Rubber Molding Asia-Shortest Cycle

Dr.
Hans-Joachim Graf
Rubber Molding ASIA 2014
Determination
of the
Shortest Possible
Vulcanization Time
in
Rubber Injection Molding
TechnoBiz – Asia
March 2014
Dr. Hans-Joachim Graf Bangkok, Thailand
Introduction
Determination of shortest Porous Point
possible cycle time in Cycle Time and Porous Point
Injection molding Operating Window
Shortest Vulcanization Time
Summary
 Content of this presentation

 Introduction
 Operating window
 Porous point of different Rubbers
 Vulcanization time and physical properties
 Experiments guiding to shortest molding time
 Summary
Dr. Hans-Joachim Graf 3

Introduction
Porous Point
Finding of the Cycle Time in Cycle Time and Porous Point
Injection Molding Operating Window
Summary
 The vulcanization time is Dependent from:

 Mold temperature
 Compound cavity entrance temperature
 Thickness of the part due to restricted
temperature conductivity
 Determined by trials
 No simulation tool, because of lack of
precision
 Physical properties must be evaluated

Introduction
Porous Point
Summary
 Heat rise in injection unit

Reason for heat rise – shortening of the vulcanization time
Temperatur
e
End of injection
Time
Introduction
Porous Point
Summary

Introduction
Porous Point
Summary
Regression equations to describe the injection molding

process
 TMplast = f (VSc, PStau, Tcyl)
 TMinj = f (Vinj, TRunner, TMplast)
 tvulc = f (TMold, Vcure, TMinj)

Consequently
Consequentlythe
thetime
timeisisaaresponse
response(and
(andnot
nottaken
takenas
asaa
factor
factoranymore)
anymore)because
becauseititisisdependent
dependentfrom
fromTMold
TMoldand
and
TMinj
TMinj

Introduction
Porous Point
Summary
Regression equations to describe the injection molding

process
 tvulc = f (TMold, Vcure,V inj , VSc, PStau, Tcyl)
In
Incase
casethat the TTmold
thatthe is a constant as well as the compound
mold is a constant as well as the compound
((VVcure ))vulcanization
vulcanizationtimetimedepends
dependson
onfour
four[[44!]!]factors.
factors.
cure
The
Thedifficulty
difficultyis,
is,totodetermine
determinethe
thevulcanization
vulcanizationtime
timewhich
which
corresponds
correspondstotothe
themold
moldtemperature
temperature

Introduction
Porous Point
Summary
 Vulcanization of rubber in injection molding happens under

pressure of 250 bar – 450 bar
 All volatiles are compressed and probably expand if mold opens
and pressure is reduced to atmospheric pressure.
 The definition of the porous point:

Modulus of rubber, which just prevent pores.
 Question:
What is the correlation between porous point and physical
properties?

Introduction
Porous Point
Summary
 In this work to evaluate the cycle time 3

WOCO compounds used:
 NBR 1 – 51D50 (polar)
 NR 1 – 51A45 (slightly polar)
 EPDM 1 – 51M50 (none polar)
 All 3 materials are sulphur cured.
 The test mold: rectangular cup

Introduction
Porous Point
Summary
 1. Trial
 Vulcanization time until none pores observed
 2. Trial
 None pores time +20 sec
 Measurement of
 Crosslink density with equilibrium swelling (Flory
Rehner)
 Compression set

Introduction
Porous Point
Summary Source: Putera Thesis

Introduction
Porous Point
Summary Source: Putera Thesis

Introduction
Porous Point
Summary
 Conclusion from compression set measurement

(in conjunction with the other tests):
 NBR1 tpores + 45 sec

 NR1 tpores + 55 sec
 EPDM1 tpores + 40 sec

Introduction
Porous Point
Summary
force
EPDM
NBR
NR
t90 time

Introduction
Porous Point
Summary
 Operating window in injection molding:

The “Operating Window” gives a view about
process limits due to:
 Machine design
 Plastification Unit
 Nozzle length and diameter
 Mold design
 Runner length, diameter,
 Gate cross section
 Length to total flow path
 Processing parameter
 Plastification parameter setting
 Mold temperature
 Compound Cure
 Part design
 Pressure loss due to flow until cavity is filled

Introduction
Porous Point
Summary
TP Moulding Rubber Molding

Operating window: comparison with IM-moulding of rubber compound
Scorch
Underfill

Introduction
Porous Point
Summary Source: Graf, DESMA
 Lines are showing

the injection time at
Pressure loss (bar)
800
Max. Injection Pressure various pressures at
different mold
temperatures.
 No scorch during
700 filling
 The maximum
190 180 170C hydraulic pressure
Mold temperature (resp. specific
600 pressure) results the
0 10 15 shortest possible
time (sec) injection time.

Introduction
Porous Point
 Lines are showing the

scorch index at
50 Mold temperature various mold
190 180 170 C temperatures.
Scorch Index (%)
 The maximum allowed

scorch index is
25 defined at 20%
prevulcanization.
0
0 10 15
time (sec)

Introduction
Porous Point
 Crossing points from

Mold Temperature (Grad C)
previous Curves are

now transferred to a
Mold Temperature /
190
Time Diagram
 Both curves showing
the operating window
180
170
0 10 15
time (sec)
Introduction
Porous Point
 Dotted Line shows

in addition the 90%
Tcmpd 95C state of cure.
 This Line is parallel

190 to scorch index
line if activation
energy of cure is
similar for scorch
180 and vulcanization
time
170
0 10 15 2 3
time (sec) time (min)
Introduction
Porous Point
 In case of compound
temperature variation
the line will shift.
Tcmpd 105C  For increase of
compound temperature
Line will schift to shorter

190 95C times.
 The operating window
will also move to shorter
times
180
170
0 10 15 2 3
Introduction
Porous Point
 Stages of Processing.
 Shortest possible cycle
time at maximum mold
Tcmpd 105C and compound
temperature
 Best cycle time in an

190 95C operating window, which
fits demands of SPC due
to machine repeatability
 Safe cycle time, which is
recommended, if
180 machine repeatability is
questionable.
170
0 10 15 2 3
Introduction
Porous Point
Summary
 Statistic Experimental Design (DoE) procedure

 Factor 1 = TM Mass Temperature
 Factor 2 = Tmold Mold Temperature
 Factor 3 = vinf Injection Speed
(little influence EPDM, but big with NBR)
 3 Factor Design,
 but detect the porous point,
 add the appropriate time or increase stepwise
Design-Expert® Software
Factor Coding: Actual
 mold t + taddition swell
porous X1 = A: T mass
X2 = B: T mold
Actual Factors 220

C: V inj = 20.00
D: t vulc = 75.00
Name Units Low High

210
200
swell
T mass °C 95 115 190
180
T mold °C 160 200

200.00
V inj mm/sec 15 25 192.00
184.00 115.00
110.00
176.00
B: T mold 105.00
168.00 100.00
160.00 95.00 A: Tmass

Introduction
Porous Point
Summary
 Vulcanization to meet physical properties

 Porous point of rubbers is a good orientation, if the correlation
between
 Crosslink density and physical properties are known
 Croslink density can be measured with equilibrium swelling test
precisely
 Physical properties with the standard methods in rubber industry
 As a rule of thumb the following can be conluded:

 NR + 55 sec (for 10 mm thickness)
 EPDM / NBR + 40 sec for 10 mm thickness)
 This is in line with experience

Introduction
Porous Point
Summary
 Statistic Experimental Design (DoE) procedure

 Factor 1 = TM Mass Temperature
 Factor 2 = Tmold Mold Temperature
 Factor 3 = vinf Injection Speed
(little influence EPDM, but big with NBR)
 Factor 4 = tvulc vulcanization time, but dependent from factor 2
Design-Expert® Software
Factor Coding: Actual
swell
X1 = A: T mass
X2 = B: T mold
Name Units Low High
Actual Factors 220
C: V inj = 20.00
D: t vulc = 75.00
210
T mass °C 95 115
200
swell
T mold °C 160 200 190
180
V inj mm/sec 15 25
200.00
t vulc sec 30 120 192.00

115.00
184.00
110.00
176.00
B: T mold 105.00
168.00 100.00
160.00 95.00 A: Tmass

Introduction
Porous Point
Summary
 Post cure operation

 For parts with even higher thickness post cure operation is
saving machine time
 Vulcanization time must succeed the porous point!
 It is recommended for compounds based on NR
with an early porous point
and high wall thickness
 Post cure is a pressure less vulcanization, but there is no negative

effect on physical properties because the starting modulus is high
enough to prevent pores.

Introduction
Porous Point
Summary
 Conclusion
 Optimum cycle time depends on temperatures in injection
molding:
 Compound cavity entrance temperature
 Mold temperature
 None porous point depends on compound modulus at a time,

when the vulcanization has progressed
 Porous point is different for each compound / polymer
 With the knowledge about the correlation between porous point
an physical properties a optimum cycle time can be determined.
 Introducing the vulcanization time as a factor, the shortest
vulcanization time can be determined with 9 experiments

Introduction
Porous Point
Vulcanization to performance
Summary
 Thank you for attention and your comments

Rubber Molding Asia-Shortest Cycle

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Dr.

 Content of this presentation

Dr. Hans-Joachim Graf 3

 The vulcanization time is Dependent from:

Dr. Hans-Joachim Graf 4

 Heat rise in injection unit

Dr. Hans-Joachim Graf 6

Regression equations to describe the injection molding

 TMinj = f (Vinj, TRunner, TMplast)

 tvulc = f (TMold, Vcure, TMinj)

Dr. Hans-Joachim Graf 7

Regression equations to describe the injection molding

 tvulc = f (TMold, Vcure,V inj , VSc, PStau, Tcyl)

Dr. Hans-Joachim Graf 8

 Vulcanization of rubber in injection molding happens under

 The definition of the porous point:

Dr. Hans-Joachim Graf 9

 In this work to evaluate the cycle time 3

 The test mold: rectangular cup

Dr. Hans-Joachim Graf 10

Dr. Hans-Joachim Graf 11

Dr. Hans-Joachim Graf 12

Dr. Hans-Joachim Graf 13

 Conclusion from compression set measurement

 NBR1 tpores + 45 sec

Dr. Hans-Joachim Graf 14

Dr. Hans-Joachim Graf 15

 Operating window in injection molding:

Dr. Hans-Joachim Graf 16

TP Moulding Rubber Molding

Dr. Hans-Joachim Graf 17

 Lines are showing

Dr. Hans-Joachim Graf 18

 Lines are showing the

 The maximum allowed

Dr. Hans-Joachim Graf 19

 Crossing points from

previous Curves are

 Dotted Line shows

 This Line is parallel

Line will schift to shorter

 Best cycle time in an

 Statistic Experimental Design (DoE) procedure

 mold t + taddition swell

Actual Factors 220

Name Units Low High

T mold °C 160 200

V inj mm/sec 15 25 192.00

Dr. Hans-Joachim Graf 24

 Vulcanization to meet physical properties

 As a rule of thumb the following can be conluded:

 This is in line with experience

Dr. Hans-Joachim Graf 25

 Statistic Experimental Design (DoE) procedure

t vulc sec 30 120 192.00

Dr. Hans-Joachim Graf 26

 Post cure operation

 Post cure is a pressure less vulcanization, but there is no negative

Dr. Hans-Joachim Graf 27

 None porous point depends on compound modulus at a time,

Dr. Hans-Joachim Graf 28

 Thank you for attention and your comments

Dr. Hans-Joachim Graf 29