1. Category: Engineering: Materials and Bioengineering RMSST 1/8/14 By: Jacob Brown EFFECT OF MOLD RELEASE COMPOUNDS ON MOLD RELEASE QUALITY

2.  Mold release compounds are commonly used in the molding process to reduce adhesion between a molded object and the surface of the mold it is molded in.  The problem in this process is that previous and even current compounds are both inefficient and possibly harmful to the environment.  Now, more people are turning towards a newer, more efficient and safer release compound to release and protect their molds.  One downside to the turnover to these new compounds is that they might not know what they are getting into, or if the compound is even effective.  This uncertainty is the basis for my research and experimentation. PURPOSE/ RATIONALE

3.  No real in depth research has been done  The only claims made concerning the compounds are those that were instituted by the company producing them  The compounds were not shown to have been tested yet (possibly due to their recent creation and introduction) BACKGROUND RESEARCH

4.  The Independent Variables for this project are:  Diamondkote Compound  Aqualift Compound  The Dependent Variables for this project are :  Surface quality of the molds  Smoothness/roughness  Pitting  Marring  Visual Deforming IVS AND DVS

5.  Of the two compounds and one control tested; if compound Diamondkote is tested, then it will create molded objects with the greatest surface quality. HYPOTHESIS/ GOALS

6. 1.Gather materials (Mold, timer, silicone rubber, Aqualift/ Diamondkote compounds, goggles, Dino-Lite, logbook, and pen) 2.Control: Take mold, set on flat surface, do not coat with compound, fill to surface with silicone rubber, let harden, pull mold out, label, set aside. Repeat 2 more times 3.Aqualift: Take mold, set on flat surface, do not coat with compound, fill to surface with silicone rubber, let harden, pull mold out, label, set aside. Repeat 2 more times 4.Diamondkote: Take mold, set on flat surface, coat with Diamondkote compound fill to surface with silicone rubber, let harden, pull mold out, label, set aside. Repeat more times PROCEDURES

7. PROCEDURES CONTINUED Dependent Variable: Temperature, Roughness, Shearing Constants: The time, RPMs, depth, drill, application method, and drill bit type used will all be the same. IV: Mold Release Compound Used GroupsMold w/o Release Compound (Control) Diamondkote Compound Aqualift Compound Trials333

8.  Junior Applicator  Stand Up Drill Press  Lab Goggles  IR Temperature Thermometer  MQLs (LB 1000, 1100, 2000, 6000, and 6100)  6 Cobalt Infused Drill Bits  Air Compressor  Steel Bar Stock  Aluminum Bar Stock  Log Book  Pen MATERIALS

9.  In disfavor to my hypothesis, after testing, it was determined that lubricants LB 6000 and 6100 outperformed lubricant LB 1000 EXPERIMENTATION RESULTS

10. CHARTS/ GRAPHS (ALUMINUM)

11. CHARTS/ GRAPHS (STEEL)

12.  How to properly use a drill press, applicator, and IR thermometer  How to use ANOVA and Minitab to analyze results  How the effects of any form of lubrication in the drilling process (MQLs, flood lubricants, etc) can increase tool life WHAT WAS LEARNED

13.  Mrs. Baskett for actually making this project feasible by taking the initiative, and by helping me in the early stages of my project  Mr. Bolen for allowing me lab time to work on my experimentation, and for helping me with the usage of Minitab  RMSST for allowing me to use their equipment and tools  ITW Fluids, Bob Romines, and Rob Myers for allowing me to use their applicator, MQLs, and IR thermometer for testing ACKNOWLEDGEMENTS

14.  Bienkowki, K. (1993, April). “Coolants & lubricants – Staying pure”,. Manufacturing engineering, pp. 55-61.  Boelkins, C. (2009, March). MQL: Lean and Green. Cutting Tool Engineering.  Davim, J. S. (2006). Experimental studies on drilling of aluminium (AA1050) under dry, minimum quantity of lubricant, and flood- lubricated conditions. PROCEEDINGS- INSTITUTION OF MECHANICAL ENGINEERS PART B JOURNAL OF ENGINEERING MANUFACTURE, 1605- 1612.  Heisel, U. (2009, April 12). Publication Server of the University of Stuttgart. Retrieved from The University of Stuttgart: http://elib.uni- stuttgart.de/opus/volltexe/2010/5072/pdf/hei135.pdf  ITW ROCOL. (2010). Junior Applicator. Retrieved from ITW ROCOL: http://www.itwfpg.com/acculube/applicators/junior.html  Milton, R. (2009, June 30). Metal Machining - A Glimpse at Different Types of Machining Operations. Retrieved from EzineArticles.com: http://ezinearticles.com/?Metal-Machining---A-Glimpse-at-Different- Types-of-Machining-Operations&id=2547806  Simon, T. (1999). The actual stage of machine-tool technology. Revista Maquinas e Metais, 88-108. REFERENCES

15.  Men of Distinction  Mostly community service based group  Also helps with assisting teacher activities and school related functions  I have been a part of this group for a little over a semester, and have helped with a breakfast, dance setup, and after school get-together through it. ACCOMPLISHMENT