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Polyamide : Crystallinity
Crystallinity : Most polyamides have a partially crystalline structure. This means that a proportion of the polymer solidifies in a certain ordered and regular crystalline structure. The rest solidifies in an amrphous state having now regularity. Most important properties of crystaline material in contrast to amorphous materials : Big volume changes with temperature when changing from liquid to solid state and viceversa. This is the mean reason for voids/bubbles in the sensorbody ! As you can see on the graph, a volumechange from over 15% is normal !
Polyamide : Viscosity
Shear rate is a parameter characterising deformation velocity of the material flow. It is dependent on velocity of the flow and geometry of the flow channels. Therefore, by increasing the injection speed the viscosity can be reduced ! On the Engel machines, the viscosity is measured as the average pressure during a part from the injection cycle. It is the so called Flownumber It can be used to see the effect of parameter changes !
Screw is pushed forward with hydraulic pressure. Material (melt) in front of the screw (red) is pressed in to the mold The non-return valve (R) prevents that the melt goes backwards in the screw The injection speed is regulated
Screw is under pressure for volumecompensation from shrink No speedregulation, only pressureregulation ! When the gate is solid, no melt can come into the cavity anymore : end of post pressure fase At the end of this fase, there is still some material in the screw : buffer ! This buffer is normally in the range 5 to 15 mm for a screw from diameter 30mm
Continental Automotive Systems
Jan Heynen / 12-04-2005 Continental AG
Screw is rotating, melt is pushed in front of the screw. Non-return valve opens (pressure in screw is higher then pressure in cylinder) Material cannot escape throuhg nozzle : runner is solid, nozzle still against mold Dosing fase ends when the stroke is reached for next shot Dosing and cooling fase is simultaneous
Continental Automotive Systems
Jan Heynen / 12-04-2005 Continental AG
Injection time monitoring : the injection time (time from start injection until switch-over point). Min and max time can be guarded. Out of limit : immediate INTERRUPTION, no Post pressure !
The injection pressure limit can be seen as a safety limit. Under normal circumstances, this limit may not be reached ! (no speed regulation anymore !)No process interruption ! Only warning ! FEEDBACK from IST values : Max inj speed : max speed that is reached during injection Injection time Zsx : actual time from last injection Use this feedback when changing parameters !!
Setting up heating
Setpoints : Temperature from nozzle and cylinder zones. For PA66 : max 315C, min 270C. Setpoint temperature hydraulic oil (normal 40C)