Compression molding is a technique that forms and cures resin under high pressure and heat simultaneously. It was developed in the early 1900s and utilizes molds to shape thermoset or thermoplastic resins into solid parts. Compression molding offers advantages like low cost molds, dimensional accuracy, and fast cycle times. Common applications include automotive body parts, medical devices, and aerospace components. Considerations for the process include mold temperature, compression rate, and curing time.
Compression molding is a technique that forms and cures resin under high pressure and heat simultaneously. It was developed in the early 1900s and utilizes molds to shape thermoset or thermoplastic resins into solid parts. Compression molding offers advantages like low cost molds, dimensional accuracy, and fast cycle times. Common applications include automotive body parts, medical devices, and aerospace components. Considerations for the process include mold temperature, compression rate, and curing time.
Compression molding is a technique that forms and cures resin under high pressure and heat simultaneously. It was developed in the early 1900s and utilizes molds to shape thermoset or thermoplastic resins into solid parts. Compression molding offers advantages like low cost molds, dimensional accuracy, and fast cycle times. Common applications include automotive body parts, medical devices, and aerospace components. Considerations for the process include mold temperature, compression rate, and curing time.
Jesse McGrath Compression Molding: What? Is a processing technique that combines forming the product along with simultaneous curing of the resin. High Pressure Higher Temperature Curing Agent Development 1909 when Leo Hendrik Baekeland phenol-formaldehyde resins Patents on a automatic compression machine date back to 1930 Development of C.M was hindered by reaction knowledge.
Thermosets Heat compression causes an irreversible chemical charge in the plastic which solidifies the part . The plastic wont soften, so the mold doesnt need to be cooled. After short interval, the press is opened and the molded part is removed. Any plastic remaining in the mold is removed by compressed air. The operator breaks the flash.
Thermoplastic Preheated in a dielectric heater. The mold is cooled to a point where the plastic retains enough integrity to be removed from the mold without partial distortion. The same steps used for thermosets are repeated here as well. Advantages Molds are inexpensive Labor costs vary Great for large parts Minimum waste Dimensional accuracy Warping and shrinkage minimized Fast cycle(1-5 minutes)
High volume output High quality surfaces Complex parts Disadvantages No delicate pieces Uneven parting lines High initial investment secondary operations (e.g. trimming) Mold depth is limited Product consistency
Considerations Mold heating Temperature, heating rate and heating method Compression rate Max compression force Curing time How long until part can be removed from mold. Mold cooling rate Mold cycling rate
Equations T * = (T-T 0 )/(T 0 -T ad ) = Reduced Temperature t * = (xt)/(h) 2 =Reduced Time
y* = y/h = distance form slab centerline T 0 =Original Temperature T ad =Adiabatic Temperature X=Thermal Diffusivity h=Heat Transfer Coefficient between. Mold and polymer h= half thickness of slab. Range of Materials Thermoset Thermoplastic Bulk molding compound (BMC) Sheet molding compound (SMC) Unidirectional tapes Woven Fabrics Chopped Strands Randomly oriented fabrics Preforms
Pellets Sheets Extruded
Elastomers Extruded Typical Products Automotive parts Hoods, bumpers, fenders, spoilers, etc. Medical equipment Caps and plugs to blood separation machines and ultrasound equipment Aerospace Electrical connectors to guided missiles
http://www.tqc.co.uk/images/bumper7.jp g http://www.rdmoulds.com/rdmoulds/ma/24%20fr ont%20bumper%20molds.jpg http://www.compositesworld.com/uploadedimages/Publications/CW/Artic les/Internal/hoodHyundai.jpg Transfer Molding Hybrid between Injection and Compression molding Cross linking reaction is started prior to placement in the mold Resin is heated and put under pressure Slushy mix is then forced into the Mold.
This point on Transfer molding follows the Compression molding process. Benefits/Constraints of T.M. Advantages Disadvantages Rapid production rates Largest Benefit over C.M. Geometrical Accuracy Intricate Parts Possible
Expensive molds Expensive equipment Much material loss Size limitations of products References
Welding Engineering Prof. Dr. D. K. Dwivedi Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee Module - 4 Arc Welding Processes Lecture - 7 Gmaw