Blow_Molding.pdf

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EMA 4666C - Polymer

Processing

Blow Molding Operations

Dr. Anthony Brennan

University of Florida

Department of Materials Science &

Engineering

EMA 4666C - Polymer Processing 18/24/2012



Agenda

• IntroductionExamples of blow molded

products

General Principles

Equipment Design

• Process Parameters

Troutonian Viscosity

Flow

Properties




Blow Molded Products




Blow Molding Examples

• Automotive

• Bottles

• Storage Vessels

• Films

• Sporting Goods




Rubber Parts

• Automotive

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5

http://www.tigerpoly.com/images/Air%20Induction%20Pix/AIC.jpg



Co-extrusion Blow Moldingof Thermoplastic

Elastomers

Phone: (573) 221-8933Fax: (573) 221-7144

www.buckhornrubber.com





XY Manufacturing System




Total System Cost Reduction

– Up to 50% reduction in tool leadtime and tool cost.

– Up to 70% reduction in systemweight.

– Overall piece price reduction.

– Complex system designs.

– Reduction in number of systemcomponents.

– Buckhorn wi ll design a systembased on your parameters. Datatransfer capabili ties areavailable.

– A variety of plast ic mater ialformulations are available toselect the best, cost effectivematerial for your application.






XY Blow Molding Cycle

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EMA 4666C - Polymer Processing

11

Parison enters mold Mold is closed, air introduced

Mold opens Part is trimmed



Features & Benefits

•Dual durometer

•Part consolidation

•Seamless parts

•Produces complex

parts with reduced

flash

•Parts incorporate

both strong, rigid

and soft, flexible

features



Inserts in Blow Molded Parts




Secondary Operations




Parts Trimming

•Produces consistently

trimmed/drilled parts

•Quick cycle time

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EMA 4666C - Polymer Processing

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Blow Molding Thermoplastic

Elastomers

•Thermoplastic

elastomers for

hard-soft-hardapplications

• A wide range of

fi llers are available

for improvingmaterial properties

over different

temperature rangesEMA 4666C - Polymer Processing 168/24/2012



Blow Molding Material

•Polypropylene

•Polyethylene

(High or lowdensity)

•Polyamides

(Nylons)

•Santoprene

•Geolast



Blow Molded Products

• Air Intake Hoses• Air Resonators

• Steering Column

Cover• Gas Intake Tubes

• Automotive Air

Ducts

• Fluid Reservoirs

• HVAC Ducts




Applications

•OEM Truck

• Agriculture

•Lawn & Garden

•Marine

•ConstructionEquipment

•Recreational Vehicles

• Automotive

•Industrial

•Gen-Set



Tooling


High-performance machined aluminum or

cast aluminum production tooling



Prototype Tooling


High-performance cast aluminum



Lead Times



Rubber Injection Molded Parts




Blow Molded Insulated Coolers




Insert Blow Molded Tanks




Blow Molding Process Equipment




Bottles

•Bottles•http://www.uniloymilacron.com/u

nirecip.htm


Injection Blow

IBS 122 Injection Blow

•Completely refurbished

•2.5 inch screw •250 gram shot size

(HDPE)



Injection Stretch Blow


U750-120 (1) & U750-130

(2) Injection Stretch-Blow

for PET - WIDEMOUTH

•Single-stage, 4-station

process (conditioning)

•120-ton or 130-toninjection

•2 to 10 cavities

•Accepts common

tooling •Movie of Process:

http://engr.bd.psu.edu/pkoch/plasticdesign/Blow_Molding.htm



Extrusion Blow Molding Process




Extrusion Blow Molding Cycle




Continuous Blow Molding Equip


HDIE

HEAD

EXTRUDER

MOLD

CONTINUOUS EXTRUSION

BLOW MOLDINGPARISON



CBM – Ram Accumulator


RAM ACCUMULATOR

SHUT-OFF VALVE

RAM ACCUMULATOR BLOW

MOLDING MACHINEPARISON

MOLD



Extrusion Blow Molding


Jomar Continuous Extrusion Blow Moulding

http://www.jomarcorp.com/ebm_process.asp



Parison Molding


Parisons



Injection Blow Molding

•Station 1:

Injection MoldPreform(Parison)

•Station 2:Inflate

•Station 3: Strip

•Time: 32bottles percycle. 9 to 20sec per cycle.




DIE SWELL BEHAVIOR

EMA 4666C - Polymer Processing 36

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Basis for Die Swell

Die Swell

• Two Causes:

• 1. Elastic Recovery

• 2. Velocity ProfileChange

Elastic Recovery

• 1. Chains diffuse from

elongated to random

coil.• 2. Orientation

dependent upon

processing conditions







Parison Morphology







Die Swell Behavior: HDPE v ABS




Influence of L/D on Die Swell




Process Time line




Velocity Profi les for Stress Fields




Velocity Profiles – Planar Deformation


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END OF EXAM 1 Material

Spring 2012




Viscosity Response


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Viscosity: Temperature Response


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Effect of Blow Up Ratio


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Blow Molding Process

Variables

Thermal Properties/History


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PPS DSC P fil



PPS DSC Profile


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Effect of Rapid Quench - Xtal


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Crystallization Behavior - PPS


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Critical Factors for Blow Molding

Material

• Melt Strength

• Die Swell

• Impact Strength

• ESCR

• Chemical

Resistance• Printability

Process

• High/Low Rate

• Planar Extension

• Blow Pressure

• Stock Temperature

• Mold Temperature


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Blow Molding - Films


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T bl Sh ti G id



Trouble Shooting Guide


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R f



References

• Introduction to Physical Polymer Science,

2nd Edition, Lesley H. Sperling, WileyInterscience (1992) ISBN 0-471-53035-2

• Some figures were reproduced from: Polymer

Processing Fundamentals, Tim A. Osswald

(1998), Hanser/Gardner Publications,

Cincinnati, OH.

• The Physics of Polymers, Gert Strobl (1996)

Springer-Verlag, New York.

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Blow_Molding.pdf

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