Metallic powder injection molding using low pressure

The demand by high performance materials that have to support severe service conditions at a reasonable cost has been forcing the powder metallurgy to improve constantly. The most recent and more important innovation in the area is the process of powder injection.Powder injection molding (PIM) is a technology capable of producing a new range of components from powders. This advanced technology overcomes the existent limitations in the forming of products with complex geometry. The process presents countless variations which are used in the industry today. Invariably, it consists of mixing the powders and a thermo-plastic binder, injecting the mass in the mold in the wanted form, debinding, sintering and making optional secondary operations, as for example, machinery.The purpose of this work is to review the metal injection molding techniques and apply the low pressure injection molding process to family of parts using metallic powder with 10 mum particle size. This work also comments the design and construction of a low pressure injection machine and injection molds. (C) 2001 Elsevier B.V. B.V. All rights reserved.

Análise comparativa entre sistemas de resfriamento de injeção de plástico

This study aims to prove the economic feasibility of the installation of mechanical compression chillers on plastic injection molding machines in order to reduce the production cycle time of toothbrush cables in a specific case study. This evidence was confirmed by the comparative analysis of the system replaced and the new system installed. The old system had only one closed loop cooling tower which pumped chilled water to the injection molds, and the new system has the same tower sending cold water to the condensers of individual chillers installed on each injection machine. We conducted an analysis of energy efficiency in each system, showing that in terms of thermal efficiency virtually nothing has changed, but in terms of electricity demand the new system consumes 60.3 kW more. We conducted an analysis of machine productivity for both systems, showing a much higher productivity of the new system due to reduced cycle times caused by the presence of chillers and their greater cooling capacities. Equipped with data such as electricity rates, increases in operating costs and initial investments, the increase in consumption and demand of electricity plus the cycle time reduction were also calculated over so the simple payback 1 year and 2 months was reached

Análise da troca de calor em sistemas de injeção de termoplásticos – um estudo de caso: polipropileno

The purpose of this work was to define the processes through which the cooling of thermoplastics parts occur inside the mold cavity in an injection process. The plastic materials have become more widespread in the automobile industry and, among its manufacturing processes, injection moulding develops quickly, allowing the manufacturing of quality parts in great volumes. Data was collected from the injection of Volkswagen Gol NF 23X (Gol Generation 5). Using approximated methods for calculation for the heat Exchange inside the mould, in the cooling system, the required water flow was determined to properly cool the parts. Comparing the obtained value with Project specifications, it was verified that the method, in spite of incurring in some mistakes, is efficient in determining the flow of cooling fluid and serves as a verification tool for the parameters defined on project, and can be applied to simple projects. The definition of the cooling system, in practice, is dependent on innumerable variables and each case must be approached in itself, since the parameters for one product may not be ideal for another

Production of reinforced composites with natural fibers for industrial applications - Extrusion and injection WPC

The aim of this work is to study the replacement of currently used thermoplastics by composites reinforced with vegetable fibers with several advantages, mainly better mechanical properties, low weight and competitive cost compared to its counterparts. Extrusion and injection molding processes were studied using polypropylene (PP) matrix. The raw materials used were sugar cane bagasse, elephant grass, wood, milk cartons and recycled polypropylene. The composites were tested for bending, tension, hardness and impact resistance, following ASTM standards. The results obtained were extremely positive since they proved that natural fibers as reinforcement can be an important alternative to replace talc and other fillers.

Comparison of accuracy between compression- and injection-molded complete dentures

Statement of problem. A clinically significant incisal pin opening may occur after processing complete dentures if a compression molding technique is used. To recover the proper vertical dimension of occlusion, a time-consuming occlusal adjustment is necessary that often destroys the anatomy of the artificial teeth. A new injection molding process claims to produce dentures that require few, if any, occlusal adjustments in the laboratory after processing.Purpose. This laboratory study compared incisal pin opening, dimensional accuracy, and laboratory working time for dentures fabricated by this new injection system with dentures constructed by the conventional compression molding technique.Material and methods. Two groups of 6 maxillary and 6 mandibular dentures were evaluated as follows: group 1 (control), Lucitone 199, compression molded with a long cure cycle; and group 2, Lucitone 199, injection molded with a long cure. Incisal pin opening was measured with a micrometer immediately after deflasking. A computerized coordinate measuring machine was used to measure dimensional accuracy of 3-dimensional variations in selected positions of artificial teeth in 4 stages of denture fabrication. Analysis of variance (ANOVA) and t tests were performed to compare the groups.Results. A significant difference was found in pin opening between groups (t test). Horizontal dimensional changes evaluated with repeated measures ANOVA revealed no significant differences between groups. However, analysis of vertical dimensional changes disclosed significant differences between the groups. There was no appreciable difference in laboratory working time for flasking and molding denture bases between the injection and compression molding techniques when polymethyl methacrylate resin was used.Conclusion. The injection molding method produced a significantly smaller incisal pin opening over the standard compression molding technique. The injection molding technique, using polymethyl methacrylate, was a more accurate method for processing dentures. There were no appreciable differences in laboratory working time between the injection and compression molding techniques.

Estudo da viabilidade de produção da peça alimentação/ladrão para banheiras

The product development field daily works in the chase of new materials and technologies that fulfills the requirements of the consumer market. So, projects are developed in order to theoretically predict what will actually happen. The production of household appliance is not different. To provide a pleasant bath to the costumer, the manufacture of a bathtub counts on many components. With this in mind, this work goal is to study the possibility of production by plastic injection of the assembly water source/overflow pipe used in bathtubs and compare its production cost with the cost of the assembly acquired from third parties. The injection process is widely used on the world stage because of its numerous advantages, however, due to the high cost of the molds, it is important to estimate the time required for the return of the initial investment. To do this, a model was designed to examine its dimensions and then initiate the study of the possibility to inject the components with the available injection machine and the production cycle. With the results, it was found that there was a reduction in the cost of the finished assembly, but a very long time to return the initial investment due to the current financial scenery of the country

Morphological, mechanical and rheological properties of nylon 6/acrylonitrile-butadiene-styrene blends compatibilized with MMA/MA copolymers

The morphological, mechanical and rheological properties of nylon 6/acrylonitrile-butadiene-styrene blends compatibilized with MMA-MA [poly(methyl methacrylate-comaleic anhydride)] copolymers were studied. A twin screw extruder was used for melt-blended the polymers and the injection moulding process was used to mold the samples. The main focus was on nylon 6/ ABS blends compatibilized with one MMA-MA copolymer. This copolymer has PMMA segments that appear to be miscible with the styrene-acrylonitrile (SAN) phase of ABS and the anhydride groups can react with amine end groups of the nylon 6 (Ny6) to form graft copolymers at the interface between Ny6 and ABS rich phases. Tensile and impact and morphological properties were enhanced by the incorporation of this copolymer. Transmission electron microscopy (TEM) observations revealed that the ABS domains are finely dispersed in nylon 6 matrix and led to the lowest ductile-brittle transition temperatures and highest impact properties. It can be concluded that the MMA-MA copolymer is an efficient alternative for the reactive compatibilization and can be used as a compatibilizer for nylon 6/ABS blends.© 2003 Kluwer Academic Publishers.

Desenvolvimento e caracterização de compósitos poliméricos reforçados com fibras lignocelulósicas: HIPS / fibra de casca do coco verde e bagaço de cana de açucar

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Aplicação de redes NeuroFuzzy ao processamento de peças automotivas por meio de injeção de polímeros

The injection molding of automotive parts is a complex process due to the many non-linear and multivariable phenomena that occur simultaneously. Commercial software applications exist for modeling the parameters of polymer injection but can be prohibitively expensive. It is possible to identify these parameters analytically, but applying classical theories of transport phenomena requires accurate information about the injection machine, product geometry, and process parameters. However, neurofuzzy networks, which achieve a synergy by combining the learning capabilities of an artificial neural network with a fuzzy set's inference mechanism, have shown success in this field. The purpose of this paper was to use a multilayer perceptron artificial neural network and a radial basis function artificial neural network combined with fuzzy sets to produce an inference mechanism that could predict injection mold cycle times. The results confirmed neurofuzzy networks as an effective alternative to solving such problems.

Um estudo sobre a preparação metalográfica da liga de aluminio AA7075-T6

The increasing technological innovation and demand for materials with better properties boosts research into new materials and new alloys. To do so, aluminum alloys are being developed, among them the AA7075-T6, having many applications in aerospace and military industries, machinery and equipment, molds for plastic injection and structures. To study and understand the properties, characteristics and especially the microstructure of the material, the metallographic preparation is essential. This paper presents new methodologies to achieve the metallography of samples of scrap alloy AA7075-T6, with emphasis on methods of polishing. For the five samples, the best results were those with specific grinding, the samples only going down on the sander. For polishing, the most effective method so far has been using the polishing cloth 16.3, of ATM enterprise, solution of diamond 3 μm, solution of diamond 1 μm, and colloidal solution of OP-S. For the etching, the reactive agent used was phosphoric acid (H3PO4) 85% P.A., as 90% in the proportion of distilled water to 10% acid. The best results were obtained in the attacks of 300 and 240 seconds, revealing the grain boundaries in most areas. Methodologies need more studies and more tests, but the results have proved to be satisfactory

Estudo sobre eficiência energética em uma indústria de injeção plástica

The reason of this work is perform a study about using of electrical energy to identify the opportunities through rational use of electrical energy. For that it was necessary perform an analysis of hired energy against consumption. Based in a guide of energy analysis were found the main consumers and verified the main problems, which generate excessive use of electrical energy in a plastic injection factory. It was also analyzed the painting line because there are some thermal equipment that use electrical energy. Based on the data obtained will be proposed ways to reduce the needless consumption and energy use of rationally and efficiently, in addition to re-evaluate the contracted demand based on the new policy of supplying and charging.It were also proposed thermodynamics solutions to reduce the energy consumed in thermal process

Fresamento de aço para moldes e matrizes em condições criogênicas

Pós-graduação em Engenharia Mecânica - FEIS

Injectable gels of anionic collagen : rhamsan composites for plastic correction: Preparation, characterization, and rheological properties

The present article describes the preparation and characterization A anionic Collagen gels obtained from porcine intestinal submucosa after 72 h of alkaline treatment and in the form of rhamsan composites to develop injectable biomaterials for plastic for construction. All materials were characterized by SDS/polyacrylamide gel electrophoresis, infrared spectroscopy, thermal stability, potentiometric titration, rheological properties, and fluidity tests. Biocompatibility was appraised after the injection of anionic collagen:rhamsan composites at 2.5% in 60 North Folk rabbits. Independently of processing, the Collagen's secondary structure was preserved in all cases, and after 72 h of hydrolysis the Collagen was characterized by a carboxyl group content of 346 :L 9, which, at physiological pH, corresponds to an increase of 106 17 negative charges, in comparison to native Collagen, due to the selective hydrolysis of asparagine and glutamine carboxyamide side chain. Rheological studies of composites at pH 7.4 in concentrations of 2, 4, and 6% (in proportions of 75:1 and 50:1) showed a viscoelastic behavior dependent on the frequency, which is independent of concentration and proportion. In both, the concentration of the storage modulus always predominated over the loss modulus (G' > G and delta < 45 degrees). The results from creep experiments confirmed this behavior and showed that anionic collagen:rhamsan composites at pH 7.4 in the proportion of 50:1 are less elastic and more susceptible to deformation in comparison to gels in the proportion of 75:1, independent of concentration. This was further confirmed by flow experiments, indicating that the necessary force for the extrusion of anionic collagen:rhamsan composites, in comparison to anionic Collagen, was significantly smaller and with a smooth flow. Biocompatibility studies showed that the tissue reaction of anionic collagen:rhamsan composites at 2.5% in the proportion of 75:1 was compatible with the application of these gels in plastic reconstruction. These results suggest that the association of Collagen with rhamsan may be a good alternative in the replacement of glutaraidehyde to stabilize the microfibril assembly of commercial Collagen gel preparations. (c) 2005 Wiley Periodicals, Inc.

FAT-TISSUE INJECTION VERSUS GRAFT - EXPERIMENTAL-STUDY IN RABBITS

An experimental study of fat-tissue implants in the ears and frontal regions of rabbits was conducted, starting with blocks of tissue for surgical implantation or with multifragmented pieces for injection. The implants were observed from day 7 to month 12. Low integration levels were observed in all animals, except for 1 case that had 20% and 42% of integration, respectively, for the block grafts and for the injected multifragmented tissue.

Uso da avaliação do ciclo de vida para a determinação na redução de emissões de gases do efeito estufa e do consumo de energia associados a reciclagem de EPS

Pós-graduação em Engenharia Mecânica - FEG