The “Right” machine for the job?

Introduction The Tool The Material

But which Machines?????????

MSDS Legal Requirement

Moulding

What is Polycarbonate? C CH 3 O n

Molecular Weight Vs. Strength Molecular weight (x10 ) Tensile strength (kg/cm2) Izod impact strength (kg cm/cm) 800 700 600 100 50 2 2.5 3.0 4

Molecular Weight Vs. Flow Flow Value (10 m/sec) 1.5 2 3 4 5 6 10 20,000 25,000 30,000

Injection Moulding Hopper Clamping unit Screw & Barrel Nozzle

Clamping Pressure Calculated by multiplying the projected area of the cavity (cavities), including runner system by the maximum internal pressure (hold pressure).

Clamping Pressure ABS 0.45 to 0.65 T/cm2 LCP 0.75 to 0.8 T/cm2 PA 0.65 to 0.75 T/cm2 PBTP 0.65 to 0.75 T/cm2 PC 0.5 to 0.8 T/cm2 PE 0.15 to 0.55 T/cm2 PETP 0.65 to 0.75 T/cm2 PMMA 0.45 to 0.75 T/cm2 POM 0.85 to 1 T/cm2 PP 0.15 to 0.55 T/cm2 PPS 0.3 to 0.6 T/cm2 PS 0.3 to 0.5 T/cm2

Injection Unit Hopper Screw & Barrel Nozzle

Screw Design

Screw Types

Screw Tangential Speed-M/S ABS 0.2 (GR,FR) - 0.3 ETPV 0.2 PA 0.15 (GR,FR) – 0.4 PBTP 0.2 (GR,FR) – 0.3 PC 0.2 (GR,FR) - 0.3 PE 0.5 – 0.6 PETP 0.15 (FR) – 0.20 PMMA 0.2 (ST) – 0.3

Screw Tangential Speed-M/S POM 0.15 (GR,ST) – 0.3 PP 0.3 (GR) – 0.6 PPA 0.15 PPS 0.15 PS 0.3 (HI) - 0.6 PVC <0.1 SAN 0.3 TPC-ET <0.2 TPUR <0.15

Screw Speed Calculation Beware: High speed = high heat (through shear). High speed = high abrasion with filled Materials. Beware: High back pressure increases shear (temperature) and cycle time but not necessary melt quality.

Melt Viscosity characteristics Shear Rate (Sec ) Melt viscosity (poise) 10 3 4 -1

Pressure Vs. Flow Spiral flow length (cm) Polycarbonate PPH PA 6 GPPS PPC HDPE LDPE POM ABS Polycarbonate Injection Pressure Spiral flow length (cm) 40 140 (Kg/cm G) 2 80 120

Temp. Vs. Molecular Weight 100 1000 10000 350 340 320 300 280 Moulding temp (deg.C) Lowering of mol. wt. (Mv) 35 min 20 min 5 min Residence time

Hold-on-time Toughened Nylon 6.6

Temperature Profiles

Conclusion The right Melt temperature The right Melt quality

A Polymer for Every Application