aaron lapinski. to prove to industry that using a temperature controlled mold helps improve cycle...
TRANSCRIPT
Aaron Lapinski
To prove to Industry that using a temperature controlled mold helps improve cycle consistency and part dimensions
To determine how a temperature controlled aluminum mold and non-temperature controlled Ren Shape mold of the same dimensions will affect shrinkage of a thermoformed ABS part.
To gain experience on the set up and operation of the industrial scale MAAC thermoformer
To develop a thermoforming lab experiment on the MAAC thermoformer for student education in Pennsylvania College of Technology’s BPS program.
To demonstrate to the thermoforming industry that a temperature controlled mold is essential for maintaining consistency in the finished product.
MAAC ThermoformerREN MoldAluminum temperature controlled
moldCirculator
Sterlco VISION 4410-C 250°F max temp
Hardness Density Density Tensile Compressive Compressive Modulus Flexural Flexural Glass Coefficient
Colorg/cc lbs/ft.3 Strength Strength Elasticity (psi) Strength Modulus Trans. Thermal
psi psi psi psi Temp (°F) Expansion (in/in/°F)
Ren Shape 472 81 0.88 55 7,000 10,900 460,000 9,540 416,000 248 25.8 x 10-6 Lt. Gray
Spartech ABS Amorphous Terpolymer .125 x 40 (W) x 22.5 (L) inches Premium Grade Natural Polished Finish
Sheet temperature 285-400of 340oF
Circulator settings 175-215oF 200oF
De-molding temperature 180-190oF
Dry ABS 180°F 24 hours
Hang the Mold Placement Center
Form partsCollect DimensionsPerform Mechanical Testing
Turn on Main Power Turn on Air Turn on Vacuum Turn on Fume Hood Enter MAAC software
PC62 Log in
Load or Build Program
Choose set up Turn on Vacuum
Pumps and Oven Index Clamps into
Oven on Diagnostics screen
Remove preheated clamps from oven
Open clampsPlace sheetStart cycle
Ren Shape Mold Production Trial
Aluminum Mold Production Trial
DOE
TimersOvensEncoders I.R. EyeMAACFlex
380°F55 Second Forming Time
HumidityRoom TemperatureMold Temperatures
Front Back TopClamp Temperature
Sheet Temperature De-molding Molding
B 8(Y1) 7(Y2) 6(Y3)
9 (X2) 5 (X2)
10 (X1) 4 (X1)
F 1(Y1) 2(Y2) 3(Y3)
Jig Dimensions
Y Direction (MD) 15.875
X Direction (TD) 33.500
Mold Dimensions
Y Direction (MD) 15.25
X Direction (TD) 31.125
Mold Dimensions
Y Direction (MD) 15.25
X Direction (TD) 31.125
Mold Dimensions
Y Direction (MD) 15.25
X Direction (TD) 31.125
Run Cooling Time Circulator Temp I.R. Eye Temp
1 - - -2 - - +3 - + -4 - + +5 + - -6 + + -7 + - +8 + + +
High Low
Cooling Time 100 40
Circulator Temp 205 170
I.R. Eye Temp 400 340
HolesStuck to mold
cost/hr ($)
# of hours
Number of sheets
cost per sheet
Material Cost n/a n/a 75 $40.00 $3,000.00
Mentor 50 20 n/a n/a $1,000.00
Consultant 50 10 n/a n/a $500.00
Labor 18 100 n/a n/a $1,800.00 Thermoformer
cost100 85 n/a n/a $8,500.00
Testing Equipment
100 15 n/a n/a $1,500.00
REN Mold Cost n/a n/a n/a n/a $3,800.00 Aluminum Mold
Cost n/a n/a n/a n/a $7,500.00
Total cost$27,600.0
0
More Predictable dimensionsHigher mechanical propertiesShorter cycle times
Forming time from 100 to 55 seconds
Ren
ShapeAluminum
Heating Time (seconds) 120 120Forming Time (seconds) 100 55Ejection Time (seconds) 2 2
Remove and load next part 30 30Total (seconds) 252 207
Time saving (seconds)/Part 45Time saving (seconds) /24 hour
day1080
Extra Parts/day 4.3Extra Parts/ 5 day week 21.4
Extra Parts/20 day month 85.7Extra Parts/50 week year 1071.4
Cost ($) / Sheet $40.00Extra Production / Year ($) $42,857.14
REN Mold Cost $3,800.00 Aluminum Mold Cost $7,500.00
Total Profit $39,157.14
Lack of KnowledgeMeasurement DeviceDryingGridsMold PositionCirculator Machine access
To determine how a temperature controlled aluminum mold and non-temperature controlled Ren Shape mold of the same dimensions will affect shrinkage of a thermoformed ABS part.
To gain experience on the set up and operation of the industrial scale MAAC thermoformer
To develop a thermoforming lab experiment on the MAAC thermoformer for student education in Pennsylvania College of Technology’s BPS program.
To demonstrate to the thermoforming industry that a temperature controlled mold is essential for maintaining consistency in the finished product.
Mr. Roger Kipp Mr. John Bartolomucci Mr. Gary McQuay Mr. Howard Troup Mr. Todd Kennedy Mr. Todd Crismer Mr. Brett Braker Mr. Chris Denmon McClarin Plastics Inc. Spartech Plastics Tooling Technology KYDEX LLC.
"Acrylonitrile, Butadiene and Styrene (ABS) - FormTight Plastic
Thermoforming." Custom Packaging - Clamshells, Food Packaging, Blister Packaging - FormTight Plastic Thermoforming. Web. 27 Oct. 2010. <http://www.formtightinc.com/materials/ABS/default.html>.
"Acrylonitrile Butadiene Styrene." Wikipedia, the Free
Encyclopedia. Web. 27 Oct. 2010. <http://en.wikipedia.org/wiki/Acrylonitrile_butadiene_styrene>.
"Acrylonitrile-butadiene-styrene Copolymer (ABS) (chemical
Compound) -- Britannica Online Encyclopedia." Encyclopedia - Britannica Online Encyclopedia. Web. 27 Oct. 2010. <http://www.britannica.com/EBchecked/topic/4259/acrylonitrile-butadiene-styrene-copolymer>.
"ASTM D638 - 10 Standard Test Method for Tensile Properties of
Plastics." ASTM International - Standards Worldwide. Web. 24 Apr. 2011. <http://www.astm.org/Standards/D638.htm>.