time are often only obtained "on request". Up to today there has been no organisation of used injection moulding machine dealers that specifies minimum requirements on offer information in the form of certificatio...

Kunststoffe international, 2005-11-21, Driving the Automotive Industry: Engineering Elastomers
... In response to this, Zeon commissioned a 240t/a plant in Shanghai in May 2005. In Russia, Krasnoyarski Zavod SA. – the largest if still relatively small NBR producer – doubled its capacity in the last five years (30kt/a). The exact development of regional capacities and consumption over the last ten years has been comprehensively described elsewhere [1 to 3, 5]. Global SR production in the last three years [6] has developed by region as shown in Fig.1. Production quantities for 2005 are estima...

Kunststoffe international, 2005-11-21, Electronic Components and Displays: Intrinsically Conductive Polymers
...employed. In-situ polymerisation produces coatings of poly(3,4-ethylene dioxythiophene) with high conductivities of over 500 S/cm. However, in-situ polymerisation is a chemical transformation involving several process steps requiring exact control of the process parameters. These process steps are - coating, - polymerisation and - removal of the undesirable by-products such as iron(II). In contrast, processing is noticeably simpler when using prepolymerised polymer dispersions, solutions or fo...

Kunststoffe international, 2005-11-21, Evolution, Not Revolution
...tterns for vacuum casting. Stereolithography prototypes are unbeatable when it comes to reproducing the finest of structures. The dual-capability Viper si2 SLA from 3D Systems allows high-speed prototyping at "standard" resolution or very exact prototypes and the finest of details, the choice depending on the specification. Accuracy of detail is stereolithography's particular strength. Tooling for Small Runs LMC, the newly released CNC layer milling centre from Zimmermann, Denkendo...

Kunststoffe international, 2005-11-21, Exactly Suited Material Preparation: Reliable Use of PET Flakes
Recycling Reliable Use of PET Flakes Exactly Suited Material Preparation. Economic supply of PET ground stock from beverage bottles offers an attractive potential for lowering manufacturing costs. Drying and crystallisation plants should not be regarded as unnecessary evils, but as important process units for qualitatively high-value production. Michael Zlotos PET finds application in many production processes, be it in the field of packaging for bottle production or production of packaging foil...

Kunststoffe international, 2005-11-21, Expectations and Performance: The Importance of Numerical Simulation
...iosity and creativity and therefore be key factors in technical and economic progress. Despite all the fascinating aspects of simulation, realistic thinking should prevail, since we will probably never ever succeed in achieving truly complete and exact 1:1 simulation of our world. Nevertheless, it is precisely this that remains a spur and a vision. Dedicated to Prof. em. Georg Menges on his 80th birthday. References 1 N.N.: Informationen – Wissen.de, URL: http://www.wissen.de, 2003 2 Marquardt;...

Kunststoffe international, 2005-11-21, Experimental Testing: Ring-shaped Reinforcements Made of Fibre-reinforced Composites
...LIP) test method newly developed from this knowledge provides important benefits and is suitable for quasi-static as well as fatigue tests to test ring-shaped fibre-reinforced composite reinforcements and to determine exact fibre tensile strengths. References 1 Schwarz, M.: Die gezielte Ringverstärkung von Bauteilen – ein werkstoffgerechtes Einsatzgebiet für Faser-Kunststoff-Verbunde? In: Tagungsband des 11. Nationalen Symposiums SAMPE Deutschland e.V., conference report, TU Darmstadt, 2005 2 ...

Kunststoffe international, 2005-11-21, Extremely Fast
...ength and good stretching properties. To take account of these different requirements for spray systems, specially modified amines and isocyanate prepolymers have been developed that can be used to tailor the reaction profile and physical properties exactly to suit the particular needs of the application. Table 1 shows the results of tests on four different formulations. Formulation A contains the standard prepolymer M 544 with the amine mixture PC AMINE DAX 127 (mixture of aliphatic and aromati...

Kunststoffe international, 2005-11-21, FE Method: Design Concept for Stacked-type Spiral Dies
...aid of the Simflow FEA software package developed at the Institute of Plastics Technology (IKT) [3]. A major advantage of the numerical flow simulation is that it considers the interaction between spiral flow and annular gap flow, which permits an exact description of the flow processes taking place. All the relevant results are read off and visualised by means of postprocessors. Optimisation Criteria To assess the flow-channel geometry, the design concept uses optimisation criteria, which char...

Kunststoffe international, 2005-11-21, Fewer Production Stages, Shorter Cycles
...the quality of the moulded part can be most affected by the compressing parameters (compression stroke, compression speed, stepped profile for mould opening during injection and closing compression moulding and the starting point for compression). Exact moulded part radii are a key quality feature. With concave radii, the rule of thumb is that the moulded-part radius consists of the mould radius minus the film thickness; with convex radii, it is the mould radius plus the film thickness. With thi...

Kunststoffe international, 2005-11-21, Film Extrusion: For Flexible Packaging
...r ring module, which served as the design basis for the double-deck “Multicool D” air ring presented in 2001 (Fig.1). The Multicool D is claimed to offer 25 to 35% better performance than simple external air rings (the exact figure depending on the film to be produced), especially on account of a three-stage air flow. It additionally offers extensive scope for varying the physical strength properties of the film. Another unit intended for the blown-film process is the new “Nostic Air Cage” calib...

Kunststoffe international, 2005-11-21, Friction Behaviour of Thermoplastics
...f friction behaviour, it is possible to dispense with a trial injection mould. The test apparatus also enables the direct effect of a single factor to be studied. Further Research Work Further research work in this area will be concerned with more exact interpretation of the results and study of other materials. The aim of the "Mouldfriction" project is to derive a mathematical relationship to describe the friction behaviour between plastics and moulding surfaces with a view to correct...

Kunststoffe international, 2005-11-21, Gas Phase Fluorination: Reducing Plasticiser Migration
...g weight. The mass loss of the plasticised PVC was measured at regular intervals and the migration was determined thusly. It was shown that the fluorination of plasticised PVC reduces softener migration significantly. The investigations of the exact connection between the choice of the fluorination parameters and the reduction of softener migration are still running. In this connection whether softener migration can be prevented completely will also be investigated. Summary and Outlook To recap...

Kunststoffe international, 2005-11-21, Gas-assisted Injection Moulding: Accurate Determination of the Injection Points
...ds for melt guidance were introduced in the region of the openings. As a consequence of this, the filling simulation shows a significantly improved flow-front advance as regards the above-defined requirements for the filling behaviour. An exact analysis of the filling images on the computer shows that the requirements regarding the post-filled regions are also fulfilled. According to an estimate of the unfilled residual volumes remaining at various degrees of filling, the three unfilled regions...

Kunststoffe international, 2005-11-21, Gas-assisted Injection Moulding: The Cross-section is Crucial
...ongitudinal and cross-section of an ideally developed gas channel. For the practical application, it would be desirable to know the gas threshold cross-section and quantitative effect of the process parameters – in other words, the exact description of the curves shown in Fig.6. However, determination of the threshold cross-section and the exact description of the effects of the parameters are only possible for the respective application. Time/Pressure Behaviour of the Gas Injection Pin Affects...

Kunststoffe international, 2005-11-21, Germ-free Precision Pumps: Dosing without Side-effects
...ies, this directly affects the pump mechanism. If the diameter of the protective cap is too short, the user will have difficulty removing it, if at all. Manufacturing tolerances are therefore very narrow. They vary between 1/100 and 15/100mm, the exact figure depending on the function of the various parts. At critical points, such as plunger guide, the limit is ±1/100mm. The plunger itself is the smallest plastic part in the pump and is the size of a pin head. Its sealing lip is 0.5mm thick. The...

Kunststoffe international, 2005-11-21, Gravimetric Precision Metering
...em for measuring, instrumentation, control, communication, operating, reporting and documentation. It is noted for its innovative technology and ease of operation. The following data can, among other things, be entered into the MCG control unit: the exact formulation, the formulation management, the batch size and the post-running time of the mixer. The data output gives details of the composition of the material, as is required by the regulations of DIN ISO 9000 ff. Through the integrated seria...

Kunststoffe international, 2005-11-21, Handling of Deformation-sensitive Inserts:
... transported to a separator station. A transfer mandrel picks up the individual oil filter blanks and stacks them with a gap of 1mm. Sensors are used to monitor this process. They ensure that each individual insert is placed in the exact same position, a prerequisite for further processing by the injection moulding machine. Depending on the cavity requirements, the alignment and transfer station passes the right number of oil filter blanks to the CNC-controlled slide, which is a copy of the moul...

Kunststoffe international, 2005-11-21, High Requirements - Low Investment Costs
...m on a small surface or by oscillating it to cover a bigger area. Four individually controlled air nozzles let the ray oscillate at a rate of approximately 20 changes per second. The oscillations can be steered during the entry process according to exactly which mould part is to be covered with the PU glass fibre-mixture. Fast application of the right quantity and the right distribution of the material is very important because only a limited time is available before the mixture reacts. Leftover...

Kunststoffe international, 2005-11-21, High-performance Machines for Short Cycle Times: New "High-Speed" for Thin-Wall Part
...ovement of the mould mounting platen have been optimised to accommodate the new toggle geometry. The interaction of all individual measures taken aimed at producing high dynamics leads to very short dry cycle times, which vary from 1.1 to 2.2s, the exact value depending on the size of the machine (Table 2). The guideway for the movable mounting platen in the clamping unit has a unique feature. In order that the mould region may be kept free of oil (important for many applications), the tie bar h...

Kunststoffe international, 2005-11-21, Injection Moulding Simulation: Support for Component Development
...ns are made, which causes difficulties in the manufacture. Also the development of the injection mould requires early decisions that are important for the later manufacture. These decisions are based predominantly on experience. However, because the exact conditions of the component production are not yet known at this time, also here again and again there are unsuitable decisions. During manufacture only a few degrees of freedom are at the disposal of the user to produce the component that was ...

Kunststoffe international, 2005-11-21, Injection Moulding: Compounding Wood Fibres with Plastics
... cost-saving potential for the processor from using wood fibre/plastic composites is considerable. At the same time, the properties of the final part are just as good and in some cases, even better than those of the unfilled plastic. Exact figures can only be established – as always – for a specific application and by making a comparison with other materials such as unfilled or mineral-filled plastics. The mechanical and optical specifications made on the part will naturally play an important ro...

Kunststoffe international, 2005-11-21, Inline Compounding of Long-glass-fibre-reinforced Thermoplastics
...ials in one step for the first time. Dieffenbacher is the first machinery manufacturer in the world to market this type of plant and produces all the plant components itself, including the automation system. A processing line control system ensures exact process management and therefore reproducible material quality [2]. In the production of underbody mouldings, LFT-D-ILC technology is already in the industrial launch phase (Fig. 3). The first components with excellent mechanical properties and ...

Kunststoffe international, 2005-11-21, Innovative Direct Processing of Natural Fibres
...was virtually impossible to separate them without destroying them. The analytical results (Fig.9, bottom) show that the long-fibre fractions (lF >1.0mm) of the D1 and D2 specimens varied from 40 to 66wt.% (D1) and from 14 to 23wt.% (D2), the exact figure depending on the arrangement of the combing section. The effects of the composites‘ structure on the flexural strength and the IZOD impact strength are illustrated in the normalised results in Fig10. The flexural strength is barely affected by t...

Kunststoffe international, 2005-11-21, Innovative Solutions from VDI-K: Outside and Under the Bonnet
...ical, thermal and acoustic) have not changed. Nevertheless, at least in the engine compartment where the thermal and mechanical demands are high, it is becoming increasingly difficult to conquer new worlds. The days of replacing metal parts with exact plastic copies are long gone. The competing materials, such as aluminium, steel and magnesium, have improved both in price and technology. And plastics are struggling increasingly with the relentless upward trend in crude oil prices. The only way f...

Kunststoffe international, 2005-11-21, Inserting, Foaming and Coating
...erator to place inserts in two machines set up as mirror images of each other (Fig. 6). Manual insertion of parts into the foaming mould results in extensive non-productive time. This can amount to between five and eight seconds per insert part, the exact time varying with the size and fitting accuracy of the insert part and the operator's familiarity with the operation. For example, experience shows that twelve inserts would generate a non-productive time of around 70 seconds. If it were po...

Kunststoffe international, 2005-11-21, Integrated Automation: Manufacture Economically – Exploit Resources
...the golf balls, the core inserts were first supplied to an industrial robot (Fig.3), which then placed them, from the non-operator side of the clamping unit, into the cavities of the 4-cavity mould. Integrated vacuum nozzles held the cores exactly in position. These were then overmoulded with PU in two successive steps of one half-shell each in the clamping unit from a KM65 injection moulding machine from the C series. A second robot on the operator side removed the finished balls and simultaneo...

Kunststoffe international, 2005-11-21, Interface Definition: Design of Fabric-reinforced Thermoplastics
...stress/strain curve results from an untangling and sliding of the macromolecules under load. The relatively large scattering of the results can be attributed to the coarse structure of the fabric used and to difficulties in maintaining exact fibre orientation during production. The FE analysis with rebar element and a non-linear material model for the matrix shows good agreement with realistic behaviour even in regions of high strain. With the previous computations based on shell elements, and a...

Kunststoffe international, 2005-11-21, Joining, Texturing, Modifying: Selecting the Right Laser
Special Selecting the Right Laser Joining, Texturing, Modifying. While the use of laser technology was often limited to expensive products in the past, inexpensive diode lasers and more compact Nd:YAG lasers are finding an ever-wider field of application in the plastics industry. For every specific application, the question always arises as to what is the right laser beam. Arnold Gillner Applications within the field of plastics range from products for packaging, electronics, household appli...

Kunststoffe international, 2005-11-21, Laser Booth with Great Functionality: A Good Step
...firm high reproducibility as well“, according to Helge Jansen. The cast steel body of the robot transmits very little vibration. Moulded-in stresses or postmoulding shrinkage of the in-mould laminated (backmoulded) parts can reduce the exact reproducibility of the trimming operation. A sophisticated workpiece holder that EuWe developed together with Robot-Technology limits this problem to a minimum. A locating system with bushings and quick-connect lines permits the holder to be changed within ...

Kunststoffe international, 2005-11-21, LFT-D Processes: Visible Parts from Continuous-strand-Reinforced Thermoplastics
...r thermal expansion and low anisotropy. Seamless mMould filling is achieved in back-compression moulding without weld lines by a flow compression process. The flow compression process can produce preserve glass fibre lengths of up to 40mm, the exact fibre length is depending on the screw configuration and the way in which the compounding extruder is useddeployed. Accordingly, not only are outstanding strength properties are achieved in the LFT materials or and film-LFT composites, but also comme...

Kunststoffe international, 2005-11-21, Logistics: Centralised Painting of Plastic Parts
... the problems of colour matching. Studies by the consulting company Miebach Logistik, Frankfurt am Main/Germany, have shown that centralisation of plastic parts painting can potentially save from 10 to 30 EUR per vehicle in any model series, the exact figure depending on the details. A decision in favour of centralisation does not necessarily mean reverting to owner operation. The following alternatives are conceivable: - Operation by the vehicle manufacturer - Outsourcing to a selected plastic ...

Kunststoffe international, 2005-11-21, Marking Plastic Products
...etermined by comparing the different methods. Patric Lamprecht, Stuttgart/Germany There are various reasons why a plastic product is marked. In the first place, legislation specifies, for example, that a plastic product should be marked with the exact polymer designation to facilitate recycling. Marking is also becoming increasingly important to ensure clear traceability in the event of a product liability claim. At the same time, marking by manufacturers for the purposes of internal logisti...

Kunststoffe international, 2005-11-21, Materials of the 21st Century: Plastics Producers Remain on Path to Growth
...stic Exports Trade and Plastic Streams in Europe For years, it was a truism that German plastics producers manufactured in Europe for Europe. The figures for 2003 show impressively that this has not changed: two-thirds of German plastics exports – exactly 64.4% – went to EU countries (Fig. 2), while imports from the EU made up as much as 80% (Fig. 3). The foreign balance of trade is also positive. It rose in value by 6.8% from 2001 to 2002 and by 6% from 2002 to 2003. At the end of 2003, the ba...

Kunststoffe international, 2005-11-21, Meaningful Aid or Expense?
...re. The question whether the results of the simulation are plausible is not always easy for the inexperienced user to answer. Unfortunately, in individual cases it has been necessary to accept that follow on versions of well-known software used with exactly the same input data produced different, sometimes conflicting results. A remedy was found using methods involving proof of perfect program function [12]. The state of the art today is that the quality of the simulation still depends on the ex...

Kunststoffe international, 2005-11-21, Microtechnology: A Question of Detail
... all further activities in the field of microtechnology. The standards are communicated to the customer with the first contact. Visualisation prototypes provide optical support for registering and understanding the order. This ensures extremely exact harmonisation with the customer from the start. Intensive Exchange in Both Directions The mould maker must work out the part(s) stage by stage together with the customer. He decides how the parts are produced and clarifies how the decision affects ...

Kunststoffe international, 2005-11-21, Mixing, Conveying, Metering: From Silo to Screw
... an intermediate container. The components for mixing are sucked in by new venturi lances and mixed in a container of wear-resistant borosilicate glass. Different suction distances for the respective components can be taken into account to obtain an exact mixing result. The automatic filter-cleaning function developed especially for this series also makes for virtually maintenance-free operation. After purchasing Motan Materials Handling GmbH, Weingarten/Germany, Zeppelin Silo- und Apparatetech...

Kunststoffe international, 2005-11-21, Mobile Financial Tool: Always Up to Date
...PE-LLD, PE-LD and PE-HD) of over USD 40 billion, as well as the processed forms, including film and sheet, packaging, toys and pipes – for example in sanitary applications or irrigation systems. The LME subsequently defined the exact contract specification: in the case of linear PE-LLD, including with an MFR of 0.8 (–0.1/+03) without additives and according to EU and FDA standards. The trading unit (24.75 tonnes, packaged in bags), and the detailed delivery conditions were also specified. An E...

Kunststoffe international, 2005-11-21, More elegance . . .
...s. These moulds permit efficient production in a fully automated, cost-optimised process in which handling robots with a complex gripper system play an important part. Despite its relatively low inherent stability, door frame finishers must have an exact geometry. This applies particularly to angle accuracy in the profile. This can be ensured by correct arrangement of the cooling channels and choice of gate location. Through its experience in making moulds for door frame finishers, IBS Brocke ca...

Kunststoffe international, 2005-11-21, Motor Vehicle Interiors
...er, wood, metal and plastics give the passenger a feeling of comfort and cosiness. And this impression is reinforced by subdued colour schemes. Expressing an Individual, Personal Lifestyle Several major suppliers demonstrated exactly where developments in motor vehicle interiors are headed in the next vehicle generations, e.g. the “Ariston” study from Johnson Controls (JCI; Fig.1). This study revealed a new dimension in the future of interiors for luxury vehicles of the future. A mulitplicity ...

Kunststoffe international, 2005-11-21, Mould Filling during Magnesium Injection
...simulation calculation returns a loss of pressure of approx. 80 bar, which is clearly too high. Figure 4 shows the subsequently improved filling and qualitative agreement between test and simulation. The simulation calculation cannot yet predict the exact position of a cold flow site at moderate gate speeds (20 to 70 m/s). Formation of such a cold flow site can be reliably simulated even without prior testing. At very high gate speeds (120 to 200 m/s) - too high for part quality - the simulation...

Kunststoffe international, 2005-11-21, Mould Preliminary Costing: The Devil is in the Detail
...ention is still paid to preliminary costing , which could be utilised for precise planning of job preparation. There are Risks in Neglecting Preliminary Costing Unreliable costing is often defended with the excuse that “correct prediction of the exact costs of an injection mould demands fundamental knowledge about the mould in question, and a lot of time.” In plain words, that means that a detailed prediction can only be made if the best trained and most experienced employees in a company wast...

Kunststoffe international, 2005-11-21, Moulds for Micro-Injection Moulding
...lenges To be able to take account of all the various, sometimes contradictory demands and wishes of mould making, processing and application, it is advisable to merge the expertise of all participants into a development team. - The user knows the exact functional (e.g., strength, surface quality) and dimensional requirements of the moulded part or module. However, he often does not know how to achieve this in plastic. - The processor, drawing on his experience, plays a crucial role in choosing ...

Kunststoffe international, 2005-11-21, Multi-component Injection Moulding: New Properties through Rigid/Flexible Combinations
...e a high core in the mould. The melt pressure had to be optimally adjusted to ensure that the core did not move during the injection process. Balda managed to do this by first carrying out a comprehensive mould flow analysis that helped to exactly fix the position of the gating point and thus prevent any premature advance of the melt. To stop the core from moving, cones were used to secure it. Apart from that, the depth of the core insert was selected in such a way as to achieve a securing effec...

Kunststoffe international, 2005-11-21, Multi-component Processing: Plasma Makes for a Strong Bond
...he robot arm, together with the start and finish of plasma pre-treatment, are controlled directly by means of an add-on in the machine control system (Fig.2). The plasma beam can activate widths ranging from several millimetres to approx. 25mm, the exact figure depending on the power and geometry of the nozzle. Similarly, the level of treatment can be varied – the beam can be moved at a height of 10–40mm above the surface and at a rate of 6–900m/min over it [9]. The resultant short exposure tim...

Kunststoffe international, 2005-11-21, Multi-Material Mould with Rotary Mechanism
... times with minimal loading on the system. The indexing time with the mould is 1.3 s (as measured at Braun Formenbau GmbH on the customer's machine). The rotary plate is located in the end position by an hydraulic mechanism. This always assures exact positioning of the rotary plate and attached mould. Because of the high mould weight, the rotary indexing mechanism is equipped with supplemental support clamps. These clamp the rotary plate to the stationary clamping plate of the rotary indexin...

Kunststoffe international, 2005-11-21, Multi-orbital Friction Welding: Welding with Motion
...ond application of the process (Fig.2). It demonstrated the integration of welding and corner cleaning in one machine. The machine has a small footprint. A frame’s ultimate tensile strength has a very low margin of error, and the exact positioning of the profiles at the end of the process provides the frame with much more precise final dimensions than with melt-welding processes. Title photo. Unusual material combinations and workpiece combinations and workpiece geometries can be joined. Multi-...

Kunststoffe international, 2005-11-21, Multiprocess Technology: Production Solution for Complex Air Intake Systems
... the mould cooling system and number of gates were optimised. As a result of this simulation, for example, the runners were overdimensioned in the injection mould by about 4mm to compensate for warpage and post-shrinkage and to obtain exactly positioned pipe ends (Fig.2). In the subsequent operation, the runners are first annealed and then inserted, four at a time, into a second injection mould, where they are overmoulded with the flange bank. In this operation, the runner surface melts in the o...

Kunststoffe international, 2005-11-21, Natural Fibre: Industrial Quality Management for Agricultural Feedstocks
...wn up for the optimised odour measurement of natural fibres based on VDA 270. This produces results with a higher degree of reproducibility, mainly due to the precisely defined specimen preparation, the training of the group of test persons and an exact division of the evaluation criteria into a subjective and an objective intensity scale. Suitability of Measuring The suitability of incoming control tests and predictability analyses was also evaluated. In Table 3, this affects only the measuri...

Kunststoffe international, 2005-11-21, New Possibilities for the Injection Moulding of Thin-wall Parts
...nly a minor influence because the cooling takes place within fractions of a second. Particularly with applications for the electronics industry in which the geometries tend to be more complex, it is essential to adjust the injection speed profile exactly, and above all to provide for rapid, finely tuned pressure monitoring, otherwise there is a risk of damaging the expensive moulds. A high injection capacity is necessary to ensure complete filling of the mould. In addition, there must be suffici...

Kunststoffe international, 2005-11-21, News
...dification are among the segments of the Chinese plastics industry with the highest growth rates. Therefore, the new facility is specially designed to meet the booming demand for these specialties in the region. The new production site is an exact copy of the company’s existing US facility and is equipped with identical technical installations, processing methods, specifications and quality assurance systems. Ethylene copolymers made in Shenzhen are mainly produced for the regional market, but t...

Kunststoffe international, 2005-11-21, Pedestrian Safety
...e bodywork. The design of active systems requires extensive investigation into the movement sequences and energy distribution directly after impact. Even with slow-motion film it is difficult to record these processes. Exact analyses of deformation and energy distribution are only possible at all by means of computer simulations. Such processes based on finite element methods are currently being developed by Bayer. The aim was first to allow improved analysis of the effects in the vehicle interi...

Kunststoffe international, 2005-11-21, Physical Blowing Agents: Foaming Plastics with Inert Gases
...ored to specific user needs. Depending on gas consumption and the necessary gas pressure, the optimum concept must be selected on the basis of economic and technical criteria. Special metering pumps are needed, suitable for liquid CO2 and capable of exact metering at pressures of up to 500bar. They generally require liquid CO2 completely free from gas bubbles and, if possible, with a high feed pressure of about 60bar. The Linde DSD 500 high-pressure metering unit has demonstrated its suitability...

Kunststoffe international, 2005-11-21, Plastics al dente
...screw extruder with an output of 350 kg/h. The coextruder, a conical twin-screw extruder was developed especially to create a good link to the main extruder. Together with all downstream devices, the extruders permit web speeds of up to 5 m/min, the exact figure depending on the profile weight. Inductively Heated Nozzle Guzzinin, Civitanova Marche, is exhibiting a new nozzle for injection moulding machines. It facilitates rapid material and colour changes. The TP 100 (Fig. 5) is a copper/beryl...

Kunststoffe international, 2005-11-21, Polyaryletherketones (PAEK)
...ure resistance is one of the most important criteria for these tubes, since they must insulate the hot needles from the balloon and the patient. The dimensional stability and strength at these temperatures are also highly important, since exact guidance and positioning of the needles must be possible at all times (Fig.4). The company ifm-electronic chose PEEK for the new generation of position sensors for food processing and the pharmaceutical industry. The decision was based on the optimised pe...

Kunststoffe international, 2005-11-21, Polypropylene (PP)
...on, metallocene plastomers (PE-LLD with very high butane or octane concentrations) have, in the meantime, also emerged as a new class of impact modifiers. Notable examples include Dow’s Engage and DEX Plastomers’ Exact products. Compared with conventional elastomers, such as EPR or EPDM, these materials have the advantage of being available in a wide MFR range, which extends their usability to high-flow compounds [8]. As well as fulfilling mechanical properties, they also permit improvements in ...

Kunststoffe international, 2005-11-21, Polypropylene Films: Versatile Packaging Solutions
...as the future hope for specialty and niche products. One of the main reasons for this is that as plants grow ever larger, changes of grade are becoming increasingly difficult. In the future, metallocene catalysts will permit even more exact polymer design but first an acute productivity and therefore cost problem will have to be overcome. References 1 Neißl, W.; Gahleitner, M.: Tailor-made Polymers Through Selective Modification. Macromol. Symp. 181 (2002), pp. 177–188 2 Galli, P.; Vecellio, G;...

Kunststoffe international, 2005-11-21, Practical Comparison of Simulation Techniques: 2.5D or 3D?
...on of the weld line region. Thus, in practice, the melt advances extensively through the ribs at the start of filling; the 2.5D simulation yields a poor reproduction of this (Fig. 4). Similarly, only the 3D simulation is able to predict the exact position of the weld lines at the end of filling (Fig. 5). The conclusion to be drawn is that 3D simulation predicts a more accurate filling pattern when it comes to the details of compact parts than does conventional injection moulding simulation based...

Kunststoffe international, 2005-11-21, Pressure-Sensitive Adhesives ...
...he wall and the towel is lying on the ground. Most people have experienced situations like this before, suffering the inconvenience because a so-called pressure-sensitive adhesive failed. Pressure-sensitive adhesives are compounds or, to be more exact, polymeric compounds, that are permanently tacky. Scientific theories abound as to what influences tack and ultimately good adhesion to a wide variety of materials. However, it may be safely said that the strength of a bond is determined by the f...

Kunststoffe international, 2005-11-21, Process Integration: Short Cycles for Injection Moulded Microfluidics Parts
...y in the injection mould and not separately in an additional covering station downstream. In addition, handling the parts between the injection moulding machine and the covering station is eliminated – resulting in a shorter total cycle time, more exact positioning, reduced quality variation and thus altogether lower costs. In no other way can a micro-structured part and cover be positioned as accurately as in the injection mould, independent of whether it is a foil or a somewhat thicker plastic...

Kunststoffe international, 2005-11-21, Process Reliability through Full Automation
...ing. Using simultaneous engineering Wilden has co-ordinated tooling and plant construction as well as product development from the outset and thus completely automated manufacturing and assembly. A unique plant has thus come to the market. It is exactly adapted to the application profile of Siemens products. For the models C45, M50 and MT50 of the most recent generation of Siemens mobile phones Wilden, prominent manufacturer of engineering plastics systems, produces display lenses and overhead...

Kunststoffe international, 2005-11-21, Process Technology: Polyurethane Processing Systems
...ssential for the reaction are already contained in the two primary components. However, it is also possible to have premix stations inject the additives directly into lines connected to the metering pumps. Metering pumps convey the components in exact ratios from the day tanks to the mixhead. This mixture is then discharged from the mixhead into either an open mould or, via a runner system, into the cavity of a closed mould. Once the reaction (cure) time has elapsed, the finished part is demould...

Kunststoffe international, 2005-11-21, Producing for Medical Engineering
..., qualified and validated. The surrounding conditions must be monitored and every single job process must be documented. The Food and Drug Administration supervises the launching of medical engineering products in the USA. Manufacturers must provide exact proof of how they manufacture. Take an orthopaedics application at Sulzer, for example. Sulzer has to audit the manufacturer and the manufacturer must document his production sequences. The FDA or a Notified Body then checks the documentation p...

Kunststoffe international, 2005-11-21, Product Development: Rapid Analysis of Film Properties on Pilot Lines
...or test films in the lengthwise and crosswise directions is shown in Fig. 1. The correlation coefficients determined are 93.4 and 89.9%. Considering the boundary conditions discussed previously, this result can be judged as quite good. A more exact analysis of the two diagrams shows further areas of agreement: - the individual values deviate from the straight-line correlation by only 5 to about 10% – this is within the range of standard deviation for the respective mean values, - the slope valu...

Kunststoffe international, 2005-11-21, Production Control: Press Process Transparency
...files are placed by hand in a mould, which is then inserted into the press mould carrier. The actual hardening lasts from a few minutes up to several hours depending on the shape and materials used. The temperature has to follow an exact time profile, for example, quickly be brought up to 90°C, maintained there for a while, increased to 140°C, maintained there again and then quickly be lowered to the beginning level. The control systems were outdated and the error rate increasing, resulting in ...

Kunststoffe international, 2005-11-21, Profitability Comparison: Cycle Time is Money
...l estimation of cooling times according to equation (5). - The different curves arise from the assumption that wall thickness can be adapted to the specified requirements. Since corresponding trials were carried out in the BASF Technical Centre, the exact “operating point” for this production process could also be plotted in the graph. Since the same mould was used for PP and ABS, the results had to be compared with the calculations for the same wall thickness. With a PP/ABS price ratio of 0.82 ...

Kunststoffe international, 2005-11-21, Qualification of Polyurethane Foams
...eat capacity and are easy to handle. They interfere little with foam formation, not at all with the other parameters and may be used repeatedly. The maximum core temperature is measured by placing the thermocouple in the lower third of the foam. The exact height of the thermocouple above the bottom of the vessel can be established after the experiment by projecting the temperature rise onto the rise curve. Rise Pressure Pressure builds up in the foam after the components have set. A network of...

Kunststoffe international, 2005-11-21, Quality Assurance for Class A
...pecial demoulding robot was fitted (for diagram showing mode of operation, see Fig. 4). By a rotary movement, the component is removed from the bottom force when the press has opened. Because of the risk of slide waves in the brake light area, very exact process management is required. Determination and monitoring of these process parameters is undertaken by a data acquisition and analysis system. System Configuration A schematic diagram illustrating the configuration of the press and data acq...

Kunststoffe international, 2005-11-21, Quality Improvement: Cooling Time as Variable
...ed cavity pressure sensor detects the point of volumetric filling, the start of cooling (Fig.2). All the information is thus available to automatically solve the cooling time formula, cycle for cycle by means of further algorithms, and to supply the exact cooling time for initiating the demoulding process to the injection moulding machine. Expectations Confirmed in Production In the interim, the method presented above has also been tested on a large housing part (part weight approx. 1kg) of A...

Kunststoffe international, 2005-11-21, Reorganization with an ERP system
...nagement, PPS and inventory management are collected in this system so that the management can be fully informed of the latest company position. In work planning, lot sizes and order throughput times were the main areas of improvement. Today, more exact planning of production orders in relation to free capacity and available stock is possible. A significant innovation was the introduction of the infor order control module. "With this tool, we can plan orders and monitor them", explained ...

Kunststoffe international, 2005-11-21, Retrofits: No Fear of Foaming
...G, Wolfertswil/Switzerland. If necessary, this nozzle can be equipped with limit switches and connected to the safety system on the injection moulding machine. A metering station equipped with proportional valves and mass flow sensor supplies an exact amount of blowing agent under high pressure (Fig.5). In close cooperation with Maximator Gmbh, Zorge, and the IKV, Sulzer Chemtech developed the station exclusively for Optifoam. Essential operating controls are also integrated into the station. T...

Kunststoffe international, 2005-11-21, Sandwich Moulding Technology: Exact Distribution of the Core Material
Injection Moulding Exact Distribution of the Core Material Sandwich Moulding Technology. In sandwich moulding, distribution of the core material in the component is strongly influenced by the filling pattern and can only be varied within narrow limits through adjustment of process settings. This article shows a new way in which design freedom can be increased by suitably adapted mould technology and development engineers can confirm the reliability of their decisions with simulation tools. Chri...

Kunststoffe international, 2005-11-21, Sealing Through Contamination
...packed inevitably contaminates the seal area. The ability to provide a high performance seal in the presence of contaminants is thus an important attribute. This study presents the results of the comparative testing of metallocene plastomers (grade: Exact, manufacturer: DEX-Plastomers) versus conventional sealing polymers for various contaminants. Ionomer, which has traditionally been used for sealing through contaminants [4,5], has been selected as a reference polymer. In laboratory and practic...

Kunststoffe international, 2005-11-21, Self-contained Chemical Factory
...ter 76 mm from a double cartridge (mix ratio 10:1) using the 3M EPX manual applicator and the newly developed 17-element mixing nozzle. The Doyma employees also use a spacer. "In this way the adhesive can always be applied around the pipe at an exact distance from the outer pipe edge", explained Frank Mendel. Then the parts to be joined are mounted in an assembly jig and with the aid of the jig, the pipe is pushed into the sleeve. "The adhesive is applied in such a way that during th...

Kunststoffe international, 2005-11-21, Silicones: Preserving a Heritage
...tural artefacts and artistic treasures. Structures and monuments are restored, and provided with durable protection against the ravages of the environment. Archaeological excavations are reconstructed, unique works of art and statues are copied, and exact reproductions made. Silicone chemists and applications engineers work hand-in-hand with technicians in reproduction studios, museums, monumental protection agencies and cathedral reconstruction workshops, and with architects, engineers and craf...

Kunststoffe international, 2005-11-21, Simulation under Pressure
...n be realistically simulated in a 3D-modell since the geometry has three-dimensional regions and the process of displacing the plastic melt by the gas is three-dimensional. In gas injection moulding (GIM) the mould cavity is partly filled with an exactly defined quantity of melt. Thereafter an inert gas under pressure, usually nitrogen, is injected after a defined delay time. The gas injection takes place through the gate or through gas nozzles arranged in the cavity. In the moulded part gas c...

Kunststoffe international, 2005-11-21, Strategies for Cooling Moulds
...is why the system has so far mainly been used for mass-produced articles and high- budget moulds. Small mould inserts (100x100x140mm³) can be made from tool steel by generative techniques, such as laser melting (Fraunhofer ILT, Aachen). The exact dimensional deviation of the inserts has to be established beforehand. Since the incorporated cooling channels can sometimes run very close beneath the surface, there is often little scope for post-machining the inserts. Furthermore, the new arrang...

Kunststoffe international, 2005-11-21, Successful Conversion to 3D
...the most important criteria. As Edgar Madlener, CAx coordinator at Alpla explains: "Particularly in the case of bottles with an integral handle or that consist of free-form surfaces, it was always a very complicated and uncertain science keeping exactly to the required volume in the 2D process." For this purpose, it was necessary to construct sections from which volume could be determined. With this approach, it took a whole day to determine the volume. In addition, with each change to t...

Kunststoffe international, 2005-11-21, Surface Inspection: Big Brother for Films
...ctical Application Film extrusion has to contend with the occurrence of several classic flaws such as streaks, flow marks, gels, black specs with gel ring and chatter marks. When detected, these defects must be classified. Moreover, the exact position of the flaw on one particular roll and one particular lane must be determined. A 3-D-flaw analysis provides film producers with a three-dimensional display of the flaws, which allows a deduction of the cause. Thus, film producers can develop a bet...

Kunststoffe international, 2005-11-21, Synergy Creates New Technology
...ld were determined and a partial folding identified (Fig. 5). A considerable amount of attention must be paid to the fitting accuracy of the film when designing the mould and to the temperature during the thermoforming of the film to ascertain the exact level of shrinkage. The decisive aspects are in any case the dimensions (contours) of the injection mould at processing temperature. The nominal measure of the thermal shrinkage of a film is only valid two- dimensionally. For the three-dimensiona...

Kunststoffe international, 2005-11-21, Tailor-made Compression Moulding Process: Automatic Compression Moulding Machines for Powder Materials
..., not to be damaged and for the product height to be strictly observed. The new brake disc is much lighter than the cast iron brake discs used to date. The greater than 50% weight saving reduces vehicle weight by up to 20 kilograms, the exact reduction depending on the size of the brake. This not only improves fuel economy, but also reduces the unsprung weight, a fact which improves shock-absorber response and ultimately makes for better road-handling. The new system also has a substantially lon...

Kunststoffe international, 2005-11-21, Testing Technology: Fully Automated Serial Testing
...ting from it is no longer possible because human factors of influence are impossible due to the robot handling of the samples. From this results a further important advantage for close-to-reality measurement results: The robot achieves by far more exact reproducibility (

Kunststoffe international, 2005-11-21, The Case in Favour: Tiebarless – What Are the Benefits?
...m for injection moulding machines developed by Engel offers both technical and economic advantages. These range from larger usable platen areas and lower clamping forces through unobstructed access for robots and even complex automation systems to exact platen parallelism adjustable to one hundredth of a millimetre. Werner Kappelmüller Georg Steinbichler Hans Wobbe Engel has been building injection moulding machines with a tiebarless clamping unit (HL machines) since this type of machine was la...

Kunststoffe international, 2005-11-21, The Handmaster Project
... glass fibres align themselves, how much warping occurs and what quality of surface is feasible with the materials (30 % glass fibre content). To be able to get as close as possible to the goal described above, the gating point in the mould must be exact. More than 80 % of subsequent warping is governed by the orientation of the glass fibres in the part - and thus by the position of the gate. As revealed by the results of the Moldflow analysis, cooling is responsible for just 20 % of warping in ...

Kunststoffe international, 2005-11-21, The Journey is the Reward
...s difficult in medium-sized companies to adapt, through hiring and firing, the numbers of personnel to the quantity to be produced; therefore, they are considered fixed costs here. Depreciation A 1000-kN automatic press costs around 230,000 DM, the exact figure depending on the accessories. Added to this are the prorated costs of 14,500 DM for deflashing equipment and 10,000 DM for planning, transport and commissioning. In Germany, investment costs may be recouped tax-free over a depreciation p...

Kunststoffe international, 2005-11-21, The Right Wall Thickness
...anger of wrong interpretation is minimised by recourse to the mathematical approximation described above. The approximation algorithm always considers the effects that the wall-thickness-adjustment system has on the overall parison and thus permits exact comparisons. Sample Results of an Approximation For our PFT, the approximation produces the results visualised in Fig. 4. The approximated wall thickness is plotted as surface area against the optimum surface area shown in Fig. 2. Four calcula...

Kunststoffe international, 2005-11-21, Thin and Decorative to Boot
...asks incumbent on it besides the primary ones of inserting the pre-formed film and removing the finished part from the injection mould are preparation and finishing: - Separating the film from the stack, - precentering the film to ensure exact positional transfer to the mould, - discharging the statically charged films with ionised air, and - stacking the finished parts in trays. The following boundary condition applies: the machine cycle determines the overall cycle time. The robot therefore ha...

Kunststoffe international, 2005-11-21, Trends in Flat Film Extrusion
...ng metering systems in the system. All important data can be saved according to time, order or batch, and processed directly with Microsoft Office programs on connected PCs. ER-WE-PA Davis Standard GmbH, Erkrath/Düsseldorf, Germany, with the "Exact-S", offers an automation system that allows individual, decentralized plant components to communicate via standard networks (IEE 802.3 and EN 50170) with a master computer, with the option of connecting further operating systems via the networ...

Kunststoffe international, 2005-11-21, Trends in Plastics Research
...r specific problems. In particular with new products, customers again want to have as objective an overview as possible of all the available materials and their pros and cons, without already having to make statements about quantity and exact specifications. Here friction losses are pre-programmed because of subjective materials recommendations, preferably from own product ranges, and reduced commitment because of allegedly small sales volumes. The R&D service providers’ materials consultants of...

Kunststoffe international, 2005-11-21, Tubes for Drip Irrigation
...d hole relative to the dripper. Additional software is available to automatically evaluate the production and generate a quality protocol for each reel. Any reels with faults are put to one side. Each protocol contains an indication of the exact position of the fault so that the discarded reel can be repaired at a later date. Production of Tubes with Cylindrical Drippers This technique was described in the first patents [6] as early as the 1970s. The production process described there has bas...

Kunststoffe international, 2005-11-21, Water-assisted injection moulding: Water Increases Productivity
...equipment and process engineering. Summary and Outlook WIT complements GIT and offers a means of tapping new applications and markets. So far, comparative tests have revealed cycle-time reductions of 50-70%, relative to GIT, the exact figure depending on the material and the part geometry and the resultant wall thickness. Using water instead of gas as a process fluid also lowers costs because it is much cheaper. Numerous tests have shown that the right process control, appropriate WIT equipmen...

Kunststoffe international, 2005-11-21, Which Way is the Wind Blowing for GRP?
...tain level of stiffness for demoulding. The resin attains its final properties in a post-curing process at 70 to 80°C, which can be carried out at the same time as the curing of the adhesive joints, either via the moulds or in the oven. Exact Resin-fibre Ratio One alternative to the wet processes is to use ready-made epoxy (EP) prepregs, for which the proportion used in rotor blade production world-wide is currently 20 to 30%. These are placed on top of each other in layers, taking the fibre o...

Kunststoffe international, 2005-11-21, Wide Area of Applications: Upward Trend for Thermoplastic Polyurethanes
... blend may change over the years. The laws of chemistry state that a polar material is widely resistant to non-polar solvents. The reverse applies, too. Under certain conditions, TPU systems consisting of polyester or polyether, or, to be more exact, TPU systems with a soft segment of either ester or ether may be broken down by concentrated acids or alkali solutions. The fact that TPU is resistant to oils, greases and fuels was mentioned above. Chemical resistance however, plays only a minor rol...

Kunststoffe international, 2005-11-21, Zero-clearance Connection: For Complex Riveting
...ements could be fulfilled by a series unit characterised by small space requirements and compact construction methods. A unit consists of a retrainer, a heating element and a rivet tool and it is adjustable. Servo-motor drives provide for the most exact final positioning. If several rivet directions are necessary, these units are likewise servo-motor driven. The high integrity of this unit facilitates exchange in a few minutes. During the rivet procedure the units do not affect each other and it...

Kunststoffe international, 2005-11-30, Extrusion Dies: Variety by the Meter
Special Variety by the Meter Stefan Seibel Extrusion Dies. Production of high-quality semi-finished plastic goods requires product-specific extrusion lines that incorporate a number of critical processing operations. Regardless of where the extrusion die is located in this sequence of important components, there is no doubt that it is ultimately responsible for the shape of the product. It is this responsibility that results in the variety of products that can be produced via extrusion. Within...

Kunststoffe international, 2005-11-30, Fluoro Polymers: Safe Construction of Chemical Apparatus and Plant
...tunities for realising complex geometries such as large-scale bottom end caps. Furthermore, the materials are also very easy to machine, e.g. turn or mill. These processes afford great scope for producing even complicated geometric parts to the exact requirements in a solid plastic construction. Particularly in the case of welding and thermoforming, it is vital to observe the relevant safety precautions for handling fluoro polymers. Semifinished goods made from PVDF and ECTFE are ideal for produ...

Kunststoffe international, 2006-01-15, State-of-the-Art and Perspectives: Laser Beam Processing of Polymers
...e today covers a wide range of applications in plastics processing and in the electronics, automotive, packaging, medical and optics sectors, and must be counted among the everyday tools for production. Flexible beam control and introduction of an exact amount of energy assure high-quality processing results with minimal effects on the part. Laser technology has become accepted wherever extremely small geometries and a noncontact processing technique are important in terms of product specificati...

Kunststoffe international, 2006-01-25, Added Value: Compounding at Maximum Power Density
Compounding Compounding at Maximum Power Density Werner Wiedmann Added Value. In compounding, the limiting factor on throughput is usually the available power density. A disproportionate increase in economics and product quality requires a finely balanced increase in extruder torque, speed and free volume. The technological development of compounding on co-rotating extruders has been decisively influenced by improvements in design, material and computational methods. This has made it possibl...

Kunststoffe international, 2006-02-22, Cockpit Surfaces: Workplace and Living Room on Wheels
...this case, the paint is usually sprayed into the open mould before the moulding compound is injected. Complete wetting, which is influenced significantly by matching of the surface tensions and the application itself, is a prerequisite for exact replication of the surface. The primary difference versus positive painting is that the paint can replicate almost any surface textures (graining). In contrast, with positive painting, extremely fine structures in the surface become “flooded” to a greate...

Kunststoffe international, 2006-02-22, Film Processing: Embossing of Microstructured Plastic Film
...t can be seen clearly that the accuracy of replication increases noticeably with increasing static temperature of the roll. However, the surface defects in the embossing roll and sharp edges from the structures are reproduced in the film exactly only when the induction heater is used. Regardless of the static temperature of the roll and the use of induction heating, a difference in the accuracy of replication of the structures is noticeable in the extrusion direction compared to transversely to ...

Kunststoffe international, 2006-03-23, Energy Contracting: Preparatory Analysis Ensures Success in Contracting
... compressed air volume generated, available idle- and leakage ratios, as well as the requirements to be fulfilled by compressed air level and quality may be derived from these values. Based on this analysis, the requirement parameters are exactly defined, savings potentials are calculated and deliberate improvement steps for energy optimisation are developed. Energy savings in compressed air generation of up to 30% and more is absolutely feasible. By focussing on dimensioning according to requi...

Kunststoffe international, 2006-03-23, Stress Test: Ejection Without Damaging the Moulded Part
... are needed. In this regard, determination of the coefficients of friction under injection moulding conditions is of special interest, since such a procedure would eliminate the sources of error associated with determination of these values. A more exact calculation of the shrinkage would provide more reliable information on the residual stress distribution in the moulded part at the moment of ejection. Acknowledgment: These investigations were funded by the German Economics Ministry (BMWA) thr...

Kunststoffe international, 2006-03-29, Bioplastics: Converting Risks to Opportunities
...dvertised? Although most biodegradable plastics contain high proportions of renewable raw materials, this content has not yet been used as a distinguishing characteristic. It is true that the exact composition of the product has to be quoted by the manufacturer for the purposes of certification but it is never published. Whether and how the content of renewable raw materials in the product should be advertised in future is presently the subject of debate within the industry. Here it is important...

Kunststoffe international, 2006-04-25, Filler Dispersion: Ultrasonic Spectroscopy for In-Line Monitoring
...illers, such as chalk, are incorporated into the melt in extruders at the pressures and temperatures that are typically used in plastics processing. It is a long-cherished wish of many processors to be able to monitor dispersion of the fillers, the exact composition of composites, and the composition fluctuations, directly during the manufacturing process. For some years, polymer composite melts have been investigated by vibrational spectroscopic methods, e.g. near infrared (NIR) and Raman spec...

Kunststoffe international, 2006-05-24, Process Control: The ABC of Mould-Sensor Systems
...dard mounting nipple and substantially shortens the length of the sensor [3]. A second series (Model 6006B) is manufactured without thread and mounted with a spacing housing; this makes for sensor bodies of very small diameter (Fig. 4). Exact Reproduction of the Melt Position. It is becoming more and more common to use cavity temperature sensors to control the injection moulding process. Applications range from automatic switch-over to holding pressure, to melt-position-dependent core pulls and...

Kunststoffe international, 2006-06-29, Quality Planning: From Customer Requirement to Industrial Mass Production
... end product, documentation using a control plan is also necessary here. To help employees throughout the production process, but especially those in the production and quality area, to “visualise” the importance and need for exact compliance of the particular process or work step, Kraiburg TPE has introduced special characteristic symbols in the control plan (Fig.5) for “classification of the influencing process characteristics”. With the current introduction of a new FMEA software, new and com...

Kunststoffe international, 2006-06-30, UTECH 2006: PUrists Together
... conventional pulse transmitters and a simple mathematical refinement. At the same time the VSE developers exploit the sinusoidal pattern of the inductive signal on passing through one pump element under the sensor. From this signal pattern genuine, exact intervals can be determined which allow more accurate calculation of the volume conveyed. Hilger und Kern, Mannheim, are pilot users of this method of measurement which they already employ in some of their metering machines. Apart from these t...

Kunststoffe international, 2006-07-04, Company History (3): The Road to Global Player
... to the customer’s individual requirements, Arburg has developed and built its control systems in-house from the very beginning. As the first fully solid-state control system, the Polytronica II permitted what was at the time considered fast and exact execution of all commands. In 1975, Arburg introduced the world’s first standard microprocessor controls in the Allrounder H. An engineering quantum leap in plastics processing, since for the first time a microcomputer system was employed to permi...

Kunststoffe international, 2006-08-06, Laser Forming: Cores for Garden Equipment
...uniformly rough surface. This roughness can be controlled in laser forming by building up the cores more or less rapidly. "In this way we can shorten cycle times by about 20%." reckons Robert Olz. He concedes, however, that there is no exact comparison because the product is new. The geometry of the parts and the nature of the material are also contributory factors determining the shape of the cooling curve. According to Robert Olz, contact with inno-shape GmbH, the manufacturer of the c...

Kunststoffe international, 2006-09-05, Viscosity Measurement: Material Characterisation in Powder Injection Moulding
...h often result in poor part qualities. Such flaws can mostly be avoided by simple modifications in the process cycle. In order to obtain good results, it is always indispensable to adapt the component’s geometry to the process and to provide for exact temperature control as well as good mixing of the ingredients. So as to find out how homogeneous a blend is, generally the feedstock’s viscosity is determined. Rheological Characterisation of the Blend. The feedstock blend is characterised in a rh...

Kunststoffe international, 2006-09-08, Carrier Film: New Possibilities for Decorating Thanks to 3-D Dye-Sublimation Printing
...h- and abrasion-resistant. - No change in the surface characteristics of the object: glossy remains glossy, matte remains matte, textured remains textured. - Suitable for objects with complexly shaped surfaces (tight radii, undercuts). - Permits exact and reproducible patterns. - No change in mechanical properties (Table 1). - UV resistance: if the resin used is UV-resistant, the decoration is UV-resistant, since the pigments penetrate the surface. Nevertheless, sublimation printing is not a uni...

Kunststoffe international, 2006-09-08, Data Collection: Virtual Development of Crash-stressed Parts
...ty has been accompanied by ever more powerful computer systems. An end to these developments is nowhere in sight. The informativeness of any computer model can only be as good as the underlying descriptions of the individual components involved. An exact description and capturing of the material’s behaviour especially as regards crash loads is essential. Substantial advances have recently been made in polymers, especially short-fibre-reinforced engineering thermoplastics [1, 2]. Improved, theore...

Kunststoffe international, 2006-09-18, PU Machine Engineering: Room for Foam
...e laboratory metering unit to its range. The machine, equipped with gravity tanks and gear pumps, completes the range of machines below the Eldomix 101 and is ideal as an entry-level machine for processing reactive resins or as a pilot plant. Exact Temperature Control The Swiss company ATP Kunststofftechnik AG showed a fully heated low-pressure unit of very compact design with the name Swissmini Thermo (Fig.7). It is suitable for temperatures up to 160°C. The feed lines are designed in such a...

Kunststoffe international, 2006-09-27, Progress and Trends: More Condition-oriented than Preventive
...trict adherence to delivery dates; second, lower maintenance costs, for instance for spare parts and service. Other pluses include the fact that downtimes can be scheduled, allowing for satisfactory repair time, and higher reliability based on exact knowledge of the production equipment’s and components’ wear state [1]. However, the potential of condition-oriented maintenance can only be fully utilised by applying these concepts in an integrated manner, in conjunction with continuous supervision...

Kunststoffe international, 2006-09-28, Reactive Processing: From Expanded Foam to Structural Part
...ompany can now reach pressures of up to 200bar in gear-type pumps. The volume flow rates in these are controlled by measuring devices installed directly ahead of the static mixer. In this way precise regulation of the actual discharge volumes and exact adherence to the mixing conditions are possible. In the form of the portable Eldomix 001, Hilger und Kern have added an extremely compact low-pressure laboratory metering unit to their range. The machine equipped with gravity tanks and gear-type p...

Kunststoffe international, 2007-01-22, Preserving our Cultural Heritage
...raisal within a day. The number of industry users who regard this service as an indispensable tool for their daily work is constantly increasing. With the aid of this service, restorers can also, for the first time, hit on the exact shades they require without any compromises and so optimally preserve the spirit of the ageing design pieces (Fig.4). It follows, then, that chemical companies such as BASF are not only contributing to the preservation of our threatened cultural assets but are also e...

Kunststoffe international, 2007-01-22, Simulation of the Heating Cycle during Thermoforming
...ature gradient across the thickness of the sheet were solved using the finite difference method. The solution methodology is too complicated to be dealt with in the framework of this article, but interested readers are very welcome to request an exact description from the authors. The core of the heating calculation program was written in C++ in order to achieve higher computational speeds. The input interface for both data entry and analysis of the results was written in the Microsoft Excel exe...

Kunststoffe international, 2007-03-15, From Family Saloon to Transporter
...idespread SL synthetic resins currently used in Europe and North America. The transparent material, which appeared on the market in 2001, was the first to be based on Somos Oxetane Advantage chemistry, which guarantees not only very rapid and exact moulding of the model, but also a high green strength and permanent dimensional stability. Since being launched onto the market, the range of potential applications for this SL material has grown enormously. The fact that WaterShed can be used also on...

Kunststoffe international, 2007-03-15, Higher Qualities, Lower Costs
...module is part of the PDA system and shows the states of all injection moulding machines. It presents every feedback from the machine in a way so that even an untrained operator can easily understand it. To give an example, the user can see exactly when an order will be finished, subject to lot size. The real time plant viewer is also the starting point for the other modules of the PDA system. From here, the operator can access e.g. adjustment data management. "For every order we store the r...

Kunststoffe international, 2007-03-15, More Lightweight Construction for the BMW 3 Series Coupé and Convertible Models
...quent drying of the car body at 195°C presents the greatest challenge to the implementation of thermoplastic side panels. The operation of the slide elements must be guaranteed 100% at these high temperatures. For this there has to be an exact dimensional match between the slide elements made of metal and the plastic side panel. Any blockage in the course of heating or cooling during passage through the dryer would result in lasting deformations of the side panel. After this the car bodies run t...

Kunststoffe international, 2007-04-17, Dual Head in the Drilling Cell
...oulding process into 2-to-3-mm-thick panel support parts made of PC+ABS (dimensions: 600 x 900mm2). These suction holes are needed for applying the laminating material, e.g. a decorative film with leather grain, accurately in the mould in order that exact reproduction of the part contour may be achieved. The robot working in the drilling cell RBZ-2H (design: Remak Maschinenbau GmbH, Reinheim/Germany) has just 50 seconds to make the holes. In practice, this means that the installation has to make...

Kunststoffe international, 2007-04-17, Fibre Composite Robot Arms
...) is cured at 100°C with a process pressure of 4.5bar for four hours. The individual prepreg sheets were not layed-up in a female mould as is usual but were built up on a male tool. With the requirement for a complex part geometry and exact fibre orientation within the laminate this procedure enabled a more precisely controlled lay-up to be achieved. These male lay-up tools are inexpensive and can be duplicated at low cost so that a supply of pre-formed prepreg assemblies can be cost effectively...

Kunststoffe international, 2007-06-18, Economical Production with Complex Manufacturing Cell
...ations, each having two drawers and eight containers in each case. Each container holds around 1,000 parts. This allows up to 16,000 parts to be buffered in the deposition system. To allow production to continue without interruption when the exact number of parts has been produced, the system is laid out in tandem. The complete deposition system can be moved to meet the requirement that the mould should be accessible from the operator side. Depending on which mould is currently being used, diffe...

Kunststoffe international, 2007-06-18, Improving Product Properties by Cutting Back on Material
... the filler particles in the polymer matrix must be characterised and compared with the starting product. The characteristics of the CaCO3 both in the pure material and in the polymer matrix are determined by scanning electron microscopy (SEM). The exact concentration of filler in the compound is determined by thermogravimetry. Comparison of Two Fillers ACC was converted to dried amorphous calcium carbonate (DACC, see Fig. 1) by drying it for six hours at 200°C in a vacuum oven. In the course ...

Kunststoffe international, 2007-07-18, Guide Wire for Intervention Using Magnetic-Resonance Tomography
...zation is to maximize the processing speed, which is the equivalent in the pultrusion process to the amount of material produced per time unit. During production, the temperature profile in the die can be adjusted as necessary. Accordingly, an exact knowledge of the time- and temperature dependence of the curing behavior of the epoxy system used is necessary. For this purpose, non-isothermal DSC analyses (Differential Scanning Calorimetry) were conducted at heating rates of 5, 10 and 15°C/min. U...

Kunststoffe international, 2007-07-18, High-Quality Pharmaceutical Film
... (production, customer, QC), specifications can be prepared and implemented, and production that is meaningful to the customer is assured. The knowledge gained from recent work on customer validations confirms exact agreement between detected and tagged/removed defects. Validation binders in which the pertinent investigations are retained have been and will be compiled for appropriate types of film (pharmaceutical field – white opaque and transparent films). OCS has also recently developed val...

Kunststoffe international, 2007-09-19, Polycarbonate Automotive Glazing
...overns the process demands and the mold requirements. In order to guarantee a trouble free transfer to the downstream coating unit an automation solution using an intelligent cleanroom concept is required. A high degree of process uniformity and exact documentation of the individual process steps are imperative because negative interactions within the process chain are often not directly visible. For example changes in the injection molding process can vastly increase the reject rate during pain...

Kunststoffe international, 2007-09-19, Prior to Film Extrusion
...ch are calculated from the recipe specifications and the total batch weight. During metering, the system tries to meet each of these setpoints as accurately as possible. This approach is suitable for filling weighers where maintaining an exact batch weight is important. Compensation method: For the plastics processor it is irrelevant whether the total batch weight varies. It is essential that the components in the batch correspond precisely to the prescribed recipe. Taking this requirement and t...

Kunststoffe international, 2007-09-19, Producing PP Cups Faster
...ps with 70 mm in diameter per cycle, with a maximum draw depth of 180 mm. Forming takes place on the basis of the pressure-forming principle using compressed air in conjunction with a servo-driven assist stamp. The electric drive provides fast and exactly reproducible stamp movements, and even tooling using air-saving technology can be operated. In the rugged forming station, which is designed for 600 kN of forming force, the forming tool and the pivoting lower table are guided using a new seque...

Kunststoffe international, 2007-09-19, PUre Evolution?
...esolution helps determine changes in throughput more quickly and precisely. It also provides more information and more details concerning the actual state of the throughput. This way, even for small volumes, the new system safeguards exact measurement and monitoring, thus guaranteeing exact metering. What is more, engineers can use the amplifier also with large-volume sensors for highly viscous media and low throughput rates. Conclusion and Outlook Using spray technology for PU systems has bee...

Kunststoffe international, 2007-09-19, Tailored to Your Timeline
... textiles can change color at certain temperatures or under certain light conditions. The fiber laboratory is fully equipped to conduct colorimetric, analytical or material property investigations in order to provide the customer with exact information quickly (Fig. 7). Lifocolor Farben GmbH & Co. KG, Lichtenfels, Germany, is intimately familiar with laser applications and offers masterbatches for laser marking or laser welding. The polymer-specific batches are available as Lifocolor multifuncti...

Kunststoffe international, 2007-09-19, Technology Barometer Indicates Fair Weather
...njection molding and extrusion (Fig. 1). A mold insert that creates a shape, e.g. a profile, is shifted transversely with respect to the machine’s lengthwise axis in a motion synchronized with injection of the melt. Filling of the cavity requires exact synchronization of the melt flow rate resulting from the screw’s forward motion and the speed at which the mold insert is shifted. Displacement of the insert continually creates unfilled space in the cavity that is filled by the incoming melt. Hol...

Kunststoffe international, 2007-09-19, Transparent Processes and Tested Products
...rature range of -70°C to 600°C. The thermo-microbalance, which is based on the same platform, has a resolution of 0.1 µg and operates between room temperature and 1,000°C with heating rates between 0.001 K/min and 100 K/min. The specimen’s exact temperature is measured by a thermocouple in direct contact with the specimen cup. The vertical arrangement with specimen holder lift makes the top-loading thermobalance reliable and easy to operate. A specimen changer that holds up to 20 specimens is op...

Kunststoffe international, 2007-10-21, Four Ways towards a Multi-Component Bottle Crate
...ot-runner systems and additional side cores for cavity separation have to be integrated, but the process engineering advantages outweigh the technical complexity. The production sequence is like that of the transfer method, but is the exact opposite to that of the insert technique. Whereas, in the insert method, the cold small articles are inserted first and then over-molded along with the crate, in the two-component method, the large volume of the bottle crate is injected first. Side cores in t...

Kunststoffe international, 2007-10-21, Is the Formulation Right?
... (Fig. 3). Characterization of stabilizers and processing aids with the help of TG-FTIR coupling is explained in [4] using PVC mixtures for pipe extrusion as examples. Conclusion Thermogravimetric analysis (TGA) is a very easy to use and exact measurement technique that provides information on the composition and thermal stability of polymers. In addition, stabilizer decomposition and the age of the resin specimen being tested can be assessed with the aid of TGA. Moreover, the results of the a...

Kunststoffe international, 2007-10-21, Perfect Eyes
... for the film and sheet manufacturers to obtain indicators about the causes of the defect. Today, they demand precise defect detection, which requires crystal clear images, along with a classification system which describes the defects exactly. Smash does not only inspect for the typical defects such as gel, fisheye, scratches, burn marks, condensation drops, insects, die defects, double-layered film, angle or polishing defects (Fig.1). It also recognizes optical defects which can result from i...

Kunststoffe international, 2007-11-21, Stylish Inconspicuousness
... Table 1. Conventional versions of roof racks Fig. 1. Klaus Münker, Project Leader for Innovation at the Decoma Engineering Center, with a painted roof rack made from PA 6-GF 50: "WIT can give us exact and constant wall thickness over this enormous component length: With more than two meter long flow paths, that is very important." (photos: Provvido) Fig. 2. WIT creates an excellent surface, as a look at the slit-open roof rack demonstrates Fig. 3. Extreme flow paths: The roof rack...

Kunststoffe international, 2007-11-21, Successful 3-D Simulation of Decorative Parts
... very reliable warpage analyses to be performed. The quality of the program is shown particularly in its high-quality mesh capabilities. Besides tetrahedrons, hexahedrons, prismatic and pyramidal elements can also be used. These structures permit an exact reproduction of the part geometry and insert. The mold, too, enters three-dimensionally into the simulation. This is particularly important for new developments in mold technology, such as conformal cooling. The first task is to replace the con...

Kunststoffe international, 2007-11-21, Water Injection via an Additional Injection Unit
...logy that allows a precisely controllable and reproducible process. Gas injection is generally run with pressure control. However water, unlike the nitrogen used as inert gas in GIT, is a practically incompressible medium. This property allows an exact control of the volumetric flow rate via a pump with rotational speed control or a pressurized water generator with a control valve or a piston injection system [3]. A piston injection system with integrated travel measurement allows precise contro...

Kunststoffe international, 2007-12-17, New Laser Sources Expand Field of Application
... weld seam widths down to a minimum of 100µm by means of mask welding. This, however, is associated with a loss in flexibility regarding geometry changes, poor utilization of the laser’s energy and a great deal of effort to position the mask exactly. With contour welding, it is possible to attain a beam diameter of 150µm through use of a short focal length and stationary optics, which makes it possible to have a weld seam width of about 200µm. The feed rate, however, is quite low, about 10mm/s o...

Kunststoffe international, 2008-01-15, Bringing Measurement to Optical Effects
...ystem) and SILS (Sequence-in-line-Supply). Whilst currently around 40% of automobile output is manufactured using these techniques, this is predicted to rise to about 70% by 2010. The ILVS manufacturing process, where components are produced in the exact sequence in which the orders are placed, offers many advantages from the point of view of the automobile manufacturers, but at the same time places great demands on the logistics. Alongside reliable color measurement in the automobile supply cha...

Kunststoffe international, 2008-01-15, Focus on Wall Thickness
...n rules and thus provide the designer with access to valuable knowledge for the design and calculation of a part. The material can thus be chosen according to the permissible and desired tolerance range. Additionally, the knowledge of the exact component thickness, in addition to other factors, such as mechanical and specific properties, forms an important basis for the creation of crash simulations. Wall thickness measurement makes a significant contribution to the characterization of the shapi...

Kunststoffe international, 2008-01-15, More Complexity, Speed, and Intelligence
...city for up to 2.5 years continuous operation), the black box records process-relevant data, which can be read out and evaluated by a PC at any time. Apart from a shot counter and a potentiometric displacement sensor for exact measurement of the mold position, there are twelve analog channels for temperature measurement, and four channels for recording the signals from pressure sensors and/or flow quantities, e.g. of an external tempering unit. Up to three months storage capacity is available fo...

Kunststoffe international, 2008-01-15, Production of Hollow Parts by Rotation
...set in two positions – oscillating and static – and it is possible to switch between the two modes. Trials aimed at automating the entire oven unit are currently being conducted. It should then be possible to adapt the hot air flow online to the exact mold conditions. Molding Large Containers Caccia Engineering S.r.l., Samarate, Italy, exhibited a Rotaut A4C-6000 rotational molding machine (Fig.2) on which molds with a swing of up to 6m per arm can be used. It is therefore possible per rotary ...

Kunststoffe international, 2008-02-17, As Good as Welded
...d design freedom high. Due to the high energy density of laser radiation rapid, selective heating of the metal component, if need be within localized bounds, is possible. If the thermal radiation emitted by the parts is measured by a pyrometer the exact joining temperature needed can be set as a function of the material used. In doing so the pyrometer signal together with the desired temperature are processed in a controller and a corresponding setting signal equivalent to the laser power is pas...

Kunststoffe international, 2008-02-29, Design and Lighting Technology
...ghts with Incandescent Bulbs: A unique appearance can, however, also be achieved with incandescent bulbs. Sculpture-like, free-standing reflectors such as those used in the Audi A4 Cabrio (Fig.7), Q7 or in the TT not only look good; the exact delineation of the surfaces also contributes to creation of a unique signal. At the same time, the functional surface must satisfy esthetic requirements, flow lines, flash or other flaws are absolutely unacceptable. Innovative Lights and Light-assisted Sys...

Kunststoffe international, 2008-02-29, Hot Forming instead of Compression Molding
...sotropic laminated structure, the forming radius was selected such that the swage geometry satisfies the requirements described above as well as the static requirements. The parameters were verified in preliminary trials. Tool Design To ensure exact positioning of the preform sandwiched between the diaphragms over the forming tool for the DD technique selected, the tool was designed as a deep-drawing tool with an elevated rim for outside centering of the laminate (Fig. 7). Table 1 lists the cr...

Kunststoffe international, 2008-02-29, Thermal Analysis for High-Quality Cars
...red to aluminum. Since the carbon fibers absorb four to five times more energy than aluminum or steel, this complex material structure improves collision safety. Developing even more efficient composites and ensuring uniform quality require an exact understanding of the individual components and their interactions. Conventional basic DSC is pushed to its limits, while innovative developments, such as multifrequency temperature-modulated DSC (TOPEM), provide much more information about a material...

Kunststoffe international, 2008-04-14, No Chance for Product Pirates
...produced for each customer or application resulting in an unmistakable fingerprint. Authentication composites can be designed for a wide range of thermoplastic polymers. In production highly concentrated masterbatches are used which are dosed in an exact let down ratio on an injection molding machine. Pilot Project for a Leading Pharmaceutical Company Alongside these tried and trusted RFID and micro tagging technologies there is now another concealed security solution on offer which 3M Deutsch...

Kunststoffe international, 2008-05-10, Controlled Forces and Temperatures
...ully electric laboratory press from Rucks Maschinenbau GmbH, Glauchau, Germany (model: KV 265, Title picture, right) has a pressing force range that starts at 0.1kN and extends up to 50kN (10kg to 5t). The difficulty with normal hydraulic presses is exact control when approaching and regulating small forces. Hydraulic drives are typically limited to operate reliably from 10% of the maximum force up to the maximum force – here, that would be the range of 5 to 50kN. While specially designed hydrau...

Kunststoffe international, 2008-05-10, Hand in Hand with the User
...ndard solution did not come into consideration. Accordingly, together with an associate company possessing past data on different measurement techniques in various sectors of industry Billion developed a special sensor. The result is exact regulation of injection pressure, holding pressure and back pressure over the plasticizing phase (Fig. 7). Compensating for Mold Temperature Fluctuations A known effect at the start of production is expansion of the mold caused by the rapid temperature rise ...

Kunststoffe international, 2008-06-16, But it Does Move!
...ne positions, for automatically opening shut-off nozzles in sequential injection molding [3] or for ventilating cavities automatically via an automatically triggered venting core (Fig.5). In many cases, it is not possible to predict the exact melt position or the end of the flow path due to complex parts geometry. It is also possible for the melt position to shift due to various machine settings. In family molds, for example, it is often impossible to make all cavities fill simultaneously. For s...

Kunststoffe international, 2008-08-14, Bio – Sense or Nonsense
...tituents, which otherwise have their origin in petrochemistry. Plastics produced in this way offer the same capabilities as the fossil-based analogs. Polyethylene (PE) is a representative of this group in which exactly the same material is obtained from bio-based components: the resource (ethanol) can be obtained from sugar cane, so that the resultant product can be called bio-based PE. The BASF products Ultramid Balance, a PA 6 10 based on sebacinic acid that is obtained from or...

Kunststoffe international, 2008-08-14, Transparency in Production
...lanning and tracking, integration into existing PPS/ERP systems, monitoring of process parameters, preventive maintenance and, ideally, remote access via Intranet/Internet. Such a system should be modular in design to permit configuring to the exact needs of small to medium-sized processors. This will ensure that the user does not become lost as the result of being overwhelmed by the immense amount of information provided. Communication between the machines and the host computer system is also a...

Kunststoffe international, 2008-09-23, Reliable Testing in the QA Lab and Production
...t temperatures between -70°C and 600°C, without using liquid nitrogen. Starting from the same basis of devices, there is also the new thermal micro balance named TG 209 F3 Tarsus. Outstanding features are its solution of 0.1 µg, exact measurement of specimen temperature, thanks to direct contact between thermal element and crucible, as well as its vertical design with a sample carrier lift. There is also the option of calculating a DTA signal. For the two devices, electronic...

Kunststoffe international, 2008-09-23, Software Solutions also Automate
...is located outside the transport system it is inscribed by a standard RFID unit. The transponder can store additional items of information about the product such as article, series and production numbers or machining sequences and in this way allows exact retracing of the production pathway. In addition, the company is exhibiting its maintenance-free Montrac shuttle system with new components. The transport system is of modular construction and consists of self-propelled shuttles reaching speeds...

Kunststoffe international, 2008-09-23, Success is a Question of Detail
...h a low risk of contamination. Fully electric machines are especially suited for use under cleanroom conditions. The reasons for this – high precision, low energy consumption, low heat load (heat emitted to the cleanroom), was well as exact maintenance of constant operation windows – are well known. Especially when it comes to heat load, an optimized, fully electric model offers clear advantages: an Engel e-motion type medical machine emits approx. 80% less heat load to the...

Kunststoffe international, 2008-10-17, COsub>2/sub>– Climate Killer or Plastics Feedstock?
...hus loses most of its foundation because of this dual use. As Figure 4 shows, breaking down water into hydrogen and oxygen requires <10 kWh per kg methanol or, put another way, adds a premium of around EUR 0.5 per kg to the price of methanol, the exact amount depending on the price of electrical energy. Since carbon dioxide is available for free or, because money is received for it, the energy costs are no longer an argument. Thanks to its four hydrogen atoms, methanol is also an excellent, s...

Kunststoffe international, 2008-10-17, DSC – More than Just Identifying Materials
...n e.g. DIN EN ISO 728 or ASTM D 3895. As determined in cooperative tests [5], the important items are comparable sample weight and removal from the part, good sample preparation, reproducible gas switch from nitrogen to oxygen in the DSC cell and an exact oxygen flow usually controlled and displayed via so-called Mass Flow Controllers (MFC). Modern DSC measurement software also enables OIT detection and monitoring. Here the operator defines a threshold value for exothermic oxidation. If ...

Kunststoffe international, 2009-01-26, Just the Right Dose
...itives to ensure that the specified set value is not undershot in the event that the tolerance band is quite wide. Gravimetric systems can particularly avoid the overdoses that prove costly at high material throughput rates. By measuring the exact weight, they make for a constant, defined material mix of narrow tolerances, even when there are changes in the bulk density, grain shape and size or the flow properties of the materials. At RKW Gronau, the gravimetric metering and mixing system used i...

Kunststoffe international, 2009-01-26, Preventing Theft of Ideas
...opically-small marker of the metal object that can only be found if its location on the workpiece is accurately known. Otherwise the marker disappears in the random variations of the surface structure. Exact proof is naturally obtainable with atomic force microscopy and 3-D microscopy. A more sophisticated variant includes a signature that depends on additives of metals or metal oxides at the marker position that can be “read”with X-ray spectroscopy. At U-nica the name for this technology is nxC...

Kunststoffe international, 2009-02-17, Impact Modified and Highly Filled PVC Profiles
...ue, to plate-out, that is, that higher filler content results in more plate-out build up on the tools during extrusion. The following discussion addresses these issues. Experimental Methodology The dry blends used in this study were similar (exact formulations shown in Table 1) and prepared with commercially available products. Only the modifier and filler were changed. The modifiers were used at a rate of 7 phr, even though it is known that in industry values as low as 5.7 phr of modifier are ...

Kunststoffe international, 2009-02-17, Learning Controller as a Guarantee of Quality
...sues over a process cycle. This has the advantage that the setting of the controller does not respond to the instantaneous regulating error, but rather a specified target course within the framework of the system limits can be replicated exactly after a few learning cycles. In contrast a classic feedback controller delivers almost exactly the same suboptimal control result from one cycle to the next. During a cycle the iteratively learning control system does not intervene in the process. From t...

Kunststoffe international, 2009-02-17, Peripheral Equipment with Transparency
...d perhaps a little extremely, we examine every seal and every valve from inside and outside, think through every detail and as a general rule require construction in stainless steel” adds Andres. “We want to know everything exactly and in addition to clear answers we of course expect the corresponding documentation. What initially appears very abstract is often seen in better perspective in the detailed planning” opines Andres. The decisive factors are the understanding of the contractors and th...

Kunststoffe international, 2009-02-17, Process Innovations with Potential
...es or optimizations in the flow behavior. In medical technology, these effects can be used selectively, e.g. to allow medical equipment to be easily cleaned or medical containers to be completely emptied. These effects can also be used for exact dosing of medication. High precision reproduction of microstructures can be achieved with high mold temperatures. The disadvantage is a high cavity temperature, and therefore longer cycle times and problems with demolding. In the variotherm process, the ...

Kunststoffe international, 2009-04-16, Precise Pressure Measurement without Mercury
Pressure sensors play a central role in the control of the extrusion processes. Without exact pressure measurement, it is almost impossible to control the production process in most cases. The melt pressure values measured are used not only to control the speed of rotation of extruders and pumps, but also represent an indispensable control variable when it comes to achieving high-quality melt filtration. Despite this central function, the importance of pressure sensors is almost overlooked in ma...

Kunststoffe international, 2009-06-16, The Time is Ripe
...le the overall order situation or the commodity prices are set by the market and are difficult, if not impossible, to influence, automated control methods afford a way of greatly boosting competitiveness with existing machinery. Nothing Works if the Exact Position of the Melt Front is Unknown Control and regulation of the injection molding process are predicated on automatic determination of the melt front [1]. After all, unless it is known, it cannot be influenced. Premature or delayed switchov...

Kunststoffe international, 2009-07-16, Automatically Optimizing Profile Dies
... FEA Simplifies Mold Design The almost limitless complexity of the possible profile cross-sections makes it very difficult to produce the dies dimensionally true and economically [1]. Determination of a complex flow-channel geometry based on exact mathematical simulations is only possible with great technical difficulty, if at all. During production, therefore, only the inlet crosssection of the melt stream into the die and the cross-section of the desired extrudate are specified. The diemaker c...

Kunststoffe international, 2009-07-16, Plastic Bodies
... and all other required tests. The fact that all the functions of the original parts could be incorporated reduced part complexity from 30 individual parts to five. The rear seat backrests are 20–30 % lighter than the original metal version, the exact saving depending on the design. Body Concept For all the modern-day controversial debates about new drives, alternative forms of energy and energy-efficient models, there is one undisputed fact: the smaller the moving mass, the less energy that nee...

Kunststoffe international, 2009-10-14, Endless Energy Savings
...sed if the flow of cooling air or ozone exposure or paraffin exposure in polymer production is excessive, in which case the carbon brushes undergo extreme wear. The carbon brushes are wear parts and must be replaced every 6 to 12 months, the exact interval depending on the mode of operation. These maintenance measures also present a chance to clean the motor housing, and always lead to production interruptions. A further disadvantage of DC drives with linecommutated power converters is the high ...