MDR 3000 PROFESSIONAL

MDR 3000 PROFESSIONAL

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INSTRUMENT DESCRIPTION


MDR 3000 Professional

Oscillation strain

+/- 0.01° to 20° (+/- 0.01° to 90° optional)

(+/- 0.14% to 280% (0.14% to 1260%))

Static and dynamic testing

The MDR 3000 Professional is designed for measuring the viscoelastic properties of polymers and elastomeric compounds before, during and after cure. The acquired data gives exact information about advanced material properties, processability, cure characteristics, cure speed, and the behavior of the compound at the after-cure, as well as final compound dynamic mechanical properties.

The MDR 3000 Professional is a unique hybrid testing system; it can be operated in static testing (MDR) mode and with a single click in the MonControl Software, be switched over into dynamic testing (RPA) operation mode. This provides the highest possible flexibility to the user as the MDR 3000 Professional can cover everyday routine QC tasks by working like a normal static Moving Die Rheometer at highest accuracy, repeatability and reproducibility while offering full Rubber Process Analyzer testing capabilities for even complex R&D testing, allowing the user to program, execute and evaluate arbitrary test sequences with the included MonControl Software.

The instrument is equipped with MonTech‘s unique, patented direct precision drive system, offering variable oscillation amplitude and frequency along with precision temperature control, enabling testing according to almost every DIN / ISO and ASTM test standard in reference to Moving Die Rheometers and Rubber Process Analyzers.

Due to the rugged and flexible construction and various options such as cooling and automation, this device can be used for extended quality control and production monitoring purposes not only in the laboratory, but also directly on the shopfloor.

Automation options

All MonTech Moving Die Rheometers as well as Rubber Process Analyzers can be easily automated, allowing customers to increase productivity and release operators for other important tasks.

MonTech offers the worlds largest Rheometer Automation portfolio designed for our customers to rely on – in the lab or on the shopfloor, in multiple shifts, 365 days, every year. Depending on the selected type of automation system, samples are loaded and unloaded automatically from linear or rotary trays, film is fed and tested samples are removed automatically.

Of course, every automated machine can – within a single click – also be switched into manual operation mode.

Instrument options

For specific testing requirements MonTech offers a variety of instrument options to customize a testing solution exactly for your specific requirements:

– Forced air and low-temperature cooling systems

– Axial force transducers

– Cavity pressure control systems

– High speed data acquisition systems

– Data, IT and software integration

– Advanced productivity options


APPLICATIONS


Isothermal Cure

Isothermal cure experiments are the most common type of test for quality control in rubber and elastomer processing. MonTech Moving Die Rheometers provide high precision data as well as a simple operation of the instruments. All the important characteristics, such as minimum / maximum elastic torque, scorch times, cure times and reaction rates are precisely calculated, with over 3500 different datapoints. All data is available in numerical as well as graphical form; limits, control gates and tolerance graphs can easily be set, and Pass / Fail status is automatically evaluated after each test.

Cure with simultaneous Sponging / Foaming / Blowing Reaction

Especially for sealing applications, blowing agents form a vital part of compound recipes in order to produce a cellular structure via a foaming process that runs in parallel to the cure reaction. The cellular matrix structure which is created during the foaming process reduces density, increases thermal and acoustic insulation, and affects the relative stiffness of the mix. Therefore, MonTech Rheometers can be fitted with a precision normal force measurement transducer in the die cavity in order to calculate cavity pressure simultaneously during the curing and reaction in a single test, and revealing interrelations between the two reactions.

Non-isothermal Cure

In addition to isothermal static cure testing, MonTech MDRs and RPAs can perform tests at variable temperatures. These non-isothermal sequences can be programmed in order to follow virtually any temperature profile, making them especially valuable for the simulation of manufacturing processes which are usually not isothermal. Typical processes that can be simulated are mixing, milling, extrusion, compression moulding, injection moulding, and storage conditions. Of course, non-isothermal test sequences can be executed in a single test with any other static or dynamic sequence, such as strain and frequency sweeps, providing the most accurate data of the material‘s behavior at any production stage and material state.

Advanced cure kinetics modeling

Test data from similar static or dynamic test sequences executed at different temperatures can automatically be evaluated and modelled for an advanced cure kinetics analysis, providing information about Reaction Rate, Order of Reaction (n), Rate Constant (k), Activation Energy (E) and Incubation Time (ti).

Frequency sweep material analysis

In general, the mechanical properties of materials depend on frequency. A good under-standing of the influence of frequency on a material is therefore very important for its practical use. For example, a material appears stiff under the action of a force at high frequency, but soft when the force is applied slowly. Isothermal frequency sweeps provide information about the weight distribution MWD (crossover modulus) as well as average molecular weight AWM (crossover frequency). But the behavior of viscoelastic materials like polymers not only depends on frequency, it also depends on temperature. MonTech has incorporated further advanced testing capabilities such as the Time-Temperature Superposition principle (TTS), which is based on the equivalence between frequency and temperature behavior during transition processes, forming the basis of WLF master-curve modelling available on MonTech dynamic Rheometers, even for predicting material performance at frequencies outside the range that can be measured with a dynamic mechanical analyzer.

Structural characteristics and processability

The rheological properties of rubbers are related to their structural characteristics and will influence the behavior of the rubber during processing and the performance of the final product. While Mooney testing does not provide sufficient information to clearly differentiate branching and Molecular weight distribution the Rubber Process Analyzer can easily be used as a tool for solving production problems. Using frequency sweeps to scan the material over the whole shear rate range can reveal substantial material
differences and variations e.g. causing a particular material to be very sticky and therefore difficult to process while others can be perfectly processed.

These test can be performed in the linear and also non-linear viscoelastic range to cover all different processing methods and material states. ISO 13145 suggests a simple and quick test procedure utilising a rotorless sealed shear rheometer (RPA) for rheological evaluations as an alternative to traditional Mooney Viscometer testing.

Non-Linear material response at high strain

Dynamic oscillatory shear tests are common in rubber rheology - more specifically, small-amplitude oscillatory shear (SAOS) tests are the most common test method for measuring linear viscoelastic properties of rubber compounds and polymers.

But in processing operations, the shear rates can be large and rapid; non-linear material properties form an even more important part in understanding material response. Therefore, MonTech Rheometers provide Fourier transformation analysis capabilities of periodic data, along with full raw-data access, for in-depth analysis to investigate and quantify the nonlinear viscoelastic behavior by using large-amplitude oscillatory shear (LAOS) testing in order to characterize and quantify material stress response which is no longer purely sinusoidal (linear), allowing a better understanding of filler content and structure, as well as the polymer architecture.

Isothermal Curing at Variable Strain

Typically, cure experiments on rubber compounds - especially for quality control purposes - are performed with a fixed oscillation angle of +/- 0.5° and a frequency of 1.67 Hz. However, for specific rubber compounds or challenging materials such as silicones or epoxy resins, this might not be ideal as either reaction torque readings are too low, providing only a limited ability to distinguish between different batches, or might be too high causing high result variability as the material is damaged as strain already exceeds the linear viscoelastic range. MonTech Rheometers provide the possibility of testing with variable oscillation angles to allow measurements within the ideal strain amplitude for optimal signal-to-noise ratio and the most precise test results, while avoiding any structural breakdown or slippage of the sample in the die cavity.

Structural Breakdown of rubber compounds - process simulation

Rubber compounds are extremely sensitive to processing operations such as milling. Increasing strain causes the carbon black network - which is held together by Van der Waals-London attraction forces to break, causing a decrease in shear modulus of filled rubber vulcanizates. Therefore, MonTech Rheometers provide simulation capabilities for almost any possible production process, providing irreplaceable data for developing rubber compounds, as well as understanding and simulating manufacturing processes and environments.

Strain Sweep for Filler Loading "Payne-effect"

The Payne effect is a particular feature of the stress-strain behavior of rubber, especially rubber compounds containing fillers such as carbon black and silica. Physically, the Payne effect can be attributed to deformation-induced changes in the material‘s microstructure, i.e. to breakage and recovery of weak physical bonds linking adjacent filler clusters.

Measurement of modulus vs. strain is therefore essential to understanding and quantifying filler loading, filler dispersion and filler-filler interaction in the low strain region, and polymer-filler interaction at higher strain. The resulting characterizations of material structure are essential as they directly impact dynamic stiffness and damping behavior of final products such as rubber bushings, automotive tyres and all other rubber goods. Similar to the Payne
effect under small deformations is the Mullins effect, which is observed under larger deformations in the non-linear viscoelastic range.


TECHNICAL SPECIFICATION


International standards

ISO 13145 , ISO 6502, ASTM D 5289, ASTM D 6204, ASTM D 6601, ASTM D 6048, ASTM D 7050, ASTM D 7605, DIN 53529

Die configuration

Biconical, closed die system, sealed

Drive system

Direct, wearless servo drive system with ceramic bearings

Oscillation frequency

0.001 Hz to 33 Hz (0.001 Hz to 50 Hz optional)

Oscillation strain

+/- 0.01° to 20° (+/- 0.01° to 90° optional)

Temperature range

Ambient to 232 °C

Measured Data

Torque, temperature, frequency, strain; Optional: Normal force

Calculated Data

S΄, S˝, S*, G΄, G˝, G*, tan δ, η΄, η˝ and η*

Die gap

0.45 mm nominal

Sample volume

approx. 4.5 cm³

Closing system

Soft closing to prevent foil rips and damage of test sample

Torque range

0.01 to 225 dNm

Temperature control system

Ambient to 232 °C, precision +/- 0.03 °C, Max. heating and cooling rate: 85°C/min, digital, microprocessor controlled (Pneumatic double channel cooling system optional)

Temperature check system

Recordings of the temperature gradient on the screen, microprocessor monitored

Subroutines

Isothermal, Non-Isothermal, Timed, Temperature Sweep, Strain Sweep, Frequency Sweep, Shear rate Sweep, Relaxation, Retardation, Hysteresis, Tension tests, LAOS, ...

Data Interface

Ethernet (10/100 MBit), USB (int.), CF card (int.), RS232 (opt.)

Data points

Over 3500 data points available for each static subtest; Including S‘ Min, S‘ Max, TS 1, TS 2, TC 10, TC 30, TC 50, TC 90; Integrated, automatic reporting features for dynamic tests

Pneumatics

min. 4.5 Bar / 60 psi

Electrical

200 V - 240 V, 6 Amps, 50/60 Hz

Instrument options

Instrument control panel with 5“ touchscreen display and printer; Torque transducer for low-viscosity torque range; Normal force / Pressure measurement; Double channel forced air cooling system; Low-temperature cooling system MCool 10 /MCool -40; Autoloader 5 or 10 sample linear; Autoloader with 24, 48 or 100 sample tray or tray changers; R-VS 3000 constant volume sample cutter

CALCULATED DATA

PARAMETER

Tray automation with either 24, 48 or 100 samples

With direct tray-to-chamber handling, the sample arm picks samples from the tray.

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