Experimental and analytical procedures for flow dynamics of sheet molding compound (SMC) in compression molding

A package of procedures have been developed to collect and analyze the response of dynamic variables such as pressure, temperature, and mold separation during the compression molding of Sheet Molding Compound (SMC). From the dynamic responses, the molding process was found to consist of two regions: the flow and the subsequent curing reaction region. With an R-25 formulation and a mold closing rate of 30 mm/s, these two regions are well separated and the average flow time is not significantly affected by the maturation time for the material up to 30 days. Several mechanical parameters were estimated based on relatively simple flow models. The relationship between the press force, mold separation, and mold closing rate is found to be sensitive to the restrictions of the flow.     

汽车用高性能SMC复合材料

本文主要从原材料配方和成型工艺两个方面探讨了如何降低SMC模塑料的收缩率、改善制品的表面质量,来制备具有低收缩率（〈0．05％）、A级表面质量及优良力学性能的高性能SMC复合材料。通过原材料的科学匹配,选择最佳配方,SMC片材生产工艺的严格控制（如树脂糊中水分和粘度的控制）,优化SMC模压工艺参数（如选择合理的铺料方式、两段式压制、合理的加压时机等）,压制出高档的SMC汽车制品。     

Cure shrinkage analysis of epoxy molding compound

EGA (ball grid array), one of the structures Used for semiconductor packages, involves a laminated structure. BGA inevitably involves significant warpage, owing to differences in shrinkage among constituent materials. The extent of warpage is governed by total shrinkage (= cure shrinkage + thermal shrinkage) of the epoxy molding compound that encapsulates the IC chip. In particular, the cure shrinkage exerts great influence on warpage. Cure shrinkage has been understood as the decrease in free volume at the time of curing. However, the cure shrinkage rate cannot be sufficiently explained by the free volume of the cured epoxy resin. We have developed an evaluation method based on the epoxy group reaction ratio, and have eventually confirmed that cure shrinkage depends on the reaction ratio of the epoxy group after curing, and on epoxy group density.     

Simulation of injection–compression‐molding process. II. Influence of process characteristics on part shrinkage

A numerical algorithm is developed to simulate the injection–compression molding (ICM) process. A Hele–Shaw fluid‐flow model combined with a modified control‐volume/finite‐element method is implemented to predict the melt‐front advancement and the distributions of pressure, temperature, and flow velocity dynamically during the injection melt filling, compression melt filling, and postfilling stages of the entire process. Part volumetric shrinkage was then investigated by tracing the thermal–mechanical history of the polymer melt via a path display in the pressure–volume–temperature (PVT) diagram during the entire process. Influence of the process parameters including compression speed, switch time from injection to compression, compression stroke, and part thickness on part shrinkage were understood through simulations of a disk part. The simulated results were also compared with those required by conventional injection molding (CIM). It was found that ICM not only shows a significant effect on reducing part shrinkage but also provides much more uniform shrinkage within the whole part as compared with CIM. Although using a higher switch time, lower compression speed, and higher compression stroke may result in a lower molding pressure, however, they do not show an apparent effect on part shrinkage once the compression pressure is the same in the compression‐holding stage. However, using a lower switch time, higher compression speed, and lower compression stroke under the same compression pressure in the postfilling stage will result in an improvement in shrinkage reduction due to the melt‐temperature effect introduced in the end of the filling stage. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 75: 1640–1654, 2000     

Monitoring cure in sheet molding compound processing

During the sheet molding compound (SMC) compression molding process, a premeasured polymer charge is placed between the heated halves of a mold which are then brought together to squeeze the polymer and fill the mold, after which pressure is maintained while the part cures. The cure stage constitutes the larger part of the molding cycle and thus affords the largest potential for cycle time reduction. In general, cure times in SMC processing are set longer than necessary, since the inherent material and process variation make it difficult to predict cure times with more than 10 to 20% accuracy. Accurate methods to detect the end of cure would be very beneficial and would permit opening the mold as soon as the material has cured, avoiding unnecessary waste of time. In this paper, several techniques that show promise for monitoring the state of cure are reviewed and experimental results given. Their relative advantages and accuracies are compared. In particular, the use of linear variable displacement transducers, pressure transducers, and thermocouples is discussed. We also show how the measurements compare to theoretical predictions of the state of cure.     

Reaction and thermal analysis for SMC (sheet molding compound) molding in complicated geometries

A finite element technique has been developed for coupled reaction and heat transfer analysis in which mass diffusion is negligible. The temperature unknowns are located at nodal points, while the reaction variables (species concentrations, reaction rates) are at the Gauss points in each element. With a mechanistic kinetic model, the SMC (sheet molding compound) cure in 2-D and 3-D geometries was analyzed. The results for plate-and-rib configurations show the progression of cure and heat transfer and the influence of geometry on the progression. The analysis for a flat sheet of SMC in a mold with localized heating using bubblers indicates the thermal interaction between the mold and the curing SMC. Temperature and reaction profiles are given for each case.     

Development of a dilatometer and measurement of the shrinkage behaviour of adhesives during cure

The rheological properties of thermosetting adhesives change from liquid to solid via a gelation phase during cure. Accompanying these changes, shrinkage occurs in the adhesives. A dilatometer, designed in-house and developed specifically for this investigation, enables the volume change of the adhesives to be monitored and measured automatically and continuously during the cure in the heating and cooling phases. Furthermore, the different contributions to the volume changes due to thermal expansion, polymerisation shrinkage, and cooling contraction can be separated. During the cure process, the adhesive not only contracts, but this is also coupled with heat generation due to the exothermic nature of the reaction. By recording the variation of temperature within the adhesives being tested, an indication of the shrinkage rate, and the uniformity of contraction within the adhesive during cure was obtained. It has been shown that among the different volume change stages, the largest change generally takes place in the middle stage of the cure process, due to polymerisation shrinkage.     

SMC轻量化初步探究

为实现SMC轻量化,通过模压工艺,从原材料选型、配方设计以及工艺过程控制三个方面对轻质SMC(片状模塑料)进行了探究。首先,通过研究不同类型中空玻璃微珠(HGS)对制品比重、光亮度以及弯曲强度的影响发现,VS5500和H40适合作为轻量化SMC轻质填料,制品的设计密度和真实密度比较接近,且力学性能损失较小。其次,通过配方设计,研究了中空微珠用量、增稠剂类型以及增稠剂用量对制品比重的影响。同时研究了玻纤含量和树脂类型对制品力学性能的影响。研究结果表明,轻质SMC的设计密度不能过低,否则制品中HGS的破损比例将会增加。研究发现EK100作为增稠剂,树脂糊前期粘度可以有效控制,后期粘度快速上升,可以有效防止中空微珠相分离的发生。此外,随着玻纤含量从25%增加到30%,制品力学性能呈现增加趋势,弯曲强度从148 MPa增加到172 MPa,但随着玻纤进一步提高,弯曲强度反而出现大幅度衰减,降到140 MPa。通过研究三种不同类型树脂对制品外观和力学性能的影响,使用P18-03树脂压制的制品外观最好,其弯曲强度为172 MPa,满足汽车外饰件力学性能要求。最后,通过工艺过程控制,研究了微珠处理工艺对制品比重的影响。结果表明,烘干处理的HGS可以有效降低树脂糊的水含量,从而保证树脂糊后期粘度可以达到适合模压的窗口。     

Practical guidelines for predicting steady state cure time during sheet molding compound (SMC) compression molding

The longest part of the molding cycle during SMC compression molding is the curing stage. Thus it is extremely important to be able to predict its duration to estimate the cost of manufacturing a new part. During an SMC molding cycle, the mold surface temperature drops suddenly when it contacts the cold charge. The surface temperature then gradually recovers as heat is conducted from the interior of the mold and the resin releases heat during curing. In general, this exchange of heat remains locally unbalanced, causing a gradual decrease in the local surface temperature. To avoid blistering, the cure time must be increased with consecutive moldings until a steady state value is achieved (t_css). In this paper, we present a series of charts that can be used to estimate the steady state cure time for new parts. These values can then be used to estimate the manufacturing cost.     

Development of rapid heating and cooling systems for injection molding applications

The injection molding process has several inherent problems associated with the constant temperature mold. A basic solution is the rapid thermal response molding process that facilitates rapid temperature change at the mold surface thereby improving quality of molded parts without increasing cycle time. Rapid heating and cooling systems consisting of one metallic heating layer and one oxide insulation layer were investigated in this paper. Design issues towards developing a mold capable of raising temperature from 25°C to 250°C in 2 seconds and cooling to 50°C within 10 seconds were discussed. To reduce thermal stresses in the layers during heating and cooling, materials with closely matched low thermal expansion coefficient were used for both layers. Effects of various design parameters, such as layer thickness, power density and material properties, on the performance of the insert were studied in detail with the aid of heat transfer simulation and thermal stress simulation. Several rapid thermal response mold inserts were constructed on the basis of the simulation results. The experimental heating and cooling response agrees with the simulation and also satisfies the target heating and cooling requirement.     

Optimization of polyester sheet molding compound. Part II: Theoretical modeling

A mechanistic kinetic and heat transfer model is used to describe the cure of sheet molding compounds (SMC). Kinetic parameters such as rate constant of initiator decomposition and rate constant of propagation are estimated from the induction time and the time to reach the peak exotherm of isothermal reaction curves measured by the differential scanning calorimetry (DSC). Temperature and conversion profiles inside plate sections of SMC parts during molding are measured. The predicted results compare well with the experimental data except the limiting conversion. A set of predictive parameters are proposed from this model as guidelines for the optimal molding of SMC. Several moldability diagrams are also constructed which can be easily used to design the optimum SMC recipe for a given processing condition.     

不饱和聚酯片状模塑料的研究

采用聚氨酯预聚物作增稠剂对带端羟基的不饱和聚酯进行增稠,制备出一种新型的不饱和聚酯片状模塑料(SMC),并研究了其增稠性能、增韧性能及贮存稳定性。结果表明,增稠剂PU400的用量要控制在8％～10％,否则树脂糊无法正常浸渍玻璃纤维;不饱和聚酯SMC的体积收缩率随PU400加入量的增加而明显变小;当PU400含量为36％,时,不饱和聚酯SMC固化物的拉伸强度、断裂伸长率、冲击强度都维持在一个较高的水平;该不饱和聚酯SMC有良好的贮存稳定性。     

Simulation of cavity filling and curing in reaction injection molding

This report describes a procedure to stimulate the reaction injection molding process. The analysis considers the conversion that occurs during cavity filling with reactive fluids and the subsequent cure in the mold based on initial conditions derived from the filling analysis. Extensive conversion can occur during cavity filling when highly reactive resins are used. High conversion material with attendant high viscosity can be found in the cavity during filling without flow seizure because the conversion is non-uniform. The overall cycle time can be decreased by promoting conversion during cavity filling as long as flow seizure is avoided. Temperature and conversion profiles during cure in the mold elucidate thermal runaway and its importance in reaction injection molding. The simulation can be used to explore material and process parameter sensitivity, predict the cycle time and the maximum exotherm temperature, and evaluate moldability.     

Effect of two stage pressure molding on surface quality of sheet molding compounds

The goal of this work was to investigate the effect of two stage pressure molding on the compression molding of a sheet molding compound (SMC). It has been shown in previous studies that a rapid drop in pressure during SMC curing significantly reduced severity of sink marks. This study concentrated on a method of predicting the optimum time during curing to release pressure by examining material behavior through process data from in-mold sersors. A simple control scheme was them applied for automatic pressure release at the optimum time corresponding with the peak of the material expansion and the onset of the reaction exotherm.     

基于正交试验的高铁橡胶外风挡注射成型工艺参数优化

基于Moldflow软件,采用正交试验和响应曲面法,对高铁橡胶外风挡注射成型的模拟方案优化设计,并对注射成型工艺参数进行研究。结果表明:模具温度是影响橡胶外风挡顶出时的体积收缩率和缩痕指数的最显著工艺因素,其次分别是熔体(胶料)温度、保压时间、保压压力、注射时间;优化的注射工艺参数为:模具温度185℃,熔体温度65℃,注射时间160 s,保压时间14 s,保压压力110 MPa。在此工艺参数下的橡胶外风挡顶出时的体积收缩率最大值为4.165%,缩痕指数最大值为5.103%。     

Optimization of polyester sheet molding compound. Part I: Experimental study

A series of differential scanning calorimetry (DSC) and molding experiments were carried out to measure the effect of curing agents, namely initiators and inhibitor, on the SMC reaction. Results showed that the induction time, the reaction rate, and the limiting conversion of sheet molding compounds can be modified through the change of curing agents. The SMC resin with a higher concentration of low temperature initiator and molded at higher temperature may cure in a shorter period of time and reach a higher conversion. The shortened scorch time and shelf life can be balanced by adding small amount of inhibitor. Surface quality of molded SMC parts measured by solvent extraction process showed that limiting conversion is an important factor in SMC molding.     

Void formation and transport during SMC manufacturing: Effect of the glass fiber sizing

The present study investigates the origin of voids in sheet molding compounds (SMCs) sheets and their transport during the manufacturing steps. Paste mixing, impregnation, thickening, and molding have been performed with five different SMC sheets, one without fibers and the others with four different types of glass fiber bundles. The fiber surface energy and bending rigidity were quantified, together with the paste surface energy. Void content was then measured at each manufacturing step. Two main void origins in SMC sheets have been observed: (i) air entrapment during paste mixing and (ii) poor bundle impregnation. These voids may be largely removed during SMC manufacturing. The quality of impregnation and void elimination during the flow is found to depend on the bundle characteristics (rigidity and surface energy) conferred by their sizing and over sizing. POLYM. COMPOS. 27:289–298, 2006. © 2006 Society of Plastics Engineers     

Sheet molding compound characterization using spiral flow

Sheet molding compound (SMC) is a fiber‐reinforced polymeric composite. It is often used in automotive, marine, and industrial applications over other materials because of its high strength to density ratio, resistance to corrosion, and low cost. There is a demand in the SMC industry to be able to characterize SMC processability. This is particularly true for heavy truck body panels, one of the fastest growing applications of SMC. Because of their large size and high strength requirement, the molding forces have a major influence in the molding cycle. Also because of the long flow paths involved, the ability of the paste to carry glass needs to be properly characterized when developing new SMC materials. In this article, we demonstrate the benefits of using spiral flow as a processability tester. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Internal stress control in epoxy resins and their composites by material and process tailoring

The development of internal stress during cure of epoxy and hyperbranched polymer-modified epoxy resins was characterized, taking into account the evolving viscoelastic properties, the volumetric shrinkage due to the chemical reaction, and the thermal expansion. A criterion for void formation during cure in a constrained mold was proposed, providing guidelines for the construction of a process window for manufacturing of void-free composites. It was shown that the internal stress development in epoxy resins during cure is strongly influenced by the presence of hyperbranched polymer modifiers. The role of these modifiers was illustrated for the case of autoclave processing of glass fiber/epoxy composites. This study showed that higher fiber volume fractions could be used with hyperbranched polymer-modified resins than with unmodified resins, for producing void-free laminates. It also appeared that by suitable tailoring of the process cycle, a fully stress-free laminate could be obtained after cure, using the modified resin.     

A study of the impact behavior of chopped fiber reinforced composite

The impact behavior of sheet molding compound (SMC) plaques was determined by using an instrumented Instron puncture test machine and the failure mechanism was qualitatively assessed by examining the damage. The impact response of SMC in terms of the load-deflection curve is fairly consistent and shows the characteristics of a composite, intermediate between a brittle and a ductile material. At the speed of 2 m/s (about 5 miles per hour) the fracture energy, i.e., energy to break, was determined to be about 10 J for a regular 3 mm thick R-25 SMC panel. This value decreases exponentially with a decrease in the thickness of the panel (power of 2.7). The failure process could also be affected by the material factors (resin and fibers used in the composite). For instance, an examination of the length distribution of the fibers in the damage region indicates that a combination of fiber pull-out and severe fiber breakage have contributed to the impact resistance. Also, the fiber length in the composite could alter the failure modes. With the 25 mm fibers, the damage consists of an even mixture of fiber breakage and fiber pull-out, but with a mixture of equal numbers of longer (38 mm) and shorter (13 mm) fibers in the composite, the damage is shifted to predominantly breakage of the longer fibers.