Effect of processing conditions on warpage of film insert molded parts

In order to investigate effects of injection molding conditions on viscoelastic behavior and thermal deformation of film insert molded (FIM) parts, injection molding was performed with various conditions such as injection speed, melt temperature, and packing time. It was shown that variation of the warpage was decreased monotonically with increasing injection speed and exhibited a bell-shaped curve as a function of melt temperature. Warpage variation was not affected by the packing time significantly and the proportional relationship between warpage of the film insert molded part and shrinkage of the injection molded part without film was observed. The FIM specimens produced with unannealed films showed the warpage reversal phenomenon (WRP) during annealing and the magnitude of reversed warpage was affected significantly by the injection parameters and the extent of thermal shrinkage of the unannealed film. Warpage of the FIM specimen was predicted by three dimensional numerical flow and stress analyses and the predicted values showed a good agreement with the experimental results.     

Optimization of multiple quality characteristics for polyether ether ketone injection molding process

This study examines multiple quality optimization of the injection molding for Polyether Ether Ketone (PEEK). It also looks into the dimensional deviation and strength of screws that are reduced and improved for the molding quality, respectively. This study applies the Taguchi method to cut down on the number of experiments and combines grey relational analysis to determine the optimal processing parameters for multiple quality characteristics. The quality characteristics of this experiment are the screws’ outer diameter, tensile strength and twisting strength. First, one should determine the processing parameters that may affect the injection molding with the L₁₈(2¹×3⁷) orthogonal, including mold temperature, pre-plasticity amount, injection pressure, injection speed, screw speed, packing pressure, packing time and cooling time. Then, the grey relational analysis, whose response table and response graph indicate the optimum processing parameters for multiple quality characteristics, is applied to resolve this drawback. The Taguchi method only takes a single quality characteristic into consideration. Finally, a processing parameter prediction system is established by using the back-propagation neural network. The percentage errors all fall within 2%, between the predicted values and the target values. This reveals that the prediction system established in this study produces excellent results.     

Prediction and measurement of residual stresses in injection molded parts

Residual stresses were predicted by a flow analysis in the mold cavity and residual stress distribution in the injection molded product was measured. Flow field was analyzed by the hybrid FEM/FDM method, using the Hele Shaw approximation. The Modified Cross model was used to determine the dependence of the viscosity on the temperature and the shear rate. The specific volume of the polymer melt which varies with the pressure and temperature fields was calculated by the Tait’s state equation. Flow analysis results such as pressure, temperature, and the location of the liquid-solid interface were used as the input of the stress analysis. In order to calculate more accurate gap-wise temperature field, a coordinate transformation technique was used. The residual stress distribution in the gap-wise direction was predicted in two cases, the free quenching and the constrained quenching, under the assumption that the shrinkage of the injection molded product occurs within the mold cavity and that the solid polymer is elastic. Effects of the initial flow rate, packing pressure, and mold temperature on the residual stress distribution was discussed. Experimental results were also obtained by the layer removal method for molded polypropylene.     

Study on kenaf flame retarded by halogen-free flame retardant/HIPS composites

In order to improve the thermostability and fire resistance of kenaf, kenaf was treated with halogen-free flame retardant triethyl phosphate (TEP) adopting dipping principle. Adding flame retardant kenaf (fbk) to high impact polystyrene (HIPS) resin, fbk/HIPS composites were prepared by extrusion molding and injection molding. The differences of untreated kenaf and treated kenaf on structure, thermal behavior, combustion, mechanical properties of HIPS were contrasted and analyzed. The results showed that kenaf treated with TEP had superior thermal stability at high temperature and produced significantly reinforcing effect on HIPS resin.     

New insight into compressive shrinkage finishing in a garment company: The effects on physical,mechanical and colorimetric properties of cotton woven fabrics

Compressive shrinkage or compressive shrinkage finishing is one of the most important finishing procedures in the textile industry to improve the dimensional stability of cotton fabrics. Study of the physical and mechanical properties of compressive shrinkage finished fabrics could be useful for optimizing the treatment conditions. This research was carried out in a production line of a recognized garment company on cotton woven fabrics with two different woven patterns (twill and plain). The samples were first dyed with reactive and sulfur dyes in a jigger dyeing machine and finished with a silicone softener. The dried fabrics were then processed in a compressive shrinkage machine. Several physical and mechanical properties of the samples were evaluated including area shrinkage, crimp percentage, thickness, abrasion resistance, drapeability, mechanical and colorimetric properties. The results showed that the thickness of all treated samples increased due to compressive shrinkage. The fabrics were analyzed with a Martindale Abrasion Tester to determine the abrasion resistance. Interestingly, we noted an increase in the abrasion resistance. After the compressive shrinkage process, the strength of the plain woven fabrics decreased in the warp direction, but increased for twill woven cotton fabrics. On the contrary, the strength of all samples increased in the weft direction. Colorimetric evaluation of the samples showed that the effect of compressive shrinkage on the color of all samples was negligible.     

Flame retarding PC/ABS resins having superior thermomechanical properties

Triphenyl phosphate (TPP) is well known to be one of the most effective flame retardants for acrylonitrile-butadiene-styrene copolymer (ABS) and its blending resins, such as polycarbonate (PC)/ABS, among various phosphorous-based compounds. However, TPP can also play a role as a plasticizer, which decreases the mechanical properties of PC/ABS resins at high temperature. Furthermore considerable amount of TPP has to be evaporated during molding process due on its much lower evaporation temperature. To overcome these shortcomings, we tried to immobilize TPP by grafting on butadiene moiety of ABS. FT-IR analysis of prepared TPP-grafted ABS (ABS-g-TPP) comparing with TPP, ABS and their blend confirmed that chemical reactions happened between TPP and ABS resins and it was attributed to the graft reaction of TPP onto butadiene moieties. Prepared ABS-g-TPP resins were blended with PC at various compositions to be prepared as testing specimens by injection molding. The physical characteristics such as mechanical properties, thermal stability, and flame retarding properties of the PC/ABS-TPP graft copolymer were analyzed through Vicat softening temperature, IZOD impact strength, transmission electron microscope, and UL94 flame retardation tests. Results showed that PC/ABS-g-TPP resin takes better thermomechanical properties than the existing PC/ABS resins at relatively low additional TPP amounts.     

The effect of the processing factors on the physical properties of high shrinkable nylon composite yarns

This paper is aiming to develop high shrinkable differential shrinkage and mixed fibre nylon composite yarns by applying the high shrinkable polyester manufacturing technology. The wet and dry thermal shrinkages and mechanical properties of developed nylon composite yarns are measured and discussed with processing factors in the spinning and texturing processes. And the effects of the processing factors on the physical properties of high shrinkable nylon composite yarns are investigated. For this purpose, twenty seven nylon 30d/12f SDY were prepared with variation of spinning temperature, 2nd godet roller temperature and draw ratio on the spinning machine. The optimum spinning condition which showed maximum wet thermal shrinkage and stress was determined and high shrinkable nylon 30d/12f SDY spun under this optimum condition used as a core and three kinds of regular nylon filaments used as sheath were processed on the texturing machine with variation of 1st and 2nd heater temperatures. The optimum texturing process condition was decided through analysis of dry thermal shrinkage of these core and sheath nylon filaments. Finally, high shrinkable differential shrinkage and mixed fibre nylon composite yarns were made under the optimum texturing condition on the texturing machine, its wet thermal shrinkage was 13.8 %, which was much more higher than that of regular nylon composite yarns. The differential shrinkage effect of the developed nylon composite yarns was found in the yarn surface and cross section profiles by microscope and SEM.     

Injection molding analysis of a needle cover — Optimum filling for gate location design

Injection molding is one of the most popular manufacturing methods for the cost-effective mass production of the plastic parts. Filling analysis of the molten polymer provides useful information to investigate the process conditions to ensure successful replication. To validate appropriate gate location for a NEEDLE COVER, flow fronts and flow stresses for four different gating options and three different design options are analyzed and compared to the field results. Based on the results, the optimum gate location for the minimum flow stresses and uniform fill patterns appears to be at gate 3. Thus it also provides minimum possibility of part warpage throughout PORT HOUSING and NEEDLE HOUSING. The results of analysis on the increased wall thickness, lower melt temperature, and longer injection time indicated that higher melt temperatures were recommended to achieve successful molding. Injecting the polymer at a longer time (1.2 second) leads to a significant increase in flow stresses throughout the part and the increase of wall thickness achieve successful replication of the parts.     

Study on thermal treatment of hybrid technical yarns

The present paper reports the impact of thermal treatment on the characteristics of core-sheath type hybrid technical yarns. The core-sheath type hybrid yarns are prepared using DREF-III technology. Polyester and glass multifilaments are used as core components whereas the cotton and polyester staple fibers are the sheath components wrapped around the core filament with different proportions to form a hybrid structure. The thermal treatment is carried out both in dry and in wet state under relaxed condition and the thermal shrinkage, sheath-slipping resistance and tensile and bending properties of hybrid yarns have been studied. Thermal treatment markedly increases the thermal shrinkage and sheath-slipping resistance of hybrid yarns with polyester multifilament in core, but insignificant effect for yarns with glass multifilament in core. Breaking elongation of hybrid yarns with polyester multifilament in core increases with treatment temperature. The hybrid yarns with glass multifilament in core are least affected by thermal treatment.     

A comparison between the thermomechanical and structural changes in textured PET yarns after superheated steam and dry heat treatment

PET yarns textured at different texturing conditions were treated with superheated steam or dry heat at different temperatures for different times. The effects of the treatment conditions on the thermomechanical and structural changes of the yarn were examined by shrinkage, X-ray diffraction and birefringence measurements. With increase in superheated steam temperature, the crystalline orientation factor and birefringence decreased, whereas crystal size increased. Dry heat treatment had a smaller effect on shrinkage and structural properties in comparison with superheated steam treatment. The additional shrinkage after texturing process was investigated. The effect of heat-setting in both media was more significant at 200 °C. The time dependence of the properties was not linear.     

Isothermal and non-isothermal shrinkage behaviors of highly oriented PET yarns

The isothermal and non-isothermal shrinkage behaviors of highly oriented Poly(ethylene terephthalate) yarns were investigated. In isothermal measurements, shrinkage and shrinkage stress firstly monotonously increased due to more and more activated frozen molecular segments with increasing time and temperature, and then relaxed at high temperature resulting from intermolecular slipping of micro-fibrils. According to the different contributions of amorphous and crystalline regions to shrinkage behavior, non-isothermal shrinkage and shrinkage stress curves were fitted by Gauss curves and the entire shrinkage process was divided into three stages: contraction of micro-fibrils, contraction of extended interfibrillar tie molecules and relative displacement of micro-fibrils.     

Direct manufacturing of flax fibers reinforced low melting point PET composites from nonwoven mats

There have been many interests in using natural fibers as substitutes for glass fibers to prepare fiber reinforced composites. Flax fibers, due to their specific strength, have been a hot issue in this field. The focus of this research work is to manufacture flax fiber reinforced low melting point PET composites directly from nonwoven mats. No consolidation methods are applied to the carded nonwoven mats before the hot-press molding. The effects of operating parameters like carding method, molding temperature, molding time, etc. on the mechanical properties of composites have been investigated. Results show it is a facile and cost-saving method to produce composites specifically in the application areas like automobile interior ornament and decoration materials, etc.     

Effect of fiber reinforcement on mechanical and thermal properties of poly(ɛ-caprolactone)/poly(lactic acid) blend composites

Optimized palm press fiber composites of poly(?-caprolactone)/poly(lactic acid) were produced and their mechanical and thermal properties were studied. The composites were melt blended using twin screw extruder and test specimens were produced by injection molding. The composites mechanical and thermal performances were tested using standard methods. The incorporation of dicumyl peroxide as compatibilizer significantly increased the tensile strength, flexural modulus and impact strength of the composites as compared to the uncompatibilized composites. Crystallization temperature of the composites initially increased after which it dropped as fiber load increased. The composites melting point and percentage crystallinity slightly decreased as fiber load increased.     

Thermoplastic films from wheat proteins

We show that the wheat proteins gluten, gliadin and glutenin can be compression molded into thermoplastic films with good tensile strength and water stability. Wheat gluten is inexpensive, abundantly available, derived from renewable resource and therefore widely studied for potential thermoplastic applications. However, previous reports on developing thermoplastics from wheat proteins have used high amounts of glycerol (30-40%) and low molding temperature (90-120 °C) resulting in thermoplastics with poor tensile properties and water stability making them unsuitable for most thermoplastic applications. In this research, we have developed thermoplastic films from wheat gluten, gliadin and glutenin using low glycerol concentration (15%) but high molding temperatures (100-150 °C). Our research shows that wheat protein films with good tensile strength (up to 6.7 MPa) and films that were stable in water can be obtained by choosing appropriate compression molding conditions. Among the wheat proteins, wheat gluten has high strength and elongation whereas glutenin with and without starch had high strength and modulus but relatively low elongation. Gliadin imparts good extensibility but decreased the water stability of gluten films. Gliadin films had strength of 2.2 MPa and good elongation of 46% but the films were unstable in water. Although the tensile properties of wheat protein films are inferior compared to synthetic thermoplastic films, the type of wheat proteins and compression molding conditions can be chosen to obtain wheat protein films with properties suitable for various applications.     

Changes of pulling-out length and shrinkage ratio in polyester/spandex power net warp knitted fabrics

Power net fabric is one of the highly extensible two-way fabrics. Power net structure shows special characteristics in the wearing of final functional clothes. This research evaluated effects of treatment temperature on proportional extensibility and shrinkage ratio of spandex at a given wale length. As treatment temperature increased, extensibility increased proportionally to the standard length of the sample and the shrinkage ratio in the direction of course and wale increased. The pulling-out length increased proportionally to the standard length of the sample. However it was affected by the effect of treatment time and temperature due to the thermal properties of spandex filament yarn.     

基于UG的U盘盖模具设计

UG软件系统功能强大，应用广泛，在模具设计和制造行业具有很大的优势。探讨基于UG平台实现注塑模具CAD的方法和途径，以U盘盖壳为例，设计带有侧抽芯的注塑模具，阐述UG设计注塑模具的过程和要点及其优势。     

吉林水稻品种耐冷性研究

冷害胁迫是造成水稻减产的重要因素。为探讨不同水稻品种的抗冷性,以吉林省25个主栽品种为材料,测定分析了在冷害胁迫条件下这些品种的脯氨酸、丙二醛、叶绿素及可溶性糖含量的变化情况。结果表明,所有参试水稻品种在冷害胁迫下其游离氨基酸含量升高,丙二醛含量显著增加;吉粳515、通禾66及秋田小町脯氨酸积累较多;与常温条件下相比,吉粳809、吉宏9和通禾66的叶绿素含量冷害胁迫下变化不是很显著,生长较好,耐冷性较为突出;吉粳515 、吉农大538和吉农大853在冷害胁迫条件下积累了更多的可溶性糖,进而提高了抗逆性;吉香6、宏科88抗冷性较弱,在栽培过程中,应注意对低温冷害的防御。     

Effect of temperature, time and wheat gluten moisture content on wheat gluten network formation during thermomolding

A plastic-like material can be obtained by thermomolding wheat gluten protein which consists of glutenin and gliadin. We studied the effect of molding temperature (130-170 °C), molding time (5-25 min) and initial wheat gluten moisture content (5.6-18.0%) on the gluten network. Almost no glutenins were extractable after thermomolding irrespective of the molding conditions. At the lowest molding temperature, the extractable gliadin content decreased with increasing molding times and moisture contents. This effect was more pronounced for the α- and γ-gliadins than for the ω-gliadins. Protein extractabilities under reducing conditions revealed that, at this molding temperature, the cross-linking was predominantly based on disulfide bonds. At higher molding temperatures, also non-disulfide bonds contributed to the gluten network. Decreasing cystine contents and increasing free sulfhydryl and dehydroalanine (DHA) contents with increasing molding temperatures and times revealed the occurrence of β-elimination reactions during thermomolding. Under the experimental conditions, the DHA derived cross-link lanthionine (LAN) was detected in all gluten samples thermomolded at 150 and 170 °C. LAN was also formed at 130 °C for gluten samples containing 18.0% moisture. Degradation was observed at 150 °C for samples thermomolded from gluten with 18.0% moisture content or thermomolded at 170 °C for all moisture contents.     

东风农场橡胶树云研77-4区域性栽培试验示范

报道云南西双版纳东风农场1998年试验示范种植的橡胶树新品种云研77-4近10年的观测资料,结果表明,云研77-4品种在抗寒、高产、生势、抗性等性状都优于对照品种GT1,充分表现出该品种的优良特性,适于在东风农场橡胶树宜林地推广种植。     

Characterization of PET/PP blend fiber and it’s application to wig

As PET (Polyester) fiber has better heat resistance than PVC fiber or modacryl fiber, it has been used as wig fiber for human hair alternatives. However, PET is heavier and has higher specific gravity than human hair, and therefore the authors attempted to make lighter wig fiber by blending PP (polypropylene) into PET by mixing the PET/PP blend with a compatibilizer, a ethylene-acrylic ester-GMA(EAG) component grafted material, to overcome poor compatibilities of PET and PP. The thermal properties of the PET/PP blend mixed with EAG were measured using DSC, and the results showed that EAG affected melting point and crystallization temperature of the blend polymer. As blend ratio of PP increased, specific gravity of blend fiber reduced and thermal shrinkage rate increased. Blend ratio of PP was greater for shorter lengths of initial curl, although curl loosening increased as time elapsed.