Best practice: Material qualification for automotive applications for a material manufacturer Process development and optimisation of component quality for a fiber-filled thermoplastic material
© DF.FotografieIn a previous project for the same client, IKV had already demonstrated the processability of a fiber-filled thermoplastic material as granulate in additive manufacturing for a material manufacturer that supplies the automotive industry, among others. The IKV’s hybrid manufacturing cell was used for this purpose, which makes it possible to process standard granulates and additively manufacture even large components in a short time. Promising results were achieved with a cooled nozzle in the course of the previous project. The development of an actively cooled strand forming unit was intended to further improve the surface quality in the current project.
Design concept for strand forming unit
In the first phase of the project, IKV designed a unit for the precise strand forming of long-fiber-filled plastics for the extrusion nozzle used for additive manufacturing. This step was based on the findings of the previous project and formed the basis for the following project steps.
Determination of heat flow and cooling capacity
Once IKV had received the exact characteristics of the material to be processed, the heat flows and the necessary cooling capacity for strand cooling were calculated. The results were discussed with the client to ensure that the strand forming was optimally matched to the material provided.
Design and construction of the strand forming unit
The strand forming line was planned and constructed on the basis of the previous calculations. Additional components were procured to complete the cooling and heating system.
Implementation in the hybrid production cell of the IKV
The strand forming unit was implemented in the hybrid manufacturing cell so that parts could be produced to enable the evaluation of the developed system.
Processing tests with the client’s material
The strand forming unit was tested with various material mixtures provided by the customer, which differed in terms of glass fiber content, melt flow rate and fiber length.
The tests were carried out in close cooperation with the client so that process and part quality could be further optimized through targeted variation of the compound composition.
Production of test specimens
Boxes were produced on the system, from which the test specimens were then cut out. For each material variant, several test specimens were taken in the direction of installation (0°) and in the strand direction (90°).
In addition, the same boxes were produced without the strand forming unit in order to compare the results and evaluate the developed system.
Examination of test specimens
The test specimens for examining the surface quality were taken from the side walls of the boxes. A laser scanning microscope was used to determine the surface roughness of the additively manufactured boxes. The fiber orientation was determined using CT analyses.
For the mechanical test, rectangular strips with four sides each were taken from the manufactured boxes and tested on a universal testing machine.
The test results were summarized in a report and can be used for further optimization of process and material.
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