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GID/WITFluid-assist molding makes integrated media ducts Potential applications for fluid injection moldingGIT vs WITGIT-Gas injection technique Advantage:To avoid or minimize warpage and sink marks To reduce material consumptionIntegrate components Limitation:Long cooling and cycle timesA limit on part diameterThe lower level of heating eliminationPock-marked surfaceWIT-Water injection technique Advantage:To avoid or minimize warpage and sink marks To reduce material consumptionIntegrate components Lower cooling and cycle times Disadvantage:Investment is higherWhy WIT?Cycle time Up to 50%shorter cooling time Part is cooled externally by the mold Part is cooled internally by the water Greatest benefit-water continuously flowed through the partThinner walls More of the molten center of the part is cored outSmoother interior surface appearance Unfilled resins and low levels of fiberglass Highly dependent on the composition of the resinLess Slide Action in ToolBASF Ludwigshafen WAIM Unitn Flow rate 27 l/minn Max.water pressure 210 barn Control of several mold functions(needle shut-off,core pullers,injectors,.)Module manufactured by PME fluidtec,SasbachMain playersAlliance Gas SystemsUSAPME Fluidtec GermanyMaximator GID-TechnikGermanyCinpres Gas Injection-UKBattenfeldEngelIKVArburgMilacronFerromatikInjector technologyInjector typenable-positionadvantagedisadvantageAxial injector end of part high volume rates less pressure loss (mostly)relative movement necessary big installation spaceRadial injector part gate-system flexible Injector position less installation space pressure loss high effort for cleaning and deconstructOil leakageInjector technology drain pinResults(door handle mold)BASF test mould for tubesinjector35overflow 12025over-flow 2locking device*)cooperation of TiK,Zipfel Formenbau,BASFgateBASF test mould housings with channelsApplication:housings with an integrated channel for fluids=Middle part of the platen can be exchangedFurther BASF test mould for WITWater injector with hydraulic locking-deviceOverflowHot runnerInjector for water removalLocking pin for overflowK5(plate with rib)Further BASF test mould for WITOverflowRunnerDrain pinWater injector with hydraulic locking-deviceLocking pin for overflowRear Wiper ArmProcessing sequenceInjection of meltProcessing sequenceInjection and holding pressureProcessing sequence1.Opening of overflow2.Switching off hydraulic pressure on water injectorProcessing sequenceInjection of waterProcessing sequenceInjection of waterProcessing sequenceInjection of waterProcessing sequenceDecompression of waterProcessing sequenceRemovement of water by compressed airTest Results with“Rear Wiper Arm”Ultramid B3GM24 black 23228Test results with“Rear Wiper Arm”Ultramid B3WG6GP schwarz 23210WIT Modifications on ADAC Mold Door handle molded in Ultramid B3GM24Water injector with hydraulic driven locking-deviceLocking pin for runnerLocking pinfor overflowDrain pinprocedures versions for WAIM1.2.3.4.Injection phaseWater injectionWater holding timeWater reverse flowShort shot processprocedures versions for WAIM1.2.3.4.Full shot process(flush process is possible)Injection phaseWater injectionWater holding timeWater reverse flowprocedures versions for WAIM1.2.3.4.Injection phaseWater injectionWater holding timeWater reverse flowMelt push backprocessprocedures versions for WAIM1.2.Injection phaseWater injectionCore pull processprocess schema Water assisted injection moldingwatermeltinjectorcombined process Gas/Water assisted injection moldingN2H2OQuelle:TiK,Freiburg,www.tik-center.dewatermeltinjectorcombined process Gas/Water assisted injection moldingQuelle:TiK,Freiburg,www.tik-center.decombined process Gas/Water AIMequipment set upExternal tankInjectorDrain pinnitrogenoverflowfeed channeldownspot/drainNon return valveMEffect of process on the surface finish Ultramid B3GM35 black Q642WITGIDGID/WIT4,22,93,2Typical WIT problems WAIM channel surfaceUltramid A3HG6 WIT hydrolysis resistanceImpact strengthimmersionTime of immersionMinimum requirementsUltramid A3HG6 WIT hydrolysis resistanceTensile stress at breakimmersionTime of immersionMinimum requirementsknowledge transfer to Ultradur modified typeUltradur B4040G10 sw.15098 Ultradur B4040 G6 knowledge transfer from Ultramid-product developmentpure WIT processUltramid A3WGM53andUltramid B3G8possible through addition of Ultramid T1)Pump2)Heat exchanger3)Thermostat4)Flow meter5)Bypass line6)Filling hopper7)Pressure equalisation tank8)Tested parts9)Measurement instrumentationTest equipment for cooling tubes (E-KTE/EW)Test conditions467881529 Test equipment-50:50 Glycol/water mixture-Temperature:130 C-Flow rate:120 L/min-System pressure:2 barImpact of process parameter to the wall thicknessABCParting lineDPosition 1Position 2Position 3Position 4Position 5pipe section with marking requirement location of pipe sectionsmeasuring pointsImpact of process parameter to the wall thicknessRestwanddicke-Temperatur3,184,664,943,034,564,322,743,834,450,01,02,03,04,05,06,0Messposition 3BMessposition 3DMessposition 2CWanddicke mmTM 270C;TW 60CTM 290C;TW 80CTM 300C;TW 90Cwall thickness mmwall thickness-temperatureMeasuring point 3B Measuring point 3D Measuring point 2C Impact of process parameter to the wall thicknessRestwanddicke-Verzgerungszeit4,214,232,994,324,563,035,123,304,680,01,02,03,04,05,06,0Messposition 3BMessposition 3DMessposition 2CWanddicke mmtVerzgerung 3,1 sek.tVerzgerung 4 sek.tVerzgerung 8 sek.wall thickness mmwall thickness delay timeMeasuring point 3B Measuring point 3D Measuring point 2C Impact of process parameter to the wall thicknessRestwanddicke-Volumenstrom4,664,683,124,324,563,034,624,242,960,01,02,03,04,05,06,0Messposition 3BMessposition 3DMessposition 2CWanddicke mmVolumenstrom 100 cm/sek.Volumenstrom 300 cm/sek.Volumenstrom 445 cm/sek.wall thickness mmwall thickness volume rateMeasuring point 3B Measuring point 3D Measuring point 2C Impact of process parameter to the wall thicknessRestwanddicke-Wasserdruck4,914,273,184,324,563,034,754,372,974,744,503,030,01,02,03,04,05,06,0Messposition 3BMessposition 3DMessposition 2CWanddicke mm70 bar Wasserdruck100 bar Wasserdruck150 bar Wasserdruck200 bar Wasserdruckwall thickness mmwall thickness water pressureMeasuring point 3B Measuring point 3D Measuring point 2C Impact of process parameter to the wall thicknessRestwanddicke-Druckhaltezeit4,754,683,114,324,563,034,824,243,010,01,02,03,04,05,06,0Messposition 3BMessposition 3DMessposition 2CWanddicke mm4 sek.Druckhaltezeit8 sek.Druckhaltezeit12 sek.Druckhaltezeitwall thickness mmwall thickness holding time of water pressureMeasuring point 3B Measuring point 3D Measuring point 2C Impact of process parameter to the wall thicknessRestwanddicke-Gasdruck/GID4,324,563,035,064,673,104,665,023,360,01,02,03,04,05,06,07,0Messposition 3BMessposition 3DMessposition 2CWanddicke mm60 bar Gasdruck-GID/WIT40 bar Gasdruck-GID/WIT60 bar Gasdruck-GIDwall thickness mmwall thickness gas pressureMeasuring point 3B Measuring point 3D Measuring point 2C Recommended grades for WIT Ultramid A3WGM53 bk 20560 ideally fulfills requirementsfor hot oil and processingperformanceCycle time 36sRecommended grades for WITPA6 Grades:Ultramid B3WG6 GP bk 23210 e.g.coated door handles,pedals excellent mechanical propertiesUltramid 8267G HS bk 106Ae.g.uncoated door handles excellent UV-stability and surface appearanceRecommended grades for WITProduktAnwendungVerfahrenUltramid A3HG6 WITcooling tubesGID/WITUltramid A3WGM53oil tubesGID/WITUltramid A3WG10 HSstructure partsGID/WITUltramid B3WGM24car door handlesGID/WIT -WITUltramid B3WGM53car door handlesGID/WIT -WITUltramid B3WG6 GPcar door handlesGID/WIT Ultramid B3G10 SIstructure parts,(e.g.roof rack)GID/WITUltramid SEG8structure parts(armrest,office chair,pedal,mirrow bracket)GID/WITUltradur B4040G10structure parts,(e.g.roof rack)GID/WITMarket potential for WAIM-Applicationsin Europe(source:KTE/MB,KTE/VA)ApplicationTotal market jatofuture WAIM jatocommentDoor handles54001000Clutch pedal3000600Oil tubes30002000Aquilifier system20.0001000Routeing of air flow10.000500Non-Automotive?Tubes for coolants or oil-Powertrainwater tubes:Potential:weight:400 g per vehicleby 14 Mio.vehicles=5600 tgrowth:25%=3.600 t in 2010Tubes for coolants or oil-PowertrainOil dip stick tube:potential:weight:140 g per verhicleby 14 Mio.vehicles=2.000 tgrowth:45%=650 t in 2010Roof rack with WAIMRequest of Decoma,conzept introduced to VW,BMW,PSAUltradur B4040G10(WAIM mod)and Ultramid B3G10SI300t/a Product modification Ultradur B4040 G10product properties:PBT/PET-Blend,50%GFhigh stiffness on demoulding and strenghtExcellent surfacesuitable for powder coating(at 360F)Tailor-made for fluid process(gas/water)statusSecond mould proving Part with less molecular degradationParts passed the first part testsSurface quality-Ultramid B3G10SI better than Ultradur B4040G10Tests for paintability runingSaving of costs for roof racks with metall housing ca.20 Euro per couple!Potential applications for WITCooling tube produced in Gas Assisted Injection Moulding(GAIM)“Geiger-Rohr“for Daimler-Chrysler(A-class)37 mm1267 mm5 mmnon uniform wall thickness with GAIMCooling tube produced in GAIMTube for Audi(ITW)34 mm600 mmvery long cycle time with GAIMCycle time 110 sec.Patent situationPatent situation has to be considered:-USA:Alliance Gas Ltd.6,579,489 (12.000 per unit for the life of a unit)-D:TiK,Freiburg,patent-nummber:DE 103 39 859 B3 2005.01.05 (20.000 per unit over a period of 5 years)Machine cost estimatesCost analysisDETAILSMaterial CostCycle timeNumber of Cavities NeededDetermines Number of MachinesMachine Hourly RateEquipment Needed&CostOverhead&Profit FactorInvestment AmortizationInsert Costs,Cost of ExtrasFinal Price per Piece
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