compression injection moulding

Transcription

Thermoset injection moulding
Technology and know-how
f integrated
for
i t
t d solutions
l ti
Presentation selection
Agenda
• At a glance
• Special: material and cylinder modules
• Practical: modular machine technology
• Perfect harmony: the
SELOGICA control system
• Application examples
• Summary
© Copyright by ARBURG 2013
2
At a glance
Individually adapted technology
• Efficient combination: durable
hydraulic machine technology
and tailoredthermoset package
p
g
• System solution includes all
necessary features such as
- Three-platen technology with four-tie-bar guidance
and central force application – precision moulding
- Cylinder module with liquid temperature control –
exact temperature control suited to specific material
- Bimetal cylinder – long service life
- Special screw geometry –
processes material without damaging the fibres
3
At a glance
• Optimum design in terms of
application through
- Different sizes with full range of
clamping forces and injection units
- Modular product range –
horizontal as well as vertical machines
- Numerous equipment versions –
such as for processing moist polyester
• Focus: customer
customer-specific
specific
best solution
4
At a glance
• Problem-free expansion with automation
and even complex turnkey projects
•U
Universal
i
l applications
li ti
th
thanks
k tto modular
d l
design – machine can also be used
for thermoplastics processing
5
At a glance
Implementing sequences with ease
• SELOGICA – the perfect, freely
programmable control system
- Convenient sequence programming
with graphical symbols – ideal
for complex sequences
- Patented, immediate plausibility check
during sequence programming
• No special programming
knowledge required
• Full integration of peripherals
such as brush units
6
At a glance
Implementing sequences with ease
• Numerous options
for process optimisation,
monitoring
g and documentation
• High process stability
and reproducibility thanks
to ffunctions
nctions ssuch
ch as
- Adaptive mould-heating circuits
- Compression injection moulding
- Venting
7
At a glance
Exploiting sound practical knowledge
• Extensive know-how in all
areas – application technology
- specifies machines in accordance
with customer-specific requirements
- presents machine and process
technology and advises customers
- supervises detailed trials and tests
- offers assistance with moulded
part and mould design
- designs and evaluates alternative
solution concepts
• Focus: most cost
cost-efficient
efficient solution
8
Special: material
and
a
d cylinder
cy de modules
odu es
Important: adapted injection units
Thermoset processing
calls for
115-75 °C
80-50 °C
- Exact temperature
control in the cylinder
module and mould
- High wear protection
for the cylinder module
against abrasive
substances
- Specially designed
screw geometries
[°C]
400
Injecting
j
g
and
hardening
Plasticising
g
300
200
100
0
9
Special: material
and
a
d cylinder
cy de modules
odu es
• High processing quality
thanks to special cylinder
modules for pourable
p
thermosets and moist polyester
• Exact temperature control to suit
specific material b
by means of
- Liquid temperature control
- Up to four individually connected
temperature zones with separate
temperature control for the feed
10
Special: material
and
a
d cylinder
cy de modules
odu es
• High wear protection
and long service life
thanks to bimetal cylinder
y
• Screw geometries
tailored to
- Optimum material processing
- Minimum return flow during
injection and pressing
• No material backlog thanks
to adjustable play between
screw and nozzle
11
Special: material
and
a
d cylinder
cy de modules
odu es
• Constant shot weights
thanks to mechanical
screw anti-reversing
g lock
• Easy replacement of screw and
cylinder module and short set-up
times thro
through
gh
- Swivelling injection unit
- Central connection of all cylinder
module supply units
12
Special: material
and
a
d cylinder
cy de modules
odu es
Injection
unit
18
22
20
100
25
30
25
170
30
30
290
35
40
35
40
400
45
50
45
© Copyright by ARBURG
50 2013
800
70
Pourable
material
Moist polyester
Injection
volume [cm³]
Injection
pressure [bar]
23
34
31
49
70
59
85
106
144
188
154
201
254
314
318
392
2,500
2,000
2,500
2,000
1,390
2,500
2,000
2,500
2 000
2,000
1,530
2,500
2,000
1 580
1,580
1,280
2,470
2,000
13
Special: material
and
a
d cylinder
cy de modules
odu es
Pourable thermosets
• Delivery condition: granulate form
• Conventional material
f d therefore
feed
th f
possible
ibl
• Optimum material processing
thanks to cylinder module with
- Compression-free screw
with no non-return valve
- Forward-set feed zone for
L/D ratio of approximately 15:1
- Screw-in nozzle with precise
temperature control
14
Special: material
and
a
d cylinder
cy de modules
odu es
Moist polyester (BMC)
• Delivery condition: fibrous,
non-pourable material usually
pre-compressed
p
p
in bails
• Adapted material feed
via special tamping device
therefore req
required
ired
• Of particular interest:
materials
ate a s with
t no
o sshrinkage
age
available
15
Special: material
and
a
d cylinder
cy de modules
odu es
Moist polyester (BMC)
• Minimal destruction of fibres
thanks to cylinder module with
- Compression-free
Compression free screw
with deep screw channel
and vaneless non-return valve
- Forward-set feed zone for
L/D ratio of approximately 12:1
- Optimised feed opening –
prepared for attachment
of an INJESTER tamping device
- Temperature-controlled cold channel
immersion nozzle – entry depth
of 100 mm p
permits short sprue
p
16
Practical: modular
machine
ac e tec
technology
o ogy
Basis: reliable hydraulics
• Simultaneous movements through
hydraulic ALLROUNDER S with
two-pump
p p technology
gy
• Precise moulding, gentle
mould use thanks to
- Three-platen technology with four-tie-bar
guidance and central force application
- Servo-regulated mould movements
• All equipment effectively
counteracts burring and
overfeeding
17
Practical: modular
machine
ac e tec
technology
o ogy
Horizontal to vertical
• Individual adaptations through
- Hydraulic-electric expansion stages
for an energy-optimised
gy p
p
procedure
- Vertical injection unit arrangement up
to and including size 290 injection unit
with granular thermosets
• Vertical and rotary table machines
also available for encapsulation
of inserts with thermoset
18
Practical: modular
machine
ac e tec
technology
o ogy
Thermoset package
Standard basis
with all necessary features
Optional
for expansions that make sense
in individual cases
• Cylinder module for pourable thermosets
• Cylinder heating for processing
thermoplastics
• Blow-out unit with valve and pressure
relief valve
• Interface for temperature control devices
• Six adaptive mould-heating circuits –
optionally expandable
• SELOGICA functional expansions
for venting and compression injection
moulding
• Cylinder module for processing
moist
i t polyester
l
t (BMC)
• INJESTER tamping device
• Hydraulic core pulls such as for
via core pull
• Brush devices for cleaning the mould
19
Practical: modular
machine
ac e tec
technology
o ogy
INJESTER: gentle feeding of moist polyester
• ARBURG tamping devices for
- Automatic material feed – including
of dryy materials and materials
with a high filler content
- Optimum pre-compression of the material
- Minimal residual air and gas
g
in the material
• Result: void-free moulded parts
with a glossy surface
• Choice of design with
piston or conveyor screw
20
Practical: modular
machine
ac e tec
technology
o ogy
Piston feeder device
Technical
features
• Hydraulic stuffing cylinder
• Fully integrated in SELOGICA
machine control system
• Programmable conveying pressure
• 5,, 24,, 41-litre material reservoir
Advantages
• Easy cleaning when the material
is changed
• Refilling
R filli during
d i production
d ti
21
Practical: modular
machine
ac e tec
technology
o ogy
Double screw feeder device – alternative for 170-400 injection unit*
Technical
features
• Two servo-electric plasticizing screws
(conical) running in opposite directions
(conical),
• Conveying pressure can be programmed
and controlled via SELOGICA
• 20-25-litre material reservoir
Advantages
• Different supply forms of materials
can be processed
• Material Feed independent of filling level
• Optimum evacuation of air
• Easy cleaning when the material
is changed
• Refilling during production
* further sizes on request
22
Practical: modular
machine
ac e tec
technology
o ogy
Screw feeder device – alternative from size 800 injection unit upwards
Technical
features
• Servo-electric conveyor screw with large
diameter
• Conveying pressure can be
programmed and controlled via
SELOGICA
• 100-litre material reservoir
Advantages
• Material feed independent of
filling le
level
el
• Refilling during production
• Large material reservoir
23
Practical: modular
machine
ac e tec
technology
o ogy
Accessories
Brush devices and robotic systems
Technical
features
• Complete solution with injection
moulding machine and the necessary
peripherals
• Programmable via SELOGICA
control system
Advantages
• Synchronisation of robot and
machine movements
• Peripherals integrated into the
production process
24
Perfect harmony:
tthe
eS
SELOGICA
OG C co
control
t o system
syste
Reliable venting
• Advantages of venting
- Air and cross-linking gases
can escape
p
- No scorching of the surface
Inject –
80-95% filling
- Complete mould fill
- Void-free
Void free components
Open mould
slightly – vent
• Multiple venting easy to program
• Venting also still possible
in the holding pressure phase
Inject –
100% filling
filli
25
Perfect harmony:
tthe
eS
SELOGICA
OG C co
control
t o syste
system
Universal compression injection moulding
• Advantages of compression
injection moulding
- Improved surface –
prevention of sink marks
- High component strength –
less fibre orientation
- Low distortion
• Direct sprue separation
possible
Close mould to
moulding gap
Injection –
compression
Inject –
injection moulding
100% filling
core retracted
Close mould –
compression
injection moulding
Harden/
meter
Open mould/
eject finished part
26
Perfect harmony:
tthe
eS
SELOGICA
OG C co
control
t o system
syste
• SELOGICA enables the
flexible combination of
Example: simultaneous CI moulding with
main axis and two ancillary axes
- Compression injection moulding axes
and directions
- Force and speed-controlled
- Multiple and multi-level compression
injection moulding
27
Perfect harmony:
tthe
eS
SELOGICA
OG C co
control
t o system
syste
• In addition: individual selection of
the compression injection
moulding
g start conditions
Example: simultaneous CI moulding with
main axis and two ancillary axes
• This enables free programming
of the compression injection
mo lding sequence
moulding
seq ence – can also
be combined with venting
28
Perfect harmony:
tthe
eS
SELOGICA
OG C co
control
t o system
syste
Adaptive mould heating circuits
• Automatic adaptation of the
control parameters to the
control response
p
of the mould
• High temperature stability
in the mould for high
reprod cibilit
reproducibility
• Multiple heating zones can also
be controlled
co t o ed via
a a sensor
se so
29
Perfect harmony:
tthe
eS
SELOGICA
OG C co
control
t o system
syste
Fully integrated peripherals
• Brush devices and robotic
systems can be centrally
programmed
p
g
via SELOGICA
• Time and cost savings thanks to
- Central monitoring of peripherals –
d
allll processes are programmed
as a function of machine movements
- Synchronisation of movements –
short cycle times
- Convenient sequence programming
with graphical symbols – also for
6-axis robot
30
Example application
Automation, six-axis robotic system: Insulating strip
ALLROUNDER 570 S 2200-800
- INJESTER screw compression device for gentle,
continuous material p
preparation,
p
also for
large shot weights
- Completely free part handling with
six-axis robotic system – deburring of
t contour
t
outer
- SELOGICA user interface for six-axis robotic system
Single programming system: Simple, fast, convenient
creation
ti off robotic
b ti sequences
Injection mouldering company is independent –
robotic sequences can be independently programmed
Cavities
1
Part weight
290 [g]
Material
BMC
31
Example application
Automation, six-axis robotic system: Insulating strip
ALLROUNDER 570 S 2200-800
Cycle time
[s]
65
Cavities
1
Part weight
290 [g]
Material
BMC
32
Summary
Technology and expertise – in perfect combination
• Individual, made-to-measure
machine technology – to suit
every
y application
pp
• Maximum process control
thanks to freely programmable
control system
• Complete solutions
from a single source
• Professional advice and support
from the planning stage to
installation on site
33
Technology
gy and expertise
p
– in p
perfect combination
ARBURG GmbH + Co KG
Arthur-Hehl-Strasse
D-72290 Lossburg
Tel.: +49 (0) 7446 33-0
Fax: +49 (0) 7446 33-3365
E-mail: contact@arburg.com
www arburg com
www.arburg.com

compression injection moulding

Transcription

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