compression molding 1-9-08

compression molding 1-9-08 - Compression Molding Douglas J....

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1 Compression Molding Douglas J. Gardner Professor Wood-Polymer Hybrid Composites Introduction to Compression Molding • What is compression molding? • Typical products • Advantages and disadvantages of compression molding • Basic factors in compression molding of SMC
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2 What is Compression Molding? Compression molding was specifically developed for replacement of metal components with composite parts. The molding process can be carried out with either thermosets or thermoplastics. However, most applications today use thermoset polymers. In fact, compression molding is the most common method of processing thermosets. Typical Products • Automobile parts – Hoods – Roofs – Scoops – Fenders – Spoilers – Air deflectors – Lift gates • Wood composites
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3 Advantages and Disadvantages • Advantages: – Short cycle time (typically 1-6 minutes) – High volume production – Class A (high quality) surfaces • Disadvantages: – High initial capital investment – Labor intensive – Secondary operations are sometimes required Basic Factors in Compression Molding •G e om e t r y : – Wall thickness of part – Charge area vs. mold area – Charge placement (location) – Single or multiple charges • Manufacturing – Mold wall heating
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4 Cycle Time for Compression Molding • The graph below shows typical temperature and pressure profiles for SMC compression molding. Materials for Compression Molding • Resins for compression molding • Sheet molding compound
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5 Resins for Compression Molding • Common thermosetting resins used in compression molding: – Phenolic – Urea – Melamine – Gas emission can lead to voids in the final product, an
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compression molding 1-9-08 - Compression Molding Douglas J....

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