1:30 pm – 5:30 pm:
TH13-Injection Molding: Molding Industry Technologies
(Moderators: Chad Ulven and RayMcKee)-Room S320H
1:30 pm – 2:00 pm:
Flowcon Plus, Digital Water flow Regulator
Edgar Sanchez, Wittmann Battenfeld
What you didn’t think was possible with Automatic Water Flow Control. Previous methods of water flow control have proven themselves beneficial to the molding process but come with a series of headaches between setup and monitoring. Automatic water flow control is the next wave of technology in the molding industry. Imagine being able to reap the benefits of water flow control without all the hassle. The key advantage of automatic water flow control over a manually adjustable one is that it permits continuous electronic monitoring and automatic adjustment of proportional control valves to meet preset flow and temperature values. All data can be logged. Already proven in service many times over, the WITTMANN fine regulating valve of the 301 Series performs flow regulation. Generously dimensioned channels in the casing blocks guarantee the lowest possible pressure loss and high flow rates. The net benefit is being able to easily balance temperature and flow through complex tooling pathways, bubblers, thermal pins, conformal cooling and of the like. This leads to a much higher level of process repeatability because an automatic regulator reacts much quicker and with a higher accuracy than most temperature controllers, as well as provides zone control of the tool. A technician can balance the tool to avoid shrinkage or warpage in trouble areas of the tooling, and even balance fill rates. Another benefit is that once you’ve qualified the mold with certain temperature and flow settings, those setting can be saved, allowing an easier setup of the mold. Likewise all of the processing data on the machine for zone temperatures and flows can be tracked. Working with a multi-cavity tool? Great because automatic flow control ensures uniform cavity filling due a modifiable heat profile throughout the mold and it’s cavities. Lastly, if there is degradation in flow due to a blockage or restriction, the system will identify this, its location, and indicate to the operator that there is a problem. This allows a technician to proactively clean a cooling channel before a failure occurs.
2:00 pm – 2:30 pm:
Induction Heat Cool With SABIC Resins: AN Intro to High definition Plastics
Jos van Gisbergen, SABIC
With induction heat/cool mold technology it is possible to reach mold temperatures effective for low and high melting polymers with precise temperature control during the injection stage of a molding cycle. This results in enhanced flow behavior of the resins enabling, among others, thin wall molding, enhanced surface replication and generally improved part performance. There is a need to better quantify these effects for various resins. The High Definition Plastics database offers central storage for these quantified benefits according a standardized method and allows easy material selection for a specific design or purpose.
2:30 pm – 3:00 pm:
Get The Wear Out
Steve Wilson, Cold Jet, LLC
Most would agree that the mold is the heart of the molding process. From those that make them to those who use them, we all want them to last for as long as they were designed. A lot of work goes into striving toward that goal: good design, proper metallurgy selection, configuration, coatings, etc. With all that having been taken into account, why clean the mold with traditional methods that may wear out the parting line and shut-offs? This paper will demonstrate that cleaning tooling with dry ice is a safe, effective and non-abrasive way to clean common injection molds. It will provide molders, not only a way to extend the asset life of the tool, but also to improve quality, increase productivity, lower costs and improve environmental quality. This paper will focus on the first benefit of maintaining the expected life of our molds. Today, high-dollar and often complex molds, are run and maintained in varying degrees of skilled molding shops and tool rooms. Some of the cleaning methods still be utilized can contribute to tool wear.
3:00 pm – 3:30 pm:
Regional Sales Manager- Robots and Automation
Robert Arsenault, Wittmann Battenfeld
There are many options and sizes available with today’s linear robots. How do you know if your robot has the proper payload or strokes to handle your work today and in the future? In this presentation, we will review key factors for sizing robots for injection molding machine including: • Tips on choosing properly sized linear robots • How robot designs affect choosing robot size. • Tips and suggestions on how to size robots for larger tonnage injection molding machines.
3:30 pm – 4:00 pm:
Injection Molding: 3D-Printed Molds vs. Metal Tooling
Thomas Davis, Applications Engineer, Proto Labs
This presentation will compare the latest mold-making technology of 3D printing to quick-turn aluminum tooling and traditional steel tooling. It’s important to understand the pros and cons of each to determine which technique is suitable for your injection molding project. We’ll discuss the various considerations of printed plastic molds and machined metal molds such as manufacturing time, cost, durability, and part quantities.
4:00 pm – 4:30 pm:
“Smart Factories”: The Future of Plastics Production with 4.0 Connectivity & Condition Monitoring System (CMS)
Markus Klaus, Wittmann Battenfeld
“Smart Factories” are now a real possibility. Many innovations have been realized over the years, but perhaps none as interesting and valuable as Industry 4.0 and Condition Monitoring Systems (CMS). The ability to achieve complete connectivity along with the need to stay in touch have driven innovation to a point that now allows nearly all equipment to speak to each other. The capability to have full internal communication of equipment coupled to the Injection Molding Machine with nearly instant access to streaming data through the internet may have truly created the next generation of “Smart Factories”. The innovations provided by 4.0 connectivity along with CMS, a system which combines technical sensing components with predictive diagnostic analysis, allow factory monitoring at local and global levels. In this presentation we will review the integration of all injection molding components using 4.0 connectivity. This includes a complete automation system along with all the peripherals – and the connection of these cells to a Manufacturing Execution Systems (MES). We will also review Condition Monitoring Systems (CMS) and how they will affect the future of plastics production. The strategy of condition monitoring is a permanent surveillance of the actual condition of the injection molding machine components with the goal of optimizing, and subsequently, keeping the availability and efficiency at an optimal level, thus reducing their life cycle costs.
4:30 pm – 5:00 pm:
Improving Accuracy of Mold Filling Simulations With Experimental Data From Fast Scanning Chip Calorimetry
Anne Gohn, Penn State University
In this study, mold filling simulation crystallization data were compared with experimental data collected with a fast scanning chip calorimeter. This new technique gives the opportunity to collect data at higher cooling rates, which mimic the injection molding process. Experimental data showed that the crystallization temperature depends on the cooling rate, which is neglected in previous models implemented in the simulation software. It is suggested to modify the simulation software crystallization data in order to account for more realistic prediction of the crystallization process and, consequently, microstructure formation affecting properties.
5:00 pm – 5:30 pm:
Injection Molding Parts WIth Integrated All-inkjet Printed Strain Gauge for Condition Monitoring
Thomas Mitterlehner, Johannes Kepler University Linz
Injection molding parts became more and more complex and especially critical components are subjected to high safety requirements. In this paper a fully functioning injection molding test specimen with integrated condition monitoring was developed by using all-inkjet printed strain gauges and back injecting them. For the printing of electrically conductive traces a commercial available Epson printer and silver nanoparticle dispersion was used. This enables the fabrication of sensor systems without the need of a photo mask. Furthermore the applicability for monitoring injection molding parts with low-cost sensor systems was investigated. Therefore several test specimens with integrated strain gauges were fabricated and tested with a tensile testing machine. With the integrated strain gauge the relative change in resistivity was measured and the resulting strain was then compared to the results of the tensile testing. In this context the gauge factor of the printed conductive traces were characterized.