Focus

Thermoset injection moulding

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Technology and know-how for

integrated solutions

At a glance

Example: switching elements With the combination of hydraulic ALLROUNDERs and the practical thermoset package, fully functional components can be
produced in high volumes.

When technology and expertise come

from a single source as at ARBURG,
you as customer always reap the
benefit with problem-free, daily
operation - guaranteed.
The same applies to thermoset processing. Here we offer you an efficient
combination of our proven hydraulic
ALLROUNDER machines and a practical
thermoset package. This system solution includes all the features required
for the immediate production of highquality moulded parts in large volumes.
The addition of the universal high
performance of our SELOGICA control
system and our extensive experience
in application technology enables us to
offer you just what you expect from us:
the most cost-efficient production solution for your company

Special equipment for thermoset injection moulding

Special screw geometries

Cylinder module for

pourable thermosets

Precise liquid temperature control

of the cylinder module

Cylinder module for

moist polyester

Cylinder heating for

processing thermoplastics

Tamping devices for

moist polyester

Highly wear-resistant
bimetallic cylinder

Core pulls in close proximity

to the mould

Adaptive mould
heating circuits

Accessories such as
brush devices

Universal compression
injection moulding

Integrated robotic systems

Reliable venting

Turnkey solutions from

a single source

Thermoset package

Options

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Know-how allround: with many years of application expertise, ARBURG provides comprehensive customer support in all questions related to
thermoset processing.

Individually adapted technology

Hydraulic ALLROUNDER machines and the
thermoset package have been designed as
a system solution and include:
Three-platen technology with four tie-bar
guidance and central force application for
precise demoulding
Liquid temperature-controlled cylinder
module for precise temperature control
suited to a specific material
Bimetallic cylinder for a long service life
Special screw geometry for material processing without damage to the fibres
The machine technology can be precisely
adapted to the respective injection moulding task thanks to its range of sizes in horizontal and vertical design, its modular
adaptability as well as its wide variety of
equipment for processing moist polyesters,
for example. The ALLROUNDER machines
remain universally applicable, regardless of
whether they are being used for thermoplastics processing or extended to complete
turnkey systems.

01/2016 www.arburg.com

Implementing sequences with ease

The freely programmable and high-performance SELOGICA control system enables
even complex production sequences to be
transparently controlled. This is ensured by
the straightforward sequence programming
via graphic symbols and the patented realtime plausibility checks. The SELOGICAs
equipment is ideally complemented by features such as adaptive mould heating, compression injection moulding or venting. This
results in a correspondingly high level of
process stability and reproducibility for thermoset processing in particular.
The wide range of options for integrating
special peripherals such as brush units
demonstrates the universality of the comprehensive central control system for all
ARBURG injection moulding technology.
No specialist programming knowledge is
required for operation. Handling complex
tasks with ease that is the outstanding
strength of the SELOGICA.

Exploiting sound practical knowledge

The search for the most cost-effective customer solution is something that also motivates the consultant specialists at ARBURG.
In application technology, machine specifications are precisely tailored to customer requirements. This is done on the basis of intensive talks with the customer, in which
machine and process technology as well as
comprehensive support for designing the
injected part and mould are explained in
detail. PC-based tools also help when comparing the individual solution concepts and
searching for optimal alternatives.

Special: material and cylinder modules

Injection units according to EUROMAP
100

70

170

290

400

800

1300

2100

3200

Screw diameter [mm]

18

22

20

25

30

25

30

30

35

40

35

40

45

50

45

50

55

60

60

70

70

80

90

318

392

474

565

664

904

1078

1608

2036

Injection volume [cm]

23

34

31

49

70

59

85

106

144

188

154

201

254

316

Pourable material

Moist polyester

Standard: the right injection unit for every thermoset application.

Characteristics such as mechanical

strength, dimensional stability, temperature resistance, non-flammability,
resistance to abrasion and chemical
resistance as well as their attractive
price/performance ratio make thermosets very interesting as materials. They
are also replacing other materials such
as metals.
Special materials of this type require a
special machine technology. Optimum
thermoset processing calls for precise
temperature control in the process, a
cylinder module with high resistance
to the abrasive contents and specially
designed screw geometries. Our technology is tailored towards high-quality
production right from the start.

Thermoset: the material for extreme

situations
The closed-meshed, cross-linked thermoset
molecules require a completely different
temperature profile to thermoplastics. The
compound is injected from a cold cylinder module into a hot mould. Melting

and further heating of the material in the

mould causes a decrease in viscosity that is
only reversed when cross-linking increases.
The finished component is then irreversibly
cross-linked, which makes it extremely hard,
for example.

Temperature profile of pourable thermosets

150 - 200 C

115 - 75 C

80 - 50 C

[C]
300
250
200
150
100
50

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Precise: liquid temperature control with

Suited to specific material: optimal processing

Practical: short sprues thanks to temperature-

several zones.

thanks to special screw geometries.

controlled cold channel radius nozzles.

Important: adapted plasticising

ARBURG has introduced adapted injection
units for granular thermosets and moist polyesters into its modular range of technologies in order to fully meet the requirements
for thermoset processing. A high level of
production quality is achieved through liquid
temperature control with up to four zones
and separate temperature control for the
feed. Bimetallic cylinders ensure a correspondingly long service life, while special
screw geometries ensure gentle processing
of the material. Particular attention has been
paid to minimising return flows during injection and during the holding pressure phase.
The play between the screw and nozzle is
adjustable to prevent excess material here.
Constant shot weights are achieved via the
screws mechanical anti-reversing lock.

Pourable thermosets
Pourable thermosets are supplied in the
form of granulate, which means they can
be fed in the conventional way. The special
ARBURG cylinder modules ensure optimum
material preparation thanks to the following features:
Compression-free screws without
non-return valves
Forward-set feeds for L/D ratios of
approx. 15:1
Screw-in nozzles with precise temperature control

Moist polyester (BMC)

The fibrous, non-pourable material is mostly
supplied pre-compressed in bales. Of particular interest: there are also moist polyesters that do not shrink during processing,
which can be extremely advantageous for
various applications. An adapted material
feed ideally takes place via special tamping
devices such as the INJESTER from ARBURG.
The special BMC cylinder modules from
ARBURG ensure minimal destruction of fibres through the following factors:
Compression-free screws with deep screw
channel and vaneless non-return valve
Forward-set feeds for L/D ratios of
approx. 12:1
Optimised feed openings prepared for installing an INJESTER tamping device
Temperature-controlled cold runner radius
nozzles with an entry depth of 100 mm
for short sprues

01/2016 www.arburg.com

Practical: modular machine technology

1

Basis: reliable hydraulics

The hydraulic ALLROUNDER machines use
dual-pump technology that permits simultaneous movements. Precise moulding is ensured by the three-platen technology with
four tie-bar guidance of the clamping units,
central force application and servo-regulated
mould movements. The entire technology effectively counteracts flash and overfeeding.

Horizontal to vertical
The ALLROUNDER machines can be individually adapted through different hydraulic
and electric expansion stages as well as
through different arrangements of the injection units. Vertical and rotary table machines are also available for injection moulding inserts. The technology is not, therefore,
limited to a specific solution concept.

Adapted: rotary table machines for the overmoulding of inserts.

In order to implement your respective application in large volumes with

precision and high quality, you need
customised injection moulding technology. Only a modular product range such
as that from ARBURG enables you as
a user to configure not just an acceptable machine, but precisely the right
machine for your application.
The reliable hydraulic ALLROUNDER
machines form the ideal basis for this:
they are perfectly matched to the
universal high performance of our
SELOGICA control system and the material-oriented thermoset package. The
result is a production unit that is always
perfectly tailored to your requirements.
With this combination, you can do precisely what you want to do on a dayto-day basis: produce moulded parts
smoothly and reliably.

INJESTER:
gentle fee
moist poly
Horizontal to vertical

Further information:

Hydraulic ALLROUNDERs brochure

Vertical ALLROUNDERs brochure

Basis: reliable hydraulics

www.arburg.com 01/2016

Accessories
3

INJESTER: gentle feeding of

moist polyester
INJESTER tamping devices have been developed to cope with the automatic feeding
of dry materials with a high filler content.
They contribute towards optimum pre-
compression, which results in minimal air
and gas inclusions. This keeps products free
from voids and lends them a glossy surface.

ARBURG offers several INJESTER

versions with hydraulic piston and servoelectric conveyor screw. What they all share
in common is full integration in the
SELOGICA control system. The delivery
pressure is programmable and the refill
container can also be filled without problem
during production. In addition, the INJESTER
features regulated delivery pressure.

Brush devices and robotic systems

Complete solution with injection moulding machine and the necessary peripherals
Programmable via SELOGICA
control system
Piston INJESTER
Design with hydraulic tamping cylinder
Conveying pressure can be programmed
via SELOGICA
Easy cleaning during material changes
INJESTER screws
Alternative from size 800 injection unit
Design with servo-electric conveyor screw
Conveying pressure can be programmed
and controlled via SELOGICA
Large material reservoir

:
eding of
yester

01/2016 www.arburg.com

Perfect harmony: the SELOGICA control system

1

User-friendly: brush devices integrated in the

Universal compression injection

moulding
Compression injection moulding is an important function for improved surface quality, high component strength and reduced
distortion. The compression injection
moulding sequence is freely-programmable
via the SELOGICA, for example through individual selection of the starting conditions.
It can also be combined with venting. Compression injection moulding via core pull
permits direct sprue separation.

Reliable venting
Venting of cavities is crucial with thermoset
processing. It provides an effective means of
allowing air and cross-linking gases to escape. As a result, the surface is not
scorched and complete mould filling for
void-free components is guaranteed. Both
single and multiple venting operations can
be quickly and reliably programmed via the
SELOGICA, even during the holding pressure phase.

production sequence

Maintaining control over sophisticated

machine, mould and robotic technologies is the domain of SELOGICA. With
this setting and monitoring system,
you can quickly set up both simple and
complex injection moulding processes,
operate them intuitively and perform
reliable optimisation. In a word: central
management. All technical features of
the SELOGICA control system, such as
the graphical sequence editor, are also
ideally suited for thermoset processing
and aimed at making operation quicker,
more reliable and more convenient. Here
too, ARBURG guarantees you decisive
competitive advantages: because we
have already integrated all the necessary
functions for high-quality and cost-effective part production in the SELOGICA.

Universal compression
injection moulding

Further information:
SELOGICA control system brochure

www.arburg.com 01/2016

Highlights
3

Adaptive mould heating

The adaptive mould heating automatically
adapts the control parameters to the control response of the mould. Several heating
zones can also be controlled in parallel via a
sensor. This achieves high temperature stability in the mould for excellent
reproducibility in production.

Fully integrated peripherals

The SELOGICA central control system integrates robotic systems as well as all necessary peripherals such as brush devices. All
processes can be programmed as a function
of and synchronous with machine movements. They are therefore part of the overall sequence, appear in the sequence editor with their own symbols and can be
centrally monitored.

Adaptive mould
heating

Reliable venting

Fully integrated
peripherals

01/2016 www.arburg.com

Control centre for the entire injection

moulding technology
Convenient sequence programming
with graphic symbols
Real-time plausibility checks
Free programmability of the production sequences
Common data record for the entire
production unit
Watercooling for continuous temperature control in the control cabinet

Application examples
1

Integrated refinishing: free programming of robotic system and peripherals centrally via the SELOGICA

Optimum material feed: piston INJESTER.

machine control system.

Thermosets have a wide range of applications thanks to their special characteristics such as high mechanical strength
and rigidity. Thermoset parts are typically used for extreme situations in
the automotive industry (engine compartment and lighting components) as
well as in the electrics and electronics
industries (power and miniature circuit
breakers, printed circuit boards).
To process thermosets quickly, reliably
and economically, you will need special
machine technology and special knowhow. At ARBURG, you can get everything from a single source.

Pistons made from pourable

material
The pistons with internal thread are used in
the clutches of passenger vehicles. This is a
substitution component, which is far less
expensive to produce using the injection
moulding process. For processing the highly
abrasive filled material, an extremely wearresistant cylinder fitting is used. The 4-cavity
mould operates using three-platen technology and separates the sprue directly inside
the mould. The heart of the system is a hydraulic ALLROUNDER combined with a
MULTILIFT V robotic system. Downstream
processing stations such as those for removing burrs and grinding chamfers as well as
for visual quality inspection can be centrally
programmed and monitored via the
SELOGICA control system.

Switch casing made from BMC

The switch casings for domestic fuses are
injection moulded from a moist polyester
(BMC). Feeding of the material is handled
by an INJESTER piston feeder device, part
removal by a MULTILIFTV. The four casings
are picked up, the sprue separated and the
articles placed on a conveyor belt. The highprecision 4-cavity mould is electrically
heated to an operating temperature of approx. 150 C. Scorching and porosity are
prevented through the use of an optimised
mould venting system. A vacuum can also
be applied. All of these functions are fully
integrated in the SELOGICA control system.

Further information:
Robotic systems brochure

10

www.arburg.com 01/2016

High process reliability: consistent cycles through

Individual solution: six-axis robotic system with SELOGICA user interface ideal e.g. for

automation.

near-contour refinishing.

Precision encapsulation of inserts

Producing an armature shaft calls for precision across the entire process chain. Moist
polyester (BMC) is processed on an
ALLROUNDER T rotary table machine with
MULTILIFTV robotic system. The inserts are
preheated to guarantee a reliable connection between the shaft and the laminations
as well as uniform cross-linking of the thermoset. To reliably avoid overfeeding, the
mould is designed with extreme precision.
The precise positioning of the inserts in the
mould via the robotic system is therefore
important. Automation of the system, together with the servo-electric rotary table,
ensure highly consistent cycles.

01/2016 www.arburg.com

Insulating rail turnkey project

A good example of the implementation of
customer-specific turnkey projects are insulating rails for domestic irons made from
moist polyester (BMC). The system includes
a hydraulic ALLROUNDER, the INJESTER
screw feeder device, a six-axis robotic system as well as a camera system for quality
and functional checks. The six-axis robotic
system with implemented SELOGICA user
interface is ideal for near-contour refinishing
of the thermoset parts. This enables the robotic system to be programmed using the
same graphics-based system as the machine. No special programming knowledge
is required for independent set-up of the robotic sequence.

11

Distances between tie bars of 270 x 270 to 920 x 920 mm | Clamping forces from 400 to 5,000 kN |
Injection units from 70 to 3200 (according to EUROMAP)

Film

ARBURG GmbH + Co KG
With locations in Europe: Germany, Belgium, Denmark, France, United Kingdom, Italy, Netherlands, Austria, Poland, Switzerland, Slovakia,
Spain, Czech Republic, Turkey, Hungary | Asia: Peoples Republic of China, Indonesia, Malaysia, Singapore, Thailand, United Arab Emirates | America: Brazil, Mexico, USA
For more information, please go to www.arburg.com.

2016 ARBURG GmbH + Co KG

The brochure is protected by copyright. Any utilisation, which is not expressly permitted under copyright legislation, requires the previous approval of ARBURG.
All data and technical information have been compiled with great care. However we accept no responsibility for correctness. Individual illustrations and information may deviate from the actual
delivery condition of the machine. The relevant valid operating instructions are applicable for the installation and operation of the machine.

ARBURG GmbH + Co KG
DIN EN ISO 9001 + 14001 + 50001 certified

522948_EN_GB_012016 Subject to alterations

Printed in Germany

Postfach 11 09 72286 Lossburg Tel.: +49(0)7446 33-0 Fax: +49(0)7446 33-3365 www.arburg.com e-mail: [email protected]