Acrylic resins

TECHNICAL MANUAL

Injection Moulding Resins

CONTENTS

INTRODUCTION
ALTUGLAS GENERAL CHARACTERISTICS OF ALTUGLAS THE RANGE APPLICATIONS

PRODUCT FEATURES
PROCESSABILITY HEAT RESISTANCE WEATHERABILITY MELT FLOW OF ALTUGLAS GRADES COMPUTER ANALYSIS DATA

MOULD DESIGN
MOULD DESIGN

9 19

INJECTION MOULDING PROCESS

EQUIPMENT CONSIDERATION MATERIAL HANDLING CONSIDERATION PROCESSING TEMPERATURES PRESSURE AND INJECTION SPEED

ORIENTATION AND STRESS

ORIENTATION AND STRESS ASSESSMENT OF STRESS

24

POST MOULDING OPERATIONS

POST-MOULDING OPERATIONS

25 27

FINISHING OPERATIONS
DECORATION MACHINING POLISHING ASSEMBLY

MOULDING DEFECTS
TYPICAL EXAMPLES OF MOULDING DEFECTS INJECTION MOULDING TROUBLESHOOTING GUIDE

28

HEALTH AND SAFETY PRECAUTIONS

HEALTH AND SAFETY PRECAUTIONS

32

INTRODUCTION

ALTUGLAS
Altuglas is the registered trade name for Altuglas International products made of polymethylmethacrylate (PMMA) in the form of granules for injection-moulding and extrusion. Altuglas acrylic resin has excellent resistance to many chemicals including solutions of inorganic acids and alkalis and aliphatic hydrocarbons such as VM & P naphta and heptane. In addition, Altuglas acrylic resins is virtually unaffected by a wide range of commercial products including many detergent solutions and cleaners, beverages and foodstuffs. It is not recommended for use with chlorinated and aromatic hydrocarbons, esters and ketones. The chemical resistance of Altuglas acrylic resin is summarized in Table 5. Altuglas acrylic resin is a rigid plastic with good strenght properties. Although the resistance of Altuglas resin to sudden impact is lower than that of some plastics, it is several times greater than that of glass. If your design requires even greter impact strenght ask us about the familly of Altuglas impact-modified acrylic resins. Properties like excellent clarity, good chemical resistance and high rigidity, as well as the availability of UV transmitting resins, enable Altuglas acrylic moulding resins to be used throughout the medical industry.

GENERAL CHARACTERISTICS OF ALTUGLAS

Altuglas resins offer high thermal stability, excellent transparency and a hard surface which protects their brilliance and impacts high resistance to abrasion. Most Altuglas products are rated HB according to the UL94 standard. Among the many desirable properties of Altuglas acrylic resin, two are pre-eminent: Unexcelled durability indoors and outdoors Superlative optical properties and clarity Most applications of Altuglas acrylic resin take advantage of one or both of these outstanding properties. For example, Altuglas resin is the material of choice for moulding signal light lenses for automotive, aircraft and marine applications because of its superb optical characteristics as a light transmitting medium and its proven ability to endure many years of continuous outdoor exposure with little or no change in properties, colour or appearance. Other applications which demand the ultimate in weather resistance provided by Altuglas resin are outdoor lighting lenses and shields and moulded letters or extruded sheets for internally illuminated signs. In addition to unsurpassed resistance to sunlight, Altuglas acrylic resin is unaffected by long-term exposure to fluorescent light, and it is the material most commonly specified by lighting engineers and architects for lighting applications. Colourless Altuglas acrylic lighting fixture lenses are widely available either as injection moulded parts or extrusions with prismatic patterns: also diffusers are extruded from white translucent Altuglas resin. Fluorescent fixtures with Altuglas acrylic lenses can be operated continuously for many years without significant yellowing or measurable effect on physical properties. Parts moulded of Altuglas moulding resins are strong, light in weight and dimensionally stable.

THE RANGE
Altuglas moulding resins are available in a complete range of transparent, translucent and opaque colours as well as in colourless form. Colours can be supplied to meet the requirements of federal, military and other specifications for coloured materials. - Two series of injection moulding and extrusion grades - A wide range of grades offering high impact strength combined with normal or easy flow - Modified formulations to give heat resistant grades high impact strength - Formulations which guarantee the best possible mould release properties - Special formulations to filter or transmit UV - Special grades for food industry applications - Colours which meet AAMVA requirements Parts moulded of Altuglas moulding resins may be decorated easily by any of variety of methods including painting, silk screening, hot stamping, vacuum metalizing and selective chrome plating.

INTRODUCTION

APPLICATIONS
Altuglas resins are used in many industries, including: Transportation Automotive lighting, cluster lenses, number plates, reflectors, badges, coextruded body panel, interior and exterior trims, etc... Building Extruded panels for buildings, glazing and coextruded profiles for window frames. Lighting Light fittings, bowls, diffusers globes, etc... Household equipment Salad and mixing bowls, drinking glasses, bathroom accessories, etc... Medical/Hygiene Diagnostic test-cuvettes, blood pressure filters, toothbrushes. Electronic and Optical Projection TVs, light pipe, optical media, office machine components, mobile phone lenses, DVD, light guide panels for LCDs. In addition, there are many other specific applications; furniture, signs, displays and more. This manual contains a summary of the physical, chemical and weathering properties of the basic Altuglas V-series acrylic moulding resins, as well as a listing of the wide variety of applications that each of the grades is best-suited for. The latter part of the manual provides details on mould design and for handling, processing (including troubleshooting), and post moulding operations.

P R O D U C T F E AT U R E S

PRODUCT FEATURES
Altuglas acrylic resins are differentiated by two primary characteristics: processability and heat resistance. Individual grades have been formulated with varying trade-offs on these characteristics to provide the best property balance for specific application needs. All Altuglas acrylic resins possess the following features: unsurpassed optical clarity proven outdoor weatherability high tensile strength and stiffness excellent surface hardness.

HEAT RESISTANCE
The heat resistance of Altuglas acrylic resin varies by grade and is a function of part stress. Generally, heat resistance is gained at the expense of processability. Vicat softening point is a thermal property used to estimate the ability of a material to perform at elevated temperatures. Two loadings shown in figure 2 provide an indication of the effect of part stress on heat resistance. Actual service temperature will depend on the level of stress (moulded-in and applied) within the part. Maximum service temperature is obtained through good design practice and low stress moulding conditions.

PROCESSABILITY
The processing characteristics of a material are a function of its formulation and the processing conditions employed. Melt flow rate is a measurement of a materials flow characteristics under a set of standardized test conditions and is often used as a comparative measurement of material viscosity. Refer to the spiral flow data on page 8 for a more thorough comparison of flow characteristics under varying temperature and shear conditions.

WEATHERABILITY
Altuglas acrylic resins remain virtually unchanged after long-term outdoor exposure. The weathering of exposes samples in Arizona and Florida is summarised in table 1.

FIGURE 1: MELT FLOW RATE

FIGURE 2: VICAT SOFTENING POINT

10 N 50 N 130
128 121 114 108 102 96 107 103 101 93 90 84 85 80

ISO 1133 (230C/3.8 kg load)

ISO 306 (50C hour)

30 Vicat Softening Point C Mer gr/10 min. 25 20 15 10 5.0 0.0

HT121 V044 V045 V825T V920T V920 VM VS

120 24 110 100 90 80 70 60

V044 V045

14.5 8

6 2 2.3 2.5 2.8

HT121

V825T

V920T

V920

VM

VS

Altuglas Resin Designation

Altuglas Resin Designation

P R O D U C T F E AT U R E S

Table 1: Effect of Outdoor Exposure on Light Transmission and Appearance of Altuglas Moulding Resins
Years Exposure Property Light Transmission Haze Yellowness Index Surface Appearance Units % % ASTM Test Method D 1003 D 1003 D 1925 Control 92.4 1.0 0.5 NC 1 92.4 1.3 0.4 NC 2 92.0 1.3 0.5 NC Arizona 3 92.0 1.5 0.6 NC 5 91.5 2.0 0.8 NC 1 92.4 2.3 0.5 NC 2 92.0 2.4 0.8 NC Florida 3 92.0 3.4 1.4 NC 5 91.5 3.8 1.6 NC

Table 2: Applications for Altuglas V-Series Acrylic Resins

TYPICAL APPLICATIONS TRANSPORTATION Taillights Turn signal lenses Instrument Clusters Medallions Light guides Marine/Aircraft lenses Roadside reflectors Moulded fixture lenses Moulded louvers Moulded refractors Extruded lenses/diffusers Extruded profiles Rods Tubes Specialty Films Sheet Display Profiles Solar Panels Appliances Microwave Oven Doors Glassware/mugs Utensils Faceplates/Dial panels Bath accessories Optical discs Magnifying lenses Cellular phone lenses Camera lenses In Vitro diagnostics Medical devices Desk top accessories Nameplates Faucet knobs Meter covers Toys VOD VS VM ALTUGLAS MOULDING RESIN GRADE V920 V920T V825T V045 V044/45 HT121 (UVT)

LIGHTING

EXTRUSION

HOUSEWARES

(UVT)

OPTICAL

MEDICAL MISCELLANEOUS

Table 3: Specialty Altuglas Acrylic Injection Moulding Grades

Resins Altuglas V 825 HID

Description Equivalent to Altuglas V 825 T resin but especially formulated to withstand continuous exposure to high intensity discharge lighting sources up to 90C.

Typical Applications Lighting lenses, particularly with HID sources. Used for medical diagnostic components. Optical discs (DVD...). Extruded profiles and large lighting lenses. Automotive lens, third stop, lighting fixtures, micro wave oven doors.

Altuglas VS UVT Altuglas VOD Altuglas V 045 I Altuglas HT 121

Identical to Altuglas V 920 resin except they transmit nearly all ultraviolet radiation above 275 nanometers. Specially processed ultra-clear colourless resin for optical application. 50% increase on toughness vs other Altuglas V-series resins. Heat resistant PMMA up to 121C (VICAT 50 N) Highest surface resistance (Pencil test: 5 H).

Table 4: Chemical Resistance of Altuglas Grade Acrylic Resins

Altuglas series acrylic resins have good resistance to a variety of common cleaners and application environments. The chemical resistance of Altuglas series acrylic resins will vary with the stress level, temperature, reagent, duration of exposure and resin grade. Atoglas recommends that parts made from Altuglas resins be tested with all reagents under appropriate conditions for the end-use application.

Increasing Chemical Resistance

Altuglas Series Resin
Compound Class/Name

VS
Concentration (%)

VM

V 920 - 920 T

V 825 T - HT 121 V 044 - V 045

Compound Class/Name Concentration (%) Qualitative Ranking*

Qualitative Ranking*

ACIDS Acetic Acid, Glacial Acetic Acid Chromic Acid Citric Acid Hydrochloric Acid Hydrochloric Acid Lactic Acid n-butyric Acid Nitric Acid Nitric Acid Nitric Acid Oleic Acid Oleic Acid Stearic Acid

100 5 40 10 38 10 100 70 40 10 100

N E F E E E E N F G E E E E

Sulfuric Acid Sulfuric Acid Sulfuric Acid Tartaric Acid Trichloroacetic Acid BASES Ammonium Phosphate Ammonium Hydroxide Ammonium Hydroxide Sodium Carbonate Sodium Carbonate Sodium Hydroxide Sodium Hydroxide Sodium Hydroxide

98 80 3 50

E E E E N

28 10 20 2 60 10 1

E E E G G E E E

* All tests run at ambient temperature. Quantitative rating is based on visual appearance. LEGEND: E - Excellent G - Good F - Fair N - Not recommended.

P R O D U C T F E AT U R E S

Table 4 (cont.)
Compound Class/Name Concentration (%) Qualitative Ranking* Compound Class/Name Concentration (%) Qualitative Ranking*

COMMERCIAL PRODUCTS Ammonia Based Cleaners Anti-freeze Aviation Fuel Bathroom Cleaners Beer Brake Fluid Car Wash detergent Chlorine Based Cleaners Coffee Cosmoline Removers Cottonseed Oil Detergent Solution Epoxy Adhesives Fruit Juice Glass Cleaners Kerosene Lacquer Thinner Milk Mineral Oil Motor Oil Olive Oil Paint Removers Paint Thinner Polishing Compounds Power Steering Fluid Silicone Oil Soap Solution Transformer Oil Transmission Fluid Turpentine (White Spirit) Unleaded Gasoline Wine INORGANIC COMPOUNDS Alum. Potassium Sulfate Ammonium Carbonate Ammonium Chloride Ammonium Nitrate Ammonium Phosphate Ammonium Sulfate Barium Chloride

(100 Octane) _

E E A G E G E E E G E G E E G E N E F E E N N E E E G G E N G E

Saturated Sol. Saturated Sol.

E E E E E E E

Calcium Chloride Calcium Hypochlorite Copper Chloride, Aqueous Copper Chloride Copper Sulfate Distilled Water Ferric Chloride, Aqueous Ferrous Chloride Ferrous Sulfate Hydrogen Peroxide Hydrogen Peroxide Iron Perchlorate Manganese Sulfate Magnesium Chloride Magnesium Sulfate Mercury Chloride Potassium Bicarbonate Potassium Carbonate Potassium Chlorate Potassium Chloride Potassium Cyanide Potassium Dichromate Potassium Permanganate Potassium Sulfate Potassium Sulfite Silver Nitrate Sodium Chloride Sodium Cyanide Sodium Fluoride Sodium Nitrate Sodium Phosphate Sodium Sulfate Sodium Thiosulfate Tin Chloride Zinc Chloride Zinc Sulfate SOLVENTS & ORGANIC COMPOUNDS Acetaldehyde Acetic Anhydride Acetone

Saturated Sol. 2

10

28 3

10

10

Aqueous/40)

E E E E E E E E E F G F E E E F E E E E E E E E E E E E E E F E E E E E

100

N N N

* All tests run at ambient temperature. Quantitative rating is based on visual appearance. LEGEND: E - Excellent G - Good F - Fair N - Not recommended.

Table 4 (cont.)
Compound Class/Name Concentration (%) Qualitative Ranking* Compound Class/Name Concentration (%) Qualitative Ranking*

Solvents & Organic Compounds (cont.) Acetonitrile Acetophenone Alcohol, Allyl Alcohol, Amyl Alcohol, Benzyl Alcohol, Ethyl Alcohol, Ethyl Alcohol, Ethyl Alcohol, Isopropyl Alcohol, Isopropyl Alcohol, Isopropyl Alcohol, methyl Alcohol, methyl Alcohol, methyl Alcohol, n-butyl Amyl Acetate Aniline Benzaldehyde Benzene Benzoyl Chloride Butyl Acetate Butyl Acetyl Ricinoleate n-Butyl Chloride Butyl Stearate Butyraldehyde Carbon Disulfide Chloroform Cyclohexane Cyclohexanone Cyclohexene Dialkyl Phthalate Dialkyl Sebacate Dibutyl Phthalate Dibutyl Sebacate Diethyl Ether Dimethyl Formamide Dinonyl Phthalate

10 50 100 10 50 100 10 50 100

N N N N N F F N F F F G F N N N N N N N N F N F N N N N N N F F F F F N F

Dioctyl Phthalate Dioctyl Sebacate Ethyl Acetate Ethylene Dibromide Ethylene Dichloride Ethylene Glycol Ethylene Oxide (Dry) Ethylene Oxide (Moist) 2-Ethylhexyl Sebacate Formaldehyde, Aqueous Glycerol Heptane Hexane Isooctane Meta-Cresol Methyl Benzoate Methyl Cyclohexanol Methyl Ethyl Ketone Methyl Naphthalene Methyl Salicylate Methylamine Methylene Dichloride Monochloro benzene n-Octane Naphthalene Nitrobenzene Paraffin, Medicinal Perchloroethylene Petroleum Ether (100-120C) Phenol, Aqueous Polypropylene Adipate Polypropylene Laurate Polypropylene Sebacate Pyridine Toluene Trichloroethane Trichloroethylene Xylene

40

F F N N N E E F E E E E E G N N N N N N F N N F N N E N F N E E E N N N N N

* All tests run at ambient temperature. Quantitative rating is based on visual appearance. LEGEND: E - Excellent G - Good F - Fair N - Not recommended.

P R O D U C T F E AT U R E S
MELT FLOW OF ALTUGLAS GRADES
When selecting the proper grade of Altuglas acrylic resin for an intended application, the moulding characteristics of the grade must be considered. One of the most important moulding characteristics is the flow of the material because it determines whether the particular grade will fill the mould with which it will be used. Figures 3 and 4 show the effect of barrel temperatures on the flow length of the various Altuglas V-Series resins at the thicknesses of 2 mm and 3 mm.

COMPUTER ANALYSIS DATA

Many engineers are using computer software packages to determine whether a mould can be filled at a given wall thickness, the clamping force required, where to gate the part and its size, how to minimize warpage of the part, cycle time required, etc. To perform these analyses, certain material constants are required. Listed in table 6 are some of these constants for the Altuglas V-Series moulding resins.

FIGURE 3: SPIRAL FLOW (injection pressure 1500 bar)

FIGURE 4: SPIRAL FLOW (injection pressure 1500 bar)

3 mm thickness

2 mm thickness

Spiral flow (cm)

Barrel temperature C

Spiral flow (cm)

Barrel temperature C

Table 6: Mould Analysis Material Constants for Altuglas Resins

Altuglas Resins Thermal Diffusivity M2/sec
6.964 6.884 7.046 7.053 7.072 7.022 7.022

Flow Temperature C
150 151 158 160 165 175 170

Melt Density kg/cm3

1047 1057 1057 1057 1057 1057 1057

Vicat Temperature C (50 N) (10 N)

85 90 101 103 108 121 102 86 90 99 107 114 128 102

Specific Heat J/kg/C

2093 2093 2093 2093 2093 2093 2093

Thermal Conductivity W/M/C

0.157 0.157 0.157 0.157 0.157 0.157 0.157

VS VM V920 V920T V825T HT121 V044-V045

MOULD DESIGN

MOULD DESIGN
Introduction
Although two-plate moulds are the most commonly used mould types, either three-plate or hot manifold tools can be used where needed. Careful design of the sprue, runner and gating system is needed to obtain defect-free parts with good physical properties. Since Altuglas moulding resins are relatively viscous at moulding temperatures, mould design should minimize heat and pressure losses in the sprue and runner system to insure fluidity when the melt enters the cavity. short sprue bushing approximately 12 to 25 mm. The minimum diameter of such short sprue bushings may be as little 6 mm. Extended nozzles and short sprue bushings will reduce cycle time, increase pressures in the mould and result in less scrap.

Runners
Runners distribute the Altuglas acrylic melt from the sprue to the cavities. They should cause minimum cooling and resistance to flow. To do this, runners should combine maximum cross section with minimum surface area and be as short as possible. A full-round runner meets these requirements better than any other shape but is more difficult to machine because both sides of the mould must be cut individually and the half rounds in each section must mate when the mould is closed. The trapezoidal runner is next best since it approaches the full-round in one side of the mould. Half-round or shallow rectangular runners are not desirable because of their high surfaceto-volume ratio and restricted flow area. Figure 6 illustrates these runner shapes. Experience has shown that full-round runners of the following diameter give good performance when moulding Altuglas acrylic: Runners less than 125 mm long - 6 mm diameter Runners more than 125 mm, but less 200 mm long 7.5-8 mm diameter Runners more than 200 mm - 9.5-10 mm diameter. It is important to avoid sharp bends or sudden changes in direction of the runners. It is also important to use the shortest path possible. This ensures greater flexibility in filling the cavity and produces parts with a good visual finish and high performance. Runner dimensions depend of the shape and number of cavities. In general, the primary runner should be 3.5 to 5 mm diameter for parts 2 to 4 mm thick. For thickers parts the primary runner diameter should be 7 to 15 mm. The diameter of the secondary runners is generally 1 to 2 mm less than that of the primary runner.

Sprues
In a typical two-cavity, two-plate mould, melt is injected through the nozzle, sprue bushing and runners into the cavities. When the mould is opened, the sprue pulls out of the sprue bushing, parting at the hot nozzle where the material is still fluid. For Altuglas resins, the optimum sprue bushing diameter at the nozzle is 7 mm for most moulds, when used with a 6 mm orifice free-flow nozzle. Moulding a deep part with a long sprue bushing may require long cycles to permit the sprue and sprue puller to harden enough to hold together when the mould is opened. Long cycles may be avoided by using an extended nozzle that penetrates the mould and seats on a FIGURE 5: TYPICAL EXTERNALLY HEATED SPRUE BUSHING
VENT HOLE 16 mm LEADS TO HEATER

HEATER BAND

STATIONARY HALF

1.5 - 2 mm 0.25 mm STD TAPER SPRUE MOVABLE HALF 2.4 mm LAND

MOULD DESIGN

MOULD DESIGN (contd)

FIGURE 6: TYPICAL RUNNER CROSS SECTION
FULL ROUND BEST HALF ROUND POOR MOLD PARTING LINE

TRAPEZOID GOOD

RECTANGULAR POOR

Gating
Gate-size, shape and placement affect the flow pattern of material entering the mould and may influence temperature, fill time and overall part quality. In parts of variable cross section, the gate should be located in the thickest section to minimize fill problems. Parts are usually weakest in the region near the gate: therefore, unstressed areas should also be considered for location of the gate. Gate transitions from full-round and trapezoidal runners are shown in Figure 7. The round runner terminates in a spherical shape which traps cool material at the outside while passing hot material at the centre of the runner. Runners of trapezoidal or other shapes cut into one plate tend to drag cold material into the cavity because of the unsymmetrical transition shape. A streamlined transition section minimizes this tendency. Several gate designs suitable for moulding parts from Altuglas acrylic are illustrated in Figure 8 through 19 and specifications and applications for the various designs are listed in Table 7.

FIGURE 7: RUNNER TO GATE TRANSITIONS

FULL ROUND

Parting line

d 3/4 W f

aWs s
2/3 W

TRAPEZOIDAL

Parting line

10

Table 7: Specifications and Applications of Gate Designs for Altuglas Acrylic

Type of Gate Figure Specifications Minimum tab size: 6.5 mm by three-quarters of the part thickness: gate depth: 80 % of tab thickness. Maximum land length is 1.5 mm. For thick parts: gate thickness may be the same as or greater than the runner thickness. Applications and Remarks Recommended for relatively flat thin parts: tab minimizes gate stress and eliminates jetting. Suitable for thick as well as thin parts: permits keeping melt under pressure longer during cooling. For thick sections and to minimize jetting.

Tab

Egde

Fan

Smooth transition from runner to part. Gate should be at least 80 % of part thickness. Gate should be 0.8 to 1.5 mm thick, no more than one-quarter the length of the part. Maximum land length is 1.5 mm. Maximum diameter is 2.5 mm. Maximum land length is 1.5 mm.

Flash

For thin dials with an uninterrupted straight edge.

Centre

Recommended for deep circular parts such as bowls, cup shapes.

SprueConventional Sprue-Short
(13 to 26 mm long)

Diameter: 9 mm for a long sprue.

Use when it is possible to run the sprue directly into the mould (leaves degating scar). Hot sprue bushing eliminates all but a very small degating scar.

Diameter: 6 mm.

Sprue-Hot Submarine

Diameter: 2.5 mm. Oval shape: 1.5 by 2.5 mm minimum. Part degate automatically when the mould opens.

SubmarinePlug

Plug diameter approximately equal to the wall thickness of the part. Diameter of approximately 3 mm is adequate (knockout pin cut-off). Gate: 1.5 mm to 2 mm. Note: larger plugs will cause sinks while smaller plugs may cause jetting and surface defects.

Part degate automatically when the mould opens, leaving the plug to be removed from the part.

11

MOULD DESIGN

Table 7 (Cont.)
Type of Gate Figure Specifications Diaphragm thickness may vary from 3 mm to 5 mm and may be used as 360 flash gate or may be open to the full thickness of the part. Applications and Remarks For cylindrical shapes or parts requiring a large cut-out.

Diaphragm

Ring

3 to 5 mm diameter ring with short land of 0.8 to 1.5 mm thickness.

For hollow cylindrical parts such as tubes, pen barrels, etc.

Spoke

Gate dimensions can vary from very large to pin-point depending on whether the material flows directly into an open area or impinges on the mould.

Same application as diaphragm gate: produces less scrap.

12

MOULD DESIGN (contd)

Cavity and Runner Layout
For best results, all cavities must fill uniformly, continuously and simultaneously. The balanced H runner layout, shown in Figure 20, uses the same runner length from the sprue to each cavity and contains the same number of equivalent tums and identical gates to help ensure uniform moulding conditions in each cavity. The balanced H runner system requires slightly more material for each shot than unbalanced runner systems but this is offset by improved yields of good parts. FIGURE 20: BALANCED H RUNNER LAYOUT

Three-Plate and Hot-Runner Moulds

Centre or sprue gating of multi-cavity moulds is an efficient method of gating many Altuglas acrylic parts even though it requires a more complex three-plate mould or hot runner mould. Typical specifications for centre or sprue gating moulds to be used for Altuglas acrylic are shown in Table 8.

Table 8: Typical specifications for Three-Plate, Sprue-Gated Moulds for Altuglas

Section mould Nozzle Sprue Bushing Main Runner Secondary sprue Dimensions 8 mm free flow design 9 mm 9.5 mm full-round 9.5 mm diameter to match main runner, tapering to 6 mm diameter at gate end sprue well polished 0.8 to 2.5 mm diameter 1.5 mm land length

Gate The balanced H runner layout can be used to fill 4.8.16, etc., cavities only. Should a different number of cavities be desired, the spoke runner system show in Figure 21 can be used to provide a balanced layout system. As with the balanced H runner layout, the spoke runner layout uses the same runner length from the sprue to each cavity. A modified spoke layout is shown in Figure 22. Combinations and modifications of the balanced H system and balanced spoke system can be used to meet specific mould design requirements. FIGURE 21: SPOKE GATE LAYOUT FIGURE 22: MODIFIED SPOKE LAYOUT

The three-plate mould permits centre gating of multi-cavity moulds but sprues and runners must still be removed and reprocessed. All of this can be avoided by using a hot runner which is a modification of the three-plate mould in which heat is applied to the runners to keep the plastic melt hot and fluid during the entire moulding cycle. Hot runner moulds minimize sprue or runner scrap, give shorter cycles, increase the effective plasticating capacity of the machine and are adaptable to automatic operation. The hot runner block or manifold can take several forms. The most successful are those externally heated with cartridge heaters or with a combination of cartidge heaters and heat pipes for even temperature distribution (similar to Figure 23). Insulated runners can be used with Altuglas acrylic resins, but their low initial cost is generally not worth the greater operating problems relating to freeze up from cycle interruptions. The internally heated variation of an insulated runner (shown in Figure 24) is not recommended due to problems associated with flow and overheating of the resin.

13

MOULD DESIGN

MOULD DESIGN (contd)

FIGURE 23: HOT RUNNER BLOCK
EXTERNALLY-HEATED MATERIAL CHANNEL

FIGURE 25: EXTERNALLY HEATED HOT DROPS

SPHERICAL RADIUS

HEATERS CARTRIDGE HEATERS ARE LOCATED IN THE BLOCK TO PROVIDE UNIFORM TEMPERATURE THROUGHOUT THE BLOCK NOZZLE

FIGURE 24: HOT RUNNER BLOCK

INTERNALLY-HEATED MATERIAL CHANNEL
SEAL

MANIFOLD

CARTRIDGE HEATER

The most critical sections of the hot manifold assembly are the secondary nozzles or hot drops. Nozzles that are too hot will cause drooling and possible degradation: those too cool will freeze-up. Therefore, nozzles should have individual temperature regulated zones. Externally heated drops tend to work best, but those internally heated can be used. Nozzle orifice size frequently must be modified for acrylics. Due to the striffer flow of acrylic resins than styrenics for example, acrylics generally require a more open nozzle. Shot size and cycle time will determine the optimum orifice size. A large orifice is needed with large parts and long cycles. Size details should be discussed with a manifold manufacturer and your Altuglas International technical service representative. Straight flow, externally heated designs (shown in Figure 25) work well but leave a short stem that may have to be removed from the moulded part. Internally heated types or those with a spreader leave an almost invisible gate vestige. However, these tend to restrict flow and can lead to thermal instability problems. Also, they are more troublesome to size properly and frequently act to narrow the moulding range of the material.

Valve gate designs (see Figure 26) are more expensive but provide the best combination of unrestricted, easy flow with a wide processing window. Moulded parts will have a nearly invisible gate vestige and low stress in the gate area. If economics permit, they should be considered for any multi-cavity hot manifold application. FIGURE 26: VALVE GATED MANIFOLD HOT DROP
CYLINDER ASSEMBLY LOCATING RING CLAMPING PLATE

MANIFOLD PIN SEAL PIN NOZZLE

14

MOULD DESIGN (contd)

Mould Shrinkage
Cold-mould to cold-piece shrinkage (or simply mould shrinkage) is the difference between the dimensions of the moulded part and the corresponding dimensions of the mould cavity, both measured at room temperature. The magnitude of mould shrinkage varies appreciably with the part shape, mould design, direction of flow and moulding conditions. The typical mould shrinkage for Altuglas acrylic is approximately 0.004 mm per mm but under extreme conditions it may go as high as 0.007 mm per mm. Table 9 shows the changes in operating variables that will increase or decrease mould shrinkage. The mould shrinkage generally increases as the part thickness is increased. Moulded parts exposed to high temperatures may show additional shrinkage due to relief of moulding stresses. For best high temperature dimensional stability, moulding stresses should be minimized.

Table 10: Dimensional Correction Factor, Increase in Dimensions of As-Moulded Parts After Reaching Equilibrum with Atmospheric Moisture
Relatively Humidity to which Correction Factor to be added parts will be exposure in to parts measured after service at 23C cooling to 23C in a dry atmosphere 40 % 65 % 80 % 0.001 mm per mm. 0.002 mm per mm. 0.003 mm per mm.

Table 9: Effect of Moulding Conditions on Mould Shrinkage

To Increase Mould Shrinkage Increase mould temperature Decrease injection speed Decrease holding pressure To Decrease Mould Shrinkage Increase injection pressure Increase cylinder temperature Increase ram forward time Increase injection speed Increase cooling time

Venting
As the mould is filled, the hot plastic displaces the air in the cavities. Many moulds have adequate clearance around the knockout pins and at the parting line to serve as vents; however, if voids or burned areas are encountered in the part, adequate clearance for venting must be provided. The continuous venting technique ensures adequate venting and, since it is incorporated into the initial design of the mould, continuous venting may cut down the time required to put the mould into production. To obtain continuous venting, a groove is cut into the mould or around the inserts as shown in Figure 27. This permits air to pass quickly out of the mould through the short lands and large grooves. Another method of venting is to cut vents up to 0.075 mm deep and 9.5 mm wide in a sunburst pattern around the mould: however, this approach provides a more localized type of venting. Additional clearance may be provided around the knockout pins to provide localized venting in the cavities.

In designing moulds for parts requiring extreme dimensional accuracy, a sample cavity should be built and tested before production is undertaken. Parts should be moulded in the sample cavity using the same formulation and moulding conditions that will be used in production. Moulded parts will reach temperature equilibrium several hours after moulding and can be measured to determine shrinkage. Moulded parts will undergo further dimensional changes as they absorb moisture from the atmosphere and they may take more than 30 days to reach equilibrium dimensions at a given relative humidity. To eliminate the need for waiting for humidity equilibrium, the parts may be cooled to service temperature in a dedicated atmosphere and a correction factor added to the part size based on the humidity conditions the parts will encounter in service. Table 10 shows the correction factors for various relative humidities. Gate size may influence mould shrinkage. A gate that is too small freezes quickly, preventing extended compression of the part. A larger gate will transmit pressure to the part and minimize shrinkage. However, an oversize gate or over-long screw forward time may cause other moulding defects.

15

MOULD DESIGN

MOULD DESIGN (contd)

FIGURE 27: VENTING TECHNIQUES Inexpensive immersion thermometers should be installed in both inlet and outlet lines so the temperature rise of coolant flowing through the mould can be measured. The temperature of the outlet water should be no more than 5C different from the inlet water and the temperature differential between the mould surface and the cooling water should be at a minimum; otherwise, excessive cooling of the mould will take place during any interruption in moulding and several shots will be required to get back on cycle. Pressure losses in the circulation system should be minimized for efficient heat transfer and maximum flow. To accomplish this, hoses should be as short as possible and have a minimum inner diameter of 9 to 12 mm coring should be of the largest practical diameter. Large moulds can accommodate 18 mm diameter coring; minimum 12 mm diameter coring is recommended for all other moulds. Coring should be located as shown in Figure 28. FIGURE 28: SPACING FOR COOLING LINE

3 mm HALF-ROUND GROOVE

VENT TO ATMOSPHERE

1.5 mm LAND/RELIEVE (if necessary .025 mm)

CENTER-GATED PART
VENT TO ATMOSPHERE

EDGE-GATED PART
X

GROOVED CAVITY INSERT

CLEARANCE AROUND KNOCKOUT

D = 12 to 18 mm X = 18 to 30 mm

Coring
Moulds are cored for the circulation of a liquid, usually water, to provide adequate control of mould temperature. Good mould temperature control is important for uniform cooling of the part and it helps minimize stresses and shorten the moulding cycle. Good mould temperature control is achieved if the mould surface returns to the same temperature at the beginning of each cycle and the temperature differentials across the mould surface served by the cooling are at a minimum.

Polishing
To obtain optimum clarity and lustre in parts moulded of Altuglas acrylic, the mould should be ground to eliminate all tool marks and polished to a high lustre. Draw polishing in the direction of ejection of parts will minimize any tendency for the parts to stick in the mould.

16

MOULD DESIGN (contd)

Cavity Support
Pilar blocks providing a generous area of support for the mould plates should be placed behind each cavity. If the cross-sectional area of the pillar blocks is less than one-half of the projected area of the part, the mould plates may bow, causing a thickness variation of several hundred microns in the moulded parts. Severe lack of support may lead to flash even though the clamping pressure is adequate to prevent it, given sufficient support. Support pillars should also be placed behind the runners. FIGURE 29: MODIFIED EJECTORS OR KNOCKOUT PINS
MINIMUM THICKNESS FOR SUFFICIENT STRENGTH TO PULL PART AND MINIMIZE SCARRING OF PART

SECTION GROUND AWAY TO PROVIDE A Z PULLER SYSTEM

EJECTOR OR KNOCKOUT PIN IN EXTENDED POSITION

Ejection
In some moulds, the sprue puller alone will not assure that the moulded part remains on the movable half of the mould so it can be ejected by the knockout pins. Undercuts on the runners or on the part itself will often correct this problem. If the gate is too weak to pull the part from the stationary mould half, and if the part cannot tolerate an undercut, knockout pins can be used for this purpose. Several knockout pins can be modified as show in Figure 29. The depth of grinding should be less than the knockout throw so that in the fully ejected position, the small tabs, which moulded against the pins, will be completely free of the mould. These tabs can be clipped from the part. Clipping causes a scar that is little more noticeable than the mark left by the pin itself. For economic reasons, the cooling time in the mould should be kept to a minimum. Thus, parts removed from the mould should be as warm as possible and no forces should be exerted on them that will cause distortion or stress. Adequate draft, 1 to 2, should be provided wherever possible but some draft should be provided in all cases. Knockouts should be well placed to move the part evenly and without undue local stress. In addition, there should be a minimum radius of 0.075 mm on all comers of the parts to avoid cracking the parts on ejection from the mould. Pins are the most widely used type of knockout. They are usually placed around the periphery of a flat or nearly flat part, or under a lip. The pins should be as large in diameter as possible so the unit pressure on the part will be small. A satisfactory spacing of knockouts will usually be obtained if the pins are placed every 40 mm around the periphery.

CLEARANCE FOR VENTING

FIGURE 30: KNOCKOUT PLACEMENT ON DEEP PARTS

ADVANTAGE PINS PUSH THE PART FROM THE FORCE DISADVANTAGE AIR DOES NOT ENTER

DISADVANTAGE PINS DRAW THE PART TIGHTER AGAINST THE FORCE ADVANTAGE AIR CAN ENTER

17

MOULD DESIGN

MOULD DESIGN (contd)

Deep parts with little taper on the sides can be removed best if they are pushed from the force rather than draw from it. This is accomplished by placing the knockouts around the base of the force as shown in Figure 30. A disadvantage of this knockout placement is that air entering around the pins does not help break the vacuum formed as the part is separated from the force. Inability to admit air between the mould and the moulded part during ejection may cause trouble with large-area flat parts as well as with deep parts. If a small scar due to the metal joint can be tolerated, a spring-loaded poppet valve installed in the mould as shown in Figure 31 will correct this condition. It is also possible to apply low-pressure compressed air through such a valve and use the entire area of the part rather than local spots, thus giving uniform nondistorting knockout. The knockout distance is limited, however, to the travel until the air cushion is lost. Stripper plates are often used in place of pins on moulds for parts, such as tumblers, boxes, etc., where there is a thin, plane edge. Stripper plates have an advantage over pins because of the continuous surface of contact and lack of marring. They have the disadvantage of requiring an extremely close fit to the force if flashing is to be avoided. Certain parts such as lenses cannot tolerate the scars caused by knockouts on the part itself. Such parts may be removed by knockouts in the runners if the gates are sufficiently strong, and if there is adequate draft on the part. Tab-gated parts have been successfully handled with a single knockout in the tab. This eliminates the dependence on the gate to lift the part from the cavity. In a similar manner, knockouts in bleeder tabs can be used. FIGURE 31: SPRING-LOADED POPPET VALVE KNOCKOUT

LIGHT SPRING TO RETURN VALVE TO CLOSED POSITION

SEATING SURFACE SMALL WITH RESPECT TO EXPOSED FACE FOR GOOD SEALING PRESSURE

VALVE INSTALLED TO BREAK VACUUM

18

INJECTION MOULDING PROCESS

EQUIPMENT CONSIDERATION
Clamp Tonnage Recommendations
Altuglas International experience has shown that for every cm of projected surface area of a part there should be 3-4 tons of clamp on the moulding machine being used. The projected surface area of the part may be defined as the part area seen by the plastic entering the mould. Less clamp tonnage will tend to produce flashed parts. More tonnage will not hurt and may be necessary for thin-walled part (< 2mm) or other difficult-to-fill parts where high injection pressures are used.
2

Equipment and Screw Design

Altuglas acrylic resins can be moulded satisfactorily in reciprocating screw moulding machines for nearly all applications using general purpose screws. The screw in an injection moulding machine differs from that in an extruder in that it is not only used to help melt or soften thoroughly mix or plasticate the thermoplastic material but is also used to inject the plasticated material into the mould. The screw has three basic parts: the tip, the non-return valve and the helical screw. The function of the non-return valve is to prevent the plastic from flowing backward on the screw when the screw is used to inject the material into the mould. There are two basic types of nonreturn valves: the ball check and check ring. The check ring type is

recommended for acrylics. The ball check valve is a possible hang-up area which can result in thermally degraded material. Typical screw nomenclature is shown in Figure 32, (next page). For non-vented barrels, the feed section length is considerably longer than that of the transition and metering sections. A vented barrel would require a considerably longer screw because of its 2-stage design. For most moulding machines up to 450 tons in size, the manufacturers so-called general purpose screw is suitable for acrylics. These screws typically have a L/D ratio of 18-24 to 1 with a compression ratio of 2.3 to 3.0 and a square pitch or helix angle of 17.6. This change generally results in an erratic screw recovery which induces air into the melt, resulting in splay and diesel burning in the moulded parts. It is, therefore strongly recommended that only a square pitch (17.6 helix angle) be used for acrylics. Suggested screw designs for various size machines are listed in Table 11. For large moulding machines, in addition to using a square pitch screw with the proper compression ratio, the number of turn in the transition zone may need to be fewer than used for other thermoplastics to facilitate the melting of the acrylic. The nose cone and check valve are not included in the length of the screw since they do not affect the pumping capacity and plasticating ability of the flighted section; however, they may contribute to improved mixing and greater homogeneity of the melt.

Table 11: Suggested Screw Designs for Altuglas Moulding Resins (20/1 Length/Diameter Ratio; Pitch Angle 17.6)
Normal Diameter mm Depth, mm Feed Section Length, turns Transition Length, turns Metering Section Depth, mm Length, turns

40 50 70 90 150 170

7 7.5 8 10 13 16

11 11 11.5 11.5 12 12

4 4 3.5 3.5 3 3

2.6 2.8 3 3.5 5 6

5 5 5 5 5 5

Compression Ratio

Volume of the first turn = past the feed opening Volume of the last turn at the output end

Depth Compression Ratio

Depth of the channel = in the feed section Depth of the channel in the metering section

NOTE: When comparing various screws, be sure that the Length/Diameter ratios of the different screws are based on the same definition of length.

19

INJECTION MOULDING PROCESS

EQUIPMENT CONSIDERATION (contd)

FIGURE 32: NOMENCLATURE - METERING-TYPE SCREW

Table 12: Drying Temperature for Altuglas Moulding Resins

Altuglas Resin Grade VS VM V 920 Hopper Dryers 65C 70C 75C 80C 85C 80C 95C Shallow Trays 70C 75C 80C 85C 90C 85C 100C Time Hr 2-4 2-4 2-4 2-4 2-4 2-4 4-6

MEASURED FROM THE FRONT OF THE FEED THROAT TO SCREW FORWARD

FEED SECTION CHANNEL DEPTH FEED SECTION L L (EFFECTIVE) FLIGHT LAND PITCH FLIGHT

V 920 T V 825 T V 044 - V 045 HT 121

COMPRESSION CHANNEL OR TRANSITION SECTION DIAMETER METERING SECTION CHANNEL DEPTH

METERING SECTION CHECK VALVE AND NOSE CONE

MATERIAL HANDLING CONSIDERATION

Drying
Excessive moisture will cause surface defects. Altuglas acrylic resins are packaged in specially constructed containers at low moisture levels and can frequently be used with no additional drying. Critical jobs or old material will require drying. Absorbed moisture in Altuglas moulding resins does not affect the physical properties of the moulded parts but thin parts may show a surface defect sometimes referred to as splash; thick parts may contain bubbles. These defects can be overcome by drying the moulding resins in warm air circulating ovens, vacuum dryers, or in hopper dryers. If drying trays are used, the layer of moulding resins should be no more than 25 mm deep. Recommended drying temperatures are given in Table 12.

Moisture levels should be 0.05 % or less for demanding jobs. Noncritical jobs may tolerate as much as 0.1 % moisture in the resins. Circulating air must be dehumidified to a dew point of 40C or less for effective drying. Drying times range from one to four hours depending on the method and temperature employed, prevailing weather conditions, initial moisture content of the moulding resins and moisture content that can be tolerated in producing acceptable parts. Failure to properly dry the material will result in moulding defects known as splay, splash or silver-streak. Many Altuglas acrylic parts have been moulded successfully without predrying. Since predrying exposes the material to possible contamination, it should be avoided, if possible, especially with moulded lenses, edge-lighted dials, or other parts that cannot tolerate contamination.

20

MATERIAL HANDLING CONSIDERATION (contd)

Contamination and Material Handling
The excellent colour, clarity and sparkle of Altuglas acrylic resins can be jeopardized with poor material handling. We seal our resins in heavy gauge, moisture resistant, polyethylene lined cartons. The liner should be slit with a knife: tearing the liner may cause contamination with polyethylene particles. When loading hoppers, the container lid should be wiped clean to avoid contamination. The container should be kept covered during the run to keep dust and dirt from contaminating the contents of the container. Containers should be resealed when not in use. Hopper loaders must be assembled and cleaned before loading if previously used for anything other than acrylic. Similarly, the machine hoppers should be vacuumed and wiped down before use. A small amount of polystyrene or other plastic resins can contaminate an entire hopper load. Drying ovens must also be checked to avoid contamination from blowing fines and stray resins. Moulded lenses and edge-lighted parts require the most extreme care in material handling to avoid visible contamination.

Colour changes can be handled in a similar manner but will take slightly longer to clear the last traces of the previous material. When switching from another type of plastic, it is frequently more economical to pull the screw and thoroughly clean all the equipment. An alternate procedure involves sustained flushing with virgin or regrind Altuglas acrylic resins until the air shots are clear of contamination. Cast acrylic sheet scrap or a granulated purging material can be used to clean out badly contaminated machines. One suggested source of purging material that has been tested and proven to be highly effective is Altuglas GR 100 high molecular weight polymer. The cleaning of nozzle and hot runner system are not possible with this polymer. The cleaning procedure is as follows:

Completely empty the barrel

Regrind
When regrind is used, the level should be kept to 10 to 20 % of virgin material. The use of regrind does not harm physical properties, but will affect colour and appearance due to the increased risk of contamination during handling. Regrind should not be allowed to accumulate since it will readily pick up moisture and be very difficult to dry adequately. For critical lens moulding, it may be necessary to remove the fines in the regrind to prevent white spots or streaks in the moulded lenses.

Remove the nozzle

Heat the cylinder to 250-270C

Manually fill with 50 to 500 g of Altuglas GR 100 with the piston rotating slowly Remove all Altuglas GR 100 from the cylinder and introduce approx. 1 kg of polymer at the same temperature. Empty the cylinder

Purging
Changing from one grade of Altuglas resin to another is readily done by emptying the cylinder, resetting the heats for the new grade and running the machine like an extruder to clear the screw. A good purging procedure is to empty the cylinder of all previous material and to clean the hopper and feed throat. Start the cleaning with clean acrylic regrind using cylinder temperatures of 230C to 260C.

Refit the nozzle

Adjust the machine for the new production cycle

21

INJECTION MOULDING PROCESS

PROCESSING TEMPERATURES
Start-Up Temperatures
Starting conditions depend on the Altuglas resin used. Typical cylinder and mould temperatures are listed in Table 13. The high end of the mould temperature range produces parts with minimized moulded-in stress, but at the coast of longer cycle times. Temperatures lower than those suggested should be avoided for thick parts, as higher stress level can lead to part failure due to crazing (microcracks just below the part surface). Melt temperature can be varied to suit the part. With proper drying and reasonable residence time, melt temperatures up to 270C can be tolerated. At this temperature, flow is maximized, stress is minimized, but cycles are longer.

Shot Size
Ideally, the shot size should be about 50 % of the cylinder capacity. A smaller shot size will give longer residence time and in extreme cases, can give thermal stability problems and poor screw pick-up.

Table 13: Suggested Start-Up Temperatures for Reciprocating Screw Machine

CYLINDER TEMPERATURES Altuglas Grade VS VM V 920 V 920 T V 825 T HT 121 V 044 - V 045 Rear C 170 - 185 170 - 190 180 - 200 195 - 215 205 - 225 215 - 220 210 - 230 Centre C 170 - 190 175 - 195 185 - 205 205 - 225 215 - 235 225 - 235 220 - 235 Front C 180 - 195 185 - 200 195 - 220 210 - 230 225 - 245 235 - 245 230 - 245 Nozzle C 175 - 190 180 - 195 190 - 215 210 - 220 225 - 240 235 - 240 230 - 240 Mould Temp. C 50 - 60 50 - 60 60 - 70 70 - 80 80 - 90 85 - 90 70 - 80 Melt Temp. C 195 200 225 230 240 245 240

22

PRESSURE AND INJECTION SPEED

Injection Pressure
The injection pressure required to fill a mould depends on the shape and size of the part. With large or very thin parts, high injection pressures may be needed. When hydraulic pressures are higher than about 1500 psi, some effort should be made to either raise melt temperature or enlarge gates, runners and sprue. FIGURE 33: EFFECT OF WALL THICKNESS ON CYCLE TIME

Holding pressure and cushion

To obtain good results, particularly a top-class visual finish, it is important to maintain a residual pressure after filling the cavity. This pressure compensates for shrinkage during cooling and holds the molten polymer against the mould faces. The finish is consequently better. The pressure and the time it is applied must be selected to avoid overpacking the cold polymer which will cause excessive stress in the areas around the gate. The dimensions of the secondary runners and the gates must be carefully selected to guarantee that the holding pressure is effective. For the pressure to have a real effect on the part, ensure there is an extra cushion of polymer available after injection.

Cycle Time (seconds)

E NG A R AL M R NO

Wall thickness (mm)

Screw Speed
Screw speed be selected so as to complete screw recovery a few seconds prior to mould opening. Higher speeds will not harm Altuglas acrylic compositions but are not needed except as an aid to raise melt temperature.

Injection Speed Back pressure during filling

A moderate back pressure can be applied during screw return to achieve suitable compacting of the polymer. The back-pressure is generally between 5 and 10 % of the machine capacity. It eliminates air bubbles which can lead to visual defects (splash marks). However, an excessive back pressure can lead to high stresses in the material and damage the polymer. Fast injection speeds are preferred, because this minimizes orientation and moulded-in stress. Thick parts may require slower fill speeds to minimize flow lines in the moulded part. When purging the machine prior to moulding, attention should be given to the condition of the melt. Foaming or severe bubbling of the melt generally is due to poorly dried material which causes splay in moulded parts. Other moulding defects, their cause and suggested cures are listed in Table15.

Cycles Times
Cycle times depend on part thickness and the resin selected. All other things being equal, the high-temperature Altuglas resin V 825 T gives somewhat shorter cycles than other Altuglas V-Series resins. The effect of part thickness on cycle time is shown in Figure 33.

Shutdown Procedure
For a short hold period (one hour or less), do the following: 1. Stop resin fed 2. Retract carriage 3. Lower barrel heat to 150C 4. Run screw to empty barrel 5. Leave screw in forward position with carriage back. For an extended shutdown, follow the above procedure, except all heaters can be turned off when the barrel is empty.

23

O R I E N TAT I O N A N D S T R E S S

ORIENTATION AND STRESS

The moulding process basically consists of two stages: - the pressure drives the molten polymer into the secondary runners and then the mould cavity - once in the mould, the polymer solidifies and retains the shapes of the cavity. These two operations cause cooling and shrinkage stresses, respectively.

Cooling stresses
These stresses are caused by non-uniform cooling of the part. The surface layers of polymer, close to the mould, begin to solidify while the inner layers are still hot. Consequently, a hard external skin forms with molten polymer in its centre. Since the specific volume of the material depends on temperature, and therefore rate of cooling, the various layers contract differentially causing residual stresses. These stresses are compressive at the surface and tensile in the centre. As the hot centre cools, it generates tensile stresses which remain in the part even when it is completely cold. The stresses are higher in thick parts and are increased by high cooling rates caused by cold moulds.

Orientation stress
Viscous forces tend to align the polymer chains parallel to the flow direction. This orientation becomes fixed during cooling. In practice, different orientations still exist in the moulded parts depending, obviously, on the conditions applied during the process. Melt-temperature High temperatures reduce orientation in the polymer since the latter becomes more fluid and the viscous forces, which have a direct effect on the alignment of the molecular chains, are reduced. High temperatures also mean the part takes longer to cool and consequently orientation is partially relieved, particularly in the centre of the part. Injection speed The effects of this parameter vary depending on the laminar structure of the polymer flow, i.e. the thickness of the moulded part. Increasing the injection speed increases surface orientation. In the centre of the part, however, the degree of orientation is reduced due to the reduction in internal forces since higher injection speeds increase the temperature due to friction. Mould temperature A high mould temperature means the polymer cools more slowly and consequently encourages stress relaxation. Injection pressure and holding pressure High injection pressures increase stress, particularly during final compression since the product is already cooling but further molten polymer is introduced, to compensate for shrinkage, until the pressure is in equilibrium. The polymer in the gates and the secondary runners hardens and stress increases.

Stresses due to post cooling shrinkage

The specific volume of the polymer depends directly on the cavity rate of cooling. An extremely long cooling time would be required to obtain volumetric stability. Such periods are impractical and therefore the specific volume of an injection moulded part is always greater than the theoretical volume at equilibrium. When stored for long periods, the parts shrink slightly particulary along the long edges. If not restrained the material tends to return to the equilibrium volume it should have attained at the temperature applied at the end of its production cycle. However the stress levels remain relatively low.

ASSESSMENT OF STRESS
Ethanol will reveal any residual stress. Strong surface orientation is seen as a film on the surface of stress concentration areas. Stresses which exceed the critical values give rise to crazing. The test involves immersing the cooled part in 90 % ethanol at 25C 1C for 15 minutes and then drying it as quickly as possible with compressed air. The temperature of the ethanol (25C 1C) is important since it determines the rate at which crazing forms.

24

P O S T M O U L D I N G O P E R AT I O N S

POST-MOULDING OPERATIONS
Degating
Submarine-gated parts are automatically degated when the mould opens. Other gates normally require a degating operation after the part is removed from the mould. Clippers are often used but they may cause fracturing of Altuglas acrylic parts in the gate area, especially if the parts are allowed to cool. It helps to heat the cutters to about 135C. Other tools used to degate and remove tabs or plugs from moulded parts are steel slitting saws, band saws and hot knives. A steel slitting saw with 4 to 10 teeth per cm without rake or set, operating at 2500 to 3700 surface metres per minute, will degate a tab gate with a smooth, notch-free finish. Conventional metal-cutting or frictiontype band saw blades are convenient for degating flash-gated parts. A hot knife for degating Altuglas acrylic parts should be flat on one side and ground to a 10 angle on the other side. The temperature of the blade should be controlled to about 135C and, for convenient use, may be held in the chuck of a drill or arbor press. Very heavy gates on thick parts may be cut on a circular saw if straight; on a band saw if curved.

Annealing Moulded Parts

The injection moulding process normally set up a surface and internal stresses in moulded parts. The purpose of annealing is to redistribute both surface and internal stresses more uniformly and also to reduce their magnitude. Annealing is simply insurance of optimum quality for a well-moulded part: it cannot overcome the defects of a poorlymoulded part. Properly annealed parts are more resistant to crazing by solvents which may be present in cements, lacquers, paints or cleaning and polishing agents. Annealing produces a substantial improvement in the strength of cemented joints. No single combination of annealing time and temperature is satisfactory for annealing all parts moulded of Altuglas resin. An annealing cycle which is good for one part may have no annealing effect whatever on another part. Although annealing is often omitted, it is an important operation and the benefits of annealing should be evaluted wherever possible, especially where moulded parts are to be machined, cemented or decorated. Annealing involves holding the parts at a constant temperature (thermostatic control). The temperature depends on the type of Altuglas and the thickness of the part. This operation only affects cooling stresses and not orientation stresses. Parts must not be distored by the annealing temperature and must be allowed to cool gradually to ambient temperature. Typically, the cooling rates is 1 to 1.5C per minute. Correct annealing will not distort the part. In table 14 are showed the recommended temperatures for Altuglas resins and in figure 34 the annealing time versus item thickness (next page).

Moulding Scrap and Regrind

To conserve material, Altuglas acrylic sprues and runners can be reground and remoulded. However, it is essential to avoid contamination of the regrind. To avoid problems in drying of the regrind, it is recommended that a dedicated, beside-the-press granulator be used and the regrind be proportionally mixed with virgin material using the hopper loader system. Immediate recycling of the sprues and runners will minimize contamination problems, conserve storage space and reduce costs by avoiding the extended drying time otherwise needed for regrind material.

25

P O S T M O U L D I N G O P E R AT I O N S

POST-MOULDIND OPERATIONS (contd)

Table 14: Average Annealing Temperatures
Altuglas Grade VS - VM V 920 V 920 T V 825 T V 044 - V 045 HT 121 Recommended temperatures (C) 65 - 75 75 - 80 80 - 85 85 - 90 80 - 85 95 - 100

Surface hardness (pencil test)

Impact grades Standard grades Speciality MI7T MI2T V 825T HT121 1H 2H 3H 5H

Antistatic Treatment
Most organic plastics have a tendency to acquire and retain surface electrostatic charges, which not only attract but firmly hold air-borne dust particles. Antistatic agents are of particular importance to end users of transparent plastics in situations where clarity must be maintained under adverse conditions. Dust particles which collect on a changed, untreated plastic surface can be blown off with compressed air. Temporary cleaning is better accomplished by washing with water, followed by air drying. Liquid household detergents added to the wash water more effectively wet the plastic surface and confer at least temporary antistatic properties on the part, but commercial destatirizers developed specifically for antistatic activity produce a longer lasting effect and should be used whenever possible. Antistatic agents may be applied to acrylic parts by wiping with a dampened cloth or by spraying or dipping the part immediately after removal from the mould, whichever is convenient.

FIGURE 34: ANNEALING TIME VERSUS PART THICKNESS

Time (h)

Thickness (mm)

26

F I N I S H I N G O P E R AT I O N S

DECORATION
Many methods of decoration can be applied to Altuglas.

ASSEMBLY
Parts can be assembled either by bonding, ultrasonic welding or overmoulding. Bonding Recommended adhesives: - Altuglas adhesive SE (fluid) - Altuglas adhesive SE (viscous) - Altuglas adhesive SI (for impact resistant grades). Overmoulding Overmoulding avoids the necessity for bonding, which is always a delicate operation when the visual finish is important. Ultrasonic welding Ultrasonic welding also gives excellent results. Consult ultrasonic equipment manufacturers who have extensive experience with this technique.

Decorative techniques
Painting It is recommended to use acrylic paints and relatively inert solvents. Silk screen printing This method gives excellent results on flat parts. Hot stamping Adhesion is excellent. It is recommended to stabilize parts by annealing. Vacuum metallization When applied to the rear surface of transparent Altuglas, metallization gives excellent results. An acrylic primer should be applied first to improve adhesion. Protective paint should be applied to increase the lifetime of the effect obtained.

MACHINING
Parts can be machined in a similar way to light alloys using the same techniques as for Altuglas EX which are described in the Altuglas CN/EX technical brochure.

POLISHING
The material can be polished to eliminate traces of gates, machining marks or scores, using the same techniques as for Altuglas EX which are described in the Altuglas CN/EX technical brochure.

27

MOULDING DEFECTS
TYPICAL EXAMPLES OF MOULDING DEFECTS
Photo A shows four factors, all inter-related: 1. Black streaks Caused by the introduction of air into the feed and subsequent carbonization when the polymer is injected into the mould. 2. Bubbles due to degradation of the polymer Caused by very high temperatures in the molten polymer, themselves caused by high screw speeds which increase the temperature. 3. Shrinkage bubbles In this case, the defect is close to the gate (injection point) and, combined with the large difference between the mould and polymer temperature, this is undoubtedly the main cause of defects 1 and 2. 4. Warped part Bearing in mind the high temperature of the molten polymer, the deformation of the part is almost certainly caused by allowing insufficient time for cooling. First action: minimize defects 1 and 2. Factors which adversely affected the real polymer temperature were finally eliminated: - by reducing the cylinder temperature - by reducing the feed speed to obtain back pressures compatible with PMMA - by reducing the injection speed. Photo B shows that, although the part is still defective, considerable improvement was achieved. In this case, the polymer temperature and feed and injection speeds, must be reduced even further. Photo C shows the results (see next page). Black streaks and bubbles have virtually disappeared, although a few remain and the part is still not regular. These defects can be corrected: - by further reducing the polymer temperature and injection speed and increasing the mould temperature to minimize shrinkage - by improving runner and gate geometries (increasing the crosssection and improving the finish) to allow better packing of the polymer in the cavity.

Ph. A.

Ph. B.

28

TYPICAL EXAMPLES OF MOULDING DEFECTS (contd)

The visual finish of the part was considerably improved by the above measures. However, the result was still not satisfactory because this part was incomplete: metal components were to be installed and the part was to be dyed by dipping. It therefore had to be completely free of any internal stresses and superficial orientation. A large number of production samples were tested with ethyl alcohol. These tests showed up slight stresses. Consequently, the manufacturing conditions (mould temperature and filling pressure) were again slightly modified and the part show in photo D, which fully complied with the specifications, was obtained.

Ph. C.

Ph. D.

29

MOULDING DEFECTS

Table 15: Injection Moulding Troubleshooting Guide

Suggested Steps to Produce High Quality Parts Moulded of Altuglas Acrylic
Defects
1. Short shot (mould not filled) or rippled surface, usually in an area farthest from the gate A. B. C. D. E. F. A. B. C. D.

Suggested Remedies
Adjust feed to minimum consistent cushion Increase injection pressure Increase injection speed Increase booster or high-pressure time Increase back pressure Increase screw speed to give higher melt temperature G. Raise cylinder temperatures H. Increase mould temperature, particularly for very thin, large-area parts I. Use a short sprue with an extended nozzle J. Enlarge gates, sprue diameters and runners K. Use screw with shallower flights in the metering zone G. Use a short sprue with an extended nozzle H. Relocate gate to change flow pattern I. Use screw with shallower flights in the metering zone J. Ensure that the vents are adequately sized and clear

2. Weld line, knit lines resulting from separation and rejoining of the melt in the mould

Increase injection pressure Adjust injection speed Increase back pressure Increase screw speed to give higher melt temperature E. Increase cylinder temperatures F. Increase mould temperature, particularly for thin, large-area parts A. B. C. D. E. Reduce injection speed Increase injection pressure Reduce back pressure Reduce screw speed Reduce metering zone and nozzle temperatures F. Increase mould temperature A. B. C. D. A. B. C. D. Increase injection pressure Increase back pressure Reduce screw speed Adjust injection speed

3. Tails and hooks appearing as welds or tears beyond raised numerals, etc., in the mould, caused by the tearing of one surface of the melt

G. Raise cylinder temperatures cautiously H. Use screw with deeper flights in the metering zone I. Relocate gate J. Reduce obstruction causing tails by rounding or by decreasing depth E. Increase feed zone temperature F. Adjust metering zone, compression zone and nozzle temperatures G. Increase mould temperature H. Dry the material more thoroughly F. Adjust back pressure G. Increase mould temperature H. Reduce cooling time in mould (may require a cooling fixture or water bath) I. Enlarge gates and runners D. Reduce mould temperature E. Reduce nozzle and metering zone temperatures D. Put cold slug well in mould opposite sprue bushing

4. Splash, tear drops, mica surface, splay marks, silver streaks, flow lines caused by escaping volatile material and/or moisture 5. Sink marks caused by the back-flow of material or shrinkage of the part

Increase injection pressure Increase injection-forward time Reduce screw speed Reduce nozzle and metering zone temperatures E. Increase feed zone temperature A. Reduce injection pressure B. Reduce injection speed C. Reduce injection-forward time A. Increase nozzle temperature B. Reduce injection speed C. Counter-ream nozzle with opposite taper at outlet to cause material to part inside the nozzle A. B. C. D. E. Increase mould-closed time Adjust injection-forward time Increase ram speed Use differential mould temperatures Raise cylinder temperatures

6. Smudge, orange peel, skids caused by the frozen skin breaking and moving in the mould 7. Cold slug caused by cooling of the melt in the nozzle

8. Warping caused by uneven forces trying to relax in the hot part

F. Use a clamping jig to cool the parts uniformly G. Decrease nozzle and metering zone temperatures H. Cool parts in water at 40C to 50C

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Table 15 (contd)
Suggested Steps to Produce High Quality Parts Moulded of Altuglas Acrylic
Defects
09. Sprue breaking or not pulling

Suggested Remedies
A. Spray sprue with release agent until machine is on cycle B. If a Z puller is used, check to see that the Z clears the mould during ejection C. Check seating and size of the nozzle and sprue bushing A. B. C. D. Decrease injection speed Decrease injection pressure Decrease clamping pressure Adjust mould temperature D. Decrease injection time and add to the mould-closed time to leave overall cycle constant E. Reduce injection pressure F. Polish sprue bushing G. Fillet Z and corners between sprue and runner to reduce stress concentration E. Decrease cylinder temperature F. Check venting of the cavity. If venting is inadequate, make provision for necessary venting G. Relocate gate C. Reduce feed zone temperature D. Use machine with larger cylinder shot size G. Increase temperature of water bath (high temperatures and long immersion time may cause crazing) H. Decrease nozzle and metering zone temperatures I. Increase feed zone temperature J. Enlarge gates and runners D. Decrease injection pressure E. Increase mould temperature F. Decrease gate size E. Increase ejection slow-down F. Decrease gate size G. Modify mould to eliminate sharp corners and undercuts and to increase draft E. Fill the part as fast as possible without causing other defects F. Reduce temperature of melt entering the mould F. Maintain both halves of the mould at the same temperature G. Anneal parts at as high a temperature as possible H. Reduce size of gate

10. Burning or trapping air in the mould caused by insufficient venting to the cavities

11. Burning or trapping air in the cylinder 12. Internal bubbles in thick moulded parts caused by insufficient packing and/or excessive shrinkage

A. Increase back pressure B. Decrease screw speed A. B. C. D. E. F. Increase injection-forward time Increase injection pressure Decrease cooling time in the mould Decrease injection speed Adjust back pressure Reduce cooling time in water bath

13. Crazing, minute surface fractures

A. Clean mould surface in area of crazing B. Increase injection speed C. Modify injection-forward time A. B. C. D. A. B. C. D. A. B. C. D. E. Adjust injection-forward time Adjust injection pressure Adjust mould temperature Adjust total mould-close time Maintain constant overall cycle Reduce machine dead time to a minimum Reduce mould temperature Immerse heavy parts in water Increase melt temperature Increase injection speed Use minimum injection-forward time Reduce injection pressure Increase mould temperature

14. Breaking, cracking of the part upon opening in the mould or ejection of the part 15. Long cycles

16. Unusually low maximum service temperature for specific grade of Altuglas resins

17. Delamination

A. Increase mould and/or cylinder temperatures B. Eliminate contamination

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H E A LT H A N D S A F E T Y P R E C A U T I O N S

HEALTH AND SAFETY PRECAUTIONS

All thermoplastic materials produce some gases or vapors at high temperatures: but no harmful concentrations of same should result if Altuglas acrylic resin is dried, moulded, extruded, or reground in accordance with recommended techniques, processing conditions and temperatures in areas with adequate ventilation. Heating Altuglas resins above 175C may release gases and vapors, including methyl methacrylate monomer (MMA). High concentrations of methyl methacrylate vapors can cause eye and respiratory irritation, headache and nausea. THe American Conference of Government Industrial Hygienists (ACGIH) Air Contaminant Standard for methyl methacrylate places the maximum permissible exposure level at a time weighted average (TWA) of 100 ppm. It is always good practice to provide local exhaust ventilation as close to the point of possible generation of vapors as practical. Suggestions for the design of exhaust ventilation systems are provided in Industrial Ventilation - A Manual of Recommended Practice, published by ACGIH (1988) and American National Standards Institute. Fundamentals Governing the Design and Operation of Local Exhaust System, Z921979. Any dust produced by the cutting or regrinding of Altuglas acrylic is considered nuisance dust, i.e., particles of little adverse effect on lungs that do not produce significant organic disease or toxic effect when exposures are kept under reasonable control. The current ACGIH Air Contaminant Standard for this type of dust places TWA exposure to total dust at 15 mg/m3 and respirable dust at 5 mg/m3. Worker exposure to dust can be controlled with adequate ventilation, vacuum dust removal at the point of generation or the use of suitable protective breathing devices. Customers dry colouring Altuglas acrylic should determine and follow the Health and Safety Recommendations of their Colourant Suppliers for the safe managing of the concentrate systems.

Caution:
Altuglas acrylic resin is a combustible thermoplastic, in general, the same fire precautions that are observed in connection with the handling and use of any ordinary combustible material should be observed when handling, storing or using Altuglas resin. The fire hazard of uses of Altuglas resin can be kept at an acceptable level by complying with building codes and applicable Underwritters Laboratories standards, and observing established principles of fire safety. Impact resistance is a factor of thickness. Avoid exposure to extreme heat or aromatic solvents.

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The information given in this brochure is based on findings from tests conducted in our research centres. It does not constitute a guarantee or a binding obligation on the part of Altuglas International. The handling of products, their machining and their application are subject to the legal standards in force in each country and can in no way engage the liability of our company.

GREATER CHINA c/o Arkema China Shanghai Unit 01-06, 28/F, Hong Kong Plaza 283 Huai Hai Zhong Road Shanghai 200021 - Peoples Republic of China Tel +86 21 6386 3028 Fax +86 21 6386 0668 c/o Arkema China Beijing Unit 1901 - 1902, Block B Jianwai Soho, N 39, East Third Ring Road, Chaoyang District Beijing 100022 - Peoples Republic of China Tel +86 10 5869 5620 Fax +86 10 5869 5637 c/o Arkema Co. Ltd Suite 3207 - 3211, Tower 1, The Gateway 25 Canton Road Tsimshatsui Kowloon - Hong Kong Tel +852 2110 1188 Fax +852 2110 1122 Connell Bros Co. (HK) Ltd Room 3601, 36/F, Citicorp Center, 18 Whitfield Road Causeway Bay Hong Kong Tel +852 2969 2727 Fax +852 2516 5642 c/o Arkema Rep. Office 8/F-5, National Enterprise Center 188 Nanking E. Road, Sec. 5 Taipei Taiwan Tel +886 2 2747 6979 Fax +886 2 2747 6574

JAPAN c/o Arkema K.K Fukoku Seimei Building 15F 2-2-2 Uchisaiwaicho, Chiyoda-ku Tokyo 100-0011 - Japan Tel +81 3 5253 9488 Fax +81 3 5251 9930

SOUTH EAST ASIA c/o Arkema Pte. Ltd 10 Science Park Road, #01-01A The Alpha, Singapore Science Park II Singapore 117684 - Singapore Tel +65 64 199033 Fax +65 64 199160

AUSTRALIA AND NEW ZEALAND c/o Arkema Pty. Ltd Ground Floor, 600 Victoria street Richmond 3121, VIC - Australia Tel +61 3 9425 7757 Fax +61 3 9425 7700

INDIA c/o Arkema India Branch Office Ruby House - B Wing - 2nd Floor J.K. Sawant Marg - Dadar (West) Mumbai 400028 - India Tel +91 22 2438 7513 Fax +91 22 2438 7550

KOREA c/o Arkema 11F, Oriental Chemical Building 50 Sogong-dong, Jung-gu Seoul 110-718 - South Korea Tel +82 2 3703 6760 Fax +82 2 3703 6893 Altuglas International 6, cours Michelet . Cedex 52 F-92064 Paris La Dfense 10 Tel +33 (0)1 49 00 80 80 Fax +33 (0)1 49 00 89 59 www.altuglasint.com

Altuglas is a registered trademark belonging to Arkema.

www.altuglasint.com

T Manual GB - 03/06 - I.O.P. 01 556 022 10 - RCS 739 805 950 - Imprim en France