Moldability

Flowability

Flowability of SUMIKAEXCEL PES improves greatly as the cylinder temperature, injection pressure, and wall thickness of molded products increase. However, mold temperature does not have a major impact. If mold release failure, glass fiber floating or weld cracking occurs, it is recommended to increase the mold temperature to 160°C or higher.

Apparent Melt Viscosity

The apparent melt viscosity of SUMIKAEXCEL PES is as follows.

Figure 4-2-1 Temperature Dependence of Apparent Melt Viscosity

Figure 4-2-1 Temperature Dependence of Apparent Melt Viscosity

Figure 4-2-2 Shear Rate Dependence of Apparent Melt Viscosity

Figure 4-2-2 Shear Rate Dependence of Apparent Melt Viscosity

Molding of Relatively Thick-Walled Products

This section focuses on the flow characteristics at a wall thickness of 3mm.

Effect of Cylinder Temperature

When the cylinder temperature increases, the melt viscosity of the resin decreases and the flowability improves. The bar flow length improves by 30 to 60% when it is set 20°C higher.

Figure 4-2-3 Temperature Dependence of Bar Flow Length

Figure 4-2-3 Temperature Dependence of Bar Flow Length
Molding machine : Neomat N47/28
  (Sumitomo Heavy Industries, Ltd.)
Injection pressure : 130MPa
Injection speed : medium
Mold : 3mm × 8mmw
Mold temperature : 120°C

Effect of Injection Pressure

The bar flow length improves by 10 to 20% when the injection pressure is set 20 MPa higher. High-pressure molding is generally recommended, but carefully check for mold release defects and residual stress due to overpacking. Select appropriate conditions by setting the secondary pressure.

Figure 4-2-4 Dependence of Bar Flow Length on Injection Pressure (4100G)

Figure 4-2-4 Dependence of Bar Flow Length on Injection Pressure (4100G)
Molding machine : Neomat N47/28
  (Sumitomo Heavy Industries, Ltd.)
Injection speed : medium to high
Resin temperature : 330°C, 350°C
Mold : 3mm × 8mmw
Mold temperature : 120°C

Effect of Injection Speed

Injection speed does not have a significant effect on the bar flow length.

Figure 4-2-5 Dependence of Bar Flow Length on Injection Speed (4100G)

Figure 4-2-5 Dependence of Bar Flow Length on Injection Speed (4100G)
Molding machine : Neomat N47/28
  (Sumitomo Heavy Industries, Ltd.)
Mold : 3mm × 8mmw
Mold temperature : 120°C

Effect of Product Wall Thickness

Flow length increases sharply with wall thickness. When the wall thickness is 1.5mm or higher, flowability can be improved 40 to 70% by increasing the wall thickness by 0.5mm.

Figure 4-2-6 Effect of Wall Thickness on Bar Flow Length (4100G)

Figure 4-2-6 Effect of Wall Thickness on Bar Flow Length (4100G)
Molding machine : Neomat N47/28
  (Sumitomo Heavy Industries, Ltd.)
Injection pressure : 130MPa
Injection speed : 60%
Resin temperature : 360°C
Mold : 8mmw bar flow
Mold temperature : 120°C

Molding of Thin-Walled Products

This section describes the flow characteristics at wall thickness of 0.1 to 0.7mm.

Effect of Cylinder Temperature

Flowability improves as the cylinder temperature increases, but this effect decreases when the wall thickness is 0.3mm or less. Considering the effects of thermal degradation, a temperature of up to about 380°C is suitable.

Figure 4-2-7 Cylinder Temperature Dependence
(Thickness: 0.7mm)

Figure 4-2-7 Cylinder Temperature Dependence (Thickness: 0.7mm)
Molding machine : Neomat N47/28
  (Sumitomo Heavy Industries, Ltd.)
Injection pressure : 130MPa
Injection speed : 75%
Mold : 0.7mm × 8mmw
Mold temperature : 140°C

Figure 4-2-8 Cylinder Temperature Dependence
(Thickness: 0.5mm)

Figure 4-2-8 Cylinder Temperature Dependence (Thickness: 0.5mm)
Molding machine : Neomat N47/28
  (Sumitomo Heavy Industries, Ltd.)
Injection pressure : 130MPa
Injection speed : 75%
Mold : 0.5mm × 8mmw
Mold temperature : 140°C

Figure 4-2-9 Cylinder Temperature Dependence
(Thickness: 0.3mm)

Figure 4-2-9 Cylinder Temperature Dependence (Thickness: 0.3mm)
Molding machine : Neomat N47/28
  (Sumitomo Heavy Industries, Ltd.)
Injection pressure : 130MPa
Injection speed : 75%
Mold : 0.3mm × 8mmw
Mold temperature : 140°C

Effect of Product Wall Thickness

The flowability depends on the wall thickness, so please pay attention to this when designing your product.

Figure 4-2-10 Wall Thickness Dependence (4100G)

Figure 4-2-10 Wall Thickness Dependence (4100G)
Molding machine : Neomat N47/28
  (Sumitomo Heavy Industries, Ltd.)
Injection pressure : 130MPa
Injection speed : 75%
Bar flow width : 8mm
Mold temperature : 140°C

Figure 4-2-11 Wall Thickness Dependence (3601GL20)

Figure 4-2-11 Wall Thickness Dependence (3601GL20)
Molding machine : Neomat N47/28
  (Sumitomo Heavy Industries, Ltd.)
Injection pressure : 130MPa
Injection speed : 75%
Bar flow width : 8mm
Mold temperature : 140°C

Effect of Injection Pressure

Thin-wall flowability tends to be greatly affected by injection pressure. Injection pressure of at least 100MPa is recommended. However, it is required to determine the proper injection pressure by taking product appearance and residual stress into consideration.

Figure 4-2-12 Injection Pressure Dependence (4100G)

Figure 4-2-12 Injection Pressure Dependence (4100G)
Molding machine : Neomat N47/28
  (Sumitomo Heavy Industries, Ltd.)
Injection speed : 75%
Resin temperature : 340°C
Bar flow width : 8mm
Mold temperature : 140°C

Figure 4-2-13 Injection Pressure Dependence (3601GL20)

Figure 4-2-13 Injection Pressure Dependence (3601GL20)
Molding machine : Neomat N47/28
  (Sumitomo Heavy Industries, Ltd.)
Injection speed : 75%
Resin temperature : 340°C
Bar flow width : 8mm
Mold temperature : 140°C

Effect of Injection Speed

Thin-wall flowability is not affected by injection speed so much. If the injection speed is too high, it may cause defects such as burns.

Figure 4-2-14 Injection Speed Dependence (4100G)

Figure 4-2-14 Injection Speed Dependence (4100G)
Molding machine : Neomat N47/28
  (Sumitomo Heavy Industries, Ltd.)
Injection pressure : 130MPa
Bar flow width : 8mm
Mold temperature : 140°C

Figure 4-2-15 Injection Speed Dependence (3601GL20)

Figure 4-2-15 Injection Speed Dependence (3601GL20)
Molding machine : Neomat N47/28
  (Sumitomo Heavy Industries, Ltd.)
Injection pressure : 130MPa
Resin temperature : 360°C
Bar flow width : 8mm
Mold temperature : 140°C

Effect of Mold Temperature

Thin-wall flowability is not affected by mold temperature so much. However, it is recommended to raise the mold temperature to at least 160°C if problems such as sticking in the mold, poor surface appearance, or low weld strength occur.

Figure 4-2-16 Mold Temperature Dependence (4100G)

Figure 4-2-16 Mold Temperature Dependence (4100G)
Molding machine : Neomat N47/28
  (Sumitomo Heavy Industries, Ltd.)
Injection pressure : 130MPa
Injection speed : 75%
Resin temperature : 340°C
Bar flow width : 8mm

Figure 4-2-17 Mold Temperature Dependence (3601GL20)

Figure 4-2-17 Mold Temperature Dependence (3601GL20)
Molding machine : Neomat N47/28
  (Sumitomo Heavy Industries, Ltd.)
Injection pressure : 130MPa
Injection speed : 75%
Resin temperature : 340°C
Bar flow width : 8mm
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