Materials

Materials

Copyright © 2001 Moldflow Corporation

All Rights Reserved
 Searching
Searching Techniques
Techniques

Copyright © 2001 Moldflow Corporation

All Rights Reserved
 Graphing
Graphing data
data

Copyright © 2001 Moldflow Corporation

All Rights Reserved
 Viscosity
Viscosity Graph
Graph

Copyright © 2001 Moldflow Corporation

All Rights Reserved
 Comparing
Comparing materials
materials
„ Use search function
„ Set up search criteria
„ Sort list by clicking on
column heading
„ Modify search criteria
as necessary
„ Click Details to look at
data specifically

Copyright © 2001 Moldflow Corporation

All Rights Reserved
Properties
Properties Needed
Needed for
for Flow
Flow Analysis
Analysis
„ Thermal
– Specific heat
– Thermal conductivity
„ Rheological
– Viscosity (Cross-WLF default model)
– Transition temperature
„ PVT
– Melt Density
– 2-Domain tait PVT
„ Recommended Processing
– Mold temperature
– Melt temperature
– Ejection temperature
Copyright © 2001 Moldflow Corporation
All Rights Reserved
 Other
Other Properties
Properties
„ Recommended Processing „ Mechanical
– Mold and melt minimum & – Modulus
maximum temperatures – Poissons ratio
– Maximum shear stress & – Coefficient of thermal
shear rate expansion
„ General „ Shrinkage
– Commercial name – Corrected residual in-mold
– Manufacturer stress
– Family abbreviation „ Filler
– Type
– Percentage by weight
Copyright © 2001 Moldflow Corporation
All Rights Reserved
 Types
Types of
of Plastic
Plastic Materials
Materials
„ Amorphous
– Same molecular
structure throughout
molding cycle
„ Semi-crystalline
– Compact molecular
structure when cool,
amorphous when hot
Copyright © 2001 Moldflow Corporation
All Rights Reserved
 How
How Plastics
Plastics Flow
Flow

Frozen Layer

Mold Wall

Fountain
Melt Flow Region

Mold Wall

Copyright © 2001 Moldflow Corporation

All Rights Reserved
 Polymer
Polymer Viscosity
Viscosity
„ Viscosity Models
– Newtonian η
– Power Law
– Cross WLF η

.
γ
Copyright © 2001 Moldflow Corporation
All Rights Reserved
 Polymer
Polymer Viscosity
Viscosity
„ Definition: Resistance to Flow
„ Decreases with increasing
shear rate or temperature
High
resistance
to flow
Material Viscosity Viscosity (Pa-s)
Increasing
Low temperature
Water 10-1 resistance
to flow
10
Polymer
10,000

Glass 1020

Copyright © 2001 Moldflow Corporation Shear Rate (1/s)

All Rights Reserved
 Melt
Melt Flow
Flow Rate
Rate
„ Test run with constant temperature and shear rate
„ Useful to compare difference between “material
grades” within a resin family
Low MFR Material High MFR Material
W W

Higher Lower
Copyright © 2001 Moldflow Corporation
All Rights Reserved
Pressure Pressure
 Material
Material Influence
Influence on
on Injection
Injection
Pressure
Pressure and
and Clamp
Clamp Force
Force
„ Different materials require different injection
pressures
„ Different materials

Inj. Pressure and Clamp Force

PMMA
exhibit a wide range Hi Viscosity

of viscosity levels
PP
Low Viscosity

Copyright © 2001 Moldflow Corporation

All Rights Reserved
Lesson 10
Fill Time (sec)
 Polymer
Polymer Thermal
Thermal Properties
Properties
„ Cp - specific heat capacity
– ability to hold heat
„ k - thermal conductivity
– ability to conduct heat

Copyright © 2001 Moldflow Corporation

All Rights Reserved
 Impact
Impact of
of Material
Material on
on Cooling
Cooling Time
Time
„ Cooling time based on the
thermal conductivity, density,
and specific heat
„ These combine to create the
“thermal diffusivity” of the
material Change Cooling Time

Thermal
Conductivity (k)

Specific
Heat (Cp)

Density (p)

Copyright © 2001 Moldflow Corporation

All Rights Reserved
 PVT
PVT Properties
Properties
„ p - pressure;
v - specific volume;
T - temperature Pressure
„ Describes how the plastic Increases

Specific Volume
contracts and expands with
changing pressure and
temperature
„ During filling and packing,
the plastic contracts due to
increased pressure
„ During cooling the plastic
contracts due to decreased Temperature
temperature
Copyright © 2001 Moldflow Corporation
All Rights Reserved
 Amorphous
Amorphous vs.
vs. Semi-Crystalline
Semi-Crystalline

„ Crystallization occurs
when plastic molecules
take an ordered structure
forming “crystal-like”
patterns
„ Higher crystallization
means more shrinkage

Copyright © 2001 Moldflow Corporation

All Rights Reserved
 PVT
PVT Characteristics
Characteristics for
for
Amorphous
Amorphous Resins
Resins

p - pressure
v - specific volume Increasing
A
T - temperature Pressure
Specific Volume
∆ν
B

Temperature
Copyright © 2001 Moldflow Corporation
All Rights Reserved
 PVT
PVT Characteristics
Characteristics for
for Semi-
Semi-
Crystalline
Crystalline Resins
Resins

Crystallization
A
Phase
Specific Volume

∆ν
B

Copyright © 2001 Moldflow Corporation

Temperature
All Rights Reserved
 Influence
Influence of
of Thermal
Thermal Properties
Properties

„ Alpha1 (flow direction)

and alpha2 (cross-flow alpha2 (mm/C)
alpha1 (mm/C)
direction) are linear
thermal expansion
coefficients (LTEC)
– Describe how much a plastic
dimension changes linearly with
change in temperature
– Differences in flow and cross-
flow alpha values cause
differential shrinkage
– Typical of semi-crystalline
resins
Copyright © 2001 Moldflow Corporation
All Rights Reserved
 Influence
Influence of
of Mechanical
Mechanical
Properties
Properties
„ Modulus values, E1 and E2 represent the flow
and cross-flow moduli, respectively
„ Higher and uniform E value, lower shrinkage
and less warpage in general
„ E1 and E2 vary sometimes withE1 semi-
crystalline resins
E2
„ Glass filled resins have significant differences
between E1 and E2, more warpage
Copyright © 2001 Moldflow Corporation
All Rights Reserved
 Impact
Impact of
of Fibers
Fibers on
on
Shrinkage
Shrinkage
•Fibers impact Strength (Strength is greater in the
direction of orientation).
•Fibers affect Shrinkage.

Copyright © 2001 Moldflow Corporation

All Rights Reserved
 Create
Create aa personal
personal Database
Database
„ Import data
– CM2K
– MPI
„ What data is required?
„ New Data
– Check data quality
» Get help from Datafitting
„ Tools and dialogs
Copyright © 2001 Moldflow Corporation
All Rights Reserved