The Institute for Plastics Processing in Aachen is drumming up support for an innovative event that will demonstrate diversity and present the unexpected. Even the event's initiator, Prof. Hopmann, is keyed up and can't wait to see what will be presented there ¿ as he divulged to us in an interview.  

IKV premiere will throw light on the fundamentals of plastics technology  

Kunststoffverarbeitung: Maschinen und Komponenten

Blasfolienextrusion

Faserverarbeitung

Spritzgießen

Extrusion

Lehrstühle und Institute

Call for papers for a symposium for lateral thinkers  

Near-mold-contour distribution systems provide temperature control for large injection molds with a number of heating-cooling channels. This setup makes it possible to arrange circuits in parallel and at the same time reduce the number of cooling-heating units. 

Automated Temperature Control and Surveillance in a Distribution System 

Temperiertechnik

The multiFlow System for Parallel Circulation  

KraussMaffei Technologies GmbH, Munich, Germany, is concentrating on the topic of digitalization. Its focus is on the question of how production that has grown organically, with older legacy machinery from different manufacturers, can be integrated into a networked manufacturing environment. A digital retrofit allows older machines to be upgraded. Depending on the available IT structure, they can thereby save process data via a gateway PC in the cloud or close to the network by means of an edge PC. 

KraussMaffei at K 2019 

Spritzgießmaschinen

Product Family Completely United  

With its products of the activeGate family, Synventive Molding Solutions GmbH, Bensheim, Germany, offers a range of control technologies in the hot runner, which, using sensor data, permit individual monitoring of the melt flow at the melt entry point of every gate in the mold. A new feature is the latest enhancement of the eGate. The electrically operated valve-gating system is now also available for large parts with high shot weights. The system permits monitoring of the valve movement at every individual hot-runner nozzle and, with a large number of setting parameters, offers possibilities for part optimization, particularly in sequential injection molding and with family molds. 

Synventive at K 2019 

Heißkanaltechnik

Individually Controlled Melt Flow 

The new cavity pressure sensor complements from RJG Germany GmbH, Karlstein, Germany, complements the company’s range of indirect-measurement pressure sensors. The 6 mm-sensor is in particular suitable for molds with high numbers of cavities, because, due to its compact size, it can be installed behind the closely spaced ejector pins. 

RJG at K 2019 

Druck- / Kraftsensoren

Indirect Pressure ¿Measurement for Multi-Cavity Molds 

In cooperation with two new subsidiaries, the Haidlmair Group, Nussbach, Austria, is showing several innovations in the field of hot-runner technology, mold monitoring and lifetime management. FDU Hotrunner GmbH, Frankenthal, Germany, markets the FDU (flat die unit) launched by Haidlmair in 2016, which, according to the manufacturer, is particularly characterized by the fact that, in comparison to circular nozzles, it introduces less shear-induced heat into the melt, shortens the cycle time and reduces the required injection pressure and energy consumption. 

Haidlmair at K 2019 

Normalien und Heißkanaltechnik

Keeping the Nozzle Flat 

Nissei is presenting a thin-wall application involving the bioplastic PLA: the production of champagne glasses in an 8-cavity mold on a NEX 280V-71E all-electric injection molding machine. 

Nissei and Michio Komatsu Present World Novelty 

Biokunststoffe

Champagne from Biodegradable Glasses 

Sumitomo (SHI) Demag Plastics Machinery GmbH, Schwaig, Germany, considers the circular economy and efficiency as future themes of plastics processing. In addition, digitalization continues to be a focus. A networked cell with remote-diagnosis options, online support, document tracking and spare parts ordering are representative of the “smart services” offered by the machine manufacturer. Visitors can use networked terminals to see how the “myConnect” software improves customer service. 

Sumitomo (SHI) Demag at K 2019 

Industrie 4.0

Medizintechnik

Smart, Fast and Sustainable 

At K 2019, Dr. Boy GmbH & Co. KG, Neustadt-Fernthal, Germany, unveiled an optional servo-electric drive for the injection unit (type: eSP) of its injection-molding machines. Martin Kaiser, Head of Design at Boy, explained the new option for the machine sizes Boy 60 E to Boy 125 E: “The newly developed injection unit, with the international size SP170, executes the injection and metering actions electromechanically via two servo motors. In its development, Boy’s experience with the design of hydraulic injection units was combined with that of the suppliers of high-quality drive components.” 

Boy Injection-Molding Machines Now Available as Hybrid Version 

Servomotoren

Servo-Electric Drive Option for the Injection Unit 

It is not always easy to reconcile a constantly high part quality with short cycle times. While rapid solidification of the melt is desirable, all the cavities in the mold must be uniformly filled in order to satisfy the various quality requirements. The manifold system plays an important role here. 

Sophisticated Manifold Technology from Günther 

Better Part Quality through Gentle Melt Guidance 

Hasco Hasenclever GmbH + Co KG of Lüdenscheid, Germany, has expanded its portfolio of nozzles with the Single Shot series of nozzles. Their development concentrated on compatible installation dimensions, precise temperature control, functionality, as well as cost-effective design. The wide variety of nozzle versions enables simple gating to sub-manifolds and direct connections to the molding. 

In addition to all standard plastics, the new Single Shot nozzles can process technical and slightly reinforced materials, as well. 

Purposeful Design 

Product geometry is subject to systematic process-related deviations when plastics are injection molded or 3D-printed. FormCorrect is a software module for product optimization by largely automated correction of CAD models. It is integrated in WinWerth, the measurement software from Werth Messtechnik of Giessen, Germany, thereby enabling reduced development costs. 

Quality Control for Plastics Injection Molding and 3D Printing 

Qualitätssicherung

Expanded Post-Processing of Measurement Data  

At K 2019, the metrology experts at Kistler AG, Winterthur, Switzerland, showed how artificial intelligence will pave the way for the smart factory. ComoNeoPredict, a module of the ComoNeo process monitoring system, allows model-based prediction of the desired part quality based on the cavity pressure and temperature profiles. 

Kistler Puts Artificial Intelligence into Plastics Processing 

Spritzgießwerkzeuge

Networked Production with an Adaptive System 

Together with its international customers, Regloplas AG of St. Gallen, Switzerland, works out complete solutions that can be easily integrated into the processes of a future Smart Factory. That is why the Swiss manufacturer’s latest generation of temperature control units communicates via OPC UA with superior IT systems (PPS, MES, ERP) in industrial production – across locations, e.g., via Cloud, if required. Theses devices also can be networked with injection molding and other plastics machines via the IOD UA communication protocol. This fulfills all prerequisites for continuous data exchange in highly automated, digitalized plastics processing. 

Temperature Control Units Networked via Dashboard  

Temperieren

Betriebstechnik für Kunststoffverarbeitung (Peripherie)

Central Visualization of Process Data 

Hot-runner manufacturer Incoe International Europe, Rödermark, Germany, is introducing its new Hot Halves (type: SealFit) to the European market. A Hot Half comprises a complete, ready-to-go system with SealFIt hot runner nozzles. 

SealFit Hot Halves 

Efficiency for Mold Makers and Injection Molders 

Chinese Company Investigates Cracking Behavior

Cracked screws are a frequent cause of customer complaints. The Chinese manufacturer EJS has identified the source of the problem.

As a screw manufacturer, E.J.S Industry Co., LTD, Ningbo, China (EJS), often receives complaints like this: “We have received your screws. Are you sure your people have carried out an inspection? Look at this crack, I think anyone can see that it is damaged. How can we install such a screw on our machine? How fast can you ship us a replacement? We need one immediately. Please let me know.”

When the first 125 hard-faced screws were ready for inspection, the employees at EJS noticed that there were cracks. How could that happen? Was it caused by poor temperature control, inferior bimetallic alloy powder, poor quality base steel, or process management? To find out why, the company scheduled a number of tests, and applied numerous labels to the product for later identification. After an extensive process of trial and error, EJS at last identified the cause of the cracks and their relationship.

Hard-faced screws are normally processed by a PTA welding machine. The energetic plasma arc generates temperatures of over 1000  °C to fuse the alloy powder and weld in the flights one by one until the screw is complete. This process inevitably results in repeated thermal expansion and contraction due to the big difference between the temperature of 1000 °C and the ambient temperature (5 to 40 °C).

Since 2015, EJS has used a special furnace to maintain the hard-faced screws at high temperature for several hours after PTA welding, which helps it to reduce the numbers of cracks. Unfortunately some cracks still remain. Is there any way to get rid of them?

As a quality-oriented company, EJS has tried everything to avoid cracks. However, it is not possible to completely exclude the possibility of cracks forming. The company has consulted senior engineers, checked with experts, analyzed together with experienced production managers and sought advice from long-term customers in different countries. In the end, the Chinese company accepted the fact that cracks are inevitable for some alloys on big sizes, because no cracks means soft flights. There are some alloys for which micro cracks cannot be avoided. They have always been present. Moreover EJS has found that

<ul><li>severe cracking is acceptable if the flights remain intact;</li><li>long cracks are acceptable if the flights remain intact;</li><li>wide cracks are acceptable if the flights remain intact;</li><li> it is acceptable if the cracks are regular in one direction;</li><li>however, it is unacceptable if the cracks cause peel-off of the facing.</li></ul>

Using these simple questions, customers can check whether their screws are okay or not. In case of doubt, the experienced EJS staff will be happy to help. (ed.)

E.J.S. Industry Co. Ltd.  

www.ejs-screwbarrel.com

Ausgabenartikel

During production, large temperature differences sometimes occur, which are one reason for crack formation

EJS has investigated the cracks in various comprehensive analyses. The result: the cracks are very small and do not reduce the quality and durability of the screws

According to the company, the cracks are not production defects

According to EJS cracks can occur on the screws, especially with large screw diameters

Name - Hauptartikel

E.J.S Industry Co., Ltd, Ningbo, China, is specialized in producing, repair and rebuilding screws, barrels and components for plastic product manufacturers, rubber product manufacturers, extruder and injection molding producer. With 25 years experience they are aim to supply screws barrels with more wear resistance and corrosion resistance.

<a href="http://www.ejschina.com">www.ejschina.com</a>

Kunststoffverarbeitung: Verfahren

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