The technical information, suggested uses and applications presented are made without charge and are believed to be reliable; however Ravago Manufacturing Americas disclaims responsibility for results of use of this information. Ravago Manufacturing Americas makes no warranties, either expressed or implied, concerning our materials, including any warranties of merchantability or fitness for a particular use. All users should rely upon their own tests in determining suitability.
Introduction: Rotational molding is a process where plastic materi- als are formed into useful articles by rotating a mold containing the plastic material in an oven sufficiently hot to melt the plastic. The mold is rotated in two directions to cause the plastic to coat all surfaces of the mold. There is little pressure inside the mold dur- ing the forming process. After the plastic is thorough- ly melted to coat the mold surface the mold and plas- tic is cooled, the part is removed from the mold. The rotational molding process is ideally suited to fabrication of hollow parts. It also lends itself to pro- duction of rather large parts. The process can ac- commodate articles with complex geometry. Because the process is carried out at low pressure, the molds can be fabricated from relatively inexpensive materials. The relatively low cost of tooling allows rotational molding to be used to produce parts whose production volume would not amortize the high cost of expensive injection or blow molds. At first examination, the rotational molding process seems simple. Those who have had experience pro- ducing parts by rotational molding understand that the rotomolding is a complex manufacturing process, with many variables that can affect the quality articles produced. Polyethylene is a particularly good material for rota- tional molding. When used as a fine mesh powder, polyethylenes melting characteristics easily form a solid part. Polyethylene has adequate heat stability to withstand the relatively high temperature and long heating cycles of rotational molding. Parts formed from polyethylene have an excellent combination of strength, toughness and other mechanical properties. In order to optimize the properties, it is necessary to use proper molding conditions to form articles. Muehlstein rotational molding products are designed for optimized processability and properties in rota- tional molding. These products are compounded from prime quality materials by a process designed to yield consistent material, box-to-box and shipment-to- shipment. This bulletin is designed to help the customer find the optimum molding conditions for their application. Because of the diversity of article made by the rota- tional molding process and the different types of rota- tional molding machines and molds used in the roto- mold process, it is impossible to establish universal optimum molding condition that are optimum for all circumstances. We can offer recommendations for starting conditions and guidelines for adjustments to the process conditions to help optimize the process for the particular part being molded. Process Control: In order to achieve consistent quality rotationally molded articles, it is important that proper molding conditions are used and, as with any manufacturing process, that all variable in the manufacturing process be controlled as closely as possible. Each rotational molding cycle must be preformed under the same conditions as the previous cycle, as nearly as possi- ble. Because different parts are often placed on the same arm or different arms of a multi-arm machine, often the molding cycle is a compromise to achieve ac- ceptable quality for all parts being molded. Mold Design: Proper mold design is critical for production of quali- ty parts. While the design of molds is outside the Rotational Molding Guide
Page 2 Ravago Manufacturing Americas 20110701 scope of this guide, there are a couple of areas of mold design that should be highlighted. Mold Venting: Mold venting is important to good part quality. Prop- er venting will allow the part to be heated and cooled at about atmospheric pressure. This will eliminate blowholes at the parting line. Proper venting will pro- long the contact of the cooling part with the inner surface of the mold, resulting in a shorter cooling cycle and post-mold warpage. Lower pressure differ- ential also results in longer mold life. In general, mold vents of sufficient size and number to allow equalization of the inner mold pressure. Vent tubes should extend to the center of the mold. The inside end should be loosely packed with fiberglass to prevent the unfused powder from exiting the mold early in the heating cycle. In order to be efficient vent tubes must be kept clean. If the fiberglass becomes clogged with plastic powder the vent tub will no longer function to equilibrate pressure. Drying: Polyethylene does not absorb moisture easily. There- fore, under normal conditions, pre-drying of the pul- verized powder is not required. Under high humidity conditions, or when specialty grades, such as flame retardant, are used drying may be necessary. Measurement of Charge Production of consistent parts requires that each step of the rotational molding process be repeated precise- ly every cycle. This is especially important that the same weight of polymer be added to the mold for each part. The bulk density of pulverized polyeth- ylene for rotational mold has some variability. There- fore, material should be measured on a weight rather than a volume basis. Oven Temperature: Proper cure of the rotationally molded part requires sufficient heat to melt the polyethylene for long enough time duration to completely fuse the polyeth- ylene. The oven temperature must not e so high that the polyethylene is oxidized. On a multi arm machine, the heating and cooling cycles must be of equal time. On one hand, the molder would like the oven temper- ature to be as high as possible to shorten the heating time to a minimum. On the other hand, keeping the oven temperature as low as possible gives optimum part appearance, part toughness, reduces the cooling required and reduces thermal stress on the mold. The rotational molder must decide what combinations of these variable results in acceptable part quality and productivity. Starting Conditions: Our experience has shown that the following condi- tions are good starting points. The molders experi- ence with existing molds and specific molding ma- chines may suggest slightly different conditions. In general, Muehlstein polyethylene rotational molding compounds can be processed at 50 to 75F lower oven temperatures than competitive polyethylenes, especially if a Muehlstein precolored polyethylene is replacing a dry-blended color. Oven temperature: 500 to 600F (260 to 315C) Oven time: 10 to 25 minutes
You can reduce the trial and error involved in time/temperature parameters by measuring the PIAT (Peak Internal Air Temperature). The following table is a general guide for PIAT for RMA standard resins. These are suggested for a wall thickness of around 0.125 in and adjustments will need to be made for thinner or thicker walls: Table 1. GRADE PIAT C HMP-304 210 HMP-305 200 HMP-307 190 HMP-301 215 HMP-315 204 HMP-325 202 AQUATUF HMP-334 205 AQUATUF HMP-337 207 Cooling Like heating cycles, there is no universal best cooling cycle. For a multi-arm molding machine, the cooling time can be no longer than the heating time. On the other hand, high cooling rates increase the potential for warped parts. It is usually best to start the cooling with several minutes of air-cooling. This is followed by atomized water, air/water or water spray for the bulk of the cooling time. It is beneficial to finish the cooling cy- Rotational Molding Guide
Page 3 Ravago Manufacturing Americas 20110701 cle with several minutes of air cooling, allowing the outside surface of the mold to dry. Polyethylene is semi-crystalline polymer. The degree of crystallinity is partly controlled by the cooling rate of the part. Rapid cooling results in lower crystallini- ty. Unfortunately, rapid cooling produces parts with low crystallinity at the mold side of the part and high crystallinity at the inner surface of the part. This dis- parity manifests itself as warpage. It has been found that warpage is minimized with slow cooling. This must be accomplished with the constraints of the cooling time available. Slow cool- ing may adversely affect other physical properties, such as impact strength. AQUATUF Higher density, high performance res- ins in the 0.942 to 0.952 range tend to be more crys- talline and have a higher shrink rate. These may need to be cooled more slowly to prevent warpage, and every attempt made to hold the part against the mold surface until the release point [This is best determined by a Rotolog type trace on the cooling cycle]. Common problems:
Part Surface: Several factors should be considered when at- tempting to improve the quality of the parts sur- face. The surface of the part can be no better than the surface of the mold. Mold design is also of importance in the production of part especially in parts with recesses, high definition or inserts. Selection of the appropriate melt index poly- ethylene is another factor. The dry flow and particle size distribution of the molding power will also affect surface quality. The selection of the proper combination of heating and cooling conditions is also im- portant factors. Rotation speed and rotation ratio effect part surface quality Consistent application and minimum use of mold release. References: 1. Introduction to Rotational Molding Seminar, Dr. Glenn Beall, Association of Rotational Molders, Chicago IL. 2. Rotational Molding Troubleshooting Manual, (ARM-102-1089), Association of Rotational Molders, 1989, Chicago, IL Rotational Molding Guide
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Typical Rotation Ratios Typical Speed (RPM)
Ratio
Shapes Major axis Minor axis 8 to 1 Oblongs (Horizontal) Straight tube (Horizontal) 8 9 5 to 1 Some defroster ducts 5 6 4.5 to 1 Balls & gloves 8 9.75 3.3. to 1 Any shape having overlap- ping lines of rotation at 4 to1 10 12 12.25 14.5 4 to 1 Cubes, balls or odd shapes Rectangular boxes, horses with bent legs 8 10
10 12.5 2 to 1 Rings, tires, balls Any rectangle that shows two or more thin sides when run at 4 to1 Picture frames, Round flat shapes Horses with straight legs, Auto crash pads (vertical) 6
8
10
12 9
12
15
18 1 to 2 Parts that should run 2 to 1 but show thin side walls. 5 7 15 21 1 to 3 Flat rectangles e.g. gas tanks, suitcases, tote bin covers, etc. 4 6 9.5 15 22.5 36 1 to 4 Tires, curved air ducts, Pipe angles, flat rectangles, Balls whose sides are thin at 4 to 1. 4 5 6 20 25 30 1 to 5 Cylinders, vertical 4 24 Vertical - Mounted parallel to major axis Horizontal - Mounted perpendicular to major axis. Rotational Molding Trouble-shooting Guide Page 5 Ravago Manufacturing Americas 20110701 Problem Probable Cause Possible Solution Warped parts Inadequate venting Provide adequate venting - 3/8-1/2 diameter vent per ft 3
of molded volume is suggested for thin walled parts. Non-uniform cooling of part caused by resin pulling away from mold. Rotate mold during cooling cycle. Provide adequate venting and make sure vents are not clogged. Use less mold release. Check for too effective mold release agent. Avoid large flat panels in part design if possible. Reduce cooling rate during initial part cooling cycle. Increase the cooling medium temperature, air cool, and then water cool. Apply air pressure through spine during cooling Non-uniform cooling caused by uneven wall thickness in the part. See suggested reme- dies under problem heading Uneven wall thickness of molded parts. Non-uniform cooling caused by sections of the mold being shielded from heat and cooling medium. Mount mold to elimi- nate shielding prob- lems, add baffles to direct heat and cool- ing into recessed or shielded areas. Uneven cooling caused by clogged water nozzles Check and clean noz- zles on a periodic schedule. Over-cured part. Deg- radation of the resin due to high tempera- ture and/or excessive- ly long heating cycle. Decrease oven tem- perature or heating time. Highly under-fused part. Some degree of under-fusion is advis- able especially in the case of low melt-index resins to prevent deg- radation; however, highly underfused parts can cause signif- icant loss of impact strength. Increase oven temper- ature or total heating time. Increase heat- transfer coefficient, e.g. steel or aluminum. Improper coloring Select pigment and pigment loading that does not affect resin. Problem Probable Cause Possible Solution Use precolored, com- pounded resin. Resin type Use proper resin hav- ing adequate melt index and molecular weight distribution for application. Moisture on resin or pigment. Only use dry powder and/or pigment. Poor impact strength Resin selection not correct Use lower density or lower melt index resin Density increase dur- ing slow cooling Increase cooling rate to maintain a lower density. Part design not ap- propriate Review and alter mold design if necessary, eliminate sharp cor- ners and narrow pas- sages. Insufficient fusion of resin Increase oven time and/or temperature. Improper coloring Select pigment and pigment level that does not effect im- pact. Use pre-colored, compounded resin. Over-curing of resin. Degradation of resin due to long-term high temperatures. Decrease oven tem- perature or heating cycle. Parts sticks in the mold Insufficient amount of mold release agent or the release agent has deteriorated with use. Reapply or use more release agent. Old release may have to be removed and a new one applied. Ineffective release agent or mold release does not withstand elevated tempera- tures. Use suitable mold release agent that is effective for resin and temperature used. Apply according to suppliers instructions. Mechanical interfer- ence during part re- moval Locate mold parting line at undercut or taper side walls of mold. Roughness and poros- ity of mold surface provide areas where resin may adhere. Refinish damaged mold surfaces, plug, weld and sand smooth. Presence of resin at parting line due to internal mold pressure forcing semi-molten Provide adequate venting, 3/8 to diameter vent per cubic foot of mold Rotational Molding Trouble-shooting Guide Page 6 Ravago Manufacturing Americas 20110701 Problem Probable Cause Possible Solution resin through parting line. volume is suggested for thin walled parts. Build-up of degraded resin in the mold may be caused by burning of thin walled sections. Clean mold periodical- ly. Reduce oven tem- perature. Shrinking onto large deep inserted areas. Provide adequate taper to mold walls. Use effective mold release on insert are- as. Remove part while warm. Provide ade- quate means for ap- plying force to sepa- rate mold halves. Undercuts in mold Design mold to place undercuts at parting linen so that mold has draft angle for part removal. Low shrinkage value for resin. Use higher density polyethylene grade. Blow holes through the part or ring- worm effect under thin wall surface other than at Porosity in the cast aluminum mold Obtain better quality castings. Drill through void and drive pin or weld from inside. Relieve from outside by drilling into void. Remove parts from molds while warm to touch. This helps drive moisture out of pores. the part- ing line Pores or holes in welds. Use proper welding rod and procedure. Weld inside surface first to get good penetration. Excessive flashing at mold parting line. Internal mold pressure during heating cycle tends to force semi- molten resin out through the parting line. Provide adequate venting and make sure vents are not clogged. Remate mold parting line and adjust mold clamp pressure evenly. Clean mold flange to prevent gapping and apply new mold re- lease on flange. Re- duce internal air pres- sure if used. Use lower melt index pressure. Bubbles on the mold parting line. During the first stages of cooling, there will be a rush of air into the part to fill the resultant partial vacu- um. If there is inade- Vent the mold to at- mosphere pressure. Relocate vent to mid- dle of mold. Use glass wool in vent. Use Teflon as vent tube. Problem Probable Cause Possible Solution quate venting, air will penetrate the molten resin, at parting line, becoming trapped as the part wall solidifies. Make sure tube is adequate size. Poor mold parting line. Remate molding part- ing line and adjust mold clamp pressure evenly. Clean mold flange to prevent gapping and apply new mold release on flange. Discol- oration of interior surface of part. Degradation of resin due to high tempera- ture and/or excessive- ly long heating cycle. .. Decrease oven tem- perature or heating cycle, or purge part with inert gas (nitro- gen). Use resin with the proper amount and type of antioxi- dant. Check pigment for heat stability. Powder bridging or not filling narrow passages of mold. Mold design incorrect. Modify mold by in- creasing width to depth ratios across the mold opening. Design corners of mold with more generous radii. Avoid ribs with less than 4x wall thickness. Poor pourability (dry flow) of powder. Make sure powder has acceptable pourability and bulk density. Powder does not melt or flow properly. Use finer mesh pow- der or resin with a higher melt index. Cold spots on mold. Avoid any shielding mold areas. Check for mold wall thickness uniformity. Improper mold rota- tion. Use correct ratio and rotation speed. Poor part stiffness Part wall too thin Add more powder to initial charge. Resin selection not correct. Use rein of higher density. Part design not ap- propriate. Review and alter mold design if necessary. Under fused parts. Increase oven temper- ature or total heating cycle. Increase heat- transfer rate by using thinner mold walls, or make the mold from materials of greater heat-transfer coeffi- cient, e.g. steel or aluminum. Try filling molds while hotter. Light- ning effect in Moisture in pigment or resin. If dry-blending, dry pigment or use pig- ment from unopened Rotational Molding Trouble-shooting Guide Page 7 Ravago Manufacturing Americas 20110701 Problem Probable Cause Possible Solution colored parts. container. Use pre- compounded color resin powder. Dry resin completely or replace. Static build-up Add small amount of mineral oil to resin or commercially available anti-stat. Make certain that all mixing and molding equipment is adequately grounded with high surface cop- per cable. Pigment not ground properly. Use 100-mesh pig- ment or pulverize pigment prior to mix- ing. Use pre- compounded color resin powder. Blow holes through part around insert Poor fit on inserts allowing moisture or vapors to be trapped around insert and expand, blowing a hole in the part. Refit insets and relieve to allow trapping gases to escape to the outside of the mold. Drill a small hole through the insert bolt to relieve gas pres- sure. Bridging of resin be- cause of close dimen- sions. Change insert dimen- sions or location to allow powder to flow without bridging. Speckled colors and lumps of pigment in dry blended colors Insufficient blending Break up agglomer- ates of pigment be- fore blending. Use high intensity mixer. If unable to achieve a desirable color bal- ance, use a com- pounded color resin powder. Long oven cycles Heat-transfer rate not adequate to melt all resin, excessively thick mold. Increase heat-transfer rate by using thinner mold walls, or make the mold from materi- als with greater heat- transfer coefficient, e.g. steel or aluminum. Heating not efficient. Increase air velocity around mold during heating cycle. Check oven for air leaks. Low oven tempera- ture. Increase oven temper- ature. Recalibrate instruments on regular schedule. Resin powder too coarse Use finer mesh pow- der Poor melt flow Use higher melt index resin. Extended cooling Reduce air-water cool- ing ratio Problem Probable Cause Possible Solution Long- term part failure Part over-cured during molding Decrease oven tem- perature or heating cycle Photo-degradation of part caused by ultra- violet light from sun or internal lighting (florescent) Use UV stabilized resin in application. Add suitable UV stable pigment. Stress-cracking due to multi-axial stresses in part. Cracking may have been accelerated by chemical environ- ment and/or tempera- ture Use polyethylene grade with good envi- ronmental stress crack resistance (ESCR). Modify design around the areas containing inserts. Examine parts in field use to deter- mine adequacy of design around stress concentration points. Inadequate resin addi- tive system. Antioxidant type and level of concentration may be inadequate. Reduce level of inter- nal mold release if used. Color change due to oxidation. Light col- ored parts may look yellow or pink. Reduce oven tem- perature. Improper colorants or blending. Use colorants that disperse well in base resin. Use pre- compounded color resin powder for op- timum dispersion of color and stabilizers. Uneven wall thickness of mold- ed parts. Improper mold rota- tion Vary ratio and speed of rotation of mold to obtain even coverage and adequate number of powder trackings Mold shielding Mount mold to elimi- nate shielding. Uneven mold wall thickness Use care in designing molds to prevent excessive variations in mold wall thickness (thin spots attract more resin) Inadequate powder properties. Low bulk density, no powder pourability, large amount of fluff, parti- cles have many tails that entangle into clumps during mold- ing. Obtain an acceptable quality powder. F using bulk powder storage, empty stage silos before refilling to prevent accumulation of fine particles in storage silo. Buffeting or air flow in deep dished areas. Avoid deep dished areas whenever possi- ble. Reduce thickness of mold in dished Rotational Molding Trouble-shooting Guide Page 8 Ravago Manufacturing Americas 20110701 Problem Probable Cause Possible Solution areas. Open handles so air can flow through kiss-offs in mold. Highly under- fused parts, with Oven temperature not high enough to drive air bubbles out of part walls. Increase oven temper- ature or total heating cycle. many small bubbles in wall or rough powdery inside Heat transfer rate not adequate to melt resin. Increase heat transfer rate by using thinner mold walls or make mold from materials with greater heat- transfer coefficient, e.g. steel or aluminum. surface. Resin powder too coarse. Use finer mesh pow- der. Moisture in mold Reduce moisture in mold by running with warm molds and dry mold before charging powder. Poor flow-out into mold recesses Poor mold design Design shallow re- cesses with generous radii on edges. Pre- heat recessed areas with torch for 30- seconds before charg- ing. Add heat deflec- tors or thermal pins. Improper mold rota- tion Change ratio and/or speed of rotation. Melt index of resin too low Increase melt index of resin.