Advances in Polymer Processing 2020 (Proceedings of the International Symposium on Plastics Technology) ||

This book gathers the proceedings of the International Symposium on Plastics Technology, which was held on March 10, 2020 in Aachen, Germany, and was organised by the Institute for Plastics Processing (IKV) in Industry and Craft at RWTH Aachen University. Peer-reviewed by an international scientific committee, the conference proceedings comprise the papers presented by the international speakers. Topics covered include - circular economy - extrusion - lightweight technologies - simulation and digitisation - injection moulding - hybrid materials and additive manufacturing. In these fields, key themes for plastics technologies have been identified that will shape the face of research and industry for the next decade. In their contributions, the authors present the latest scientific findings, and discuss topical issues in plastics technologies. The symposium offered an inspiring forum for the exchange on research and innovation, for discussing urgent questions and providing impulses for the future of plastics technology. The Editors University Prof. Dr.-Ing. Christian Hopmann has been Head of the IKV - Institute for Plastics Processing in Industry and Craft at RWTH Aachen University and Managing Director of the IKV's Association of Sponsors since 2011. He also holds the Chair of Plastics Processing at the Faculty of Mechanical Engineering at RWTH Aachen University. Christian Hopmann studied Mechanical Engineering with a particular focus on Plastics Processing at RWTH Aachen University. He received his doctoral degree with a thesis on Ceramic Injection Moulding. He held various prominent positions at the IKV before starting his industrial career as Head of Quality Management at RKW SE in 2005. From 2010 to 2011 he was Managing Director of RKW Sweden AB in Helsingborg/Sweden. Prof. Dr. rer. nat. Rainer Dahlmann is Head of the Center for Analysis and Testing of Plastics (KAP) and Scientific Director at the IKV. He studied Physics with a focus on Solid State Physics at RWTH Aachen University. He received his doctorate from the Faculty of Mechanical Engineering at RWTH Aachen University in the field of Plasma Technologies. Since 2007, he has lectured in the Bachelor's and Master's programs in Applied Polymer Sciences at the FH Aachen, and in Mechanical Engineering and Plastics and Textile Technology at RWTH Aachen University Editorial Contents Scientific Committee Photoluminescent Tracer Effects on Thermoplastic Polymer Recycling Abstract. 1 Polymers in the European Circular Economy 2 Photoluminescent Tracers 3 Tracer Based Plastic Sorting Experiences and Challenges 4 Application: PVC Profiles from the Building Industry 5 Application: Polymer Packaging 6 Tracer Substances Regime 7 Implementation of Tracer Based Sorting in Industry 8 Summary References An Efficient Strategy Based on Hyperspectral Imaging for Brominated Plastic Waste Sorting in a Circular Economy Perspective Abstract. 1 Introduction 2 Materials and Methods 2.1 Materials 2.2 Methods Portable X-Ray Fluorimeter. Hyperspectral Imaging. 3 Results 3.1 X-Ray Fluorescence 3.2 Hyperspectral Imaging Spectral Signatures and Principal Component Analysis (PCA). Partial Least-Squares Discriminant Analysis (PLS-DA). 4 Conclusion References Melt-Processing of Biopolymer Composites with Nanocellulose Additives Abstract. 1 Introduction 2 Materials and Methods 3 Results and Discussion 3.1 Morphology 3.2 Melt-Rheology 3.3 Thermal Properties 3.4 Mechanical Properties 4 Conclusion References Continuous Chemical Recycling of Polystyrene with a Twin – Screw Extruder Abstract. 1 Introduction 2 Materials and Methods 2.1 Methodical Approach 2.2 Characterisation of Residues and Condensate 3 Results and discussion 3.1 Influence of Different Polystyrene grades on Depolymerisation 4 Conclusion and outlook References Development of a Solids Conveying Throughput Model for Grooved Barrel Extruders Based on Discrete Element Simulations Abstract. 1 Introduction 1.1 Process Engineering and Conventional Calculation Methods of Grooved Barrel Extruders 1.2 Principles of the Discrete Element Method 2 Description of the Simulation Model 3 Preliminary Investigations 3.1 Variation of Coefficients of Friction 3.2 Variation of Grooves Angle 4 Development of a Regression Model 5 Conclusion and Outlook References Foam Extrusion of Elastomers using Water as Physical Blowing Agent Abstract. 1 Introduction 1.1 Potential Regulation of Chemical Blowing Agents by REACH Directive 1.2 Water as a Physical Blowing Agent for Elastomers 2 Methods 2.1 Compound Production and Incorporation of Blowing Agents 2.2 Extrusion and Evaluation of the Processability 2.3 Continuous and Discontinuous Vulcanisation and Foaming of the Profile Samples 2.4 Evaluation of the Extrudates Surface Quality 2.5 Mechanical Analysis of the Foamed Elastomers 2.6 Optical Analysis of the Cell Structure 3 Results 3.1 Barrel Temperature of the Extruder Affects Surface Quality and Foam Structure 3.2 Influence of the Vulcanisation Process on the Extrudate Quality 4 Discussion 5 Summary and Conclusion References Homogenisation of the Wall Thickness Distribution of Thermoformed Cups by using Different Pre-stretch Plugs and Process Parameter Settings to Improve Material Efficiency Abstract. 1 Introduction and Motivation 2 Design of Pre-stretch Plugs in Thermoforming 3 Process Parameters and Evaluation Methodology 4 Analysis of the Wall Thickness Distribution using Different Pre-stretch Plug Geometries 5 Analysis of Homogeneity of the Wall Thickness Distribution 6 Analysis of the Top-Load Stability of the Formed Cups 7 Analysis of Plug Force and Wall Thickness Distribution 8 Conclusion and Outlook References Barrier Screw Design for High-Performance Plasticizing in Injection Molding Abstract. 1 High-Performance Plasticizing 1.1 Comparison of Different Screw Concepts with Respect to Plasticizing Rate 1.2 Barrier Melting Sections 2 Simulation of Polymer Flow in Barrier Screws 2.1 Grid Generation and Modelling of the Plasticizing Process 2.2 Material Characterization 2.3 Experimental Evaluation of Simulation Results 2.4 Increasing the Plasticizing Performance with Barrier Screws 2.5 Summary and Outlook References Development of IoT Device for Temperature and Cavity Pressure Measurements Abstract. 1 Introduction 2 Experimental Setup 3 Results 4 Conclusion References Targeted Manipulation of Fibre Orientation Through Relative Movement in an Injection Mould Abstract. 1 Introduction 2 Process Implementation and Experimental Procedure 2.1 Process Implementation 2.2 Experimental Procedure 3 Experimental Results 3.1 Mechanical Tests 3.2 Microscopic Investigations 3.3 Computed Tomography Scan 4 Conclusion and Outlook References Data Driven Injection Moulding Abstract. 1 State of the Art 1.1 Use of Machine Learning in the Field of Injection Moulding 1.2 Goals and Risks 2 Investigations 2.1 Feasibility Study for the Usage of ML: Quality Data Prediction 2.2 Anomaly Detection: Capabilities for Predictive Maintenance 3 Conclusion and Outlook References A Holistic Approach to Part Quality Prediction in Injection Molding Based on Machine Learning Abstract. 1 Introduction 2 Methods 2.1 Data Acquisition and Preparation 2.2 Feature Selection Search Strategies. Performance Evaluation Metric. 2.3 Data Modeling and Hyperparameter-Optimization 3 Evaluation 3.1 Data Generation 3.2 Feature Selection 3.3 Learning Algorithms 4 Conclusion and Outlook References Automated 3D Skeleton Winding Process for Continuous-Fiber-Reinforcements in Structural Thermoplastic Components Abstract. 1 Introduction 2 3DSW Method 3 Development of a New Generic 3D Test Specimen 4 Experimental 4.1 Commingled Yarn Processing 4.2 Materials 4.3 Test Specimens 4.4 Robot-based 3D Skeleton Winding and Overmolding 4.5 Mechanical Testing 5 Results and Discussion 6 Conclusion References Towards Process Optimisation of Polyurethane Pultrusion Using 3D Simulation Abstract. 1 Introduction 2 State-of-the-Art 3 A New Kinetic Model and Its Parameters 4 Simulation Model and Validation 5 Criteria for Process and Part Quality 6 Parameter Study: Influence of Line Speed, Die Temperatures, Profile Thickness and Initial Material Temperature 7 Summary and Outlook References Assistance Machine Function for BMC Injection Molding Abstract. 1 Introduction 2 Experimental 3 Results 4 Discussion 5 Conclusion References The Influence of Hydrothermal Aging on the Material Properties of Continuous Fiber-Reinforced Thermoplastics and its Non-Destructive Characterization Abstract. 1 Introduction 1.1 Influence of the Fiber-Matrix Boundary Layer on the Composite Material 1.2 Aging of Fiber-Reinforced Thermoplastics 2 Experimental Investigations 3 Results and Discussion 4 Conclusion and Outlook References Integration Concept of Injection, Forming and Foaming: A Practical Approach to Manufacture Hybrid Structures Abstract. 1 Introduction 1.1 Polymer Injection Forming (PIF) 1.2 Supercritical Fluid (Sc.F.) Assisted Injection Molding 1.3 Supercritical Fluid-Assisted Polymer Injection Forming (SFPIF) 2 Design of Experiments and Process Settings 3 Measurements and Sample Preparation 4 Results and Feasibility of Integration Concept 4.1 Initial Trials and Observation 4.2 Dimensional Properties and Shrinkage 4.3 Weight and Weight Reduction 4.4 Micro-Structure: Cell Size and Density 5 Summary References Potential of Mesoscale Structural Elements in the Interface of Hybrid CFRP-Metal-Parts on the Load Transfer Abstract. 1 Introduction 1.1 Pin Structures in CFRP-Connections 1.2 Cohesive Zone Models and Parameters 1.3 Content of the Contributions 2 Experimental Tests 3 FEM Analysis Study 3.1 FEM Model 3.2 Comparative Simulation Models with and Without a Pin 3.3 Parametric Study 4 Results 5 Conclusion References Interaction Between Foam Injection Molding and Welding Process Abstract. 1 Introduction 2 Experimental 3 Results and Discussion 3.1 Mechanical and Morphological Examinations of Injection Molded Parts 3.2 Mechanical and Optical Properties of Vibration Welded Parts 4 Conclusion References Prediction of the Bond Strength of Thermoplastics Welded by Laser Transmission Welding Abstract. 1 Introduction and Objective 2 State of the Art 3 Simulation Model for Laser Transmission Welding 3.1 Thermal Simulation 3.2 Thermomechanical Simulation 3.3 Calculation of the Weld Strength 4 Results 4.1 Thermal Simulation 4.2 Thermomechanical Simulation 4.3 Calculation of the Weld Strength 5 Conclusion and Outlook References Permeation Properties of Laser-Sintered Polyamide 12 Sheets in Comparison to an Extruded Polyamide 12 Film Abstract. 1 Introduction 2 Basic Permeation Theory 3 Materials and Methods 3.1 Production of Samples 3.2 Analysis of the Material Structure 3.3 Permeation Experiments 4 Results 4.1 Porosity 4.2 Crystallinity and Crystal Structure 4.3 Water Vapor and Oxygen Permeation Properties 5 Discussion 6 Conclusion References Viscoelastic Modelling of Polymer Melts and Rubber Compounds Abstract. 1 Introduction 2 Experimental 2.1 Material 2.2 Oscillatory and Capillary Rheology 2.3 Simulation 3 Results and Discussion 3.1 Rheological Characterization 3.2 Viscoelastic Modelling 3.3 Numerical Results 4 Conclusion Literatur A Study on the Determination of Virtual Process and Quality Data in Injection Molding Simulation Abstract. 1 Introduction 2 Experimental and Numerical Setup 2.1 Design of Experiments (DoE) in Injection Molding 2.2 Simulation Setup of the Problem 3 Results and Discussion 3.1 Results from Simulations 3.2 Discussion of Results 4 Conclusion References Strength Development in Overmolded Structures Abstract. 1 Introduction 1.1 Overmolding 1.2 Interface Strength Development 2 Experimental Study 3 Numerical Study 4 Results and Discussion 4.1 Degree of Melting Modeling for Constant Heating Rates 4.2 Degree of Melting Modeling for Non-constant Heating Rates 4.3 Correlation with Structural Performance 5 Conclusions and Outlook References Simulation of Solidification of a Nucleated Isotactic Polypropylene in a Quiescent Condition Abstract. 1 Introduction 1.1 Importance of Nucleating Agents 1.2 A Multiscale Simulation Chain to Predict Microstructure Dependent Effective Elastic Properties of Injection-Moulded Polypropylene 2 A New Model to Predict the Microstructure of Semi-Crystalline Thermoplastics 3 Set of Experiments to Calibrate the Implemented Model for Simulation 4 Results 5 Conclusion References Investigations on the Influence of High Pressures on the Curing Behaviour and Material Properties of Composite Structures for the Development of a Material Model Abstract. 1 Introduction 2 Model Approach 3 Experimental Investigations on Pressure Dependency 3.1 Pressure Effects During Curing 3.2 Pressure Effects on Final Material Properties 4 Conclusion and Outlook References Digital Twin of the Polyurethane Rotational Moulding Process Abstract. 1 Introduction 2 Basics of Computational Fluid Dynamics 3 Rotational Moulding Simulation with OpenFOAM 4 Digital Twin for the Engineering Process of Roto-Moulded Components 5 Conclusion References Author Index