Compression Molding

ver 2

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Schematic of a Compression Molding Press

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Matched Die Mold

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 Typical products ■Lightweight
• Front and rear end automobile panels ■Durable
■Aerodynamic styling
• Hoods
• Roofs
• Scoops
• Fenders
• Spoilers
• Air deflectors
• Lift gates >100 SMC parts
• Battery trays 450 lb/truck
114 million lb, 1996
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Car parts by SMC - Prowler Advantages and disadvantages

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• Advantages:
– Short cycle time (typically 1-6 minutes)
– High volume production
– Class A (high quality) surfaces
• Disadvantages:
– High initial capital investment
– Labor intensive
– Secondary operations are sometimes
required
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Three Thermoset Material Types

• Preform Molding Thermoplastic SMC
– Shaped dry reinforcement
– Binder
– Matrix as liquid or powder
• Azdel
• BMC (Bulk Molding Compound) Molding
– Fibers < 30 % and < 1 inch
– PP matrix
– Resin about 25 % – glass fiber mat (30-40% by weight)
– Filler about 40 % • continuous
– Log or rope form
• chopped
• SMC Molding
• directionalized
– Fibers 30-50 % by weight (Fibers 1-3 inches to continuous)
– Resin about 25 %
– Filler 25-45 %
– Thin, flat Sheet Molding Compound
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SMC manufacture using a configuration that can make chopped-fiber

SMC-R; continuous fiber SMC-C; or continuous, random SMC-C/R
material

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SMC High Strength SMC

Weight
Component Function
Percent
Reactive monomers that provide a
Styrene 13.4
cross-linking structure
Reactive monomers that provide a
Polyester 10.5
cross-linking structure
Glass fiber 30.0 Reinforcement
Calcium Filler--increases bulk volumeand
40.0
carbonate reduces part cost
Low profile Controls part shrinkage--a
3.45
agent (LPA) thermoplastic additive
Provides free radicals to initiate
Initiator 1.00
polymerization
Magnesium
0.70 Increases viscosity
hydroxide
Zinc stearate 1.00 Lubricant / mold release agent

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 Polyester
Epoxy
• Polyesters can be thermosets or
thermoplastics.
• Do not emit gases during cure
– Thermoset polyesters, such as those used in
compression molding, are formed from linear, • Compared to polyesters:
unsaturated, thermoplastic polyesters which are
– Higher mechanical properties
crosslinked during a cure reaction.
– Longer cycle times
• Special features of polyester resins:
– Does not emit gases (byproducts) during cure – Less desirable surface appearance
– Most common

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Other resins Molding process

• Phenolic
• Urea
• Melamine

• All three of these emit gases

(condensation products) during cure.
Gas emission can lead to voids in the
final product, an obvious disadvantage.
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SMC cycle Geometry factors

• Wall thickness of part

• Charge area vs. mold area
• Charge placement (location)
• Single or multiple charges

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 Curing Time vs. Mold Temperature for
Manufacturing Factors SMC sheets

• Mold wall heating

• Closing rate
• Maximum clamping force
• Gel time (Mold filling should be
complete before the resin gels)
• De-molding time (Time to attain a
sufficient degree of cure to demold the
part)
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Viscosity variation of an SMC before and during Flow of various layers of an SMC charge during
the compression molding operation compression molding

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Fiber orientation Fiber orientation

• Planar (two-dimensional) fiber
orientation
• Fibers aggregate to form bundles
• Compaction of bundles to produce
"swirling"
• Principal direction changes throughout
plaque because flow direction varies
• Most affected by amount of flow

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Effect of cure time on the development of flexural strength
Various defects in a compression-molded
in a compression molded SMC-R laminate SMC part

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Common Surface Defects in Compression Matched Die Molding Evaluation

Molded SMC • Investment
• Quality
– High Capital equipment
– Smooth surfaces (both
– High tooling sides)
• Materials – Voids, cracking common
– Fast cure preferred – Consistent parts
– Low or no volatiles – Properties modest
– New for thermoplastics • Products
– Mostly chopped fibers – High volume
• Processing – Low cost
– Fast (1-10 min cycles) – Small projected areas
– Low labor (automated) – Fairly complex shapes
– Hazards remote (mold (avoid undercuts)
closed)
– High Pressure (> 1,000
psi, 7 MPa)
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