Thermoset injection moulding

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Technology and know-how for integrated solutions

Thermoset injection moulding

www.arburg.com · 01/20162

At a glance

When technology and expertise come from a single source as at ARBURG, you as customer always reap the benefit with problem-free, daily operation - guaranteed.The same applies to thermoset pro-cessing. Here we offer you an efficient combination of our proven hydraulic ALLROUNDER machines and a practical thermoset package. This system solu-tion includes all the features required for the immediate production of high-quality moulded parts in large volumes. The addition of the universal high performance of our SELOGICA control system and our extensive experience in application technology enables us to offer you just what you expect from us: the most cost-efficient production solu-tion for your company

Example: switching elements With the combination of hydraulic ALLROUNDERs and the practical thermoset package, fully functional components can be

produced in high volumes.

Cylinder heating for processing thermoplastics

Tamping devices for moist polyester

Cylinder module for moist polyester

Accessories such as brush devices

Core pulls in close proximity to the mould

Integrated robotic systems

Turnkey solutions from a single source

Thermoset package Options

Cylinder module for pourable thermosets

Special screw geometries

Reliable venting

Precise liquid temperature control of the cylinder module

Highly wear-resistant bimetallic cylinder

Adaptive mould heating circuits

Universal compression injection moulding

Special equipment for thermoset injection moulding

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Individually adapted technologyHydraulic ALLROUNDER machines and the thermoset package have been designed as a system solution and include:• Three-platen technology with four tie-bar

guidance and central force application for precise demoulding

• Liquid temperature-controlled cylinder module for precise temperature control suited to a specific material

• Bimetallic cylinder for a long service life• Special screw geometry for material pro-

cessing without damage to the fibresThe machine technology can be precisely adapted to the respective injection mould-ing task thanks to its range of sizes in hori-zontal and vertical design, its modular adaptability as well as its wide variety of equipment for processing moist polyesters, for example. The ALLROUNDER machines remain universally applicable, regardless of whether they are being used for thermo-plastics processing or extended to complete turnkey systems.

Implementing sequences with easeThe freely programmable and high-perfor-mance SELOGICA control system enables even complex production sequences to be transparently controlled. This is ensured by the straightforward sequence programming via graphic symbols and the patented real-time plausibility checks. The SELOGICA’s equipment is ideally complemented by fea-tures such as adaptive mould heating, com-pression injection moulding or venting. This results in a correspondingly high level of process stability and reproducibility for ther-moset processing in particular. The wide range of options for integrating special peripherals such as brush units demonstrates the universality of the com-prehensive central control system for all ARBURG injection moulding technology. No specialist programming knowledge is required for operation. Handling complex tasks with ease – that is the outstanding strength of the SELOGICA.

Exploiting sound practical knowledgeThe search for the most cost-effective cus-tomer solution is something that also moti-vates the consultant specialists at ARBURG. In application technology, machine specifi-cations are precisely tailored to customer re-quirements. This is done on the basis of in-tensive talks with the customer, in which machine and process technology as well as comprehensive support for designing the injected part and mould are explained in detail. PC-based tools also help when com-paring the individual solution concepts and searching for optimal alternatives.

Know-how allround: with many years of application expertise, ARBURG provides comprehensive customer support in all questions related to

thermoset processing.


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Special: material and cylinder modules

Characteristics such as mechanical strength, dimensional stability, tem-perature resistance, non-flammability, resistance to abrasion and chemical resistance as well as their attractive price/performance ratio make thermo-sets very interesting as materials. They are also replacing other materials such as metals. Special materials of this type require a special machine technology. Optimum thermoset processing calls for precise temperature control in the process, a cylinder module with high resistance to the abrasive contents and specially designed screw geometries. Our tech-nology is tailored towards high-quality production right from the start.

Thermoset: the material for “extreme situations”The closed-meshed, cross-linked thermoset molecules require a completely different temperature profile to thermoplastics. The compound is injected from a “cold” cylin-der module into a “hot” mould. Melting

and further heating of the material in the mould causes a decrease in viscosity that is only reversed when cross-linking increases. The finished component is then irreversibly cross-linked, which makes it extremely hard, for example.

Standard: the right injection unit for every thermoset application.

Injection units according to EUROMAP

Screw diameter [mm]

Injection volume [cm³]

Moist polyester

Pourable material

Temperature profile of pourable thermosets


Important: adapted plasticisingARBURG has introduced adapted injection units for granular thermosets and moist pol-yesters into its modular range of technolo-gies in order to fully meet the requirements for thermoset processing. A high level of production quality is achieved through liquid temperature control with up to four zones and separate temperature control for the feed. Bimetallic cylinders ensure a corre-spondingly long service life, while special screw geometries ensure gentle processing of the material. Particular attention has been paid to minimising return flows during injec-tion and during the holding pressure phase. The play between the screw and nozzle is adjustable to prevent excess material here. Constant shot weights are achieved via the screw’s mechanical anti-reversing lock.

Pourable thermosetsPourable thermosets are supplied in the form of granulate, which means they can be fed in the conventional way. The special ARBURG cylinder modules ensure optimum material preparation thanks to the follow-ing features:• Compression-free screws without

non-return valves• Forward-set feeds for L/D ratios of

approx. 15:1• Screw-in nozzles with precise tempera-

ture control

Moist polyester (BMC)The fibrous, non-pourable material is mostly supplied pre-compressed in bales. Of par-ticular interest: there are also moist polyes-ters that do not shrink during processing, which can be extremely advantageous for various applications. An adapted material feed ideally takes place via special tamping devices such as the INJESTER from ARBURG. The special BMC cylinder modules from ARBURG ensure minimal destruction of fi-bres through the following factors:• Compression-free screws with deep screw

channel and vaneless non-return valve• Forward-set feeds for L/D ratios of

approx. 12:1• Optimised feed openings prepared for in-

stalling an INJESTER tamping device• Temperature-controlled cold runner radius

nozzles with an entry depth of 100 mm for short sprues

Practical: short sprues thanks to temperature-

controlled cold channel radius nozzles.

Precise: liquid temperature control with

several zones.

Suited to specific material: optimal processing

thanks to special screw geometries.


In order to implement your respec-tive application in large volumes with precision and high quality, you need customised injection moulding technol-ogy. Only a modular product range such as that from ARBURG enables you as a user to configure not just an accept-able machine, but precisely the right machine for your application. The reliable hydraulic ALLROUNDER machines form the ideal basis for this: they are perfectly matched to the universal high performance of our SELOGICA control system and the mate-rial-oriented thermoset package. The result is a production unit that is always perfectly tailored to your requirements. With this combination, you can do pre-cisely what you want to do on a day-to-day basis: produce moulded parts smoothly and reliably.

Practical: modular machine technology

1 Basis: reliable hydraulics

The hydraulic ALLROUNDER machines use dual-pump technology that permits simulta-neous movements. Precise moulding is en-sured by the three-platen technology with four tie-bar guidance of the clamping units, central force application and servo-regulated mould movements. The entire technology ef-fectively counteracts flash and overfeeding.

2 Horizontal to vertical

The ALLROUNDER machines can be individ-ually adapted through different hydraulic and electric expansion stages as well as through different arrangements of the in-jection units. Vertical and rotary table ma-chines are also available for injection mould-ing inserts. The technology is not, therefore, limited to a specific solution concept.

Horizontal to vertical

INJESTER: gentle feeding of moist polyester

Further information: Hydraulic ALLROUNDERs brochure

Vertical ALLROUNDERs brochure

Basis: reliable hydraulics

Adapted: rotary table machines for the over-

moulding of inserts.

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Brush devices and robotic systems• Complete solution with injection mould-

ing machine and the necessary peripherals• Programmable via SELOGICA

control system

Piston INJESTER• Design with hydraulic tamping cylinder• Conveying pressure can be programmed

via SELOGICA• Easy cleaning during material changes INJESTER screws• Alternative from size 800 injection unit• Design with servo-electric conveyor screw• Conveying pressure can be programmed

and controlled via SELOGICA• Large material reservoir

Accessories

3 INJESTER: gentle feeding of

moist polyesterINJESTER tamping devices have been devel-oped to cope with the automatic feeding of dry materials with a high filler content. They contribute towards optimum pre- compression, which results in minimal air and gas inclusions. This keeps products free from voids and lends them a glossy surface.

ARBURG offers several INJESTER versions with hydraulic piston and servo-electric conveyor screw. What they all share in common is full integration in the SELOGICA control system. The delivery pressure is programmable and the refill container can also be filled without problem during production. In addition, the INJESTER features regulated delivery pressure.

INJESTER: gentle feeding of moist polyester

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Perfect harmony: the SELOGICA control system

Universal compression injection moulding

1 Universal compression injection

mouldingCompression injection moulding is an im-portant function for improved surface qual-ity, high component strength and reduced distortion. The compression injection moulding sequence is freely-programmable via the SELOGICA, for example through in-dividual selection of the starting conditions. It can also be combined with venting. Com-pression injection moulding via core pull permits direct sprue separation.

2 Reliable venting

Venting of cavities is crucial with thermoset processing. It provides an effective means of allowing air and cross-linking gases to es-cape. As a result, the surface is not scorched and complete mould filling for void-free components is guaranteed. Both single and multiple venting operations can be quickly and reliably programmed via the SELOGICA, even during the holding pres-sure phase.

User-friendly: brush devices integrated in the

production sequence

Maintaining control over sophisticated machine, mould and robotic technolo-gies is the domain of SELOGICA. With this setting and monitoring system, you can quickly set up both simple and complex injection moulding processes, operate them intuitively and perform reliable optimisation. In a word: central management. All technical features of the SELOGICA control system, such as the graphical sequence editor, are also ideally suited for thermoset processing and aimed at making operation quicker, more reliable and more convenient. Here too, ARBURG guarantees you decisive competitive advantages: because we have already integrated all the necessary functions for high-quality and cost-effec-tive part production in the SELOGICA.

Further information: SELOGICA control system brochure


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3 Adaptive mould heating

The adaptive mould heating automatically adapts the control parameters to the con-trol response of the mould. Several heating zones can also be controlled in parallel via a sensor. This achieves high temperature sta-bility in the mould for excellent reproducibility in production.

4 Fully integrated peripherals

The SELOGICA central control system inte-grates robotic systems as well as all neces-sary peripherals such as brush devices. All processes can be programmed as a function of and synchronous with machine move-

ments. They are therefore part of the over-all sequence, appear in the sequence edi-tor with their own symbols and can be centrally monitored.

Highlights

• Control centre for the entire injection moulding technology

• Convenient sequence programming with graphic symbols

• Real-time plausibility checks• Free programmability of the produc-

tion sequences • Common data record for the entire

production unit• Watercooling for continuous temper-

ature control in the control cabinet

Fully integrated peripherals

2Reliable venting

3Adaptive mould heating


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Application examples

Thermosets have a wide range of appli-cations thanks to their special character-istics such as high mechanical strength and rigidity. Thermoset parts are typi-cally used for “extreme situations” in the automotive industry (engine com-partment and lighting components) as well as in the electrics and electronics industries (power and miniature circuit breakers, printed circuit boards).To process thermosets quickly, reliably and economically, you will need special machine technology and special know-how. At ARBURG, you can get every-thing from a single source.

1 Pistons made from pourable

materialThe pistons with internal thread are used in the clutches of passenger vehicles. This is a substitution component, which is far less expensive to produce using the injection moulding process. For processing the highly abrasive filled material, an extremely wear-resistant cylinder fitting is used. The 4-cavity mould operates using three-platen technol-ogy and separates the sprue directly inside the mould. The heart of the system is a hy-draulic ALLROUNDER combined with a MULTILIFT V robotic system. Downstream processing stations such as those for remov-ing burrs and grinding chamfers as well as for visual quality inspection can be centrally programmed and monitored via the SELOGICA control system.

2 Switch casing made from BMC

The switch casings for domestic fuses are injection moulded from a moist polyester (BMC). Feeding of the material is handled by an INJESTER piston feeder device, part removal by a MULTILIFT V. The four casings are picked up, the sprue separated and the articles placed on a conveyor belt. The high-precision 4-cavity mould is electrically heated to an operating temperature of ap-prox. 150 °C. Scorching and porosity are prevented through the use of an optimised mould venting system. A vacuum can also be applied. All of these functions are fully integrated in the SELOGICA control system.

Optimum material feed: piston INJESTER.Integrated refinishing: free programming of robotic system and peripherals centrally via the SELOGICA

machine control system.

Further information: Robotic systems brochure


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3 Precision encapsulation of inserts

Producing an armature shaft calls for preci-sion across the entire process chain. Moist polyester (BMC) is processed on an ALLROUNDER T rotary table machine with MULTILIFT V robotic system. The inserts are preheated to guarantee a reliable connec-tion between the shaft and the laminations as well as uniform cross-linking of the ther-moset. To reliably avoid overfeeding, the mould is designed with extreme precision. The precise positioning of the inserts in the mould via the robotic system is therefore important. Automation of the system, to-gether with the servo-electric rotary table, ensure highly consistent cycles.

4 Insulating rail turnkey project

A good example of the implementation of customer-specific turnkey projects are insu-lating rails for domestic irons made from moist polyester (BMC). The system includes a hydraulic ALLROUNDER, the INJESTER screw feeder device, a six-axis robotic sys-tem as well as a camera system for quality and functional checks. The six-axis robotic system with implemented SELOGICA user interface is ideal for near-contour refinishing of the thermoset parts. This enables the ro-botic system to be programmed using the same graphics-based system as the ma-chine. No special programming knowledge is required for independent set-up of the ro-botic sequence.

Individual solution: six-axis robotic system with SELOGICA user interface ideal e.g. for

near-contour refinishing.

High process reliability: consistent cycles through

automation.

Distances between tie bars of 270 x 270 to 920 x 920 mm | Clamping forces from 400 to 5,000 kN | Injection units from 70 to 3200 (according to EUROMAP)

© 2016 ARBURG GmbH + Co KGThe brochure is protected by copyright. Any utilisation, which is not expressly permitted under copyright legislation, requires the previous approval of ARBURG.

All data and technical information have been compiled with great care. However we accept no responsibility for correctness. Individual illustrations and information may deviate from the actual delivery condition of the machine. The relevant valid operating instructions are applicable for the installation and operation of the machine.

ARBURG GmbH + Co KG

Postfach 11 09 · 72286 Lossburg · Tel.: +49(0)7446 33-0 · Fax: +49(0)7446 33-3365 · www.arburg.com · e-mail: [email protected]

With locations in Europe: Germany, Belgium, Denmark, France, United Kingdom, Italy, Netherlands, Austria, Poland, Switzerland, Slovakia,

Spain, Czech Republic, Turkey, Hungary | Asia: People’s Republic of China, Indonesia, Malaysia, Singapore, Thailand, United Arab Emirates | America: Brazil, Mexico, USA

For more information, please go to www.arburg.com.

ARBURG GmbH + Co KG

DIN EN ISO 9001 + 14001 + 50001 certified 5229

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Thermoset injection moulding

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