How to choose the right material for your design - Moldex3D plastic material characterization
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The document outlines the material characterization capabilities of the Moldex3D software and various testing methods employed at the Tobert Sun Material Testing Lab. It discusses the relationships between viscosity, thermal conductivity, and the mechanical properties of materials using specific laboratory equipment and procedures. Additionally, it highlights the challenges faced in polymer processing under different pressures and temperatures, and the importance of accurate material information for simulation results.
How to choose the right material for your design - Moldex3D plastic material characterization
- 1. R12.0 Moldex3D Material Characterization Capabilities Tober Sun Material Testing Lab
- 2. 2 Relationship between τ and u or viscosity, η Equations to describe melt flow Thermal conductivity, k Heat capacity, Cp Temperature-pressure dependent volume, V(T, P) Modulus, G 0 u t Mass balance Energy balance : TkT t T Cp u Momentum balance gp Dt D τ u CAE procedure Thermoset conversion balance 0 RjX Density, ρ Conversion rate, R Flow behavior Cooling, warpage analysis
- 3. 3 Accurate material information provides better simulation results.
- 4. 4 Major Laboratory equipments line-up MCR 502 Rotation and oscillation tests for viscoelastic properties CR-6000 Capillary viscosity at different temperature and shear rates Rheograph RG25 Capillary viscosity and thermal conductivity with counter pressure equipped pvT-6000 pvT change at different temperature and pressure DSC 8500 Transition temperatures and crystallization kinetics Instron-8966 Mechanical properties
- 5. 5 Viscosity measurement Rotational rheometer Drag flow Capillary rheometer Pressure driven flow Non-Newtonian
- 6. 6 > Equipment: GOTECH CR6000 & GOTTFERT RG-25 > Procedure: ASTM D3835 – This test determines viscosity-shear rate behavior of material at 3 different temperatures. Pressure drop across the die is measured for each flow rate, and viscosity-shear rate data are calculated. > Shear rates: 10~10,000 1/sec > Max Temperature: 400 oC > Shear viscosity Model : Cross-WLF model, etc. Shear Viscosity (from medium to high shear rate)
- 7. 7 > Equipment: Anton Paar MCR 502 > Procedure: ASTM D4440 – A disk sample (diameter=25mm) is placed between the parallel plates (or cone and plate) at constant temperature environment. Small amplitude oscillation shear deformation is performed, and then the complex viscosity is acquired. > Frequency: 1~ 628 rad/sec > Shear viscosity Model : Cross-WLF model, etc. Viscosity (low shear rate)
- 10. 10 > Equipment: GOTECH PVT-6000 > Procedure: ISO 17744 – The machine is heated to the processing temperature, keeping in fixed pressure, then cooling to 40oC at constant rate of 5 oC/min. Measure the volume change at least 3 different pressures. > Temperature range: 40-300 oC > Pressure range: 10~150 MPa > pvT Model : modified Tait model PVT
- 11. 11 PVT governs part shrinkage Room temp Ejection temp Temp Relativevolume Gate End of filling Average Fast cooling
- 12. 12 Unique automotive material support Autoevolution.com perspectives.3ds.com Compositesworld.com
- 13. 13 Using elliptical shape to determine fiber orientation Instruments used Scanning electron microscopeMetallographic polishing machine
- 14. 14 R F H Unique automotive material support Glass mat thermoplastics compression RTM resin viscosity / fabric permeability
- 15. 15 Testings for thermoset, EMC materials
- 16. 16 Testings for thermoset, EMC materials VCA- Optima XE Contact angle test for surface tensile DMA Dynamics mechanism analysis for relaxation modulus
- 17. 17 pvT”c” curing shrinkage measurement We use a dilatometer to determine the cure-induced volume shrinkage at constant pressure and constant temperature. The volume change is obtained by measuring height change of a disc shape sample under constant area compression
- 18. 18 High speed / Pressure Thin-wall applications
- 19. 19 Challenges with thin-wall high pressure filling > Viscosity increases at higher pressure Low Pressure Hi Pressure High pressure encountered during polymer processing causes the sliding polymer chains contact more closely with each other. Therefore the viscosity increases. This phenomena could not be analyzed by previous simple testing methods.
- 20. 20 Viscosity as a function of pressure ),,( ),( PTf Tf Past Now
- 21. 21 Viscosity as a function of pressure Hi Pressure Low Pressure SC-1004A KPA1, 300°C
- 23. 23 > Equipment: PerkinElmer DSC 8500 > Procedure: – The material is heated to its molten state and followed by quench process for 4 different constant cooling rates. > Max cooling rate: 600 oC/min > Crystallization Model: Nakamura model Crystallization
- 24. 24
- 28. 28 Viscoelasticity and Optical Property Polarized Light Material Retardation d 熔融 流動拉伸 鬆弛 Entanglements melt Flow Stretch Relaxation
- 29. 29 > Photoelastic Simulation Convex lens Effetc of Flow induced Chain- Orientation and photoelastic Effect of Thermal Shrinkage and photoelastic
- 30. 30 Modulus – time curve
- 31. 31 Solid viscoelasticity applications Annealing (Short term) Under-the –hood (Long term)
- 32. Thank you for your attention!