scholarly journals Hybrid Mold: Comparative Study of Rapid and Hard Tooling for Injection Molding Application Using Metal Epoxy Composite (MEC)

Materials ◽  
2021 ◽  
Vol 14 (3) ◽  
pp. 665
Author(s):  
Radhwan Hussin ◽  
Safian Sharif ◽  
Marcin Nabiałek ◽  
Shayfull Zamree Abd Rahim ◽  
Mohd Tanwyn Mohd Khushairi ◽  
...  
Keyword(s):  
Injection Molding ◽  
New Product Development ◽  
Epoxy Composite ◽  
Mixing Time ◽  
Mold Insert ◽  
Physical And Mechanical Properties ◽  
Critical Factor ◽  
Curing Temperature ◽  
Mass Composition ◽  
Control Factors

The mold-making industry is currently facing several challenges, including new competitors in the market as well as the increasing demand for a low volume of precision moldings. The purpose of this research is to appraise a new formulation of Metal Epoxy Composite (MEC) materials as a mold insert. The fabrication of mold inserts using MEC provided commercial opportunities and an alternative rapid tooling method for injection molding application. It is hypothesized that the addition of filler particles such as brass and copper powders would be able to further increase mold performance such as compression strength and thermal properties, which are essential in the production of plastic parts for the new product development. This study involved four phases, which are epoxy matrix design, material properties characterization, mold design, and finally the fabrication of the mold insert. Epoxy resins filled with brass (EB) and copper (EC) powders were mixed separately into 10 wt% until 30 wt% of the mass composition ratio. Control factors such as degassing time, curing temperature, and mixing time to increase physical and mechanical properties were optimized using the Response Surface Method (RSM). The study provided optimum parameters for mixing epoxy resin with fillers, where the degassing time was found to be the critical factor with 35.91%, followed by curing temperature with 3.53% and mixing time with 2.08%. The mold inserts were fabricated for EB and EC at 30 wt% based on the optimization outcome from RSM and statistical ANOVA results. It was also revealed that the EC mold insert offers better cycle time compared to EB mold insert material.

The potential of metal epoxy composite (MEC) as hybrid mold inserts in rapid tooling application: a review

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Radhwan Bin Hussin ◽  
Safian Bin Sharif ◽  
Shayfull Zamree Bin Abd Rahim ◽  
Mohd Azlan Bin Suhaimi ◽  
Mohd Tanwyn Bin Mohd Khushairi ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Epoxy Composite ◽  
Mold Insert ◽  
Physical And Mechanical Properties ◽  
Rapid Tooling ◽  
Current Application ◽  
Content Type ◽  
Manufacturing Technologies ◽  
New Formulation ◽  
Research Studies

Purpose Rapid tooling (RT) integrated with additive manufacturing technologies have been implemented in various sectors of the RT industry in recent years with various kinds of prototype applications, especially in the development of new products. The purpose of this study is to analyze the current application trends of RT techniques in producing hybrid mold inserts. Design/methodology/approach The direct and indirect RT techniques discussed in this paper are aimed at developing a hybrid mold insert using metal epoxy composite (MEC) in increasing the speed of tooling development and performance. An extensive review of the suitable development approach of hybrid mold inserts, material preparation and filler effect on physical and mechanical properties has been conducted. Findings Latest research studies indicate that it is possible to develop a hybrid material through the combination of different shapes/sizes of filler particles and it is expected to improve the compressive strength, thermal conductivity and consequently increasing the hybrid mold performance (cooling time and a number of molding cycles). Research limitations/implications The number of research studies on RT for hybrid mold inserts is still lacking as compared to research studies on conventional manufacturing technology. One of the significant limitations is on the ways to improve physical and mechanical properties due to the limited type, size and shape of materials that are currently available. Originality/value This review presents the related information and highlights the current gaps related to this field of study. In addition, it appraises the new formulation of MEC materials for the hybrid mold inserts in injection molding application and RT for non-metal products.

Effects of Sintering Variables on the Physical and Mechanical Properties of Metal Injection Molding Molded 17-4 PH Stainless Steel

2021 ◽  
Vol 1028 ◽  
pp. 403-408
Author(s):  
Apang Djafar Shieddieque ◽  
Shinta Virdhian ◽  
Moch Iqbal Zaelana Muttahar ◽  
Muhammad Rafi Muttaqin
Keyword(s):  
Mechanical Properties ◽  
Stainless Steel ◽  
Injection Molding ◽  
Relative Density ◽  
Physical And Mechanical Properties ◽  
High Hardness ◽  
Argon Atmosphere ◽  
Metal Injection Molding ◽  
Manufacturing Method ◽  
Small Complex

Metal injection molding (MIM) is a near net shape manufacturing technique for producing small, complex, precision parts in mass production. MIM process is manufacturing method that combines traditional shape-making capability of plastic injection molding and the materials flexibility of powder metallurgy. The process consists of the following four steps: mixing of metal powder and binder, injection molding to shape the component, debinding to remove the binder in the component, sintering to consolidate the debound parts. In this research, the physical and mechanical properties of metal injection molded 17-4 PH stainless steel were investigated with the variation of sintering temperatures (1300 °C - 1360 °C) and atmosphere conditions (argon and vacuum conditions). The relative density, microstructure, distortion, and hardness are measured and analyzed in this study. The results show that highest relative density of 87%, relative homogeneous shrinkage and high hardness are achieved by sintering at 1360 °C for 1.5 hours and argon atmosphere. At the same sintering temperature and time, sintering in vacuum shows lower relative density (81%) than that in argon condition due to pores growth. The pore growths were not observed in the argon atmosphere. It can be concluded that sintering stages more rapidly under vacuum condition. The hardness measurements result also showed that high hardness is obtained by high density parts. The optimum average hardness obtained in this study is 239 HV. However, the hardness properties results are still lower than 280 HV according to MPIF Standard 35 for MIM parts.

scholarly journals Effect of Filler Nature on Chemical Resistance and Microhardness of Epoxy Composite Films

2015 ◽  
Vol 16 (3) ◽  
pp. 528-533
Author(s):  
G. Martinyuk ◽  
O. Aksimentyeva ◽  
N. Skoreiko ◽  
V. Zakordonskyi
Keyword(s):  
Mechanical Properties ◽  
Chemical Resistance ◽  
Filler Content ◽  
Epoxy Composite ◽  
Composite Films ◽  
Physical And Mechanical Properties ◽  
Epoxy Composites ◽  
Mineral Filler ◽  
Operating Characteristics ◽  
Mineral Fillers

We investigated the processes of water absorption, chemical stability and microhardness of films of epoxy composites that contained as the polymer matrix the epoxy resin UP-655 and mineral fillers: graphite, mica, aluminum oxide at their content (0 - 30 % mass). It found that introduction of mineral fillers significantly affects on all complex of operating characteristics of the films. Increase of filler content, especially mica, to 20 %, resulting in slower process and reducing the quantity of absorbed moisture by films. In the study of physical and mechanical properties of filled epoxy composites was established that the introduction of mineral filler significantly affects their microhardness, and the nature of the exposure is determined by the type and filler content.

Powder Injection Molding of Ti-6Al-4V Alloy for Defect-Free High Performance Titanium Parts with Low Carbon/Oxygen Contents

2018 ◽  
Vol 770 ◽  
pp. 189-194
Author(s):  
Dong Guo Lin ◽  
Jae Man Park ◽  
Tae Gon Kang ◽  
Seong Taek Chung ◽  
Young Sam Kwon ◽  
...  
Keyword(s):  
Injection Molding ◽  
Alloy Powder ◽  
High Performance ◽  
Physical And Mechanical Properties ◽  
Powder Injection Molding ◽  
Powder Injection ◽  
Solid Loading ◽  
Injection Molding Process ◽  
Low Carbon ◽  
Molding Process

In this work, powder injection molding (PIM) of Ti-6Al-4V alloy powder has been studied. Defect-free high performance Ti-6Al-4V parts with low carbon/oxygen contents have been successfully prepared by PIM. A pre-alloyed Ti-6Al-4V alloy powder and wax-polymer binder system have been mixed together to prepare the feedstock. In mixing stage, the solid loading percentage and mixing conditions have been optimized. Rheological and thermal debinding behaviors of prepared feedstock have been characterized and numerically expressed based on rheometry and thermal gravity experimental results. In addition, the injection molding process of Ti-6Al-4V parts has been numerically analyzed to optimize the injection molding conditions. Consequently, the defect-free Ti-6Al-4V parts with low carbon and oxygen contents have been successfully fabricated by PIM, which exhibits excellent physical and mechanical properties.

INVESTIGATION OF THE EFFECT OF THE FINAL CURING TEMPERATURES ON THE COMPLEX OF PROPERTIES OF CARBON-GLASS HYBRID MATERIALS

2021 ◽  
pp. 66-73
Author(s):  
E.D. Kolpachkov ◽  
◽  
A.O. Kurnosov ◽  
P.S. Marakhovsky ◽  
A.P. Petrova ◽  
...  
Keyword(s):  
Physical And Mechanical Properties ◽  
Curing Temperature ◽  
Carbon Plastic ◽  
Glass Fiber Reinforced Plastic ◽  
Fiber Reinforced Plastic ◽  
Glass Fiber Reinforced ◽  
Reinforced Plastic ◽  
Glass Carbon ◽  
Epoxy Groups ◽  
Residual Heat

Presents the results of a study of the effect of the final curing temperatures on the complex of properties of the developed epoxy binder grade VSE-65 and glass-fiber-reinforced plastic based on it. It was found that with a decrease in the final curing temperature, the residual heat effect increases and, in turn, a decrease in the conversion of epoxy groups occurs. Presents the results of a comparative analysis of VKG-6 glass-carbon plastic samples prepared by vacuum infusion and pressure impregnation. Based on the results of the analysis, it has been established that the technologies make it possible to realize the required level of physical and mechanical properties.

Time Required to Achieve Homogeneity of Test Substances Added to Dog Feed

1991 ◽  
Vol 74 (5) ◽  
pp. 857-861
Author(s):  
Philip P Sapienza ◽  
George J Ikeda ◽  
Patricia I Warr ◽  
Richard H Albert
Keyword(s):  
Nicotinic Acid ◽  
Animal Feed ◽  
Mixing Time ◽  
Critical Factor ◽  
Laboratory Animals ◽  
Time Period ◽  
Time Test ◽  
Time Required ◽  
Carrier Animal

Abstract The homogeneity of test substances in a carrier (animal feed) is a critical factor In conducting long-term feeding studies in laboratory animals. A method for determining the adequate amount of mixing to achieve homogeneity by a mixer of the type described has been determined when 2 distinctly different compounds are added to ground dog feed. Nicotinic acid and butylated hydroxyanlsole at a concentration of 1% were separately mixed with the dog feed for 15,30,45,60, and 120 min to determine optimum mixing time. Test portions were taken from 4 different sampling sites at each time period and analyzed in duplicate for the added substance. Four batches were prepared and the results were aggregated. Very little interbatch variability was observed. The variance of the average values from the 4 sampling sites at each time period was calculated and used as a simple, crude, but effective numerical quantity to monitor the approach to homogeneity of the mixture.

scholarly journals Molecular Dynamics Simulations on the Demolding Process for Nanostructures in Injection Molding

Micromachines ◽  
2019 ◽  
Vol 10 (10) ◽  
pp. 636 ◽  
Author(s):  
Can Weng ◽  
Dongjiao Yang ◽  
Mingyong Zhou
Keyword(s):  
Molecular Dynamics ◽  
Injection Molding ◽  
Molecular Dynamics Simulations ◽  
Interaction Mechanism ◽  
Mold Insert ◽  
Sharp Decrease ◽  
Average Density ◽  
Radius Of Gyration ◽  
Good Shape ◽  
Dynamics Simulations

Injection molding is one of the most potential techniques for fabricating polymeric products in large numbers. The filling process, but also the demolding process, influence the quality of injection-molded nanostructures. In this study, nano-cavities with different depth-to-width ratios (D/W) were built and molecular dynamics simulations on the demolding process were conducted. Conformation change and density distribution were analyzed. Interfacial adhesion was utilized to investigate the interaction mechanism between polypropylene (PP) and nickel mold insert. The results show that the separation would first happen at the shoulder of the nanostructures. Nanostructures and the whole PP layer are both stretched, resulting in a sharp decrease in average density after demolding. The largest increase in the radius of gyration and lowest velocity can be observed in 3:1 nanostructure during the separation. Deformation on nanostructure occurs, but nevertheless the whole structure is still in good shape. The adhesion energy gets higher with the increase of D/W. The demolding force increases quickly to the peak point and then gradually decreases to zero. The majority of the force comes from the adhesion and friction on the nanostructure due to the interfacial interaction.

scholarly journals Molecular Dynamics Simulation on the Influences of Nanostructure Shape, Interfacial Adhesion Energy, and Mold Insert Material on the Demolding Process of Micro-Injection Molding

Polymers ◽  
2019 ◽  
Vol 11 (10) ◽  
pp. 1573 ◽  
Author(s):  
Jin Yang ◽  
Can Weng ◽  
Jun Lai ◽  
Tao Ding ◽  
Hao Wang
Keyword(s):  
Molecular Dynamics ◽  
Molecular Dynamics Simulation ◽  
Injection Molding ◽  
Interfacial Adhesion ◽  
Mold Insert ◽  
Adhesion Energy ◽  
Dynamics Simulation ◽  
Micro Injection Molding ◽  
Interfacial Adhesion Energy

In micro-injection molding, the interaction between the polymer and the mold insert has an important effect on demolding quality of nanostructure. An all-atom molecular dynamics simulation method was performed to study the effect of nanostructure shape, interfacial adhesion energy, and mold insert material on demolding quality of nanostructures. The deformation behaviors of nanostructures were analyzed by calculating the non-bonded interaction energies, the density distributions, the radii of gyration, the potential energies, and the snapshots of the demolding stage. The nanostructure shape had a direct impact on demolding quality. When the contact areas were the same, the nanostructure shape did not affect the non-bonded interaction energy at PP-Ni interface. During the demolding process, the radii of gyration of molecular chains were greatly increased, and the overall density was decreased significantly. After assuming that the mold insert surface was coated with an anti-stick coating, the surface burrs, the necking, and the stretching of nanostructures were significantly reduced after demolding. The deformation of nanostructures in the Ni and Cu mold inserts were more serious than that of the Al2O3 and Si mold inserts. In general, this study would provide theoretical guidance for the design of nanostructure shape and the selection of mold insert material.

scholarly journals Investigation of Interface Thermal Resistance between Polymer and Mold Insert in Micro-Injection Molding by Non-Equilibrium Molecular Dynamics

Polymers ◽  
2020 ◽  
Vol 12 (10) ◽  
pp. 2409
Author(s):  
Can Weng ◽  
Jiangwei Li ◽  
Jun Lai ◽  
Jiangwen Liu ◽  
Hao Wang
Keyword(s):  
Heat Transfer ◽  
Molecular Dynamics ◽  
Injection Molding ◽  
Thermal Resistance ◽  
Mold Insert ◽  
Micro Injection Molding ◽  
Interface Resistance ◽  
Interface Thermal Resistance ◽  
Packing Pressure ◽  
Non Equilibrium Molecular Dynamics

Micro-injection molding has attracted a wide range of research interests to fabricate polymer products with nanostructures for its advantages of cheap and fast production. The heat transfer between the polymer and the mold insert is important to the performance of products. In this study, the interface thermal resistance (ITR) between the polypropylene (PP) layer and the nickel (Ni) mold insert layer in micro-injection molding was studied by using the method of non-equilibrium molecular dynamics (NEMD) simulation. The relationships among the ITR, the temperature, the packing pressure, the interface morphology, and the interface interaction were investigated. The simulation results showed that the ITR decreased obviously with the increase of the temperature, the packing pressure and the interface interaction. Both rectangle and triangle interface morphologies could enhance the heat transfer compared with the smooth interface. Moreover, the ITR of triangle interface was higher than that of rectangle interface. Based on the analysis of phonon density of states (DOS) for PP-Ni system, it was found that the mismatch between the phonon DOS of the PP atoms and Ni atoms was the main cause of the interface resistance. The frequency distribution of phonon DOS also affected the interface resistance.

Study of rheological behaviours of electrostatic thermoset powder coatings

e-Polymers ◽  
2009 ◽  
Vol 9 (1) ◽  
Author(s):  
Morteza Ehsani ◽  
Ali Akbar Yousefi ◽  
Saeed Samiei Yeganeh
Keyword(s):  
Mechanical Properties ◽  
Dynamic Viscosity ◽  
Physical And Mechanical Properties ◽  
Powder Coating ◽  
Curing Temperature ◽  
Design Parameters ◽  
Powder Coatings ◽  
Gel Time ◽  
Rheological Measurements ◽  
The Impact

AbstractThe use of dynamic viscosity/time (temperature) cure curves is seen as a powerful technique to quantify formulation and resin design parameters. The behaviour of different thermoset powder coating systems, epoxy/polyester (50/50, 40/60 and 30/70) as well as the impact of the filler, the curing temperature and the frequency upon gel-time have been examined based upon the rheological measurements and compared with PE/TGIC systems. Two disparate methodologies have been utilized to determine gel-time. The behaviour of dissimilar systems bearing different formulations has been compared by means of the non-isothermal DSC test. The effects of resin percentage and the formulation on physical and mechanical properties of coating have been studied.

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