Mechanical Properties of Highly Filled Iron-ABS Composites in Injection Molding for FDM Wire Filament

2013 ◽  
Vol 773-774 ◽  
pp. 448-453 ◽  
Author(s):  
Nasuha Sa'ude ◽  
Mustaffa Ibrahim ◽  
Mohd Halim Irwan Ibrahim

This paper presents the development of a new polymer matrix composite (PMC) material for use in injection molding machine. The material consists of iron powder filled in an acrylonitrile butadiene styrene (ABS) and surfactant powder material. In this study, the effect of iron powder was investigated as a filler material in polymer matrix composite and ABS was chosen as a matrix material. The detailed formulations of compounding ratio by volume percentage (vol. %) with various combinations of the new PMC are investigated experimentally. Based on the result obtained, it was found that, vol. % increment of iron filler effected on the hardness, tensile and flexural strength. With highly filled iron content in ABS composites increase the hardness and tensile strength of PMC material through an injection molding process.

2013 ◽  
Vol 315 ◽  
pp. 582-586 ◽  
Author(s):  
Nasuha Sa'ude ◽  
M. Ibrahim ◽  
Wahab Saidin

This paper presents the development of a new polymer matrix composite (PMC) feedstock material by the injection molding machine. The material consists of iron powder filled in an acrylonitrile butadiene styrene (ABS) and surfactant powder (binder) material. In this study, the effect of powder loading and binder content on the mechanical properties was investigated experimentally. The detailed formulations of compounding ratio by Brabender Mixer and injection molding machine of the sample specimen was used with various combinations of the new PMC material. Based on the result obtained, it was found that, higher powder loading of iron filler affected the hardness, tensile and flexural strength of PMC material. With 32% iron powder loading in ABS composites increase the flexural force, maximum stress and force of PMC material through an injection molding process.


2014 ◽  
Vol 607 ◽  
pp. 747-751 ◽  
Author(s):  
Nasuha Sa'ude ◽  
N.M.A. Isa ◽  
M. Ibrahim ◽  
Mohd Halim Irwan Ibrahim

This paper presents the development of a new Copper-ABS feedstock material by the injection molding machine. The material consists of copper powder filled in an acrylonitrile butadiene styrene (ABS) binder and surfactant material. In this study, the effect of metal filled ABS and binder content on the contact angle and surface tension was investigated experimentally. The detailed formulations of compounding ratio with various combinations of a new Copper-ABS feedstock was done by volume percentage (vol. %). Based on the result obtained, an increment by vol. % of copper filler in ABS effected on contact angle and surface tension results. With highly filled copper content in ABS composites increase the surface tension value. It can be observed that, the tendency of the liquid surface that allow to resist an external force in PMC material through an injection molding process.


2020 ◽  
Vol 4 (4) ◽  
pp. 161
Author(s):  
Jochen Wellekötter ◽  
Julia Resch ◽  
Stephan Baz ◽  
Götz Theo Gresser ◽  
Christian Bonten

Although fiber-reinforced plastics combine high strength and stiffness with being lightweight, major difficulties arise with high volume production and the return of manufactured parts back into the cycle of materials at the end of their lifecycles. In a novel approach, structural parts were produced from recycled material while utilizing the so-called injection molding compounding process. Recycled fibers and recycled polyamide matrix material were used by blending carbon and matrix fibers into a sliver before processing. Injection molding was then used to produce long fiber-reinforced parts through a direct fiber feed system. Recycled matrix granules were incorporated into the injection molding process by means of an injection molding compounder to investigate their influences on the mechanical properties of the parts. The findings show that the recycled fibers and matrix perform well in standardized tests, although fiber length and fiber content vary significantly and remain below expectations.


Polymers ◽  
2020 ◽  
Vol 12 (12) ◽  
pp. 2871
Author(s):  
Paweł Brzęk ◽  
Tomasz Sterzyński

The effects such as warpage, dimensional instability and environmental stress corrosion, due to the presence of residual stresses in polymeric products, are strongly dependent on injection molding conditions. The holding time and holding pressure belongs to most important processing parameters, determining the dimensional stability and properties of injected goods. A new procedure based on a visualization technique was applied, where the levels of residual stresses of the samples were estimated. The experiments were performed for samples produced of translucent methacrylate acrylonitrile butadiene styrene (MABS), a commodity polymer with a high transparency, necessary for the optical visualization of the stress whitening. The samples produced by injecting molding were deformed to a constant elongation, to observe the dependent stress whitening effect subsequently used to evaluate the stress distribution. It was found that depending on the value of the injection holding pressure, various levels of residual stress and its distribution may be observed in MABS samples. These measurements conformed that the applied optical method is an easy-to-perform technique. The possibility to detect the residual stresses over the whole cross-section of the transparent product, without the necessity for local stress determination, is another significant advantage of this investigation procedure.


2016 ◽  
Author(s):  
Catalin Fetecau ◽  
Felicia Stan ◽  
Nicoleta Violeta Cristea ◽  
Laurentiu Ionut Sandu

In this work, the advantages of Thermoplastic Polyurethane (TPU) filled with multi-walled carbon nanotubes (MWCNTs) were combined with those of the over injection molding process in order to obtain two-component (2k) structures with very different but high mechanical and electrical properties. TPU/MWCNT composites with different MWCNTs wt.% were over-molded onto Acrylonitrile Butadiene Styrene (ABS) substrates, under different processing conditions, and the adhesion was assessed by T-peel tests at room temperature. Since adhesion is also related to flow behavior, the rheological properties were studied with a capillary rheometer at shear rates similar to those of the injection molding process (102∼104s−1). Experimental results indicated that the most effective way to control the adhesion between the ABS substrate and the over-molded TPU/MWCNT composite is to increase the melt temperature. The addition of carbon nanotubes improves adhesion in the vicinity of 0.5 wt.% MWCNTs.


2013 ◽  
Vol 594-595 ◽  
pp. 842-851 ◽  
Author(s):  
S.M. Nasir ◽  
Khairul Azwan Ismail ◽  
Z. Shayfull ◽  
Norshah Afizi Shuaib

In this study, a mold is designed in single and dual type of gate in order to investigate the deflection of warpage for thick component in injection molding process. Autodesk Moldflow Insight software was used as a medium for experimental tested. Nessei NEX 1000 injection molding machine and P20 mold material details were entered in this study to get more accurate data on top of Acrylonitrile Butadiene Styrene (ABS) as a molded thermoplastic material. Taguchi orthogonal array, analysis of Signal to Noise (S/N) ratio and Analysis of Variance (ANOVA) were implemented to get the best combination of parameter and significant factor that affect the warpage problem for both types of gates. Coolant inlet temperature, melt temperature, packing pressure and packing time are the selected parameter that used in this study. A conformation test is conducted to verify the combination parameters optimized. From the result, multi gates used was founded that can decrease the deflection of warpage for thick product. From ANOVA, the most significant factor is melt temperature for single gate, and coolant inlet temperature for multi gate. Packing pressure and packing time were slightly influence on warpage problem for both studies.


Micromachines ◽  
2020 ◽  
Vol 11 (4) ◽  
pp. 428
Author(s):  
Francesco Regi ◽  
Patrick Guerrier ◽  
Yang Zhang ◽  
Guido Tosello

A special mold provided with a glass window was used in order to directly evaluate the flow progression during the filling phase of the injection molding process in a thin-wall cavity and to validate the simulation of the process with particular focus on the hesitation effect. The flow of the polymer was recorded at 500 frames per second using a high-speed camera (HSC). Two unfilled thermoplastic polymers, acrylonitrile butadiene styrene (ABS), and polypropylene (PP), were used to fill two different 50 mm × 18 mm staircase geometry cavities, which were specifically designed to evaluate the hesitation effect with thicknesses of 1500, 1250, 1000, 750, 500 µm (cavity insert no. 1) and 1500, 1200, 900, 600, 300 µm (cavity insert no. 2). In addition to the video recordings, the simulations were validated using the timings and the data obtained by three pressure sensors and two thermocouples located in the cavity. For each injection cycle recorded on camera the machine data were collected to carefully implement the correct boundary conditions in the simulations. The analysis of the video recordings highlighted that flow progression and hesitation were mainly influenced not only by the thickness, but also by the velocity and the material type. The simulation results were in relatively good agreement with the experiments in terms of flow pattern and progression. Filling times were predicted with an average relative error deviation of 2.5% throughout all the section thicknesses of the cavity. Lower accuracies in terms of both filling times and injection pressure were observed at increasingly thinner sections.


2017 ◽  
Vol 2017 ◽  
pp. 1-11 ◽  
Author(s):  
Katharina H. Kurth ◽  
Dietmar Drummer

Polymer bonded magnets are compounds consisting of a polymer matrix with embedded hard magnetic filler particles. These materials are mainly used in applications in actor or sensor technology. One example is the application as multipolar encoder wheel in magnetic sensors. Depending on the application different requirements have to be fulfilled, such as a high pole length accuracy and repeatability. This investigation deals with the production of multipolar rings in the injection molding process for sensor applications and influences of the design of the gating system on the pole length accuracy. It is shown that the number of injection points and developing weld lines, as well as the positioning of the injection points, has a major influence on the magnetization characteristics of the molded rings. In general, a positioning of injection points and weld lines in the pole pitch and higher number of injection points lead to rings with a high reproduction accuracy of the pole length of the mold.


2013 ◽  
Vol 133 (4) ◽  
pp. 105-111
Author(s):  
Chisato Yoshimura ◽  
Hiroyuki Hosokawa ◽  
Koji Shimojima ◽  
Fumihiro Itoigawa

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