Injection molding: The effect of fill time on properties

Abstract

AbstractThe effect of fill time on the mechanical properties, surface appearance, and part dimensions of several polymers was determined. Two crystalline materials, polypropylene and nylon 6,6, and an amorphous material, acrylonitrile‐butadiene‐styrene (ABS), were used. In addition, the effect of the presence of glass fibers was examined using glass fiber reinforced nylon 6,6. The fill time was varied from 0.8 to 20 sec which included both the viscous flow controlled region (short fill times) where laboratory samples are ordinarily molded and the heat transfer controlled region (long fill times) where production parts arc commonly molded. No large variations in tensile properties were observed for polypropylene or nylon, but a 10 percent increase in peak tensile stress and strain for ABS did indicate that molecular orientation increased with increasing fill time. However, significant differences did occur in the properties of glass reinforced nylon. Peak tensile stress increased 15 percent and flexural strength decreased 10 percent as the fill time was increased. Although no change in the flexural modulus was observed, the scatter in the modulus decreased with increasing fill time. These property variations can be attributed to differences in the glass fiber orientation of the skin and core regions of the part. The measurement of molded tensile bar dimensions indicated there was little effect of fill time on the shrinkage of the various polymers except for shrinkage in the length direction for polypropylene. The shrinkage increased from 13 to 15.4 mm/m over the fill time range, a great enough difference to affect the fit of large parts. The most dramatic change with fill time was the surface appearance of the glass reinforced nylon. The surface of samples molded at short fill times had a dark uniform color and smooth appearance while samples molded at long fill times had a lighter color and a porous surface. This surface porosity is due to crystallization prior to complete pressurization of the mold. Therefore, in addition to affecting surface appearance, other surface related properties such as aging and the ability to plate plastic parts could also be affected.