The Effect of Melt Temperature On Volumetric Shrinkage

THE EFFECT OF MELT TEMPERATURE ON
VOLUMETRIC SHRINKAGE
Bisma Ali, Aleena Tariq
Department of Polymer & Process Engineering
University Of Engineering And Technology, Lahore
bismaali968@gmail.com
aleenabutt370@gmail.com
Abstract
Injection molding of plastic is one of the most widely used technique for the production of plastics
parts of both simple and complex geometries. (S.H. Tang, 2007)1. In this research the effect of
volumetric shrinkage with increasing melt temperature on a chair was observed. Various process
parameters i.e. mold temperature, melt temperature, packing pressure can have an effect on
volumetric shrinkage of part. (Tuncay Erzurumlu, 2006)2. Chair was made using Solid works
software and further analysis and simulation was observed on mold flow insight. Polypropylene
was selected to study the effect of volumetric shrinkage.
Key words: Injection molding, Melt Temperature, Volumetric Shrinkage, Polypropylene,

Analysis and Simulation
1.Introduction
Injection molding is one of the most common molding process used in the manufacturing of
different type of plastic parts. In plastic industry almost 33% of plastic parts are made from
injection molding including simple to complex parts with accurate dimensional stability and short
cycle time as it is a semi continuous process (Kamaruddin, 2011)3. Injection molding process
generally consist of four zones i.e. plasticizing zone, injection zone, packing zone and cooling
zone (Yi-qi Wang, 2014)4. Resin in pallet form is melted in the plasticizing zone and fed into the
injection zone through dye. In the mold the melt is given proper time for filling firstly filling is
slow so that in sensitives areas such as gates, runners etc the material do not solidify or damage
them. Then filling is done with high pressure for complete filling of mold and to avoid stresses
and again pressure is reduced to fill the mold completely till the edges and all the remaining parts
and to avoid shrinkage when cooled. Cooling channel is placed inside the mold for solidification
of part. Cooling can be from water channels, air etc and cooling time depend upon the size of the
part. Effect of melt temperature and volumetric shrinkage is quite significant while setting
parameters for filling a plastic part. Volumetric shrinkage depend upon how the material is being
filled, injection locations, type of material, filling time, packing pressure, part dimensions.
2.Experiments and Design

2.1. Selection of part
We selected a chair because of its wide range of applications in houses, gardens, hospitals, parks
and almost everywhere. As it is a relatively simple part which do not have too many curves and
bends we selected this part because of its wide range of applications and easy processability. This
part is important as because of its wide usage worldwide.
2.2. Selection of polymer:

Polypropylene was selected to make a chair. As it a thermoplastic and its handling easier than
thermosets materials. It is a tough material. It has a long fatigue resistance i.e. it can retain its shape
after a lot of bending, compression etc. It has a good chemical resistance so when used in outside
environment do not react much with the chemicals present in environment. Recycling of
polypropylene is easier with addition of other fillers and additives to maintain its strength. It is
easily available and is an inexpensive thermoplastic. It has high flexural strength and has good
impact resistance.
We can also use PET or ABS for making chair but it has certain disadvantages.
PP has a low density than PET. Density of PP is 34% lower than PET i.e. processing of PP is easier
and due to its low density less material is required to produce more chairs and its modulus and
strength is also high that is why PP is more preferred than PET.
ABS can also be used as its impact resistance is higher than PP but is more expensive than PP and
is economically not feasible to use an expensive resin for a common application as it will increase
its price.
2.3. Selection of processing parameters

Volumetric shrinkage is related to injection pressure, melt temperature, change in crystallanity and
dimensions of part. Different melt temperatures were selected i.e. 220oC, 240oC, 260 oC, 280 oC
and 300 oC.
Melt temperature of PP = 230-270 oC
Maximum injection pressure was 1.8 × 103 MPa.
Solid meshing of the object.
Complete filling wraping and packing of part.
Two injection locations were set.
Melt temperature was increased by 20oC after every analysis and change in volumetric shrinkage
was observed.
3.Results & discussion

Volumetric shrinkage at 220 oC
Fig. 1 volumetric shrinkage at 220 oC

Fig. 2 Volumetric Shrinkage at 240 oC


Temperature Volumetric
(oC) Shrinkage(%)
220 14.1874
240 15.2798
260 16.2118
280 17.1498
300 18.0599
20
18
18.0599
AVerage Volumetric Shrinkage(%)
16 17.1498
16.2118
14 15.2798
14.1874
12
10
0
0 50 100 150 200 250 300 350
Temperature
Fig. 6 graph between temperature and volumetric shrinkage
For filling of the chair polypropylene was selected. Two injection locations were given to reduce
the filling time. When the analysis was complete it was observed that the part was filled
completely. There were no void or unfilled region left in the part.
From graph it is concluded that as melt temperature increases volumetric shrinkage also increases.
This is because as the melt temperature increases the viscosity of melt also increases and density
decreases. As density and volume has inverse relation so due to decrease of density volume of melt
increases. And due to more volume less amount of melt will be filled in the mold as compared to
the amount filled at lower temperature. So when cooling occur and part solidify due to less density
part will shrink more and effect of volumetric shrinkage will be more prominent.
The same result is observed from graph that at low temperature i.e. 220 oC value of average
volumetric shrinkage is less i.e. 14% as the melt temperature increases due to above reason
volumetric shrinkage also increases and reaches upto 18%. It was also observed that most
shrinkage is near the leg areas this may be because of the injection location that the melt do not
reach the leg areas with required pressure.
Fig. 7 temperature vs signal to noise ratio

The above graph also shows that as the melt temperature increase shrinkage of polystyrene
increase. (Altan, 2010)5
5.Conclusion
It is concluded that with the increase of melt temperature volumetric shrinkage also increases
(direct relation). Volumetric shrinkage is not same in all parts it varies from part to part. Maximum
shrinkage allowed in any object is from 15-25%.
Volumetric shrinkage cannot be controlled exactly but can be minimized by controlling certain
parameters i.e. increasing the injection pressure, proper placement of injection location or can be
minimized by the addition of fillers compatible with the melt.
References
1
S.H. Tang, Y. T. S. S. S. S. N. I. R. S., 2007. The use of Taguchi method in the design of plastic
injection. Journal of Materials Processing Technology.
2
Tuncay Erzurumlu, B. O., 2006. Minimization of warpage and sink index in injection-molded.
Materials and Design, pp. 853-862.
3
Kamaruddin, N. M. M. a. S., 2011. Multi-Response Optimization of Injection Moulding.
Polymer-Plastics Technology and Engineering,
4
Yi-qi Wang, J.-g. K. J.-i. S., 2014. Optimization of plastic injection molding process
parameters. Materials and Design, pp. 313-318.
5
Altan, M., 2010. Reducing shrinkage in injection moldings via the Taguchi, ANOVA and
neural. Material and Design, Volume 31, pp. 533-604.

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THE EFFECT OF MELT TEMPERATURE ON

Key words: Injection molding, Melt Temperature, Volumetric Shrinkage, Polypropylene,

2.Experiments and Design

2.2. Selection of polymer:

2.3. Selection of processing parameters

3.Results & discussion

Fig. 1 volumetric shrinkage at 220 oC

Fig. 2 Volumetric Shrinkage at 240 oC

Volumetric shrinkage at 260 oC

Fig. 3 volumetric shrinkage at 260 oC

Fig. 4 volumetric shrinkage at 280 oC

Volumetric shrinkage at 300 oC

Fig. 5 volumetric shrinkage at 300 oC

Fig. 6 graph between temperature and volumetric shrinkage

Fig. 7 temperature vs signal to noise ratio

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