Institute of Plastics Processing IKV

Aachen, Germany

Institute of Plastics Processing IKV

Aachen, Germany
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Hopmann C.,Institute of Plastics Processing IKV | Theunissen M.,Institute of Plastics Processing IKV
Annual Technical Conference - ANTEC, Conference Proceedings | Year: 2016

Gas-And water-Assisted injection molding (GAIM, WAIM) can be used to produce hollow plastics parts. Previous research showed that the thermal properties of gas and water have a large influence on part properties and the formation of part defects. A new approach is to use atomized spray to adjust the thermal properties of the process fluid to the needs of the process and used material. The study will determine the effect of water percentage on the cooling effect of the atomized spray and the resulting part properties. High speed imaging will show effects of water coagulation on the part cooling.


Hopmann C.,Institute of Plastics Processing IKV | Grumer B.,Institute of Plastics Processing IKV
Annual Technical Conference - ANTEC, Conference Proceedings | Year: 2016

During the product development of injection molded parts, simulation software is used to predict process parameters and part quality during the production process. The integration of process disturbances into the injection molding simulation software leads the way to a prediction of the quality variation. Thus, the optimization regarding a robust process parameter set already during early stages of the product development process is possible.


Michaeli W.,RWTH Aachen | Michaeli W.,Institute of Plastics Processing IKV | Neuss A.,Multi Component Technology Working Group | Grundler M.,Multi Component Technology Working Group | Wunderle J.,Multi Component Technology Working Group
Kunststoffe International | Year: 2010

A new hybrid injection molding process developed at the RWTH Aachen University enables the production of complex plastic parts with integrated metallic conductors for electronics applications in short process chains. The hybrid technology combines the benefits of the two materials, metal and plastic, in one component. The object serves a pair of sports eyeglasses whose lenses can be heated by a conductor and hence kept fog-free. In this way, the flowing current can be made indirectly visible through the heat being given off. Based on the multi-component injection molding process, the mold technology is designed such that the component can be produced in a compact manufacturing cell. In order to tailor the machine and mold engineering to the hybrid multi-component process, an injection molding machine is expanded to include a unit for the processing of the metal alloy with its low melting temperature.


Hopmann C.,RWTH Aachen | Hopmann C.,Institute of Plastics Processing IKV | Theunissen M.,Fluid Injection Technology Working Group
Kunststoffe International | Year: 2013

The PIT offers the possibility of saving significant amounts of material compared with the conventional fluid injection technology. With this process, the cycle time is also shortened due to the lower residual wall thicknesses. The additional design freedom in the production of non-circular cross-sections opens up new avenues for establishing new applications in the form of design parts on the market. Results from the latest research suggest that the W-PIT, in particular, produces outstanding inner surface finishes and also allows materials to be processed going beyond the possibilities of the conventional water injection technology.


Siegbert R.,Chair for Computational Analysis of Technical Systems | Yesildag N.,Institute of Plastics Processing IKV | Frings M.,Chair for Computational Analysis of Technical Systems | Schmidt F.,Foundry Institute | And 8 more authors.
International Journal of Advanced Manufacturing Technology | Year: 2015

Individualized production, which is a major goal of many high-wage countries, describes a production process in which all elements of a production system are designed in such a way that they enable a high level of product variety at mass production costs. This paper demonstrates recent advances in the individualized production with die-based manufacturing processes, namely high-pressure die casting and plastics profile extrusion. Within these application areas, the chosen approach aiming at individualized production is based on the use of numerical die and process design. The design procedure relies on numerical process simulations based on a nonlinear optimization library and a spline-based geometry kernel. All components interact automatically without requiring user interaction; thus, a completely independent optimization cycle can be achieved. The numerical optimization helps to reduce—or even eliminate—the so far very characteristic manual reworking steps of an original die or process design. These reworking steps are a major cost factor when it comes to individual production. Their abolishment through the presented numerical approaches therefore represents a large step towards the concept of individualized production. © 2015 Springer-Verlag London


Michaeli W.,Institute of Plastics Processing IKV | Allert S.,Institute of Plastics Processing IKV
Kunststoffe International | Year: 2010

IKV has compared different cooling concepts for sliding cores in injection molds and made recommendations for their design. First a test part is constructed and designed to allow the effect of the installation position to be considered in isolation. For both installation positions, three differently cooled exchangeable cores are used. This channel profile uses a first core of conventional tool steel and a second core of a highly thermally conductive copper alloy. The different exchangeable cores are systematically compared in injection molding trials. In the trial mold, four sensors are arranged in a straight line, two of which lie in the sliding core and two in the nozzle-side mold platen. It is found that the temperature difference during mold opening rises, since the sliding core and stationary mold platen are not in contact, and the heat conducted to the surface of the sliding core is not sufficiently rapidly removed by convection.


Michaeli W.,Institute of Plastics Processing IKV | Michaelis I.,Institute of Plastics Processing IKV | Gries T.,RWTH Aachen | Deichmann T.,RWTH Aachen | And 2 more authors.
Kunststoffe International | Year: 2010

A partially resorbable polymer composite textile, made by compression molding is being developed for small intestine replacement in people suffering from short bowel syndrome. The composite structure will consist of a non-resorbable textile fabric coated with a biodegradable polymer. The job of the knitted textile structure will be to permanently withstand the mechanical stresses induced by peristalsis. It will also provide permanent support for small intestine neoplasms. To prevent leakage of intestinal fluid and escape of bacteria from the digestive tract into the surrounding tissues, the implant will have to be leakproof initially. Once the small bowel tissue re-forms, it will take on the task of sealing the textile and the polymer will no longer have to provide this function. The pores will have to be uniformly distributed across the textile specimen. It is possible, however, that strong flow processes on the part of the molten plastic will adversely affect the distribution.


Hopmann C.,Institute of Plastics Processing IKV | Becker S.,Institute of Plastics Processing IKV
Kunststoffe International | Year: 2012

To sum up, online ultrasonic analysis of gas and water-assisted injection molding permits assessment of the process as well as registration of the residual wall thickness. It can reduce costs for downstream offline testing processes. If malfunctions occur, ultrasonic analysis permits a rapid intervention in the process.As a result, reject rates in production can be clearly reduced. With increasing demands for documentation of the manufacturing process, ultrasonic measurement permits 100 % control of all parts more cost effectively than with other offline measurement methods. © 2012 Carl Hanser Verlag, Munich, Germany.


Michaeli W.,Institute of Plastics Processing IKV | Preller F.,Institute of Plastics Processing IKV
Journal of Polymer Engineering | Year: 2010

The 4-point bending tests for determining the failure curve of biaxial compression was conducted. A combination of standard carbon fibers and an epoxy resin system was used. The equality of the stress state of the test lamina in direction of thickness is higher related to the total thickness of the specimens. A total thickness of 6 mm was used with a thickness of the test lamina of 0.25 mm. The transmission of force of the 4-point-bending was realized by hydraulic cylinder. It traverses the inner points of force transmission load controlled while the outer points are the fixed bearing. The contact areas of the testing device are separated into small sections that can freely be moved in direction of bending. The fiber failure fractures typically do not go orthogonally from side to side of the specimens but rather at an angle of about 100. Fiber failure and inter fiber failure occur in the test lamina as expected.


Lammert N.,RWTH Aachen | Lammert N.,Institute of Plastics Processing IKV | Nikoleizig P.,RWTH Aachen
Kunststoffe International | Year: 2014

The above-described high-performance molds and the resulting trends illustrate the position of the mold manufacturer as a central component of injection mold manufacturing. In a changing economic environment, the industry must resolve the conflict described above between small and large-series production of plastic parts. Despite the excellent technical level that has long been achieved, mold manufacturers still manage, through a large bandwidth of solution approaches, to grow and respond to changing demand situations. Though high-performance molds are characterized by different technical properties, they still have one feature in common: they optimally meet the customer's demands. At many points, it is found that efficient injection molding production can only be ensured through the interplay of the players involved and, first and foremost, of all the required technical fields, such as plastic and steel processing, automation, control, etc. This will be promoted by further innovations and will characterize the injection mold production of the future. © Carl Hanser Verlag, Munich.

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