The role of fibers as fillers is well known, but hollow glass microspheres, in addition to reducing weight and reducing warpage, also provide flawless surfaces.
The spoiler produced on an MX 1600 injection molding machine was impressive with its weight-reducing effect and flawless paintable surface. As part of the 180th anniversary celebration, in KraussMaffei's Competence Forum, Visitors witnessed this from the shaping of car spoilers.
Light weight, high mechanical strength
The MX 1600 injection moulding machine with a clamping force of 16000 kN illustrates the two major development trends of lightweight structures and high-end surfaces.
In KraussMaffei's Competence Forum, when the linear manipulator took the spoiler out of the MX1600 injection molding machine with a clamping force of 16000 kN, the person who saw the part would not notice any abnormality at all. The parts are lighter and have a perfect surface with no flow marks. The secret is that hollow beads with an average cross section of 20 μm are embedded in PP plastic. These beads are made of chemically stable borosilicate glass. From this year onwards, as such The manufacturer of powder fillers, A. Schulman, has been collaborating with 3M to provide such granules. The size of such hollow glass microspheres determines their pressure resistance (up to 1100 bar) and the resulting mechanical properties of the material. Mode. As the percentage of glass particles increases, the rigidity of the part also increases, while the shrinkage decreases, and the weight also decreases.
Since injection molding usually requires high pressure resistance, a relatively small diameter is used, which also benefits the surface quality. Unlike many foam and fiber technologies, the hollow glass bead process provides a sprayable product, beaded Thermal performance also means shorter cooling times.
No flow mark
In order to make the spoiler installed later perfectly matched to the color of the car, visible defects must be prevented from occurring on the molded part, which is a challenging task for the sequential injection molding. Therefore, as a Crow SMARFI's partner, HRS offers the FlexFlow needle valve system, which has an electric servo motor control system that is fully integrated into the MC6 control system of the MX 1600 injection molding machine. This not only allows the FlexFlow control system to be positioned on the machine. Extend the range, and make the entire system easier to operate.
Unlike hydraulic and pneumatic systems, where the needle valve can only occupy the starting or ending position (open or closed) within a defined stroke. FlexFlow provides an option to control the position of individual needle valves independently of each other and Velocity. Through the opening and closing of the needle valve like a profile, pressure peaks are avoided. At the same time, the typical pulsating pressure distribution gives a way to obtain the best consistent pressure curve. As a result, surface flow marks on the part are avoided. More The advantage is that the controlled pressure allows the clamping force to be reduced by up to 20%. At the same time, the weight of the parts can be reduced by 5% based on the optimization of the holding pressure. The 'MX 1600 shows that the lightweight structure and the high-end surface are two trends. ' Andreas Handschke, product technology manager for KraussMaffi concluded.
Other partners participating in this exhibition are Inglass S.p.A. (for molds), Mordan Cardedoni (for material handling equipment) and Single Temperiertechnik.