DTI H11 In Process Measurements for Polymer Processingresource.npl.co.uk/materials/polyproc/iag/march... · • Compare energy consumption of fluid-assisted injection moulding to

NPL 8th IAG in Polymer Processing and Characterisation 29th March 2006

DTI H11DTI H11InIn--Process Measurements for Polymer Process Measurements for Polymer

ProcessingProcessing

IRCIRCpolymerpolymerengineeringengineering


ContentContent

•• IRC in Polymer Engineering IRC in Polymer Engineering

•• H11 project introductionH11 project introduction

•• ObjectivesObjectives

•• Role of IAGRole of IAG

•• Technical detailTechnical detail

•• OutputsOutputs

•• LinksLinks

IRCIRCpolymerpolymerengineeringengineering


IRC in Polymer EngineeringPart of University of Bradford, School of Eng.Part of University of Bradford, School of Eng.SetSet--up as a centre of expertise for up as a centre of expertise for

polymers,with Universities of Leeds & polymers,with Universities of Leeds & Durham (now also Sheffield)Durham (now also Sheffield)

Research activities include:Research activities include:•• Process monitoring & controlProcess monitoring & control•• Product property and morphology evaluationProduct property and morphology evaluation•• Process developmentProcess development•• Finite element analysisFinite element analysis


Facilities at Bradford

ProcessingProcessing•• 13 Injection moulding machines, including 13 Injection moulding machines, including

22--component moulding, water and gas assistedcomponent moulding, water and gas assisted

•• 15 extrusion lines; 10 single screw, 5 twin screw, 15 extrusion lines; 10 single screw, 5 twin screw, blown and cast film, tube, profile, fibreblown and cast film, tube, profile, fibre

•• 3 3 MicromouldingMicromoulding machinesmachines

•• Solid phase deformation Solid phase deformation –– die drawing, biaxial die drawing, biaxial stretchingstretching

•• Compression moulding Compression moulding -- sheetsheet


Facilities at Bradford

CharacterisationCharacterisation•• AtAt--process spectroscopyprocess spectroscopy

•• RheologyRheology

•• Ultrasound Ultrasound

•• Energy monitoringEnergy monitoring

•• Flow visualisation (birefringence, particle tracking)Flow visualisation (birefringence, particle tracking)

•• Surface characterisation Surface characterisation –– AFM, SEM, AFM, SEM, interferometryinterferometry

SimulationSimulation•• Moldflow, Moldflow, PolyflowPolyflow/Fluent, /Fluent, CompuplastCompuplast, , AbabqusAbabqus, , FlowsolveFlowsolve


H11 ProjectH11 Project

•• Materials measurement projectMaterials measurement project•• DTI (NMS) funded (£225k) DTI (NMS) funded (£225k) –– competitive tendercompetitive tender•• January 2006 January 2006 –– March 2008March 2008•• Run by IRC Polymer EngineeringRun by IRC Polymer Engineering•• Collaborate with UK industryCollaborate with UK industry•• Steered by Industrial Advisory GroupSteered by Industrial Advisory Group

Aim:Aim: to enhance UK industry competitiveness by to enhance UK industry competitiveness by encouraging uptake of inencouraging uptake of in--process measurementsprocess measurements


H11 BackgroundH11 Background

•• UK Polymer industry needs to remain competitiveUK Polymer industry needs to remain competitive•• Effective control requires accurate measurementsEffective control requires accurate measurements•• Complex materialsComplex materials (viscoelastic, process sensitive, (viscoelastic, process sensitive,

multimulti--phase…)phase…)•• 2 previous 2 previous dtidti projects (MMP13, MPM1.4); IAG projects (MMP13, MPM1.4); IAG

recommended further investigation into specific areasrecommended further investigation into specific areas•• Novel processesNovel processes ((micromouldingmicromoulding, fluid assisted , fluid assisted

processing)processing)•• Novel materialsNovel materials (nanocomposites, biopolymers)(nanocomposites, biopolymers)•• Sustainability Sustainability (low energy processing, recycled (low energy processing, recycled

polymers)polymers)


ObjectivesObjectives

•• Enhance competitivenessEnhance competitiveness of UK industryof UK industry•• ReviewReview range of process measurements available, range of process measurements available,

including other industries & speculativeincluding other industries & speculative•• Experimental studiesExperimental studies in key areas, in collaboration in key areas, in collaboration

with industrywith industry•• Develop measurement techniquesDevelop measurement techniques towards industry towards industry

taketake--upup•• Provide Provide outputsoutputs to help guide UK companies to help guide UK companies –– best best

practice, roadmap, industry publications, journals etc.practice, roadmap, industry publications, journals etc.


Industrial Advisory Group (IAG)Industrial Advisory Group (IAG)

•• Formed from across polymer processing industryFormed from across polymer processing industry•• Meet 3 times per annumMeet 3 times per annum•• Steer the project Steer the project –– ensure relevanceensure relevance•• InIn--kind support:kind support:

–– MaterialsMaterials–– Equipment (sensors, processing machinery)Equipment (sensors, processing machinery)–– SoftwareSoftware–– Industrial process trialsIndustrial process trials–– Expert adviceExpert advice


Technical Areas of ResearchTechnical Areas of Research

Task areas defined by measurement techniqueTask areas defined by measurement techniqueDirect relevance to industryDirect relevance to industry

•• Process spectroscopyProcess spectroscopy•• Process ultrasoundProcess ultrasound•• Optical imagingOptical imaging•• Process rheologyProcess rheology•• Process energyProcess energy•• Thermal effectsThermal effects•• Modelling LinksModelling Links


Task 1: Process SpectroscopyTask 1: Process Spectroscopy•• InfraInfra--red, UVred, UV--visvis, Raman, Raman•• Offers Offers molecular specificmolecular specific informationinformation•• Used extensively in pharmaceutical & biomedicalUsed extensively in pharmaceutical & biomedical•• Recent advances have reduced price of systems to affordable Recent advances have reduced price of systems to affordable

levelslevels

C=O str2 %

43.1 %

C=O str 1740 cm-1

O-C=O def 629 cm-1

2 %

43.1 %

C=O str 1740 cm-1

O-C=O def 629 cm-1

monitoring vinyl acetatate content in EVA extrusion


Task 1: Process SpectroscopyTask 1: Process Spectroscopy

ObjectivesObjectives•• Extrusion residence time distributionExtrusion residence time distribution•• Degradation (PET, PVC)Degradation (PET, PVC)•• Colour monitoring, melt vs. product (UVColour monitoring, melt vs. product (UV--visvis))•• Melt temperature fields Melt temperature fields –– UV spectroscopy of UV spectroscopy of

temperaturetemperature--sensitive fluorescent dyessensitive fluorescent dyes


Task 2: Process UltrasoundTask 2: Process Ultrasound•• Ultrasonic wave propagation through polymer is nonUltrasonic wave propagation through polymer is non--intrusive, intrusive,

high speed measurementhigh speed measurement•• Ultrasonic velocityUltrasonic velocity –– density, bulk modulus, pressure and density, bulk modulus, pressure and

temperaturetemperature•• AttenuationAttenuation –– loading and dispersion of additivesloading and dispersion of additives•• High temperature sensors developedHigh temperature sensors developed•• SolSol--gel sensors suited to small scale processesgel sensors suited to small scale processes

0.2 0.4 0.6 0.8 1.0 1.2

0.36

0.38

0.40

0.42

0.44

(b) UT2 : (A) 500mm/s : (B) 250mm/s

PartDetachment

Melt Arrival

AB

0.2 0.4 0.6 0.8 1.0 1.2

0.36

0.38

0.40

0.42

0.44

(b) UT2 : (A) 500mm/s : (B) 250mm/s

PartDetachment

Melt Arrival

AB

US monitoring of injection moulding cavity

Injection time (s)


Task 2: Process UltrasoundTask 2: Process Ultrasound

ObjectivesObjectives•• MicromouldingMicromoulding process analysisprocess analysis•• Water and gas assisted moulding Water and gas assisted moulding –– melt and bubble melt and bubble

propagation, wall thicknesspropagation, wall thickness•• Additives, fillers Additives, fillers –– dispersion, loadingdispersion, loading•• Recycled polymers Recycled polymers –– stability, identification?stability, identification?


Task 3: Process Imaging and Flow Vis.Task 3: Process Imaging and Flow Vis.

•• Broadly describes techniques which use imaging Broadly describes techniques which use imaging systems to monitor processsystems to monitor process

•• Product dimensionsProduct dimensions•• Surface quality, contaminantsSurface quality, contaminants•• RheoRheo--opticaloptical determination of stress and velocity determination of stress and velocity

fields (using windowed cavities)fields (using windowed cavities)•• Rapid development of imaging hardwareRapid development of imaging hardware


Task 3: Process Imaging and Flow Vis.Task 3: Process Imaging and Flow Vis.

ObjectivesObjectives•• CoextrusionCoextrusion instabilitiesinstabilities•• Surface finish of extruded profileSurface finish of extruded profile•• MicromouldingMicromoulding process analysis process analysis –– part filling and part filling and

product dimensionsproduct dimensions


Task 4: Process Task 4: Process RheologyRheology

•• Most widely used process measurement technique in Most widely used process measurement technique in industryindustry

•• SensitiveSensitive but relatively simple to interpretbut relatively simple to interpret•• Simple MFI type or processing rangeSimple MFI type or processing range•• Mainly extrusionMainly extrusion•• Injection moulding air shots (e.g. Injection moulding air shots (e.g. MoldflowMoldflow database)database)•• Has been shown to be sensitive to batch to batch Has been shown to be sensitive to batch to batch

variation, additive loadingvariation, additive loading


Task 4: Process Task 4: Process RheologyRheology

ObjectivesObjectives•• RheologyRheology during sCOduring sCO22 assisted extrusionassisted extrusion•• RheologyRheology of recycled polymersof recycled polymers•• Bleed flow Bleed flow rheometerrheometer developmentdevelopment•• Injection moulding process integrals Injection moulding process integrals -- developmentdevelopment


Task 5: Process EnergyTask 5: Process Energy

•• Simple, nonSimple, non--intrusiveintrusive method of characterisationmethod of characterisation•• Basic measurement to give Basic measurement to give energy/unit massenergy/unit mass•• High frequency gives useful indication of process High frequency gives useful indication of process

statestate•• Particularly useful for injection mouldingParticularly useful for injection moulding•• ServoServo--electric machines found to be more efficient electric machines found to be more efficient

than servothan servo--hydraulichydraulic•• Increased focus on energy reduction (Carbon Trust, Increased focus on energy reduction (Carbon Trust,

euRECIPEeuRECIPE))


Task 5: Process EnergyTask 5: Process Energy

ObjectivesObjectives•• Compare energy consumption of fluidCompare energy consumption of fluid--assisted assisted

injection moulding to conventionalinjection moulding to conventional•• Compare methods of mould temperature control Compare methods of mould temperature control

(conformal cooling, pulsed cooling)(conformal cooling, pulsed cooling)•• Supercritical fluid assisted extrusionSupercritical fluid assisted extrusion

Injection

PackingScrewback

Cooling

Clamp open, part ejection, clamp close & lockover


Task 6: Thermal EffectsTask 6: Thermal Effects

•• Temperature is a Temperature is a critical parametercritical parameter in polymer in polymer processingprocessing

•• Polymers highly Polymers highly temperature dependenttemperature dependent (viscosity, (viscosity, degradation, degradation, crystallinitycrystallinity etc..)etc..)

•• Difficult property to measureDifficult property to measure•• Range of techniquesRange of techniques: TC, infra: TC, infra--red, ultrasound, red, ultrasound,

thermal imaging, TC grid, fluorescing dyesthermal imaging, TC grid, fluorescing dyes•• Data can assist screw, die, mould Data can assist screw, die, mould design, process design, process

efficiencyefficiency•• Useful for validation of simulation codeUseful for validation of simulation code


Task 6: Process Thermal EffectsTask 6: Process Thermal Effects

ObjectivesObjectives•• Full 2D temperature field measurement in extrusionFull 2D temperature field measurement in extrusion•• Effect of temperature field on the foaming processEffect of temperature field on the foaming process•• Injection moulding mould temperature control Injection moulding mould temperature control ––

measurement of part cooling (IR sensor)measurement of part cooling (IR sensor)

170

190

210

230

-20 0 20

Radial Position (mm)

Mel

t Tem

pera

ture

(°C)

170

190

210

230

-20 0 20

Radial Position (mm)

Mel

t Tem

pera

ture

(°C)

Barrier screwBarrier screw Single Single flightedflighted screwscrew


Task 7: Modelling LinksTask 7: Modelling Links

•• Modelling benefits from Modelling benefits from accurate measurementsaccurate measurements•• To measure effects not yet included in model or to To measure effects not yet included in model or to

validate simulation codevalidate simulation code•• Difficult simulate thermally dominated processesDifficult simulate thermally dominated processes•• Aim to use process measurements to feed models Aim to use process measurements to feed models •• Run Run case studiescase studies in injection moulding and extrusion in injection moulding and extrusion

(collaborations with (collaborations with MoldflowMoldflow, , PolyflowPolyflow, , CompuplastCompuplast))


Project WebsiteProject Websitewww.polyeng.com/h11www.polyeng.com/h11

Portal for project information, contact details, linksPortal for project information, contact details, linksSecure area for download of presentations, reportsSecure area for download of presentations, reports


Project LinksProject Links

•• NPL Measurement programmesNPL Measurement programmes•• DTI MNT High Impact InvestmentDTI MNT High Impact Investment•• Yorkshire Forward Micro & Yorkshire Forward Micro & NanoNano moulding centremoulding centre•• MuPPMuPP –– 8 universities (EPSRC)8 universities (EPSRC)•• InIn--Process Measurements Network (EPSRC)Process Measurements Network (EPSRC)•• FluidFluid--assisted moulding (Bradfordassisted moulding (Bradford--Swansea)Swansea)•• Institute of MaterialsInstitute of Materials•• VinylSUMVinylSUM network (PVC sustainability)network (PVC sustainability)


Project TeamProject Team

•• Prof. Phil CoatesProf. Phil Coates•• Dr. Adrian KellyDr. Adrian Kelly•• Dr. Andrew DawsonDr. Andrew Dawson•• Dr. Mike Dr. Mike WoodheadWoodhead•• Dr. Elaine BrownDr. Elaine Brown•• Dr. Rob SparesDr. Rob Spares•• Dr. Mike Dr. Mike MartynMartyn•• Dr. Tim GoughDr. Tim Gough•• Dr. Ben WhitesideDr. Ben Whiteside•• Emma Burton

Supporting StaffSupporting Staff

•• Prof. Howell EdwardsProf. Howell Edwards•• Prof. Prof. KirillKirill HoroshenkovHoroshenkov•• Dr. Dr. HaileHaile RajamaniRajamani•• Dr. Peter Dr. Peter OlleyOlley•• Dr. John SweeneyDr. John Sweeney•• Dr. Ian Dr. Ian ScowenScowen

Emma Burton


Summary CommentsSummary Comments

•• H11: polymer process measurementsH11: polymer process measurements•• January 06 January 06 –– March 08March 08•• Key feature is industrial collaborationKey feature is industrial collaboration•• Additions to IAG welcome Additions to IAG welcome –– please contact us for please contact us for

more informationmore information

www.polyeng.com/h11www.polyeng.com/h11

Documents

DTI H11 In Process Measurements for Polymer Processingresource.npl.co.uk/materials/polyproc/iag/march... · • Compare energy consumption of fluid-assisted injection moulding to