Académique Documents
Professionnel Documents
Culture Documents
with ACRYLITE
Processing Guidelines
Contents
Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Physical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Technical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Product Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1 Storage
4.2 Material extraction
4.3 Material transport
4.4 Silo installations
4.5 Drying requirements
4.6 Miscibility and use of regrind
5
5.1 Plasticization
5.2 Barrel melt temperatures
5.3 Metering
5.4 Back pressure
5.5 Injection speed
5.6 Hold/pack pressure
5.7 Cooling time
5.8 Mold temperature
5.9 Injection compression molding
6
Introduction
Sustainability
ACRYLITE can be completely recycled, either by chemical conversion back to its base materials or by direct reuse (regrind).
These aspects, together with its environmentally sound production,
contribute to the materials sustainability. To prove this sustainability, we have subjected ACRYLITE to a comprehensive life cycle
assessment from cradle to grave. From production to recycling,
the different environmental impacts of ACRYLITE, including its
greenhouse gas reduction effect due to the materials longevity,
have been determined and confirmed in this Life Cycle Assessment
(LCA) in accordance with DIN ISO 14040ff. ACRYLITE also makes
an essential contribution to reducing the impact on the environment
during the manufacturing process. According to recent calculations,
the carbon dioxide equivalent is 3.8 kg CO per kg of molding
compound.
1. Products
The ACRYLITE molding compounds described below are used for injection molding. You can find more products with
other properties and fields of application in our Molding Compounds Product Portfolio brochure or on our website
www.acrylite-polymers.com
1.1
1.2
Basic ACRYLITE
molding compounds
ACRYLITE Hi-Gloss
for high-gloss surfaces
Depending on the grade, products of the
ACRYLITE Hi-Gloss family offer a range of
higher heat deflection temperature under
load, better flow and higher impact strength.
Key property
Mechanical strength
Hardness
Elongation at break
Flow
1.3
1.4
ACRYLITE Resist,
impact-modified (zk)
ACRYLITE Satinice,
light-diffusing (df)
Mechanical strength
increasing
Impact strength
increasing
Hardness
decreasing
Elongation at break
increasing
decreasing
Flow
decreasing
1.5
1.6
ACRYLITE LED,
for backlit and edge-lit
LED applications
ACRYMID is a polymethyl methacrylimide (PMMI) with a high heat deflection
temperature under load that is especially
suitable for high temperature applications
such as headlamp lenses, drum lenses and
built in furniture lighting. Besides their
high light transmission clarity and excellent
strength and rigidity, these specialty molding
compounds offer high chemical resistance
and extremely stable optical values after
long term exposure to heat.
1.7
1.8
Colors
2. Physical Properties
The many different grades of ACRYLITE molding compounds are distinguished by their physical properties.
Besides the specific characteristics of PMMA described here, you will find detailed material data on all product grades in
our Molding Compounds Product Portfolio brochure or on our website www.acrylite-polymers.com.
Our molding compounds are also included in the Campus material database, together with comprehensive values and
graphs (www.campusplastics.com).
2.1
2.2
2.3
Thermal properties
Mechanical properties
Electrical properties
2.4
Other properties
Parts made from ACRYLITE molding compound absorb very little water. Even after
prolonged storage in water, water absorption is normally only about 2%, and even
less under normal conditions. This does not
affect the electrical values, dimensional stability, strength and other physical properties to
any noticeable extent.
Water vapor permeability is within the
normal range for thermoplastics.
The permeation coefficient is 4.5 1010 g
cm/cm h Pa.
The Flash Ignition Temperatures range from
720F to 750F (382C to 399C) and Self
Ignition Temperatures all measure 850F
(454C) according to ASTM D1929 .
The ignition temperature of all ACRYLITE
molding compounds is 806F (430C)
according to DIN 51794. They burn without
soot and do not release any toxic gases.
Fire behavior is classified as B2, normally
flammable, in accordance with DIN 4102.
Underwriter Laboratories classifies
ACRYLITE molding compounds in class
UL 94-HB and are (f1) outdoor rated.
3. Technical Requirements
Many thousands of articles, from parts weighing a few ounces (grams) to objects weighing several pounds (kilograms),
are produced on injection molding machines for a wide variety of applications. ACRYLITE molding compounds are user
friendly and easy to process on conventional machines.
The requirements for achieving the best and most economical product results are as follows:
1) Design the plastic part to optimize the material and manufacturing process and select the most suitable
ACRYLITE molding compound grade
2) Skillful handling and drying of the molding compound
3) A sufficiently powerful injection molding machine expertly designed, and precision built injection mold
4) Correct processing techniques, skillful post treatment, clean production rooms, and equipment
3.1
Molded part
The 2006 VDI guideline "Gestalten von
Spritzgieteilen aus thermoplastischen
Kunststoffen" (Designing injection-molded
parts made from thermoplastics) gives
a good summary of all important d
esign
points. In principle, the statements it contains
also applies to parts made from ACRYLITE
molding compounds.
3.1.1
Dimensioning and design
First of all, it needs to be clarified if the
planned part will be exposed to short term
or permanent mechanical stress. The values
presented in the table of p
roperties, divided
by a factor of 2 to be on the safe side, generally apply to short term mechanical stress.
For exposure to permanent mechanical
stress, the permissible stress should not
exceed 1450 psi (10 N/mm) wherever
possible. These values apply under normal
conditions.
If a part is exposed to higher temperatures,
the safety factor should also be increased
because the mechanical values deteriorate at
elevated temperatures.
If components are subject to the influence of
solvents or plasticizers, their chemical resistance should be examined beforehand and
the safety factors correspondingly elevated.
Thin-walled parts
Wall thicknesses of less than .04 in (1 mm)
are very demanding in terms of processing
and design of the molded part. Thin-walled
parts often show deflection at temperatures
below the stated values because of their
higher molecular orientation due to rapid
cooling. This may lead to warpage at service
temperatures somewhat below the stated
heat deflection temperature.
Notch Effect
Since PMMA is sensitive to notch effects
due to its specific properties, sharp edged
transitions should be avoided when designing
the shape. Even small radii at transition sites
considerably increase resistance to breakage.
Since gate marks, especially pin gate marks,
may also count as notches, they should if
possible be located at locations on the part
that are exposed to the least amount of stress.
Weld Lines
Weld lines occur when two melt flow fronts
meet when the injection is carried out around
cores (all kinds of apertures), or when there
are local differences in flow resistance.
Apart from causing optical defects, they may
also impair the mechanical stability of the
molded part.
Thick-walled parts
Wall thicknesses of 1 in (30 mm) and more
can be injection molded with impeccable
results, given sufficient time and t echnical
effort. Injection compression molding
combined with a mold temperature that can
be varied throughout the injection molding cycle offer advantages for producing
extremely thick-walled parts.
20
15
10
5
0
385
435
485
535
Compound temperature, F
ACRYLITE L40
ACRYLITE H12
ACRYLITE M30
ACRYLITE H15
Undercuts
Undercuts are not recommended in parts
made from ACRYLITE molding compounds
since they may lead to breakage of the part
during demolding. Molds with sliders are a
better way to obtain undercuts.
Metal Inserts
Metal inserts encapsulated by injection
molded in parts made from ACRYLITE
molding compounds may be possible
depending on the application. The concern
to watch out for here is increased stress
around the insert due to mold shrinkage
and different coefficients of linear thermal
expansion. Preheating the inserts has a
favorable influence on the overall stress
level of the molded part.
3.1.2
Mold filling
The flow curves shown above help to
estimate the mold filling for materials under
consideration using the wall thickness and
the flow path to determine the most suitable
material for the application. The table above
shows you examples of flow curves for basic
ACRYLITE molding compounds.
ACRYLITE 8N
Draft angles
Demolding should be supported by draft
angles on the molded part. A draft angle of
at least one degree should be provided. A
well polished mold surface or defined surface
texture will also help improve demolding.
DE
DME
18%
22%
60%
Screw diameter
Diameter*
D (in)
Diameter of
metering zone
DME (in)
Diameter of
feed zone
DE (mm)
0.983
0.839
0.669
Pitch
t (in)
0.983
Flight land
width
E (in)
Compression
ratio
KC (in)
Ratio of screw
length/ diameter
L/D (in)
3 0.118
2.0 : 1
20 : 1
1.378
1.205
1.378
1.378
4 0.157
2.1 : 1
20 : 1
1.772
1.567
1.299
1.772
4/60.157/0.236
2.1 : 1
20 : 1
* For larger screw diameters, please take note of the recommendations made by injection machine manufacturers.
3.2
3.3
12
Guideline
Feed zone
L = 12 D (60%)
h = 0.15 D
Compression zone
Material-no.
Designation
Metering zone
L = 4 D (20%)
cylinders
1.8519
31CrMoV9
h = 0.07 x D
1.8550
34CrAINi7
Compression
2.1
1.4122
X35CrMo17
Pitch
1D
1.4057
X22CrNi17
screws
13
0.158"
2
0.787"
0.394"
2.362"
4.252"
4.724"
5.906"
2
1
0,316"
0.158"
0.039"
1
2
A
3
4
4
3
0.196"
B
Fig. 2: Runner
1 and 2 = favorable cross sections
0.158"
1.969"
12
3.4
Injection mold
The mold design and accurate mold
production are crucial for the quality of a
molded part.
3.4.1
Runners
The best cross-sections for runners are
circular or trapezoidal. Elliptical or rectangular
cross-sections are less favorable. (Fig. 2)
This is clearly shown by the example of a
molded part with a gate at the end and a
trapezoidal runner. (Fig. 3)
3.4.2
Cold runner gate
When processing ACRYLITE, it should be
taken into consideration that these molding compounds have a higher viscosity than
other amorphous or partially crystalline
engineering plastics. That is why the thickest
and shortest possible gate and an adequately
sized runner and gate configuration should
be chosen in the mold cavity.
The following gate systems should be considered, depending on the part geometries and
mold systems to be used. To provide good
results when filling the cavity and demolding the part, the gate cross-section should
usually be about one third of the parts wall
thickness, and half the wall thickness for
thick parts.
14
2 = Gate
3 = Spue bush
4 = Sprue
2,283"
2,283"
1
2
3
A
0,944"
r=0
.03
94
"
0.275"
0.393"
0.787"
0.551"
1.771"
Section A-A
B
0.393"
0.196"
0.158"
0.393"
Detail B
0.079"
15
0.158"
Fig. 7: Example of a twelve-cavity injection mold for thin-walled lenses with a restricted gate
which should be kept as short as possible.
The cross section of this particular gate is about 0.0023 in. The edges of the gate towards the
article are slightly rounded in order to prevent a free jet while the compound is injected.
Pin gate
This type of gate is often chosen for multicavity injection molds because the sprue is
automatically removed during demolding,
with no need for post treatment.
The gate vestige produced on the surface of
the molded part can often be concealed from
sight with proper gate location.
Fig. 7 shows an injection mold with 12 cavities for thin-walled lenses with a pin gate.
16
0.177"
0.275"
0.452"
1.968"
0.0394"
1.181"
0.027"
0.275"
0.590"
0.452"
0.059"
Section A-A
0.059"
2.756"
A
0.276"
0.059"
22.047"
1.969"
0.984"
1.575"
0.236"
A
0.394"
Fan Gate
This type of gate is preferred for molded
parts such as rulers, tail light lenses or trailer
windows that must not have any marks on the
visible surface.
To avoid one side loading of the injection
mold and clamping unit, two mold cavities
should be provided for reasons of symmetry.
(Fig. 10)
This also has the advantage that the runner can be appropriately sized to meet the
requirements. The thickness of the gate is
more important than its width. (Fig. 11)
0.039"
0.118"
Section A-A
0.472"
0.236"
0.079"
0.315"
11.027"
0,394"
0.197"
0.984" 0.394"
0.315"
0.236"
0.197"
1.969"
19.685"
0.079"
1.969"
4.331"
17
0.118"
0.551"
2.165"
0.157"
2
0.
0
39
4
0
"
0.
0
79
0.
02
4"
0
.0
59
"
2.953"
0.079"
0
2
0
1
2.362"
0.236"
0.079"
0.472"
cone 23
Cone
23
"
3.4.3
Hot runner systems
ACRYLITE molding compounds can be
processed with hot runner systems either
with open or with shut-off nozzles. These
systems usually ensure low pressure losses
with clearly defined, streamlined runner
cross-sections. (Fig.15)
Fig. 15: Hot runner system with shut-off nozzle and open nozzle
19
3.4.4
Shrinkage of ACRYLITE and
ACRYMID molding compounds
A fundamental distinction is made between
plastics in line with standards for molding
shrinkage, post-shrinkage and overall shrinkage. These shrinkage values are determined
in accordance with ASTM D 955.
Since ACRYLITE and ACRYMID molding
compounds are amorphous materials, the
molding shrinkage is relatively low and postshrinkage is negligible.
Material
Shrinkage
Material
Shrinkage
ACRYLITE L40
0.20.6
0.20.5
ACRYLITE M30
0.20.6
0.30.6
ACRYLITE H12
0.20.6
0.30.6
ACRYLITE H15
0.20.6
ACRYLITE 8N
0.20.5
0.30.6
0.30.6
0.40.7
ACRYMID TT30
0.20.5
0.40.7
ACRYMID TT50
0.20.5
0.30.6
ACRYMID TT70
0.10.4
0.40.7
0.30.6
0.30.6
0.40.6
0.40.7
3.4.5
Venting the mold
The air present in the cavity must be able to
escape during the injection process.
This can usually be done at the parting line
or at the ejector. If this is not possible, the
air is compressed at the end of the flow path
and causes black marks on the molded part
(diesel effect) and on the mold surface.
Permanent injection molding under these
conditions may damage the surface of the
cavity. To ensure reliable mold venting,
venting channels in the parting surface have
Both types of shrinkage are therefore taken
proved useful. A channel that is .0079 to
together. Generally, the molding shrinkage
.0394 in (0.2 to 1 mm) deep can be milled
is different in the direction of flow and at
in the parting surface of the mold. In the
right angles to the direction of flow.
transition to the cavity, an opening that is
Somewhat higher shrinkage values are
about 0.0006 to 0.002 in (0.015 to 0.051
therefore measured in longitudinal direction
mm) deep and 0.2 to 0.4 in (5 mm to 10
for ACRYLITE molding compounds.
The processing parameters also have a major mm ) wide should be inserted. It is advisable
influence on shrinkage. The holding pressure to start with a venting channel of less depth
in order to prevent any flashing.
is crucial. The higher the effective holding
pressure, the lower the resulting shrinkage.
The table above shows shrinkage tolerances
for various products, listed according to
processing conditions.
20
Temperature (F)
266
230
194
158
0.059
0.079
0.098
0.118
0.138
0.157
3.4.6
Demolding the molded part
PMMA is an amorphous polymer with very
low shrinkage. Owing to its mechanical
properties, care must be taken not to deform
the part during removal from the mold.
Otherwise the part may break.
21
Code name
1.2083 ESU
X42Cr14
Stainless steel, very suitable for high-gloss polishing
1.2343 ESU
X38CrMoV51
Hard-wearing steel, very suitable for high-gloss polishing.
Can also be used for large molds.
1.2767 ESU
X45NiCrMo4
Very tough steel, very suitable for high-gloss polishing
1.2764
1.2316
X36CrMo17
Stainless, can be polished to a certain extent
1.2738
40CrMnNiMo864
Steel for very large molds, can be polished to a certain extent
3.4.7
Tool steel and surface treatment
Basic ACRYLITE molding compounds do
not release any corrosive substances during
injection molding that might damage the
mold surface. Conventional types of tool
steel can therefore be used for the cavity
inserts. What is important is the suitability
for polishing. For this reason, very pure
grades of chrome-containing steel with a
homogenous morphology are used.
These are manufactured either by a vacuum
remelting or an electroslag remelting.
(See table above)
Conventional types of steel (e.g. 1.1730)
can be used for the master form of the
mold. In some special cases, such as when
using certain ACRYLITE specialty molding
compounds, the molding may tend to adhere
more strongly to the mold surface. In this
case, it has proved effective to coat the mold
surface with TiN or CrN.
Surface treatment
To obtain parts with a high surface quality
(Class A surface), it is essential to use cavities with completely smooth steel surfaces.
Mirror-gloss surfaces that are free from
scratches and grooves should have an
average roughness of Ra = 0.01 m.
These grades can be obtained either by
manual polishing or diamond polishing.
Depending on the field of application and
requirements, ACRYLITE molding com22
Hyundai
23
4. Product Handling
Special measures need to be taken as regards material handling and processing in order to manufacture parts and s urfaces
that satisfy high optical requirements.
4.1
4.2
4.3
Storage
Material extraction
24
Material transport
Fig. 16: Extracting material from individual bags using a suction conveyor.
To avoid damage to the PE inlet, it is advisable to attach a protective tip to the
sharp end of the suction tube.
Filtered air
Filter 5 m
right
Pellets
wrong
25
4.4
4.5
It is very important to choose the best material for storing ACRYLITE pellets when
installing silos. Since PMMA is very hard
and therefore has an abrasive effect, plastic
materials should not be used for silos.
The same recommendations apply as for
pneumatic conveying units.
Silo installations
26
Predrying
ACRYLITE is incompatible with many other thermoplastics. Even the most minute traces of other plastics
can lead to clouding or milky streaks in the molded
part. Nor are various ACRYLITE products always
compatible with each other.
Drying conditions
The basic rule is to dry the compound at
the highest possible temperature so that
maximum moisture is removed as quickly as
possible.
Individual molding compound grades require
different drying temperatures due to the
different heat deflection temperatures of the
ACRYLITE products.
0.090.30%
0.050.08%
0.04%
4.6
Dry-air-drier
This type of drier provides the best drying
results. Drying is performed by means
of hot, dry air. Almost all of the driers
available on the market are suitable for
ACRYLITE molding compound.
The recommendations as regards type
of construction and choice of material
(stainless steel) in the section on material
extraction and material transport should be
borne in mind.
27
5.1
5.2
Plasticization
Cylinder temperatures
28
In the material feed zone (throat temperature), the temperature should be adjusted to
between 122F to 185F (50C and 85C),
and between 365F to 446F (185C
and 230C) in the first cylinder heating
unit. A higher temperature may be required
in special cases (e.g. ACRYMID molding
compound). If the throat temperature is too
low and the first cylinder zone too cool, this
may cause noise during metering.
If the temperature is too high, this may lead
to bridge-building due to melted pellets and
reduced flow in the feed zone.
For producing molded parts for exacting
requirements, it has proved useful to connect
an external temperature control device to
the cylinder throat to ensure precise temperature control.
5.3
5.4
5.5
Metering
Back pressure
Injection speed
29
5.6
5.7
5.8
Holding pressure
Cooling time
Mold temperature
tk =
s2
aeff 2
In
8
2
m
E
w
w
thickness (mm)
effective thermal diffusivity (m/s)
melt temperature during injection C
cavity surface temperature C
demolding temperature determined via
the cross-section of the molded part C
tk: cooling time (s)
30
5.9
31
Remedies
Problems/Explanation/
possible cause
Check metering
Melt jetting
Check metering
Increase holding pressure
Increase holding time
Check metering
Sink marks
Cold slugs
Overloading
Make sure sprue bushing is conical and oversized in relation to the nozzle
32
Predry material
Decomposition due to
overheating of melt
Moisture content
is too high
Stick/slip effect of
melt on mold surface
Differences in wall
thickness, sharp-edged
transitions
Insufficient pressure or
holding pressure to compensate for shrinkage
Bubbles, voids
Enlarge gate
Pressure losses too high at
the gate/sprue
Remedies
Problems/Explanation/
possible cause
Remedies
Problems/Explanation/
possible cause
Additional ejectors
Contamination
Reduce metering
Fluctuations in metering
due to short or long cycle
interruptions (screw gets
too hot)
Remedies
Mold is overloaded
Rough surface
Inadequate shrinkage
of injected part
Material overheating
and oxidative decomposition/air intake
Contamination during
predrying (soiling in drier,
ambient air unclean)
Clean drier
Filter ambient air
Unfavorable venting
of mold
Optimize predrying
Enlarge gate
Included air bubbles at the edge of a molded part, burning at the end of the
flow path
Differences in
wall thickness
Control temperature of mold halves separately: cool the hollow side more than the
other side
Use a clamping jig when cooling the moldings
33
Remedies
Flashing
Increase mold clamping force
Milky streaks
Completely remove other thermoplastics
by washing
Purge (wash out) the cylinder and screw
with our ACRIFIX sp cylinder/barrel
cleaning agent
Contamination with other
thermoplastics
34
Prevent contamination from other thermoplastics in the drier and/or conveying system
Do not add regrind
Problems/Explanation/
possible cause
35
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