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ATI 584e
Application Technology
Information
General
Introduction
Photoetching
Photoetching consists of dissolving
part of a surface e.g. the cavity surface, with acid. Part of the metal surface which is not to be etched has to
be covered with acid resistant material, so that the acid will only dissolve
the exposed portions. The texture
design is applied photographically and
the technique has become firmly established in the plastics processing industry indeed, photoengraving is today the most important method of producing textured cavity surfaces.
Fig. 6 shows the various stages of
producing a photoengraved textured
surface. Nowadays, multiple etching
is mainly used in order to produce a
uniformly textured surface. The
degree of gloss can subsequently be
adjusted by blasting the surface with
glass beads, for example. Worn surfaces can be restored to very near
their original condition by this method.
Fig. 7 shows some typical textures
produced by photoetching, these
being a selection of several hundred
that are now available.
1. Degreasing
chemical + manually
2. Coating
sensitive to light
coat
Fig. 1
3. Explosure
4. Development
light
film
coat
Fig. 2
5. Correcting
6. Protecting
acid
mould protection
coating
7. Etching
remaining acid
resistant coat
8. Cleaning
9. Result 1st etching
half matt finish
Fig. 3
dissolved surface 0 x
etching depth
etching bottom
sharp edge
obtained surface
texture roughness
Fig. 4
10. Protecting
11. 2nd Etching
12. Result
rounded matt finish
dissolved surface 0 x
surface loss
etching depth
mould protection
coating
uniform
round edges
Nearly all the materials used to make
texture roughness
moulds can be textured photochemidissolved surface 2 x
Fig. 5
cally, i.e. by photoetching. It must,
however, be remembered that steels
which contain chromium are invariably more difficult to etch than those Fig. 6: Diagram showing the various stages of producing photoetched
textures (after Wagner)
that do not. In general, steels containing up to 5 % chromium can still be
photoetched satisfactorily and steels
with up to 15 % chromium can also be
etched successfully, although this is
more difficult.
the materials coarse particle structure the valleys of the etched surface
will show considerable roughness and
plastics surfaces produced from such
steels are very likely to become scratched. Fig. 8 shows the classic photoetching stages in the form of photographs of silicone rubber impressions
taken from the cavity. Here one can
see that, in the case of one photoetching operation the covered exposed
areas retain their polished finish. If an
overall matt finish is required, the
metal must be etched at least twice.
Multi-stage etching (see also Fig. 26)
results in a particularly good matt
Special techniques
photoetched
2 x photoetched
2 x photoetched and
1x photoetched and
sandblasted (glass beads) sandblasted (glass beads)
spark eroded
50 m
photoetched
50 m
Novodur
Durethan
100 m
100 m
Makrolon
Pocan
100 m
50 m
Durethan
200 m
Novodur
200 m
Novodur
100 m
Makrolon
Durethan
100 m
Pocan
100 m
50 m
mould
temperature
20 C
60 C
500 m
gate
matt
shiny
identical photoetching
steel 1.2713
steel 1.2311
(55 Ni Cr Mo 4)
(40 Cr Mn Mo 7)
matter surface
where walls
are thinner
mould I
mould II
S = 4 mm
S = 2 mm
200 m
10
cavity surface
11
Figs. 28 and 29: Radiator grille made of ABS, showing pronounced weld line. The picture on the right shows the
matt weld line in close-up.
Textured surfaces usually manage to
conceal flow or weld lines to a large
extent. If, however, the textured surface is very sharp-edged, so that the
texture is not very accurately reproduced, pressure will tend to build up
along the weld line, resulting in this
being more accurately reproduced, so
that the weld line will appear to have
a higher matt surface in the finished
part. This problem is demonstrated in
Figs. 28 and 29. This effect can be
reduced by means of a rounded texture.
Fig. 33
Fig. 31
Fig. 32
Charm No.
Ra m
Rz m
PA
Draft angel x
PC
ABS
12
0.40
1.5
0.5
1.0
0.5
15
0.56
2.4
0.5
1.0
0.5
18
0.80
3.3
0.5
1.0
0.5
21
1.12
4.7
0.5
1.0
0.5
24
1.60
6.5
0.5
1.5
1.0
27
2.24
10.5
1.0
2.0
1.5
30
3.15
12.5
1.5
2.0
2.0
33
4.50
17.5
2.0
3.0
2.5
36
6.30
24.0
2.5
4.0
3.0
39
9.00
34.0
3.0
5.0
4.0
42
12.50
48.0
4.0
6.0
5.0
45
18.00
69.0
5.0
7.0
6.0
Fig. 35: Minimum draft x as a function of roughness height for a wall thickness of 2 mm for a spark eroded
texture. For glass fibre filled materials choose one step higher.
13
Fig. 37: Ballpoint pen housing for which the core had a greater draft (0.5 )
than the outside.
Type of moulding
Max. roughness
height
RM/m
Average
roughness
height RT/m
Mean roughness
index
RA/m
Draft
Radiator grille 1
58
49
8.5
Radiator grille II
71
59
11
Degree of mattness
acceptable
Dashboard I
174
152
35
5
better 7
Dashboard II
85
72
20
Table 38
14
Comments
Demoulding problems
in some cases at 5
moulding cycles
at the start
9000
PC GF 40
Literature
Stoeckhert, K.:
Werkzeugbau fr die Kunststoffverarbeitung; Carl Hanser Verlag,
Mnchen-Wien 1979
VDI-Gesellschaft Kunststofftechnik:
Gestalten von Spritzguteilen aus
thermoplastischen Kunststoffen
Richtlinie VDI 2006, Juli 1979
Vorbach, G.:
Anforderungen an das Spritzguteil
aus der Sicht des Entwicklers und
Konstrukteurs, Reihe
Das Spritzguteil, VDI-Verlag
GmbH, Dsseldorf 1980
Christoffers, K.-E.:
Formteilgestaltung, verarbeitungsgerecht, Reihe: Das Spritzguteil,
VDI-Verlag GmbH, Dsseldorf 1980
Bhm, D.:
Oberflchenveredelung von Kunststoffteilen, Reihe Konstruieren mit
Kunststoffen, TAE,
Lehrgang Nr. 5807 1982
15.06.1988 KU 48.476 e