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1、GID/WIT,Fluid-assist molding makes integrated media ducts,Potential applications for fluid injection molding,GIT vs WIT,GIT-Gas injection technique Advantage:To avoid or minimize warpage and sink marks To reduce material consumptionIntegrate components Limitation:Long cooling and cycle timesA limit
2、on part diameterThe lower level of heating eliminationPock-marked surface,WIT-Water injection technique Advantage:To avoid or minimize warpage and sink marks To reduce material consumptionIntegrate components Lower cooling and cycle times Disadvantage:Investment is higher,Why WIT?,Cycle time Up to 5
3、0%shorter cooling time Part is cooled externally by the mold Part is cooled internally by the water Greatest benefit-water continuously flowed through the partThinner walls More of the molten center of the part is cored outSmoother interior surface appearance Unfilled resins and low levels of fiberg
4、lass Highly dependent on the composition of the resinLess Slide Action in Tool,BASF Ludwigshafen WAIM Unit,Flow rate 27 l/minMax.water pressure 210 barControl of several mold functions(needle shut-off,core pullers,injectors,.)Module manufactured by PME fluidtec,Sasbach,Main players,Alliance Gas Syst
5、emsUSAPME Fluidtec GermanyMaximator GID-TechnikGermanyCinpres Gas Injection-UKBattenfeldEngelIKVArburgMilacronFerromatik,Injector technology,Injector technology drain pin,Results(door handle mold),BASF test mould for tubes,injector,35,overflow 1,20,25,over-flow 2,locking device,*)cooperation of TiK,
6、Zipfel Formenbau,BASF,gate,BASF test mould housings with channels,Application:housings with an integrated channel for fluids,Middle part of the platen can be exchanged,Further BASF test mould for WIT,Water injector with hydraulic locking-device,Overflow,Hot runner,Injector for water removal,Locking
7、pin for overflow,K5(plate with rib),Further BASF test mould for WIT,Overflow,Runner,Drain pin,Water injector with hydraulic locking-device,Locking pin for overflow,Rear Wiper Arm,Processing sequence,Injection of melt,Processing sequence,Injection and holding pressure,Processing sequence,Opening of o
8、verflowSwitching off hydraulic pressure on water injector,Processing sequence,Injection of water,Processing sequence,Injection of water,Processing sequence,Injection of water,Processing sequence,Decompression of water,Processing sequence,Removement of water by compressed air,Test Results with“Rear W
9、iper Arm”Ultramid B3GM24 black 23228,Test results with“Rear Wiper Arm”Ultramid B3WG6GP schwarz 23210,WIT Modifications on ADAC Mold Door handle molded in Ultramid B3GM24,Water injector with hydraulic driven locking-device,Locking pin for runner,Locking pinfor overflow,Drain pin,procedures versions f
10、or WAIM,1.,2.,3.,4.,Injection phase,Water injection,Water holding time,Water reverse flow,Short shot process,procedures versions for WAIM,1.,2.,3.,4.,Full shot process(flush process is possible),Injection phase,Water injection,Water holding time,Water reverse flow,procedures versions for WAIM,1.,2.,
11、3.,4.,Injection phase,Water injection,Water holding time,Water reverse flow,Melt push backprocess,procedures versions for WAIM,1.,2.,Injection phase,Water injection,Core pull process,process schema Water assisted injection molding,water,melt,injector,combined process Gas/Water assisted injection mol
12、ding,Quelle:TiK,Freiburg,www.tik-center.de,water,melt,injector,combined process Gas/Water assisted injection molding,combined process Gas/Water AIMequipment set up,External tank,Injector,Drain pin,nitrogen,overflow,feed channel,downspot/drain,Non return valve,WIT-Unit,M,Effect of process on the surf
13、ace finish Ultramid B3GM35 black Q642,WIT,GID,GID/WIT,4,2,2,9,3,2,Typical WIT problems,WAIM channel surface,Ultramid A3HG6 WIT hydrolysis resistance,Impact strength,immersion,Time of immersion,Minimum requirements,Ultramid A3HG6 WIT hydrolysis resistance,Tensile stress at break,immersion,Time of imm
14、ersion,Minimum requirements,knowledge transfer to Ultradur,modified typeUltradur B4040G10 sw.15098,Ultradur B4040 G6,knowledge transfer from Ultramid-product development,pure WIT process,Ultramid A3WGM53andUltramid B3G8possible through addition of Ultramid T,PumpHeat exchangerThermostatFlow meterByp
15、ass lineFilling hopperPressure equalisation tankTested partsMeasurement instrumentation,Test equipment for cooling tubes(E-KTE/EW),Test conditions,4,6,7,8,8,1,5,2,9,Test equipment,50:50 Glycol/water mixtureTemperature:130 CFlow rate:120 L/minSystem pressure:2 bar,Impact of process parameter to the w
16、all thickness,X/Y/Z,A,B,C,Parting line,D,Position 1,Position 2,Position 3,Position 4,Position 5,pipe section with marking requirement,location of pipe sections,measuring points,Impact of process parameter to the wall thickness,wall thickness mm,wall thickness-temperature,Measuring point 3B,Measuring
17、 point 3D,Measuring point 2C,Impact of process parameter to the wall thickness,wall thickness mm,wall thickness delay time,Measuring point 3B,Measuring point 3D,Measuring point 2C,Impact of process parameter to the wall thickness,wall thickness mm,wall thickness volume rate,Measuring point 3B,Measur
18、ing point 3D,Measuring point 2C,Impact of process parameter to the wall thickness,wall thickness mm,wall thickness water pressure,Measuring point 3B,Measuring point 3D,Measuring point 2C,Impact of process parameter to the wall thickness,wall thickness mm,wall thickness holding time of water pressure
19、,Measuring point 3B,Measuring point 3D,Measuring point 2C,Impact of process parameter to the wall thickness,wall thickness mm,wall thickness gas pressure,Measuring point 3B,Measuring point 3D,Measuring point 2C,Recommended grades for WIT,Ultramid A3WGM53 bk 20560 ideally fulfills requirementsfor hot
20、 oil and processingperformance,Cycle time 36s,Recommended grades for WIT,PA6 Grades:Ultramid B3WG6 GP bk 23210 e.g.coated door handles,pedals excellent mechanical propertiesUltramid 8267G HS bk 106Ae.g.uncoated door handles excellent UV-stability and surface appearance,Recommended grades for WIT,Mar
21、ket potential for WAIM-Applicationsin Europe(source:KTE/MB,KTE/VA),Tubes for coolants or oil-Powertrain,water tubes:Potential:weight:400 g per vehicleby 14 Mio.vehicles=5600 tgrowth:25%=3.600 t in 2010,Tubes for coolants or oil-Powertrain,Oil dip stick tube:potential:weight:140 g per verhicleby 14 M
22、io.vehicles=2.000 tgrowth:45%=650 t in 2010,Roof rack with WAIM,Request of Decoma,conzept introduced to VW,BMW,PSAUltradur B4040G10(WAIM mod)and Ultramid B3G10SI300t/a,Product modification Ultradur B4040 G10,product properties:PBT/PET-Blend,50%GFhigh stiffness on demoulding and strenghtExcellent sur
23、facesuitable for powder coating(at 360F)Tailor-made for fluid process(gas/water),status,Second mould proving Part with less molecular degradationParts passed the first part testsSurface quality-Ultramid B3G10SI better than Ultradur B4040G10Tests for paintability runingSaving of costs for roof racks
24、with metall housing ca.20 Euro per couple!,Potential applications for WIT,Cooling tube produced in Gas Assisted Injection Moulding(GAIM),“Geiger-Rohr“for Daimler-Chrysler(A-class),37 mm,12,6,7 mm,5 mm,non uniform wall thickness with GAIM,Cooling tube produced in GAIM,Tube for Audi(ITW),34 mm,600 mm,
25、very long cycle time with GAIM,Cycle time 110 sec.,Patent situation,Patent situation has to be considered:USA:Alliance Gas Ltd.6,579,489(12.000 per unit for the life of a unit)D:TiK,Freiburg,patent-nummber:DE 103 39 859 B3 2005.01.05(20.000 per unit over a period of 5 years),Machine cost estimates,Cost analysis,DETAILSMaterial CostCycle timeNumber of Cavities NeededDetermines Number of MachinesMachine Hourly RateEquipment Needed&CostOverhead&Profit FactorInvestment AmortizationInsert Costs,Cost of ExtrasFinal Price per Piece,
