Category: Engineering: Materials and BioengineeringRMSST1/8/14By: Jacob Brown

EFFECT OF MOLD RELEASE COMPOUNDS

ON MOLD RELEASE QUALITY

Mold release compounds are commonly used in the molding process to reduce adhesion between a molded object and the surface of the mold it is molded in.

The problem in this process is that previous and even current compounds are both inefficient and possibly harmful to the environment.

Now, more people are turning towards a newer, more efficient and safer release compound to release and protect their molds.

One downside to the turnover to these new compounds is that they might not know what they are getting into, or if the compound is even effective.

This uncertainty is the basis for my research and experimentation.

PURPOSE/ RATIONALE

No real in depth research has been done The only claims made concerning the compounds are

those that were instituted by the company producing them

The compounds were not shown to have been tested yet (possibly due to their recent creation and introduction)

BACKGROUND RESEARCH

The Independent Variables for this project are: Diamondkote Compound Aqualift Compound

The Dependent Variables for this project are : Surface quality of the molds

Smoothness/roughness Pitting Marring Visual Deforming

IVS AND DVS

Of the two compounds and one control tested; if compound Diamondkote is tested, then it will create molded objects with the greatest surface quality.

HYPOTHESIS/ GOALS

1. Gather materials (Mold, timer, silicone rubber, Aqualift/ Diamondkote compounds, goggles, Dino-Lite, logbook, and pen)

2. Control: Take mold, set on flat surface, do not coat with compound, fill to surface with silicone rubber, let harden, pull mold out, label, set aside. Repeat 2 more times

3. Aqualift: Take mold, set on flat surface, do not coat with compound, fill to surface with silicone rubber, let harden, pull mold out, label, set aside. Repeat 2 more times

4. Diamondkote: Take mold, set on flat surface, coat with Diamondkote compound fill to surface with silicone rubber, let harden, pull mold out, label, set aside. Repeat more times

PROCEDURES

PROCEDURES CONTINUED

Dependent Variable: Temperature, Roughness, ShearingConstants: The time, RPMs, depth, drill, application method, and drill bit type used will all be the same.

IV: Mold Release Compound UsedGroups Mold w/o Release

Compound (Control)

Diamondkote Compound

Aqualift Compound

Trials 3 3 3

Junior ApplicatorStand Up Drill PressLab Goggles IR Temperature ThermometerMQLs (LB 1000, 1100, 2000, 6000, and 6100)6 Cobalt Infused Drill BitsAir CompressorSteel Bar StockAluminum Bar StockLog BookPen

MATERIALS

In disfavor to my hypothesis, after testing, it was determined that lubricants LB 6000 and 6100 outperformed lubricant LB 1000

EXPERIMENTATION RESULTS

CHARTS/ GRAPHS (ALUMINUM)

Control LB1000 LB1100 LB2000 LB6000 LB61000

0.5

1

1.5

2

2.5

Mean Temp Increase of Drill Bits on Aluminum (Celsius)

Mean Temp Increase of Drill Bits on Aluminum (Celsius)

CHARTS/ GRAPHS (STEEL)

Control LB1000 LB1100 LB2000 LB6000 LB61000

0.2

0.4

0.6

0.8

1

1.2

Mean Temp Increase of Drill Bits on Steel (Celsius)

Mean Temp Increase of Drill Bits on Steel (Celsius)

How to properly use a drill press, applicator, and IR thermometer

How to use ANOVA and Minitab to analyze resultsHow the effects of any form of lubrication in the

drilling process (MQLs, flood lubricants, etc) can increase tool life

WHAT WAS LEARNED

Mrs. Baskett for actually making this project feasible by taking the initiative, and by helping me in the early stages of my project

Mr. Bolen for allowing me lab time to work on my experimentation, and for helping me with the usage of Minitab

RMSST for allowing me to use their equipment and tools

ITW Fluids, Bob Romines, and Rob Myers for allowing me to use their applicator, MQLs, and IR thermometer for testing

ACKNOWLEDGEMENTS

Bienkowki, K. (1993, Apri l) . “Coolants & lubricants – Staying pure”,. Manufacturing engineering , pp. 55-61.

Boelkins, C. (2009, March). MQL: Lean and Green. Cutting Tool Engineering .

Davim, J . S. (2006). Experimental studies on dri l l ing of aluminium (AA1050) under dry, minimum quantity of lubricant, and flood-lubricated conditions. PROCEEDINGS- INSTITUTION OF MECHANICAL ENGINEERS PART B JOURNAL OF ENGINEERING MANUFACTURE , 1605-1612.

Heisel, U. (2009, April 12). Publication Server of the University of Stuttgart. Retrieved from The University of Stuttgart: http://el ib.uni-stuttgart.de/opus/volltexe/2010/5072/pdf/hei135.pdf

ITW ROCOL. (2010). Junior Applicator . Retrieved from ITW ROCOL: http://www.itwfpg.com/acculube/applicators/junior.html

Milton, R. (2009, June 30). Metal Machining - A Glimpse at Different Types of Machining Operations . Retrieved from EzineArticles.com: http://ezinearticles.com/?Metal-Machining---A-Glimpse-at-Different-Types-of-Machining-Operations&id=2547806

Simon, T. (1999). The actual stage of machine-tool technology. Revista Maquinas e Metais , 88-108.

REFERENCES

Men of Distinction Mostly community service based group Also helps with assisting teacher activities and school

related functions I have been a part of this group for a little over a semester,

and have helped with a breakfast, dance setup, and after school get-together through it.

ACCOMPLISHMENT