Termoformado

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Investigation of Plug Assist Material Properties Relative to the Thermoforming Process
Thomas J Murray and Noel J Tessier CMT Materials, Inc. Bernhard Hegemann IKP, University of Stuttgart Thomas Gallagher, Ted Gabor & Tim Roberts Sunoco, Inc.

Slide No. 1

Innovative Tooling Materials for Thermoforming

Photo Courtesy of Alga Plastics
Slide No. 2

Innovative Tooling Materials forThermoforming

Photo Courtesy of FUTURE MOLD
Slide No. 3

Innovative Tooling Materials for Thermoforming

Diagram Courtesy of ACCUFORM
Slide No. 4

Innovative Tooling Materials for Thermoforming

Plug Material Properties Relevant to Thermoforming
•Ability to be Shaped or Machined •Temperature Resistance •Abrasion Resistance •Thermal Conductivity •Thermal Mass (Specific Heat) •ThermalDiffusivity •Compression Strength •Surface Roughness •Coefficient of Friction •Coefficient of Thermal Expansion •Abuse Resistance •Cost
Innovative Tooling Materials for Thermoforming

Slide No. 5

Presentation Overview
Improved thermoforming through better understanding of the most important plug properties.
1) Thermal/Mechanical Tests of commonly used plug materials 2) Comparison ofproperties of parts formed with different plug materials.
Slide No. 6

Innovative Tooling Materials for Thermoforming

Guidelines in Measuring Plug Material Properties
1. 2. Measure the properties of the commonly used plug assist materials. Measure their properties at conditions as close to those encountered in thermoforming. Test all the materials under the same test procedures and conditions.Test random samples from suppliers, duplicating materials thermoformers are encountering in their applications.

3. 4.

Slide No. 7

Innovative Tooling Materials for Thermoforming

Material Testing - Plug Materials Evaluated • Epoxy Syntactics • Solid Polymers • Thermoplastic Syntactics

Slide No. 8

Innovative Tooling Materials for Thermoforming

Material Testing - Plug MaterialsEvaluated
Epoxy Syntactic HYTAC-W Standard 350°F Epoxy Syntactic SYNTAC  350 Standard 350°F Epoxy Syntactic SYNFORM  Standard 350°F Epoxy Syntactic HYTAC-WF High Strength/Smooth Surface 450°F Epoxy Syntactic HYTAC-WT 350°F Epoxy Syntactic with Teflon HYTAC-WFT New! 425°F Service Smooth Epoxy Syntactic with Teflon Thermoplastic Syntactic HYTAC-B1X Tough Engineered 350°F Thermoplastic SyntacticFoam Solid Polymers HYTAC-B Engineered Polymer with Excellent Heat Resistance FORMPLAST Urethane Material Specially Formulated for Plug Applications DELRIN Acetal Homopolymer with 180°F In-Air Use Temperature POLYSULFONE Transparent, Heat Resistant, Engineered Thermoplastic ULTEM 1000 High Heat Resistant, Polyetherimide Thermoplastic NYLON 6/6 Standard Grade Engineered Thermoplastic

Slide No. 9Innovative Tooling Materials for Thermoforming

Slide No. 10

Innovative Tooling Materials for Thermoforming

Material Testing – Test Program
Physical/Mechanical
Density Compressive Strength and Modulus Coefficient of Thermal Expansion, (CTE) Shore D Hardness versus Temperature Coefficient of Friction – Static and Dynamic( µ )

Thermal
Thermal Conductivity (k) Specific Heat (Cp)Thermal Diffusivity (α)

Slide No. 11

Innovative Tooling Materials for Thermoforming

Test Results – Density and Compression Strength/ Modulus
Material Density Epoxy Syntactics
HYTAC-W SYNTAC 350 SYNFORM HYTAC-WF HYTAC-WT HYTAC-WFT

Compressive Strength (psi)
6,200 6,500 6,500 18,000 8,000 17,500

Compressive Modulus (ksi)
227 230 230 450 300 325

(lbs/ft3)
40.0 45.9 45.7 55.046.0 60.0

Thermoplastic Syntactic
HYTAC-B1X 43.0 7,100 298

Solid Polymer
HYTAC-B Polysulfone Ultem 1000 Formplast 2000 72.0 77.4 80.0 75.0 12,000 13,000 22,000 12,000 400 360 480 385 450 Innovative Tooling Materials for Thermoforming

Delrin 88.0 16,000 * Measured as per ASTM D 695
Slide No. 12

(psi)
10000 15000 20000 25000 5000

0

HY TA C -W SY NT A C -3 50

SY NF O RM HY...
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