| | I spent a few years as an IMD specialist for a Tekra and Bayer films. The most helpful advice I can offer is to get all parties involved at the very beginning of the design phase- tooling, moulding, mould supplier, mould printer, mould former/trimmed (if not being done in house). Both the part and all the related tooling need to be designed as a team for a good chance of success- retrofitting for IMD after the fact is almost always a recipe for failure. If at all possible, make sure all partners in the project have IMD/IML background.
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For this task, the system will need a low molecular weight (LMW) HALS. If you have 20 - 40 % of mineral fillers, the actually you will not really need to have an organic UV absorber present as the fillers will screen of the harmful UV radiation. In addition to the LMW HALS though, you should consider an addition of a HMW HALS (as this besides the radical scavening effect for UV protection also provides LTHS (long term heat stability)), which LMW HALS cannot do.
"The dark ages", ( or moulding "before sensor technology" and process controls ), all that we could count on, were the known shrinkage rates for each resin as the starting point for your question. With this information, we would have to address "adhesion" with the draft and surface finish of the core and cavity. When we started to mould making urethane resins, much of what we knew, ( or thought we knew ;-) ), really went out the window.Sensor technology and advanced process controls have come a long way, and I suspect the information that Duncan provided you is a really great start for you. I will read this information later myself, but do look forward to the responses from other group members.
If a high number of parts don't release when the mould opens, several process-related variables can be optimized to reduce sticking. If you can measure force to push ejector pins at reasonable cost, this value can help establish better operating conditions, especially using a designed experiment (DOE). It still may not eliminate sticking.
I would go to the companies where the openings are? They have the most to gain so they should want to partner with you. Also, your local SPE chapter should be of some help. I would also go to some of the machine sales folks in your area about putting in a machine on consignment. If you could get 3 machines that would be great. They could let customers bring moulds into the school to sample them with your students and see how their products run in the machines and that would make it a win-win for everyone. Also, if you had three different machine types you could have the students do machine evaluations as part of their study.
Not sure about your part of the country(depressed!! here), but foreign and offshore high oil prices have clearly sunk this economy for 2+ years. No politician, or economist, seems to realize the cross economy effect of 2+ years of 70--90$ /barrel oil on the continuing depression-especially moulding! (petrochemical products). Until this devastating ignorance is broken and oil prices of these monopolies are bridled and defeated, and alternate, or competitive energy or oil sources produced....well,.. better find another more basic commodity market to work in. There is little surplus income to buy petro-chemical based products that are not basic and essential...unless you would work at Global Economy Wages (10-100$/week ..Target") in another country where that labor cost supports life, or.... we eventually deflate US wages and expenses to balance this global inequality. But you can bet oil will not deflate in the hands of monopolies. We could attempt to organize some sort of "block" or "specific market" boycotts.
You are looking for money -- also look for ways to avoid spending money -- good training for industry people. Don't spend too much on equipment -- most university-level stuff is too small. Get students into local factories -- make sure extrusion, blowmoulding and thermoforming are given enough time, as well as injection ... and make sure the students learn about resins (including basic chemistry), testing their properties as related to processing (e.g., melt index), and additives. | |
