l

l S h r i n k ag

The fundamentals of shrinkage of thermoplastics

Olaf Zllner

Table of contents

Page 2

1 2

The concept of shrinkage Factors that influence shrinkage

3 3.1 3.2 3.3 3.4 4

Phenomena of relevance to shrinkage Warpage Internal stresses Sink marks/voids Corner warpage References

31 32 37 38 39 40

9 10 10 15 15 17 19 19 20 22 22 23 23 23 26 27 28 28 29 30

2.1 Material 2.1.1 Amorphous and semi-crystalline thermoplastics 2.1.2 Crystallization behavior 2.1.3 Fillers and reinforcing materials 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 Processing Pressure holding time Holding pressure level Cavity wall temperature Melt temperature Injection velocity Ejection temperature

2.3 Molded part geometry 2.3.1 Wall thicknesses 2.3.2 Reduced wall thickness at the end of the flow path 2.3.3 Ribs 2.4 2.4.1 2.4.2 2.4.3 Mold Heating/cooling Gate type Gate position

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The concept of shrinkage

or semi-crystalline nature), the stiffness and wall thicknesses of the molded part also have an effect on shrinkage. Although shrinkage is based on thermal contraction, the effective reduction in dimensions after demolding is less than would be expected for pure thermal contraction. Additional mechanisms are involved in shrinkage that lead to a lower level of thermal contraction than would otherwise result. The chief mechanisms involved here are:

When thermoplastics are processed by injection molding, the dimensions of the molded part change as the part cools. Often, these changes are referred to as either shrinkage or warpage. Strictly speaking, shrinkage is due to the compressibility and thermal expansion of plastics. When thermoplastics shrink , they undergo a volume change . With warpage , by contrast, the shape changes while the overall volume remains constant. In order to obtain the desired dimensions in the plastic part, the mold cavity must be enlarged by the amount of shrinkage that will be experienced by the plastic. For this reason, the mold builder has to predict the difference, due to shrinkage, between the dimensions of the mold cavity and those of the molded part. In many cases, this is not an easy task, since shrinkage is influenced by a large number of parameters. Apart from process control (temperatures, pressures) and the properties of the material (e.g. its pvT behavior, filler content, and its amorphous

inherent stresses, influenced by the temperature profile during cooling the cavity surface temperature crystallization in the case of semi-crystalline
thermoplastics, influenced by cavity surface temperature cooling profile

mechanical obstruction of shrinkage,

influenced by mold constraint

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Apart from this, thermal contraction is influenced by the thermodynamic process sequence in injection molding, and particularly through

Figure 1 Schematic pressure (p), volume (v) and temperature (T) diagram

the pressure profile during cooling the action of pressure and the stressing of the
melt due to the design and position of the gate the melt temperature and other processing conditions. The influence of the thermodynamic process profile on shrinkage behavior is presented in a very clear fashion on a pressure (p), volume (v) and temperature (T) diagram known simply as the pvT diagram which characterizes:

Pressure p 1 < p 2 < p 3; p 1 = 1bar 0

P1 1 P2 2

Influence of pressure Start of shrinkage Specific volume V 5

V1bar

P3 4 3

compressibility
change in volume with a change in pressure and

VA

6 Influence of temperature Temperature T

TA TD T1bar

thermal behavior
change in volume with a change in temperature 0 1 2 3 4 5 1 2 3 4 5 6

volumetric filling compression action of holding pressure pressure reduction to ambient pressure cooling to demolding temperature (T ) D cooling to ambient temperature (T ) A

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The pvT diagrams supply information on the volume shrinkage, S V , from ( V = V 1bar V A ) and show shrinkage potentials. Volume shrinkage is defined below: VC V VC

When it comes to the practical layout of injection molds, however, it is the linear shrinkage that is more important. IW IF IW

SV

SI

VC: volume of cold cavity VP: molded part volume SV = 1 (1 S L )(1 S W )(1 S S )

S l = linear shrinkage l W = dimension of cold cavity l F = dimension of molded part Shrinkage is a relative value and is given in the form of a percentage.

S L : longitudinal shrinkage S W : shrinkage of width S S : shrinkage of thickness

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A real-life part cannot shrink uniformly in all three directions (over its length, width and thickness). Only over the thickness of the part does virtually unimpeded shrinkage take place. Most of the volume shrinkage, therefore, is used up in the shrinkage of the wall thickness of the molded part. Even if the mold does not impede shrinkage in any way, the fact that the layers of the molding freeze from the outside towards the inside means that shrinkage is obstructed over the length and width of the part. The following shrinkage situation generally results from shrinkage that is due to the mold and internally obstructed shrinkage

Shrinkage S L/W does not make allowance for any anisotropic shrinkage that may occur on account of fillers and reinforcing materials.

Figure 2 Internal obstruction of shrinkage in a cooling plastic panel /4/

solidified frame S

fluid center

Shrinkage over thickness

SS = 0.9 0.95 * S V

constrained length
contour after shrinkage mold contour

Shrinkage over length or width

S L/W = 0.1 0.05 * S V SV = volume shrinkage = shrinkage over thickness SS S L/W = shrinkage over length or width

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Since shrinkage is a time-dependent parameter, the point in time after demolding at which the shrinkage is measured must be specified in order to achieve a precise definition.

Figure 3 Change in a molded part dimension over time through shrinkage

2 3

Length

Time

1 = Mold dimension; 2 = Thermal expansion of mold; 3 = Demolding shrinkage S E ; 4 = Molding shrinkage S M 6 = Overall shrink. S total ; 7=Potential 5 = Post-shrinkage S P ; length increase through conditioning, e.g. for polyamides A = Cold mold; B = Hot mold; C = Molded part after demolding; D = Molded part after 24h in standard climate; E = Molded part after a prolonged period or after storage in heat; F = Molded part after water absorption, e.g. for polyamides

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A distinction is drawn between demolding shrinkage S D , which is measured immediately after the injection molded part has been ejected, molding shrinkage S M and post-shrinkage SP. According to DIN 16901, the molding shrinkage (S M ) of engineering plastics in injection molding is specified as the difference between the dimensions of the cold mold and those of the molded part after 16 hours storage in a standard climate /3/. With continued storage at high temperatures, a further change in dimensions can occur, which is then known as post-shrinkage (S P ). Molding shrinkage S M SM = I W I F1 IW

The reasons for post-shrinkage are the relaxation of inherent stresses, together with re-orientation processes and, in the case of semi-crystalline materials, potential post-crystallization /1/. With a number of thermoplastics, conditioning (water absorption) can also take place, in addition to post shrinkage. This effect is seen particularly with polyamides. The level of post-shrinkage can be quite considerable if the processing is not correctly tailored to the material. The term overall shrinkage is defined as follows: Overall shrinkage = molding shrinkage + post-shrinkage

Post shrinkage S N SP = I F1 I F2 IW

l F1 = molded part dimension before S N l F2 = molded part dimension after S N l w = dimension of cold mold

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Factors that influence shrinkage

Figure 4 Factors influencing shrinkage /2/

Plastic

Molding process

Shrinkage

Molded part

Mold

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The interplay between the different influencing factors is highly complex. There are factors which mutually influence each other and which are dependent on each other. Hence, a poorly dimensioned gate (molded part) can have a direct negative influence on the effect of the holding pressure (processing). The interaction between the different influencing factors is not covered in what follows. Instead, the basic way in which shrinkage is influenced is explained on the basis of these factors. The decisive point in this observation is that the correlation between the influencing factors and the shrinkage is always viewed in terms of the mechanisms listed at the outset:

2.1 2.1.1

Material Amorphous and semi-crystalline thermoplastics

The dissimilar shrinkage behavior of the two material types can be presented particularly clearly on the pvT diagram. Figure 5 Qualitative pressure, specific volume and temperature diagram (pvT diagram) for an amorphous and a semi-crystalline thermoplastic .

Glass-like state Specific volume V

Uncooled liquid Liquid

thermodynamic state profile, inherent stresses

and crystallization. This makes it possible to explain the dependence of shrinkage on the influencing factors in a clear manner.
VA(0) VC (0)

pho amor

us

crys semi-

talline

p = constant

Temperature T
0 TG TC

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Amorphous materials The green curve in Fig. 5 shows the dependence of the specific volume on the temperature of an amorphous thermoplastic (e.g. ABS, PC). Undercooling of the melt is evident here as the temperature falls. Below the glass transition point T G , the volume undergoes a less pronounced reduction (lower gradient), and the material is in a glass-like state undercooled liquid. The free volume remains virtually constant during this phase /5/. Semi-crystalline materials The red curve in Fig. 5 shows the path of the specific volume as a function of temperature for a semicrystalline polymer (e.g. PA, PBT).

In the case of semi-crystalline thermoplastics, crystallization takes place during cooling. If the plastic falls below the crystallization temperature, T C , then linear, or only slightly branched, chains with easily alignable repeat units will reconfigure themselves into an ordered (crystalline) state with a lower free enthalpy. The polymer chains lie parallel to each other, tightly packed in some cases, forming fine crystallites in which almost complete order prevails, with the exception of a few defect points. Contrary to the case with purely crystalline materials, there is no single point of crystallization here but a transition range instead /5/. The superposition of advancing crystallization and thermal contraction leads to the parallel-shaped curve profile in the semi-crystalline range. Higher shrinkage values are seen than with purely amorphous materials. The influence of the pressure that prevails during cooling on the specific volume is shown in Fig. 6.

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Figure 6 pvT diagram of an amorphous (left) and semi-crystalline (right) plastic during slow cooling under different pressures p 0 , p 1 , p 2

( 0 > 1 > 2 ) S,G Pressure p Melt p0

S0 > S1 > S2 Melt 1 Solidification line 1 S0

Pressure p p0

S0 p1 3

Freezing line

Free volume 3 S1

p1

S1 p2

Specific volume V

G0 G1 G2 Temperature T
TR TG0 TG1 TM

p2 S2

Specific volume V

Glass 2

Semi-crystalline range

S2

Temperature T
TR TCO TC1 TM

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Figure 6 shows that the higher packing density that results with rising pressure causes an upward shift in the glass transition point T G for amorphous plastics and in the crystallization temperature T C for semi-crystalline plastics /5/. The specific volume achieved at room temperature under a high pressure is lower than the specific volume at atmospheric pressure. When the pressure is removed, the plastic attempts to achieve the specific volume at a normal pressure of 1 bar.

Figure 7 shows linear shrinkage ranges for a number of amorphous and semi-crystalline thermoplastics. These shrinkage ranges result from the influence of processing, the process, the mold and the molded part (e.g. the wall thickness) and the fillers or reinforcing materials. The shrinkage of the non-reinforced amorphous polymers (Novodur , Bayblend , Makrolon , Apec ) is less than 1 %, while that of the non-reinforced semicrystalline polymers (Durethan , Pocan ) is more than 1 %. With the reinforced materials (GF), an increased anisotropy (directional dependence) is observed in the shrinkage. Amorphous thermoplastics S < 1% Relatively isotropic shrinkage values, hence only a slight tendency to warp Semi-crystalline and reinforced thermoplastics S > 1% Shrinkage as a function of fiber and molecule orientation, hence a pronounced tendency to warp

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Figure 7 Shrinkage ranges for amorphous and semi-crystalline thermoplastics /2/

Novodur/Lustran ABS (PC+ABS) Bayblend (PC+ABS), GF PC Makrolon PC, GF30 PC-HT Apec HT PC-HT, GF PA6 Durethan PA6, GF PBT Pocan PBT, GF30 (ABS+PA) Triax (ABS+PA), GF TPU, hard Desmopan TPU, medium TPU, soft TPU, GF Shrinkage in %
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 Speciality products up to 0.8 %

longitudinal transverse isotropic

Established on shrinkage measurement plaques (150 x 90 x 3 mm) under the recommended processing conditions. Holding pressure approx. 500 bar.

Shrinkage values relate to the product class and not to individual grades and cannot be used for the precise layout of a mold.

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2.1.2

Crystallization behavior

2.1.3

Fillers and reinforcing materials

In the case of semi-crystalline thermoplastics, crystallization occurs during cooling. This crystallization process is time and temperaturedependent. The cooling rate has a major influence on nucleation and nucleus growth and hence on the structure that develops. The more slowly cooling takes place (through high cavity surface temperatures), the higher the degree of crystallization and the greater the level of shrinkage. If the temperature falls too rapidly, then it is possible for nucleation and nucleus growth to be suppressed. This will give rise to a structure with a low degree of crystallization and hence to a low molding shrinkage. This can then lead to more pronounced post-crystallization and hence to undesirable post-shrinkage.

Fillers of a spherical shape lead to reduced shrinkage on account of their lower CLTE when compared with plastics /1/. Glass fibers have an even more pronounced effect on shrinkage than spherically-shaped fillers /6/. The glass fibers constitute an additional internal restraint, which impedes thermal contraction in the direction of the glass fibers and thus leads to lower shrinkage values. Perpendicular to the direction of orientation, the fibers act in the same way as the fillers referred to above and similarly reduce shrinkage, albeit to a lesser extent /4/. Table 1 shows that, in polyamide 6, it is possible to influence shrinkage to a large extent through the filler content and filler type.

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Table 1 Influence of filler on the shrinkage behavior of polyamid PA6 (Holding pressure: 500 bar) Material Filler Shrinkage longitudinal / transverse 1.0 / 1.2 1.2 / 1.2 0.2 / 0.8 0.3 / 0,9

Durethan B 30S Durethan BM 240 H 2.0 Durethan BKV 30 H 2.0 Durethan BG 30 X

non-reinforced mineral 30 % glass fibers 15 % spheres / 25 % glass fibers

Through the use of glass fibers, it is possible to reduce shrinkage by 50 to 80 % in the longitudinal fiber direction. Adding more than 20 to 25 % glass fiber has no further effect on the shrinkage behavior of semi-crystalline thermoplastics /2/. This is illustrated in Figure 8, which shows how the shrinkage changes with varying glass fiber content and progresses towards a limit in semicrystalline Durethan AKV PA66 resin.

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Figure 8 Influence of glass fiber content on shrinkage for semicrystalline Durethan AKV (PA66, GF) /2/

2.2

Processing

The qualitative correlations between the individual process parameters and the molding shrinkage are displayed in Fig. 9. The correlations between molding shrinkage and process parameters are explained in more detail below.

1.4 1.2 1.0 0.8 0.6 0.4 0.2 0

longitudinal transverse

Molding shrinkage in %
AKV 15 PA66 GF15

AKV 25 PA66 GF25

AKV 30 PA66 GF30

AKV 35 PA66 GF35

Shrinkage measurement panel 150 x 90 x 3 mm Mold temperature 80 C

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Figure 9 Influence of processing parameters on shrinkage behavior /2/

Shrinkage

Shrinkage

Pressure holding time

Holding pressure level

Shrinkage Cavity wall temperature Injection velocity Shrinkage Demolding temperature

Shrinkage

Melt temperature

Shrinkage

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2.2.1

Pressure holding time

2.2.2

Holding pressure level

The purpose of the holding pressure is to offset material shrinkage by conveying more melt into the cavity. Under the action of the holding pressure, Pressure holding time the material in the cavity is compressed and volumetric contraction due to the cooling process is offset. The holding pressure time thus has a major influence on the amount of extra melt injected and on the shrinkage compensation. The longer the hold time, the lower the shrinkage.
Shrinkage

With both amorphous and semi-crystalline thermoplastics, the level of holding pressure has a decisive influence on the degree of shrinkage. The higher the holding pressure, the lower the mold shrinkage.

Shrinkage Holding pressure level

The extent to which shrinkage can be influenced by holding pressure is regressive, however. In other words, as the holding pressure increases, the reduction in shrinkage becomes less pronounced. With an optimally designed gate system and molded part, it is possible to reduce shrinkage by up to 0.5 % in semi-crystalline thermoplastics by increasing the holding pressure. With amorphous materials, values of no more than 0.2 % are achieved on account of the lower shrinkage potential /1/.

With amorphous materials, the holding pressure time has slightly less influence than with semicrystalline materials due to the reduced additional volume conveyed into the cavity /1/. Using large gates with generous crosssection dramatically increases the time over which holding pressure can act. Always position gates in the area of thickest wall section.

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Figure 10 shows how dissimilar shrinkage occurs due to the dissimilar action of the holding pressure close to and remote from the gate. Figure 10 Dissimilar action of holding pressure close to and remote from the gate with a centrally-gated circular disk in a non-reinforced thermoplastic /2/

2.2.3

Cavity wall temperature

Dome warpage

The molding shrinkage increases with the cavity wall temperature. Due to the influence of cavity wall temperature, various different factors are superimposed which Cavity wall temperature affect the flow process (holding pressure phase), the crystallization and the inherent stress profile. This holds true for semi-crystalline materials in particular.
Shrinkage

Intended shape 200 bar 400 bar

0.

0.

600 bar

Gate

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Apart from enhancing or impairing the action of the holding pressure, the mold wall temperature also has a strong influence on the cooling rate (Fig. 11). A low mold temperature T W (40 C) leads to high cooling rates and hence to a low level of crystallization in the polyamide, as shown in Fig. 11. This leads to low molding shrinkage followed by high post-shrinkage. With a high cavity temperature T W (120 C), a greater proportion of molding shrinkage takes place right away (high degree of crystallization). The post-shrinkage potential is drastically reduced. Overall shrinkage is more or less identical at both processing temperatures (Fig. 13). T W V CR T W V CR TW V CR SM SM SM

Figure 11 Shrinkage as a function of the cavity surface temperature for Durethan B 30 S (PA6, non-reinforced)

Molding shrinkage Post shrinkage

1.5

1.0

0.5

= mold temperature = cooling rate = molding shrinkage

Shrinkage in %
longit. transv. 40 C

longit. transv. 120 C

Shrinkage measurement panel 150 x 90 x 3 mm

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2.2.4

Melt temperature

2.2.5

Injection velocity

The melt temperature also has an influence on shrinkage behavior. Two A counteracting effects are at play here. Firstly B an elevated melt temperature increases the Melt temperature potential for thermal contraction in the resin (increased shrinkage, A) and, secondly, it leads to a reduction in the melt viscosity and hence to better packing and, ultimately, to a reduction in shrinkage (B). As a general rule, curve profile B is measured and observed. The improved packing predominates over the contraction potential. If, however, an unfavorable wall thickness situation and poor packing conditions exist, then raising the melt temperature can actually increase shrinkage. (sink marks, curve profile A) /1/.
Shrinkage

The injection velocity has almost no influence on overall shrinkage. Apparently, counter effects such as orientation vs. re-orientation and shear heating vs. pressure distribution cancel each other out.

Shrinkage Injection velocity

When optimizing other process parameters, it is often helpful to maintain a constant melt temperature

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2.2.6 Ejection temperature (longer cooling time, increased mold restraint) The longer the part remains in the mold, the longer the cooling time and lower the ejection temperature will be. At the same time, the part will see increased Demolding temperature mold restraint. Particularly with semi-crystalline thermoplastics, lower ejection temperatures typically cause less mold shrinkage.
Shrinkage

2.3 2.3.1

Molded part geometry Wall thicknesses

When the thickness of the molded part is varied, this leads to a quantitative change in all the other variables that affect shrinkage (such as the action of holding pressure or the cooling rate). Given identical melt and mold temperatures, a thinner molded part will cool more rapidly than a thick one. All the different thermally-conditioned processes (such as crystallization and internal stresses due to cooling) thus have less time in which to act. Because the boundary conditions change with wall thickness it is very difficult to make a general statement on the influence of thickness /4/. Despite this, it is still possible to point to basic correlations between the shrinkage and the thickness of the molded part.

With higher ejection temperatures (shorter cooling times), a more pronounced temperature increase occurs in the outer layers of the molded part. A kind of virtual heat storage takes place. This relieves surface stresses and increases shrinkage /8/.

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Figures 12 and 13 show the correlation between shrinkage and wall thickness for semi-crystalline and amorphous thermoplastics. Especially in the case of non-reinforced semi-crystalline thermoplastics (Fig. 12 left), the wall thickness is seen to have a major influence on shrinkage. The thicker walls lead to slower cooling, and thus give rise to more favorable crystallization conditions.

The degree of crystallization is higher, increasing the level of shrinkage. These figures show that there can be large shrinkage differentials if there are different wall thicknesses in a plastic molded part. If dissimilar shrinkage occurs, then warpage can result. This is more pronounced with semicrystalline thermoplastics than with amorphous thermoplastics (Fig.13).

Figure 12 Correlation between shrinkage and wall thickness for semi-crystalline thermoplastics /2/
Durethan B 30 S (PA6, non-reinforced) Durethan BKV 30 (PA6, GF30)

2.0

freshly molded Shrinkage in % after 2.5 % water absorption

2.0

1.0

1.0

Shrinkage in %

freshly molded after 1.5 % water absorption Wall thickness in mm

1 2 3 4 5 6 7 8 9 10

Wall thickness in mm
0 1 2 3 4 5 6 7 8 9 10 0

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Figure 13 Correlation between shrinkage and wall thickness for amorphous thermoplastics /2/
A: Makrolon 2805 (PC, non-reinforced) B: Makrolon 8035/9425 (PC, GF)
1.0 1.0

Novodur P2H-AT und P2M (ABS, non-reinforced)

Shrinkage in %

0.6 0.4 0.2 0

0.6

0.4 0.2 0

Wall thickness in mm
0 1 2 3 4 5 6 7 8 9 10 0

Shrinkage in % Wall thickness in mm

1 2 3 4 5 6 7 8 9 10

0.8

0.8

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2.3.2

Reduced wall thickness at the end of the flow path

As Fig. 14 shows, the holding pressure has less of an effect farther from the gate than close to the gate. This leads to higher shrinkage at points far from the gate, which means that it is useful to reduce the wall thickness at these points (at the end of the flow path). The wall thickness reduction means that there is a lower shrinkage potential in these areas, so that the shrinkage differential compared with the region close to the gate is no longer so pronounced.

Figure 14 Lower tendency to warp through a reduced wall thickness at the end of the flow path on a centrallyinjected circular disk in a non-reinforced thermoplastic
Wall thickness reduction at the end of the flow path S1 Molding less prone to warpage S2 S1 > S2

200 bar

0.

35

400 bar 600 bar

0.

Gate

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2.3.3

Ribs

Ribs can have a pronounced influence on molded part shrinkage and, in particular, on the uniformity of shrinkage. Ribs should be made thinner than the wall to which they are attached, observing a specific rib wall thickness to nominal wall thickness ratio. The correlations between shrinkage and wall thickness referred to above mean that the ribs generally shrink less (i.e. they remain longer) than the other molded part dimensions. The result can be a warped part.

Figure 15 Warpage due to differences in the rib wall thickness and nominal wall thickness /2/

SR SR < SG SG

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2.4 2.4.1

Mold Heating/cooling

Figure 16 Warpage as a result of heating/cooling differentials in the mold

Different levels of heating and cooling in different areas of the molded part produce dissimilar shrinkage and hence dissimilar molded part properties (Fig. 16).
Temperature 60 C

Temperature Stress

Temperature 60 C

Temperature 90 C

When a different mold temperature exists on the inside and outside of the molded part, the plastic on the hotter side will undergo more pronounced shrinkage. During this uneven cooling, there will be a shift in the temperature profile in the solidifying melt, and hence dissimilar shrinkage potentials and cooling stresses will result. This type of differential shrinkage is similar to the effect that dissimilar metals experience when coupled together as in a bi-metallic structure and then are exposed to a certain temperature range (as in a thermostat gage). Differing degrees of thermal expansion and contraction occur within each metal.

Temperature 60 C

60 C

60 C

Fluid plastic center Temperature Stress

60 C

90 C

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Warpage can occur in the molded part as a result of the asymmetrical stress distribution that develops (see lower part of Fig. 16). Therefore, take care to ensure a uniform mold wall temperature in the injection mold. The influence of heating/cooling in the mold is considerably greater with non-reinforced thermoplastics than with glass fiber reinforced thermoplastics, for example. In the case of glass fiber reinforced thermoplastics, it is the influence of the fibers on the shrinkage that predominates.

2.4.2

Gate type

Different molded part geometries frequently call for different types of gating. Design gates to allow good packing regardless of gate type (e.g. film, pin-point or tunnel gate, etc.). Then, the holding or packing pressure is much more effective at minimizing shrinkage. The modified tunnel gate depicted in Fig. 17 will only provide optimum conditions for an effective holding pressure phase (in terms of the influence on shrinkage) if it is of the optimum design in terms of the plastic and the molded part. The version with an unfavorable design not only reduces the effect of the holding pressure but also imposes greater thermal and mechanical stressing on the melt during injection.

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Figure 17 Recommended design for a modified tunnel gate /2/

2.4.3

Gate position

Position the gate in the thickest area of the part, when possible. This allows shrinkage differentials to be minimized through wall thickness adjustment, if neccessary.

not recommended preferred dead end gate gate-crosssection

30

60

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3 Phenomena of relevance to shrinkage

Due to the large number of influencing parameters a large number of shrinkage effects occur, as shown in Fig. 18. Figure 18 Shrinkage and warpage phenomena /1/ A number of these phenomena are explained in greater detail in the following pages.

V1 y z x V2

Sink marks
SV

Linear shrinkage
S 11

Inherent stress
T (y) v (y) hP > hR hR T U (y) hP TR

Warpage
hP = hR Sr = St

SV

S 12 SA TP TR > TP St > Sr SH SH < SA Sr > St SV

Voids Stress cracks

hR > hP T W1 < T W2 T W2

TH

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3.1

Warpage

Warpage always results from differing degrees of shrinkage. This can take the form of

a shrinkage differential in the direction of flow

and at right angles to this direction for glass fiber reinforced materials shrinkage differentials due to dissimilar molded part wall thicknesses shrinkage differentials due to locally dissimilar mold temperatures shrinkage differentials due to locally dissimilar holding pressure action The high shrinkage potential of semi-crystalline plastics means that these materials generally suffer greater warpage than amorphous plastics. Figure 19 shows a molded part made of three different plastics:

It is clear from Fig. 19 that greater warpage occurs in semi-crystalline materials than in the amorphous PC with 30 % GF. The reason for this is that the shrinkage potential and the difference in directionally-dependent shrinkage behavior is greater in the semi-crystalline PA and PBT and thus gives rise to more pronounced warpage. Figure 19 Warpage of a support plate in different thermoplastics /2/

Pocan 3235 PBT 30 GF (top of Fig. 19) Durethan BKV 30 H PA6 30 GF (center of
Fig. 19) Makrolon 8035 PC 30 GF (bottom of Fig. 19)

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Figure 20 shows the basic warpage of a circular plate in glass fiber reinforced thermoplastic. The different warpage variants that can occur are evident here.

Figure 20 Warpage of a circular plate in glass fiber thermoplastic /2/

Transverse shrinkage

Gate

Longitudinal shrinkage Glass fiber

Circumferential shrinkage corresponds to longitudinal shrinkage

Possibilities of warpage

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Figure 21 shows that it is possible for different warpage behavior to result in reinforced and nonreinforced materials when identical geometries and gate types are employed. In glass fiber reinforced plastics, shrinkage is caused less through the correlation with wall thickness and more by the orientation.

Figure 21 Dissimilar shrinkage behavior in non-reinforced and reinforced thermoplastics /2/ non-reinforced reinforced

Shrinkage differentials due to dissimilar wall thicknesses lead to warpage

Shrinkage differentials due to glass fiber orientation lead to warpage

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Even when the glass fibers display a uniform orientation, warpage can still occur in flat panels (Fig. 22). This is due to the glass fibers turning around at the end of the flow path, which leads to shrinkage differentials between the center section of the panel and the area at the end of the panel. If the Figure 22 Glass fiber orientation at the end of the flow path /2/

inherent rigidity of the panel is too low (wall thickness), then warpage will result. This warpage can be reduced by making changes to the geometry (Fig. 23). Figure 23 Eliminating warpage on flat panels /2/

Warpage s

Mixed shrinkage ~23 s

High transverse shrinkage Orientation of glass fibers Reduced warpage s

Transverse orientation of the fibers at the end of flow leads to lower transverse shrinkage Warpage with thin wall thicknesses

23 s better

Reduced warpage

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Figures 24 and 25 show how the relocation of the gate changed the glass fiber orientation and reduced the amount of warpage of a waffle-iron in Pocan 3235 (PBT 35 GF). Figure 24 Warpage due to unfavorable orientation of the glass fibers
Current situation

Figure 25 Reduced warpage through longitudinal orientation of glass fibers /2/

Optimization

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3.2

Internal stresses

Figure 26 Thermal contraction in the layer model /4/

Positive interlocking with the mold can prevent certain dimensional changes in the molded part while it is still in the mold. When forces act on the molded part from the outside they are known as external contraction restraints. Also, internal contraction restraint can also exist. The solidification model according to STITZ /4/ can be used to explain the phenomena that prevail with an internal restraint. Figure 26 shows the molded part wall thickness divided up into layers. As a result of the temperature profile over the wall thickness (A), the individual layers have a different shrinkage potential. If the layers are viewed in the uncoupled state, then they can slide over each other and thus contract to differing extents (B).

A Temperature profile

molded part thickness s

TA

T = f(y)

B Without mechanical coupling of layers

s > s > s

C True profile (mechanically coupled)

thermal contraction T A = Ambience Temperature; T w = Mold Temperature

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Since the layers are coupled to each other, however, they are prevented from sliding over each other. The inside layers are extended and the outer layers compressed (C). This coupling makes it difficult for the inside sections to undergo thermal contraction in the longitudinal and transverse directions. Since there is no resistance to deformation over the thickness of the part, the volume reduction is achieved primarily through a reduction in the thickness. All forms of obstruction to thermal contraction produce internal stresses in the molded part, which, in turn, affect the level of shrinkage.

3.3

Sink marks/voids

In the case of sink marks, volume contraction leads to local depressions on the molded part surface, since the solidified edge layer is not yet stable enough to absorb the internal contraction forces. Sink marks occur primarily at points where a hot melt core and a thin edge are present at the same time. The forces of contraction will be all the greater the bigger the melt core is by comparison to the overall cross-section. This is particularly true with ribs, since heat elimination is less efficient on the side facing the rib (Fig. 27, top).

3 Phenomena of relevance to shrinkage

Page 39

Voids are air cavities inside the molded part crosssection. They occur when the solidified edge layer withstands the contraction forces and the inside layers become detached from the outer layers with further cooling (Fig. 27, bottom). Figure 27 Voids and sink marks as shrinkage phenomena

3.4

Corner warpage

The phenomenon of corner warpage is similarly attributable to shrinkage. The uneven cooling behavior in the corners causes the inside of the corner to shrink to a greater extent (Fig. 28). This then leads to stresses and forces which produce corner warpage. Figure 28 Corner warpage due to uneven thermal behavior

sink mark

accumulated melt leads to sink marks, hence ensure an appropriate rib thickness to basic wall thickness ratio sR

vaccum/void residual melt

4 References

Page 40

4 /1/

References
Ptsch, H. G. Prozesssimulation zur Abschtzung von Schwindung und Verzug Thermoplastischer Spritzgussteile Dissertation RWTH Aachen, 1991 Bayer Anon DIN 50014, Normklimate Klimate und ihre technische Anwendung Juli 1985 Stitz, S. Analyse der Formteilbildung beim Spritzgieen von Plastomeren als Grundlage fr die Prozesssteuerung Dissertation RWTH Aachen, 1973 /5/ Zllner, O. Prozessgren beim Spritzgieen von Thermoplasten als Produktionskostenfaktor paper presented at the SKZ Wrzburg, Bayer AG, 1993 Hoven-Nievelstein, W. B. Die Verarbeitungsschwindung thermoplastischer Formmassen Dissertation RWTH Aachen, 1984

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ATI 1120 e
Edition: 2001-03-01 KU 21120-0103 e

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