Blow_Molding - UNIVERSITY OF UNIVERSITY OF FLORIDA EMA...

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Unformatted text preview: UNIVERSITY OF UNIVERSITY OF FLORIDA EMA 4666C - Polymer Processing Blow Molding Operations Dr. Anthony Brennan University of Florida Department of Materials Science & Department Engineering Engineering 07/17/11 EMA 4666C - Polymer Processing 1 UNIVERSITY OF UNIVERSITY OF Agenda FLORIDA Introduction Examples of blow molded Examples products products General Principles Equipment Design Process Parameters Troutonian Viscosity Flow Properties 07/17/11 EMA 4666C - Polymer Processing 2 UNIVERSITY OF UNIVERSITY OF FLORIDA Blow Molded Products 07/17/11 EMA 4666C - Polymer Processing 3 UNIVERSITY OF UNIVERSITY OF FLORIDA Blow Molding Examples Automotive Bottles Storage Vessels Films Sporting Goods 07/17/11 EMA 4666C - Polymer Processing 4 UNIVERSITY OF UNIVERSITY OF FLORIDA Rubber Parts Automotive Automotive 07/17/11 EMA 4666C - Polymer Processing 5 UNIVERSITY OF UNIVERSITY OF FLORIDA Co-extrusion Blow Molding Co-extrusion of Thermoplastic Elastomers Elastomers Phone: (573) 221-8933 Phone: Fax: (573) 221-7144 Fax: www.buckhornrubber.com UNIVERSITY OF UNIVERSITY OF FLORIDA Capabilities Overview 3-D Blow Molding using XY Technology Produces complex parts with minimal flash Produces Dual materials are introduced to create hardDual soft-hard products for flexibility and high soft-hard performance Secondary operations are performed by robotic technology robotic Reduced cycle times compared to traditional Reduced blow molding blow UNIVERSITY OF UNIVERSITY OF FLORIDA XY Manufacturing System 07/17/11 EMA 4666C - Polymer Processing 8 UNIVERSITY OF UNIVERSITY OF FLORIDA Total System Cost Reduction – Up to 50% reduction in tool Up lead time and tool cost. lead – Up to 70% reduction in Up system weight. system – Overall piece price reduction. – Complex system designs. – Reduction in number of Reduction system components. system – Buckhorn will design a Buckhorn system based on your parameters. Data transfer capabilities are available. capabilities – A variety of plastic material variety formulations are available to select the best, cost effective material for your application. material 07/17/11 EMA 4666C - Polymer Processing 9 UNIVERSITY OF UNIVERSITY OF XY Blow Molding Process FLORIDA Parts are produced using blow Parts molding process on an XY plane for complex geometries for 07/17/11 EMA 4666C - Polymer Processing 10 UNIVERSITY OF UNIVERSITY OF FLORIDA XY Blow Molding Cycle Parison enters mold Mold opens 07/17/11 Mold is closed, air introduced Part is trimmed EMA 4666C - Polymer Processing 11 UNIVERSITY OF UNIVERSITY OF FLORIDA Features & Benefits Dual durometer Part consolidation Seamless parts Produces complex Produces parts with reduced flash flash Parts incorporate Parts both strong, rigid and soft, flexible features features UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 Inserts in Blow Molded Inserts Parts Parts EMA 4666C - Polymer Processing 13 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 Secondary Operations EMA 4666C - Polymer Processing 14 UNIVERSITY OF UNIVERSITY OF FLORIDA Parts Trimming Produces consistently Produces trimmed/drilled parts trimmed/drilled Quick cycle time 07/17/11 EMA 4666C - Polymer Processing 15 UNIVERSITY OF UNIVERSITY OF FLORIDA Blow Molding Thermoplastic Blow Elastomers Elastomers Thermoplastic Thermoplastic elastomers for hard-soft-hard applications applications A wide range of wide fillers are available for improving material properties over different temperature ranges - Polymer Processing temperature EMA 4666C 07/17/11 16 UNIVERSITY OF UNIVERSITY OF FLORIDA Blow Molding Material Blow Polypropylene Polypropylene Polyethylene Polyethylene (High or low density) Polyamides (Nylons) (Nylons) Santoprene Geolast UNIVERSITY OF UNIVERSITY OF FLORIDA Blow Molded Products Air Intake Hoses Air Resonators Steering Column Steering Cover Cover Gas Intake Tubes Automotive Air Automotive Ducts Ducts Fluid Reservoirs HVAC Ducts EMA 4666C - Polymer Processing 07/17/11 18 UNIVERSITY OF UNIVERSITY OF FLORIDA Applications OEM Truck Agriculture Lawn & Garden Marine Construction Equipment Recreational Vehicles Automotive Industrial Gen-Set UNIVERSITY OF UNIVERSITY OF FLORIDA Tooling High-performance machined aluminum or cast aluminum production tooling 07/17/11 EMA 4666C - Polymer Processing 20 UNIVERSITY OF UNIVERSITY OF FLORIDA Prototype Tooling High-performance cast aluminum 07/17/11 EMA 4666C - Polymer Processing 21 UNIVERSITY OF UNIVERSITY OF FLORIDA Lead Times UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 Rubber Injection Molded Parts EMA 4666C - Polymer Processing 23 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 Blow Molded Insulated Coolers EMA 4666C - Polymer Processing 24 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 Insert Blow Molded Tanks EMA 4666C - Polymer Processing 25 UNIVERSITY OF UNIVERSITY OF FLORIDA Blow Molding Process Equipment 07/17/11 EMA 4666C - Polymer Processing 26 UNIVERSITY OF UNIVERSITY OF FLORIDA Bottles Bottles http://www.uniloymilacron.com/un irecip.htm Injection Blow IBS 122 Injection Blow •Completely refurbished •2.5 inch screw •250 gram shot size (HDPE) 07/17/11 EMA 4666C - Polymer Processing 27 UNIVERSITY OF UNIVERSITY OF FLORIDA Injection Stretch Blow U750-120 (1) & U750-130 (2) Injection Stretch-Blow for PET - WIDEMOUTH •Single-stage, 4-station process (conditioning) •120-ton or 130-ton injection •2 to 10 cavities •Accepts common tooling •Movie of Process: http://engr.bd.psu.edu/pkoch/plasticdesign/Blow_Molding.htm 07/17/11 EMA 4666C - Polymer Processing 28 UNIVERSITY OF UNIVERSITY OF FLORIDA Extrusion Blow Molding Process 07/17/11 EMA 4666C - Polymer Processing 29 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 Extrusion Blow Molding Cycle EMA 4666C - Polymer Processing 30 UNIVERSITY OF UNIVERSITY OF FLORIDA Continuous Blow Molding Equip DIE H HEAD HEAD EXTRUDER MOLD PARISON 07/17/11 CONTINUOUS EXTRUSION CONTINUOUS BLOW MOLDING BLOW EMA 4666C - Polymer Processing 31 UNIVERSITY OF UNIVERSITY OF FLORIDA CBM – Ram Accumulator SHUT-OFF VALVE RAM RAM ACCUMULATOR ACCUMULATOR MOLD PARISON 07/17/11 RAM ACCUMULATOR BLOW RAM MOLDING MACHINE MOLDING EMA 4666C - Polymer Processing 32 UNIVERSITY OF UNIVERSITY OF FLORIDA Extrusion Blow Molding Jomar Continuous Extrusion Blow Moulding http://www.jomarcorp.com/ebm_process.asp 07/17/11 EMA 4666C - Polymer Processing 33 UNIVERSITY OF UNIVERSITY OF FLORIDA Parison Molding Parisons 07/17/11 EMA 4666C - Polymer Processing 34 UNIVERSITY OF UNIVERSITY OF FLORIDA Injection Blow Molding Station 1: Station Injection Mold Preform (Parison) (Parison) Station 2: Inflate Station 3: Strip Time: 32 bottles Time: per cycle. 9 to 20 sec per cycle. cycle. 07/17/11 EMA 4666C - Polymer Processing 35 UNIVERSITY OF UNIVERSITY OF FLORIDA DIE SWELL BEHAVIOR 07/17/11 EMA 4666C - Polymer Processing 36 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 Basis for Die Swell EMA 4666C - Polymer Processing 37 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 EMA 4666C - Polymer Processing 38 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 Parison Morphology EMA 4666C - Polymer Processing 39 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 EMA 4666C - Polymer Processing 40 UNIVERSITY OF UNIVERSITY OF FLORIDA Die Swell Behavior: HDPE v ABS 07/17/11 EMA 4666C - Polymer Processing 41 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 Influence of L/D on Die Swell EMA 4666C - Polymer Processing 42 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 Process Time line EMA 4666C - Polymer Processing 43 UNIVERSITY OF UNIVERSITY OF FLORIDA Velocity Profiles for Stress Fields 07/17/11 EMA 4666C - Polymer Processing 44 UNIVERSITY OF UNIVERSITY OF FLORIDA Velocity Profiles – Planar Deformation 07/17/11 EMA 4666C - Polymer Processing 45 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 Viscosity Response EMA 4666C - Polymer Processing 46 UNIVERSITY OF UNIVERSITY OF FLORIDA Viscosity: Temperature Response 07/17/11 EMA 4666C - Polymer Processing 47 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 Effect of Blow Up Ratio EMA 4666C - Polymer Processing 48 UNIVERSITY OF UNIVERSITY OF FLORIDA Blow Molding Process Variables Thermal Properties/History 07/17/11 EMA 4666C - Polymer Processing 49 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 PPS DSC Profile EMA 4666C - Polymer Processing 50 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 Effect of Rapid Quench - Xtal EMA 4666C - Polymer Processing 51 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 Crystallization Behavior - PPS EMA 4666C - Polymer Processing 52 UNIVERSITY OF UNIVERSITY OF FLORIDA Critical Factors for Blow Molding 07/17/11 EMA 4666C - Polymer Processing 53 UNIVERSITY OF UNIVERSITY OF FLORIDA Blow Molding - Films 07/17/11 EMA 4666C - Polymer Processing 54 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 EMA 4666C - Polymer Processing 55 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 EMA 4666C - Polymer Processing 56 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 EMA 4666C - Polymer Processing 57 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 EMA 4666C - Polymer Processing 58 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 EMA 4666C - Polymer Processing 59 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 EMA 4666C - Polymer Processing 60 UNIVERSITY OF UNIVERSITY OF FLORIDA 07/17/11 Trouble Shooting Guide EMA 4666C - Polymer Processing 61 UNIVERSITY OF UNIVERSITY OF FLORIDA References Introduction to Physical Polymer Science, 2nd Introduction Edition, Lesley H. Sperling, Wiley Interscience (1992) ISBN 0-471-53035-2 Interscience Some figures were reproduced from: Polymer Some Processing Fundamentals, Tim A. Osswald (1998), Hanser/Gardner Publications, Cincinnati, OH. Cincinnati, The Physics of Polymers, Gert Strobl (1996) The Springer-Verlag, New York. Springer-Verlag, 07/17/11 EMA 4666C - Polymer Processing 62 UNIVERSITY OF UNIVERSITY OF FLORIDA EMA 4161C EMA Polymer Physical Properties Properties 63 ...
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