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Mechanical Properties of Rapid Manufacturing and Plastic Injection Molding

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Mechanical Properties of Rapid Manufacturing and Plastic Injection Molding Mechanical Properties of Rapid Manufacturing and Plastic Injection Molding A Thesis Presented to the Faculty of the Graduate School University of Missouri – Columbia In Partial Fulfillment Of the Requirements for the Degree Master of Science By JOSEPH CONRAD AHLBRANDT Dr. Luis G. Occeña, Thesis Advisor December 2014 The undersigned, appointed by the Dean of the Graduate School, have examined the thesis entitled MECHANICAL PROPERTIES OF RAPID MANUFACTURING AND PLASTIC INJECTION MOLDING Presented by Joseph C. Ahlbrandt A candidate for the degree of Master of Science And hereby certify that in their opinion it is worthy of acceptance Dr. Luis Occeña Dr. James Noble Dr. Yuyi Lin ACKNOWLEDGEMENTS Foremost, I owe many thanks to my advisor, Dr. Luis Occeña, for his continual support during my research and studies. Without him I would not have been able to study this subject and broaden my knowledge of manufacturing methods. The guidance and wisdom that he has provided me is priceless and there is no way I can thank him enough. I am also in debt to Mr. Mike Klote for introducing me to rapid prototyping in his course at Mizzou. He presented rapid prototyping in a way that intrigued me and inspired me to pursue research opportunities related to the subject. I also appreciate his willingness to answer many of my questions that have helped me complete my thesis. I would like to thank the Engineering Technical Services department at the University of Missouri for providing me with support and access to technology that was vital to the completion of my thesis. I could not have completed my research without the occasional assistance of Greg Emanuel and Michael Absheer. Despite having their own responsibilities, Greg and Michael were always willing and available to help me. Lastly, I thank my parents, Bob and Jayne, who have supported me in everything I do and particularly my academic career. I would not be who I am or where I am without them. All of my accomplishments can be attributed to the advice, encouragement, and constant support my parents give me every day. Thank you for believing in me and giving me all of the tools and opportunity to be successful. ii TABLE OF CONTENTS ACKNOWLEDGEMENTS ................................................................................................ ii LIST OF FIGURES ............................................................................................................ v LIST OF TABLES ........................................................................................................... viii Chapter 1: Introduction ...................................................................................................... 1 1.1 Rapid Prototyping ................................................................................................ 1 1.2 Rapid Manufacturing............................................................................................ 2 1.3 Plastic Injection Molding ..................................................................................... 3 1.4 PIM vs Rapid Prototyping .................................................................................... 5 1.5 Objectives ............................................................................................................. 6 Chapter 2: Literature Review.......................................................................................... 7 2.1 Rapid Prototyping Properties ............................................................................... 7 2.2 Plastic Injection Molding Properties .................................................................... 9 2.3 Cost Analysis...................................................................................................... 13 2.4 Chen-Yu Liu’s Thesis ........................................................................................ 14 Chapter 3: Methodology ............................................................................................... 17 3.1 Tests ................................................................................................................... 17 3.2 Material Selection and Melt Testing .................................................................. 17 3.3 ASTM D638-10 Type IV ................................................................................... 22 3.4 Creating Test Specimens .................................................................................... 23 3.5 Shrinkage ............................................................................................................ 29 3.6 Tensile Strength Testing..................................................................................... 30 iii 3.7 Water Absorption ............................................................................................... 32 3.8 Shore Hardness ................................................................................................... 34 3.9 Microscopy ......................................................................................................... 36 Chapter 4: Results and Analysis ................................................................................... 37 4.1 Shrinkage ............................................................................................................ 37 4.1.1 ABS ................................................................................................................ 37 4.1.2 Nylon 12 ......................................................................................................... 39 4.1.3 Polystyrene ..................................................................................................... 41 4.1.4 Summary ......................................................................................................... 42 4.2 Tensile Properties ............................................................................................... 45 4.2.1 ABS ................................................................................................................ 45 4.2.2 Nylon 12 ......................................................................................................... 50 4.2.3 Polystyrene ..................................................................................................... 54 4.2.4 Summary ......................................................................................................... 55 4.3 Water Absorption ............................................................................................... 59 4.4 Shore Hardness ................................................................................................... 65 4.5 Microscopy ......................................................................................................... 67 Chapter 5: Conclusion and Future Work ...................................................................... 69 5.1 Conclusion .......................................................................................................... 69 5.2 Future Work ....................................................................................................... 76 References ......................................................................................................................... 79 iv LIST OF FIGURES Figure Page Figure 1 - Product Development Process with RP (Kochan) ............................................. 8 Figure 2 - Cost per Part vs Production Quantity (Hopkinson).......................................... 13 Figure 3 - Carbolite Furnace ............................................................................................. 20 Figure 4 - ASTM D638 Type IV Design (mm) (Liu) ....................................................... 22 Figure 5 - ASTM D638-10 Type IV 3D Model ................................................................ 23 Figure 7 - Aluminum Mold Blank Dimensions ................................................................ 24 Figure 6 - SolidWorks 3D Model of Mold ....................................................................... 24 Figure 8 - MasterCAM Process Planning ......................................................................... 25 Figure 9 - Final Mold Design (Top) ................................................................................. 26 Figure 10 - Lagun Mill and Centroid Controller .............................................................. 26 Figure 11 - Mini-Jector Model 45 ..................................................................................... 28 Figure 12 - Measurements for Shrinkage.......................................................................... 29 Figure 13 - Neiko Digital Caliper ..................................................................................... 30 Figure 14 - Percent Shrinkage........................................................................................... 30 Figure 15 - ADMET eXpert 2611 ..................................................................................... 31 Figure 16 - OHAUS Scout Pro Series SP200 (Chen-Yu Liu) .......................................... 33 Figure 17 - Water Absorption Equation............................................................................ 33 Figure 18 - Pacific Transducer Corp. Model 409 ASTM Type D Durometer .................. 35 v Figure 19 - Location of Shore Hardness Testing (Liu) ..................................................... 35 Figure 20 - MEIJI Techno EMZ-5TR stereo microscope (Liu) ....................................... 36 Figure
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