1:30 pm – 6:00 pm:
TH11-Automotive: Process & Simulations-Room S320E

1:30 pm – 2:00 pm:
Connecting Rheology of Polyolefin Elastomers to Dispersion in a Polypropylene Matrix Via Modeling and Experiments With Simple Flow Fields

Jeff Munro, Dow Chemical
Controlling the dispersion of polyolefin elastomers in polypropylene is critical for applications requiring low temperature impact toughness, such as for automotive TPO compounds. To better understand the role of polyolefin elastomer design and rheology on dispersion in polypropylene resins, a computational fluid dynamics model was developed to study the effect of viscoelastic behavior on particle breakup in simple flow fields. This model was applied to breakup of polyolefin elastomers with different rheological features in a high flow polypropylene matrix. Experiments were conducted with similar blends under comparable simple flow fields to validate the results of the model. The learnings were then applied to a simple TPO compound produced with typical twin screw extrusion and injection molding, demonstrating the benefits of a particular elastomer rheology on dispersion and impact toughness properties, and validating the utility of the computational fluid dynamics model to help guide polyolefin elastomer resin design.

2:00 pm – 2:30 pm:
Core-back Technology for Automotive Body Interior Applications

Steve McClintock, SABIC
Core-Back Technology enabled a 1.9mm IP substrate to be molded then expanded to 4.0 mm . Resulting in less cost & weight while increased stiffness and low emissions.

2:30 pm – 3:00 pm:
Dynamic Water Penetraiong Prediction for Push-back Process in Waster-Assisted Injection Molding

Jim Hsu, Project Manager, R&D, Core Tech. System
Water-assisted injection molding (WAIM) process has brought a breakthrough development for the traditional injection molding industry. The water cores out a network of hollow channels throughout the mold cavity to reduce the cost of energy and plastic evidently. In the recent years, the improvements both in the numerical methods and computer hardware have promoted the application of CAE in the modeling of the injection molding process. The major drawbacks of the Hele-Shaw approximation, commonly used today as a means of simplifying the simulation of WAIM process, are the inherent loss of the ability to predict the important physical three-dimensional phenomena for water penetration such as blow-out behavior, corner effect and secondary penetration. This study presents an implicit finite volume approach to simulate the three-dimensional mold filling problems encountered during the water-assisted injection molding. Full shot WAIM processes push-back molding process verify mutually with the experimental results on industrial applications. The results show that our novel three-dimensional numerical model is able to predict the complex water penetration behaviors in the real mold and the predictions are also consistent with the experimental results to further verify the accuracy of our approach.

3:00 pm – 3:30 pm:
How Plastics Helps toConquer the New Challenges of Vehicle Electrification

Werner Posch, Draexlmaier Group
The need for zero emission solutions is steadily increasing and OEMs are currently developing battery electric vehicles with a focus on providing emission-free transportation, combined with lowest total cost of ownership. The main challenges for these vehicles include: range; cost and weight. Electric vehicles are no longer a trend but an established fact. In order to make the correct decision on which technological approach – BEV (battery electric vehicle) or REEV (range extended electric vehicle) – best meets the requirements of the market, the manufacturers specific boundary conditions and economic aspects have to be balanced with a multidisciplinary approach. The development of alternative drive vehicles is driven by both consumer and government demand. Consumers want fuel-efficient, low-emission vehicles, but they do not want to pay a premium to drive a more sustainable car. Governments want improved fuel economy and low emissions, and go as far as using manufacturer tax credits and consumer write-offs to incentivize alternative drive vehicle development. However, for a solution to be truly sustainable, it must be economically feasible, as well as environmentally sound. As the market grows for hybrid-powered and electric vehicle technology, plastics play an ever more important role to help reduce carbon emissions and dependence on petroleum. The challenges of using plastics in electric vehicle technology are: • Use of plastics instead of aluminum and steel for weight reduction • Use high-performance polymers and elastomers to integrate components and functions — this miniaturization reduces space and improves packaging. • Improve battery pack performance with flame-retardant and thermoplastic materials. • Prevent electrical arcs and sparks in connectors with thermoplastic materials that meet 650-volt system requirements. • Provide electromagnetic compatibility (EMC) The presentation includes proved plastics solutions for challenges described above. Examples of developed and already in serial production electric power trains (High-voltage battery systems, power electronics,…) to identify the right plastics for design and serial production which fulfil requirements such flame resistance, EMI shielding, weight reduction,… So that automakers can build hybrid and electric vehicles that meet consumer and environmental needs.

3:30 pm – 4:00 pm:
Development of Low Emission Polyolefin Composites for Automotive Interiors

Tanmay Pathak, A. Schulman
Low Emission products are highly sought after in the automotive industry for interior applications which include measuring Odor and Fog, Volatile Organic Compounds (VOC’s) and Semi-Volatile Organic Compounds (SVOC’s). A. Schulman, Inc has developed glass and mineral filled composites that meet the regulatory requirements for VOC’s and SVOC’s in GMW and VW specs through a careful selection of base polypropylenes, additives and compounding technology which will be presented in this work. The development included a careful selection of resins, targeted additive strategy and an appropriate process to minimize the VOC and SVOC count measure via chromatography on the final compound.

4:00 pm – 4:30 pm:
Effect of Grain Pattern and Talc Content on Scratch and Mar Behaviors of Textured Thermoplastic Olefins

Shuoran Du, Texas A & M University
An investigation on the effect of talc content and grain pattern on the scratch and mar behavior of textured thermoplastic olefins (TPO) samples is reported. A set of model TPO samples with different grain pattern and talc content were provided by Nissan Motors (USA) Co., Ltd. Scratch and mar tests were carried out on these TPO samples according to the ASTM D7027-13 standard. The visibilities of the scratch and mar damages were evaluated by a contrast-based methodology, and found to correlate well with human assessment. The grain pattern and talc content are found to have significant effect on mar visibility resistance of TPO. Issues related to mar evaluation methodology and material science on improvement of mar resistance are discussed.

4:30 pm – 5:00 pm:
Vehicle Lightweighting and Improved Crashworthiness – Plastics and Hybrid Solutions

Fred Chang, Automotive Structures Project Leader, SABIC
“Worldwide, efforts are underway to save lives and reduce vehicle repair and other economic and social costs that result from motor vehicle crashes. At the same time, also worldwide, automakers are grappling with increasingly stringent fuel economy requirements. The difficulties involved in reconciling these two objectives – designing vehicles that are lighter to improve fuel-efficiency, but also more crashworthy – can seem daunting. This presentation addresses the conundrum head on with a discussion and overview of different multi-material body-in-white (BIW) weight reduction opportunities. The BIW is an obvious choice for vehicle lightweighting as this structure contributes more than 30 to 35 percent of the total weight of a car. Using engineering thermoplastic and hybrid solutions at appropriate locations on a vehicle’s BIW, automakers can achieve significant weight savings without compromising crash performance. To illustrate, this presentation provides a detailed case study on an award-winning floor rocker reinforcement. Also covered are several other lightweight solutions for applications like A/B pillars and bumper rail extensions.”

5:00 pm – 5:30 pm:
A Novel Glass Filler Reinforced Compound for Automotive Interior Parts

Cheolhee Park, GS Caltex
Scratch resistance has been issued in automotive industry, which is a measure of scratch on the plastic material for the interior and exterior of automotive. The effect of thermoplastic olefin (TPO) composition with various fillers and novel glass filler, which has high aspect ratio, on scratch resistance and mechanical properties was investigated in this study.

5:30 pm – 6:00 pm:
Bumper to Bumper – Removing Contaminants from Molded Plastic Parts with Dry Ice

Steve Wilson, Cold Jet, LLC
It is not uncommon for many automotive plastic parts to be painted. Unwanted material, either left from the molding of the part itself, or the picking up of contaminants from the transporting of the part to the paint booth, must be removed prior to painting. Many of these parts are cleaned utilizing aqueous methods requiring that the parts be dried prior to painting. Reclaiming the water, fueling the oven (and dealing with its footprint), and the fact that sometimes the parts don’t get dried, are all problems can be alleviated by utilizing dry ice. Dry ice is a non-abrasive media that does not alter the dimensional characteristics of the part nor damage the surface of the parts to be painted. It is also dry, eliminating the need to have or operate a drying oven. Dry ice also sublimates, leaving nothing to be reclaimed behind and no possible water entrapped in part geometries of complex parts that may not get thoroughly dried. This paper will discuss the distinct advantages of utilizing dry ice as a blast media for the surface preparation of plastic parts prior to painting. The process itself will be explored as well as the common results.