MDR 3000 BASIC

MDR 3000 BASIC

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INSTRUMENT DESCRIPTION


MDR 3000 Basic

Oscillation strain

+/- 0.1°, 0.2°, 0.5° (Standard), 1° or 3°, Mechanically adjustable

(+/- 1.4%, 2.8%, 7% (Standard), 14% or 42%)

Static testing

The MDR 3000 Basic is the easiest to operate and most cost-effective way to determine viscoelastic properties of polymers and rubber compounds before, during and after cure. The acquired data gives exact information about processability, cure characteristics, cure speed and the behavior of the compound after-cure, as well as optional pressure measurement for sponge rubber compounds.

The MDR 3000 Basic comes as a complete and ready-to-test set consisting of the Rheometer itself, an external Personal Computer with the latest Windows Operating System, TFT screen, keyboard and mouse, as well as a printer.

Like every MonTech Rheometer, the MDR 3000 Basic also features an Ethernet Interface and can therefore be directly integrated in any customer’s factory network, guaranteeing the most stable data transfer and communication in any laboratory or factory environment, allowing data access at the instrument and from remote and office workstations, creating a digital process chain and integrated workflow based on a digital data repository, eliminating the need of result printing after each test series.

Designed as a table top instrument utilizing only minimal benchspace, the MonTech MDR 3000 Basic is synonymous with a reliable but easy and efficient testing operation. The instrument is equipped with the latest PLC-based control and data acquisition electronics, ensuring the highest data acquisition precision and reliability, along with superior temperature control – improving overall data significance and laboratory efficiency. The instrument comes with the MonControl Analysis software for test configuration management, data recording, automated Pass/Fail testing, processing of historical data as well as online statistical process control (SPC), having more than 3500 different datapoints available for selection. With an optional 5“ instrument touch-control panel, the instrument can even be conveniently operated in stand-alone mode by directly displaying and printing the most essential datapoints – including the possibility to save and archive test data on a USB flashdrive.

Completely closed, rotor-less, sealed, biconical test chamber system

Entirely made from stainless steel, precision machined, hardened and ground to utmost precision for highest durability and testing accuracy. The lower die is directly connected to the central shaft and drive system. All these parts and components are also made from solid stainless steel, making the MDR 3000 Basic a cost-efficient, long-lasting and safe investment. The upper die is attached to the reaction torque measurement for immediate recording of the material feedback at the highest precision.

The MDR 3000 Basic features an extremely stiff, ultra-rugged loadframe paired with a unique, column-guide-free, accessible testing area along with the most simple singlebutton operation and integrated multi-color status bar making this instrument truly the most reliable testing system for quality control purposes not only in the laboratory, but also directly in the production area. Of course various different automation options for increasing testing productivity are available and can be fitted to the instrument at any time.

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 6502, ASTM D 5289, DIN 53529

Die configuration

Biconical, closed System, sealed

Drive system

Mechanical, brushless DC eccentric drive

Oscillation frequency

1.667 Hz (100 cpm)

Oscillation strain

+/- 0.1°, 0.2°, 0.5° (Standard), 1° or 3°, Mechanically adjustable (+/- 1.4%, 2.8%, 7% (Standard), 14% or 42%)

Torque range

Ambient to 232 °C

Measured Data

Torque (dNm, lbf.in, kgf.cm), Temperature (°C, °F), Pressure (bar, kg per cm²), Time (min - min / min - sec / sec), Shear rate (1/s, rad/s), Cure rate (1/min, 1/sec)

Calculated Data

S΄, S˝, S*, tan δ, phase angle, cure speed, ...

Die gap

0.45 mm nominal

Sample volume

approx. 4.5 cm³

Closing system

Pneumatic with soft-close to prevent foil rips

Temperature control system

Ambient to 232 °C, precision +/- 0.03 °C, Max. heating rate: 85°C/min digital, microprocessor PID controlled

Temperature check system

Recordings of the temperature gradient on the screen, microprocessor monitored

Data Interface

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

Data points

Over 3500 data points available for each test Including S‘ Min, S‘ Max, TS 1, TS 2, TC 10, TC 30, TC 50, TC 90

Pneumatics

min. 4.5 Bar / 60 psi

Electrical

Single phase 100 - 120 V, 8 Amps or 200 V - 240 V, 5 Amps

Instrument options

Instrument control panel with 5“ touchscreen display and printer; Normal force / Pressure measurement; Single channel forced air cooling system; Autoloader 5 or 10 sample linear; Autoloader with 24 or 48 sample tray; R-VS 3000 constant volume sample cutter

CALCULATED RESULTS

PARAMETER

Automation options with 24 samples

Completely closed, rotor-less, sealed, biconical test chamber system

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