Temperature Profile in Rubber Injection Molding: Application of a Recently Developed Testing Method to Improve the Process Simulation and Calculation of Curing Kinetics.

Injection molding of rubber compounds is an easily conducted yet sophisticated method for rubber processing. Simulation software is used to examine the optimal process conditions, identify failure scenarios, and save resources. Due to the complexity of the entire process, various aspects have to be considered in the numerical approach. This contribution focused on a comparison of process simulations with various definitions of the material's inlet temperature, ranging from a stepwise increase, but constant temperature, to an exact axial mass temperature profile prior to injection. The latter was obtained with a specially designed, unique test stand consisting of a plasticizing cylinder equipped with pressure sensors, a throttle valve for pressure adjustments, and a measurement bar with thermocouples for the determination of the actual state of the mass temperature. For the verification of the theoretical calculations, practical experiments were conducted on a rubber injection molding machine equipped with the mold used in the simulation. The moldings, obtained at different vulcanization time, were characterized mechanically and the results were normalized to a relative degree of cure in order to enable comparison of the real process and the simulation. Considering the actual state of the mass temperature, the simulation showed an excellent correlation of the measured and calculated mass temperatures in the cold runner. Additionally, the relative degree of cure was closer to reality when the mass temperature profile after dosing was applied in the simulation.

The Tension-Twist Coupling Mechanism in Flexible Composites: A Systematic Study Based on Tailored Laminate Structures Using a Novel Test Device.

The focus of this research is to quantify the effect of load-coupling mechanisms in anisotropic composites with distinct flexibility. In this context, the study aims to realize a novel testing device to investigate tension-twist coupling effects. This test setup includes a modified gripping system to handle composites with stiff fibers but hyperelastic elastomeric matrices. The verification was done with a special test plan considering a glass textile as reinforcing with different lay-ups to analyze the number of layers and the influence of various fiber orientations onto the load-coupled properties. The results demonstrated that the tension-twist coupling effect strongly depends on both the fiber orientation and the considered reinforcing structure. This enables twisting angles up to 25° with corresponding torque of about 82.3 Nmm, which is even achievable for small lay-ups with 30°/60° oriented composites with distinct asymmetric deformation. For lay-ups with ±45° oriented composites revealing a symmetric deformation lead, as expected, no tension-twist coupling effect was seen. Overall, these findings reveal that the described novel test device provides the basis for an adequate and reliable determination of the load-coupled material properties between stiff fibers and hyperelastic matrices.

Viscoelastic Behavior of Glass-Fiber-Reinforced Silicone Composites Exposed to Cyclic Loading.

The aim of this work was to analyze the influence of fibers on the mechanical behavior of fiber-reinforced elastomers under cyclic loading. Thus, the focus was on the characterization of structure-property interactions, in particular the dynamic mechanical and viscoelastic behavior. Endless twill-woven glass fibers were chosen as the reinforcement, along with silicone as the matrix material. For the characterization of the flexible composites, a novel testing device was developed. Apart from the conventional dynamic mechanical analysis, in which the effect of the fiber orientation was also considered, modified step cycle tests were conducted under tensile loading. The material viscoelastic behavior was studied, evaluating both the stress relaxation response and the capability of the material to dissipate energy under straining. The effects of the displacement rate of the strain level, the amplitude of the strain applied in the loading-unloading step cycle test, and the number of the applied cycles were evaluated. The results revealed that an optimized fiber orientation leads to 30-fold enhanced stiffness, along with 10 times higher bearable stress. The findings demonstrated that tailored reinforced elastomers with endless fibers have a strong influence on the mechanical performance, affecting the structural properties significantly.

Ammonia Distribution Measurement on a Hot Gas Test Bench Applying Tomographical Optical Methods.

Measuring the distribution of gas concentration is a very common problem in a variety of technological fields. Depending on the detectability of the gas, as well as the technological progress of the sector, different methods are used. In this paper, we present a device and methods to detect the ammonia concentration distribution in the exhaust system of diesel engines in order to increase the performance of the exhaust aftertreatment system. The device has been designed for usage on a hot gas test bench simulating exhaust gas conditions. It consists of multiple optical beams measuring ammonia line concentrations by applying nondispersive absorption spectroscopy in the deep ultraviolet region. The detectors consist of photodiodes allowing high sampling rates up to 3 kHz while providing a high signal-to-noise ratio. A detection limit of only 1 ppm has been achieved despite the short path length of only eight centimeters. The obtained line concentrations form an inverse problem. The methodology of the tomographic techniques is described in detail in order to best solve the inverse problem and obtain the ammonia concentration distribution images for each time step.