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Li Q.,Lehigh University | Coulter J.P.,Lehigh University | Beaumont J.P.,Beaumont Technologies Inc. | Rhoades A.M.,Pennsylvania State University
Annual Technical Conference - ANTEC, Conference Proceedings | Year: 2014

For some time now the effects of runner-based shear imbalances on melt flows during polymer molding processes have been studied and found to be problematic, even in cases where mold cavities are naturally balanced as traditionally defined. In such instances, melt rotation technology has been applied on many occasions to accommodate resulting cavity filling imbalances as well as shrinkage and warpage issues. In the present study, this approach was taken a step further with the goal of exploring affiliated product quality variations that exist as an extension of the imbalanced polymer melt flow problem. Molding trials were conducted with and without melt rotation using several types of polymers, and the resultant effects on final product physical, thermal and mechanical properties were explored. When this was done, it was found that important product quality parameters such as crystallinity and tensile modulus can vary significantly throughout conventionally molded products and be dramatically altered by the implementation of melt rotation technology. Specimens taken from product regions associated with higher melt flow shear levels exhibited higher crystallinity levels as well as higher tensile moduli. This supports the concept of melt rotation adoption for a broader range of problems extending far beyond cavity fill balancing alone. Copyright © (2014) by the Society of Plastics Engineers All rights reserved.


Beaumont J.,Beaumont Technologies Inc.
Plastics Technology | Year: 2012

Beaumont Technologies has developed the ''Therma-flo' Moldometer in response to a growing need for plastic melt characterization for injection molding. This new method characterizes the injection moldability of a plastic material through a wide range of mold geometries and processes using an actual injection molding machine. It significantly improves on the ability of a mold or part designer to make informed decisions when selecting or designing for a given plastic material. It also helps the injection molder to determine whether a particular machine will be capable of filling that mold. It is necessary to consider the application and the manufacturability requirements of a material during the plastic material selection process. One of the more critical considerations when selecting a plastic material for manufacturability involves trying to determine how it will flow in an injection mold.


Hoffman D.,Beaumont Technologies Inc. | Beaumont J.,Beaumont Technologies Inc.
Plastics Technology | Year: 2013

Injection molding process methodologies have evolved over a period of time from a seat-of-the-pants process to a more structured approach. One of the important process parameters to establish and record for any injection molded part is its injection or fill time. Fill time is an indication of how fast the plastic is injected into the mold. Fill time affects how much shear heating and shear thinning the plastic experiences, which affect the material's viscosity, the pressure and temperature of the plastic inside the cavities, and the overall part quality. An established fill time for a given mold needs to live with the mold forever and should be allowed to vary only slightly. Molders use several methods to establish a fill time, some of which start with evaluating the fill time used on similar parts and molds and mold-filling simulation.


Hoffman D.A.,Beaumont technologies inc.
Plastics Engineering | Year: 2014

Depending on the wall thickness, the material being molded, the process conditions, the cavity orientation, gate location, and a few other factors, gravity may finally have a chance to work its magic on the thick walled plastic parts, the first example will be the original mold that John Beaumont designed and built to study the effect of shear on material properties and the resulting mold filling variations. A second gravity example comes from an eight-cavity mold used to produce thick-walled screwdriver handles. There was more plastic at the bottom than at the top of the four bottom cavities. Again the plastic came out of the gate and had no steel around it to flow against and stick to. Simulation was run again with the new gravity orientation, and the results correlated well with the actual short shots.


Hoffman D.A.,Beaumont Technologies Inc.
Plastics Engineering | Year: 2015

Experts suggest that processors need to apply an understanding of plastic flow when marking mold cavities to get more than cavity IDs from given cavity IDs. Cavity identification markings (cavity IDs) are used to distinguish one cavity from another. This is important to help provide traceability for things, such as quality, mold maintenance issues, and short shot imbalance data. The first important point that needs to be considers concerns the location of the ID markings within the cavity itself. a second important point to make is to avoid putting cavity IDs on ejector pins.


Hoffman D.A.,Beaumont Technologies Inc.
Plastics Engineering | Year: 2015

As people begin to understand more about plastic flow and the variables in the pressure drop equation, they begin to understand how small differences can have a big impact on the molding process and part quality. Many times those small differences are found in the melt delivery system, whether it be a hot runner or cold runner or a combination of the two. When designing special features into the molds the designer must design puller pins such that they do not restrict the main flow path. Where appropriate, he must add the particular feature to both sides of the sprue and at each side of the preceding intersection.


Patent
Beaumont Technologies Inc. | Date: 2013-04-01

A material characterization system and method for quantifying the characteristics of a flowing thermoplastic material is presented. The system comprises a tool comprising first and second tool halves, a plurality of flowing material characterization channels, and a feed runner. The tool is at a temperature that causes phase changes from fluid to solid in at least a portion of the characterized material and enables solidification of the material in the flowing material characterization channels. The feed runner is connectable to a single flowing material characterization channel. The tool is adjustable to disconnect the feed runner from one flowing material characterization channel and connect it to different flowing material characterization channels. A sensor quantifies the characteristics of the material under different flow conditions. The method comprises measuring the material characteristics as it flows through the flowing material characterization channel at multiple flow rates and repeating measurements for different flowing material characterization channels.

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