All materials shrink on cooling due to thermal contraction.
The shrinkage of the plastic on cooling from the melt temperature to the mould temperature is known, somewhat perversely, as the mould shrinkage.
The principal reason for mould shrinkage is thermal contraction which is measured by the thermal expansion coefficient of the plastic.
The expansion coefficients of plastics materials are high compared with metals (Table 1.1). Typically, a 100°C rise/drop in temperature will produce an increase/decrease of between 0.001 and 0.02 mm/mm depending on the material.
Although this is small, it should not be ignored. Additionally, crystallisablc thermoplastics shrink on crystallising, the amount of additional shrinkage depending upon the amount of crystallinity developed which in some polymers is very much dependent on the rate of cooling.
For example, PET hardly crystallises at all when cooled rapidly unless it is seeded but slow cooling can produce up to about 50% crystallisation.
The rate of cooling therefore determines the total amount of shrinkage as well as the properties of the product.
The use of fillers (mineral powders, glass fibres, etc.) can reduce the amount of shrinkage on moulding because they have much lower thermal expansion coefficients.
However, processability may be adversely affected as well as dimensional stability.
It is common practice to quote a figure for mould shrinkage either in mm/mm or as a percentage for plastics materials (Table 1.1). Such figures should be regarded as indicative.
The precise shrinkage observed will depend on temperature drop, rate of cooling, shaping pressures and anisotropy due to orientation.
Anisotropy arises primarily from molecular orientation produced during Mow .
The consequence is that shrinkage is greater in the flow (orientation) direction than in the cross-flow (transverse) direction.
The difference in shrinkage depends on the material and the production methods. The inclusion of fibres also produces anisotropy.
Since mineral fibres (glass and carbon) shrink less than plastics, this tends to negate the differential shrinkage of the plastic and at fibre loadings of above about 20%, it is common to find that the differential is reversed, i.e. shrinkage is greater in the transverse direction.
In dimensioning the mould, the mould dimensions should be slightly over-sized compared with the product dimensions.
The variability of shrinkage means that product tolerances should be as generous as other requirements permit otherwise tight control of the moulding process is required.
Since amorphous materials shrink less than semi-crystalline materials, these materials are preferred where close product tolerances are necessary.
Other shrinkage factors which may need to be considered in dimensioning the mould are briefly listed below.
- (a) The mould may not be at room temperature. Allowance should be made for the cooling of the moulding to room temperature. For amorphous plastics, this is simply a matter of thermal contraction and this may be estimated from the thermal expansion coefficient. Semi-crystalline materials may contract more due to further crystallisation on cooling.
- (b) Even when cooled in the mould to room temperatures, semi¬crystalline materials may shrink over a period of time after ejection as a result of further crystallisation. This is known as post-mould shrinkage which, though usually small (less than 0.01%), may have to be taken into account for high precision products. One remedy is to ensure that crystallisation is completed during moulding by, for example, increasing the cooling time.
- (c) If the product is dimensioned for service at elevated temperatures, this may need to be taken into account when deciding upon mould dimensions.
Usually , thermoplastics reduce in size significantly as they cool down and solidify in the course of the molding operation. plastic mold designers create the custom mold impressions bigger than the preferred last components dimension to make amends for shrinking.
Custom mold shrinking data published through the polyester resin provider for the specific polymer can be utilized to calculate the quantity of compensation required.
Published custom mold shrinking data, according to easy components geometries and regular molding circumstances Custom mold shrinking, listed as length-per-unit-length figures or as proportions, presumes room-temperature dimensions.
Packing forces extra polymer directly into the custom mold to make amends for quantity reduction, lowering shrinking.
Entrance dimension, components size, and entrance situation can limit the level relating to packing which really can be accomplished through running adjustments.
Big entrance size and higher custom mold heat delay entrance freeze-off and promote greater degrees of packing.
Packing usually decreases and shrinking raises additional through the entrance, particularly in far-away thick-wall portions.
The custom mold constrains the components and prevents significant perspective adjust before after components ejection.
The kind and duration relating to this constraint can affect net shrinking among components characteristics.
For instance, the shrinking proportion among holes with a casted bloster will have a tendency to be lower than among the unconstrained edges from the bloster.
Long cycle times constrain the components within the custom mold longer and decrease preliminary shrinking, but can cause stresses that result in extra shrinking above time when the stresses relax.
As explained earlier on, several aspects make a difference to the level relating to shrinking.
It is possible to usually acquire the most precise shrink-age figures for latest molds by calculating the precise shrinking in current molds creating similar components sampled within the identical polymer.
If possible, the gating, move orientation, custom mold cool, and processing ought to be similar to that anticipated for the latest custom mold.
Prototype molds may also be a excellent source relating to shrinking values, but might not replicate manufacture circumstances.
Published shrinking data shows the typical range relating to shrinking according to laboratory circumstances.
Applying this data to some specific components and custom mold demands a combination relating to engineering opinion and knowledgeable guess.
Tend to the reduce end from the range for components thinner compared to 0.100 inch, and for extremely constrained characteristics including the distance among holes.
Anticipate move orientation in glass-filled components and utilize the move and cross-flow shrinking values appropriately.
Locations relating to random direction will have a tendency to reduce in size at a degree midway among the move and cross-flow figures.
Computerized shrinking evaluation requires a few of the guesswork out relating to shrinking prediction and is valued at thinking about in case the polyester resin has undergone the needed testing.
Think about designing crucial characteristics and measurements “steel safe” to make ease of adjustments to appropriate for errors in shrinking prediction.