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The “Right” machine for
the job?
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Introduction
The Tool
The Material
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But which Machines?????????
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LegalRequirement
MSDS
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Moulding
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What is Polycarbonate?
CC
CHCH
CHCH
33
33
CC
OO
nn
OO OO
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Molecular Weight Vs. Strength
Molecular weight Molecular weight (x10 )(x10 )
Te n
s ile
str
e ngt
h
Te n
s ile
str
e ngt
h
(kg /
c m2 )
(kg /
c m2 )
Izod
imp
act
stre
ngt
h
Izod
imp
act
stre
ngt
h (k
g cm
/cm
)(k
g cm
/cm
)800800
700700
600600
100100
5050
0022 2.52.5 3.03.0
4
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Molecular Weight Vs. Flow
Molecular weightMolecular weight
Flo
w V
alu
e F
low
Val
ue
(10
m/s
ec)
(10
m/s
ec)
1.51.5
22
33
44
55
66
1010
20,00020,000 25,00025,000 30,00030,000
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Hopper
Screw & Barrel
Nozzle
Clamping unit
Injection Moulding
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Calculated by multiplying the projected area of the cavity (cavities), including runner system by the maximum internal pressure (hold pressure).
Clamping Pressure
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• ABS 0.45 to 0.65 T/cm2
• LCP 0.75 to 0.8 T/cm2
• PA 0.65 to 0.75 T/cm2
• PBTP 0.65 to 0.75 T/cm2
• PC 0.5 to 0.8 T/cm2
• PE 0.15 to 0.55 T/cm2
• PETP 0.65 to 0.75 T/cm2
• PMMA 0.45 to 0.75 T/cm2
• POM 0.85 to 1 T/cm2
• PP 0.15 to 0.55 T/cm2
• PPS 0.3 to 0.6 T/cm2
• PS 0.3 to 0.5 T/cm2
Clamping Pressure
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Injection Unit
Hopper
Screw & Barrel
Nozzle
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Screw Design
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Screw Types
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Screw Tangential Speed-M/S
• ABS 0.2 (GR,FR) - 0.3• ETPV 0.2• PA 0.15 (GR,FR) – 0.4• PBTP 0.2 (GR,FR) – 0.3• PC 0.2 (GR,FR) - 0.3• PE 0.5 – 0.6• PETP 0.15 (FR) – 0.20• PMMA 0.2 (ST) – 0.3
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• POM 0.15 (GR,ST) – 0.3• PP 0.3 (GR) – 0.6• PPA 0.15• PPS 0.15• PS 0.3 (HI) - 0.6• PVC <0.1• SAN 0.3• TPC-ET <0.2• TPUR <0.15
Screw Tangential Speed-M/S
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Beware: High speed = high heat (through shear).High speed = high abrasionwith filled Materials.
Beware: High back pressure increases shear (temperature) and cycle time but not necessary melt quality.
Screw Speed Calculation
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Melt Viscosity characteristics
280c280c
300c300c
320c320c
Shear Rate (Sec )Shear Rate (Sec )
Mel
t vi
scos
ity
(poi
se)
Mel
t vi
scos
ity
(poi
se)
1010 1010
1010
1010
33
33
44
44
-1-1
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Pressure Vs. Flow
PPHPPHPA 6PA 6
GPPSGPPS
PPCPPC
HDPEHDPELDPELDPE
POMPOMABSABS
PolycarbonatePolycarbonate
Injection PressureInjection Pressure
Sp
iral
flo
w le
ngt
h (
cm)
Sp
iral
flo
w le
ngt
h (
cm)
4040 140140 (Kg/cm G)22
4040
8080
120120
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100
1000
10000
350 340 320 300 280
Moulding temp (deg.C)
Lo
wer
ing
of
mo
l. w
t. (
Mv)
35 min35 min
20 min20 min
5 min5 min Res
iden
ce t
ime
Res
iden
ce t
ime
Temp. Vs. Molecular Weight
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Toughened Nylon 6.6
Hold-on-time
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Temperature Profiles
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The right Melt temperature The right Melt quality
Conclusion
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A Polymer for Every Application
