CRYOGENIC SYSTEMS Featured in the January 2018 issue of

P R O C E S S

COOLING

Cryogenic Deflashing
for High Performance Materials

Used to remove parting-line flash in newly molded plastic

parts, cryogenic deflashing can remove internal and external
flash while maintaining efficiency and productivity.
By Joe Tittermary, Air Products
M
anufacturing high • Die punching. labor intensive, resulting in lower
performance materials • Cryogenic deflashing. production output.
for growing markets Manual tear trimming or manual Cryogenic deflashing is a
such as automotive and electronic cutting is the process of manually process that uses the extremely
components certainly has its removing tear trim beads from low temperature of a cryogen
challenges. Molded or machined around the parting line of the such as liquid nitrogen (LIN) to
parts must meet strict tolerances and finished part. While the capital cost remove flash. It accomplishes this
intricate finishes. When elastomer is low for this technique, the process by embrittling the rubber or plastic
parts are manufactured by way of is labor intensive. In addition, parts and subjecting the material
injection, transfer or compression manual tear trimming has relatively to mechanical stress through
molding, a thin membrane of high variability in quality and tumbling and simultaneous media
material, called flash, remains production rate due to geometry of blasting. Media blasting is the
along the mold-parting line. Flash is the part. process of blasting an item with
excess, unwanted material that must Die punching to remove flash small particles of various abrasive
be removed from finished parts. consists of placing the molded substances at an extremely high
Several techniques can be used to product into a die, shaped like the velocity to make changes to the
remove flash: finished part, and simultaneously surface. When combined with media
punching the parts out of the flash blasting, tumbling enables uniform
• Manual cutting with scissors or mat (similar to using a cookie impingement of the blast media
knives. cutter). While this method provides over the entire surface of all parts,
• Manual tear trimming at the somewhat consistent quality with removing both internal and external
mold. a low capital cost, the process is flash.

As industries continue to push the envelope towards more sophisticated and intricate molded parts, and manufacturers strive to
safely comply with increasingly rigorous quality standards, cryogenic deflashing is a viable solution that balances both needs while
maintaining efficiency and productivity in the manufacturing process.
CRYOGENIC SYSTEMS

By simply changing the process nitrogen vaporizes into a gas, equipment design, deterioration
parameters and media size, there is a volume expansion of of the insulation surrounding the
cryogenic deflashing is amenable to almost 700:1. Therefore, piping deflashing chamber, lack of precise
many molded products, including and equipment must be designed temperature control and poorly
O-rings, grommets and gaskets. for adequate ventilation to avoid maintained LIN injection piping.
With a low to moderate capital cost, overpressurization and rupture. Controls. Accurate temperature
cryogenic deflashing enables a Although nitrogen is nontoxic and control of the deflashing chamber
consistent deflash quality and high largely inert, it can act as a simple is achieved through proper
production rate. A well-designed asphyxiate by displacing the oxygen placement of the LIN injection
and operated system can result in in air. For this reason, work areas orifices and thermocouple probe
lower overall labor and operating must be ventilated properly. Oxygen to optimize deflashing quality
costs. analyzers also should be used to and LIN consumption. Accurate
monitor oxygen levels in the work control of basket-, belt- or impeller-
Cryogenic Deflashing wheel speed is required to further
Using Liquid Nitrogen optimize finish quality and system
No deflashing process can
To accurately project efficiency.
make up for poor mold design or liquid nitrogen Factors of importance regarding
mold wear that leads to a poor molded parts include:
or nonexistent parting line. The
consumption,
types of materials that may benefit deflashing trials • Durometer (hardness of the
from cryogenic deflashing can be compound).
seen in table 1, and the types of
should be conducted. • Parting-line flash thickness.
molded parts that may benefit from • Part geometry, configuration and
cryogenic deflashing can be seen in cross-section thickness.
table 2. area. Be sure to review the proper • Molded part loading.
Cryogenic deflashing is ideal safety information and consult an
when flash is thin with a good base industry professional for appropriate Durometer. Durometer can
or transition point where the flash guidance. influence embrittlement temperature
can break away from the molded To optimize operating costs, part and LIN consumption. Higher
part in a precise manner. This quality and production output, it is durometer (harder) compounds
transition in part thickness is known important to properly manage liquid embrittle at warmer temperature
as the parting line and is a key nitrogen consumption. Many factors settings and require less LIN to
factor in overall deflashing quality. — such as equipment, type of part, cool. Lower durometer (softer)
Cryogenic deflashing is not ideal for piping and geometry — can impact compounds embrittle at colder
thin cross-sectional parts such as liquid nitrogen consumption rates temperature settings and require
diaphragms; parts with thin, sharp during the cryogenic deflashing more LIN to cool.
edges; and certain medical-related process. Parting-Line Flash Thickness.
products due to contamination and Parting-line flash thickness will
cleanroom regulations. Equipment for determine the ability of the
Safety is paramount in any Cryogenic Deflashing system to finish the molded part
manufacturing process, and When selecting equipment, keep in conjunction with cycle time
cryogenic deflashing using liquid in mind: and LIN consumption. Thicker
nitrogen is no exception. When flash is more difficult to remove
handled properly, liquid nitrogen is • Type, size and capacity. and requires longer deflash cycle
a safe and effective addition to many • Age, condition and maintenance time, resulting in higher LIN
types of processes. Because liquid history. consumption. Optimum parting-line
nitrogen can reach temperatures of • Controls. flash thickness is 0.001 to 0.005”.
-320°F (-195°C), transfer equipment Type, Size and Capacity. Mold design and condition are key
and piping must be insulated Tumbler, shot blast and load capacity to optimum finish quality and LIN
and proper personal protective affect overall operating efficiency. consumption.
equipment (PPE) must be worn to Age, Condition and Maintenance Part Geometry, Configuration
avoid cryogenic burns. History. Older equipment and Cross-Section Thickness. The
Additionally, when liquid tends to be less efficient due to geometry of the molded parts also
 Types of Materials That May Benefit from Cryogenic Deflashing
Neoprene Rubber
Nitrile Rubber
Butyl Rubber
Styrene-Butadiene (SBR) Rubber
Ethylene Propylene Diene Monomer (EPDM) Rubber
Silicone Rubber
Liquid Crystal Polymers (LCPs)
Thermoset and Thermoplastic Plastics

TABLE 1. Some materials are better suited for cryogenic deflashing than others.

Molded Parts That May Benefit from Cryogenic Deflashing

O-Rings and Gaskets
Medical Implants, Catheters
Electronic Connectors, Insulators
Valve Stems, Washers, Fittings
Face Masks, Goggles
Grommets
Seals
Mountings
Bushings

TABLE 2. Cryogenic deflashing is ideal when flash is thin with a good base or transition point where the flash can break away from
the molded part in a pr ecise manner.

will have an impact on blast wheel the system, resulting in lower LIN designed piping system will cause
speeds, belt or basket speeds and the consumption ratios in terms of excessive two-phase flow, resulting
length of the deflashing cycle. Parts pounds of LIN per pounds of parts in erratic process control, longer
with thin cross-sections and sharp, deflashed. operating cycle time and increased
delicate edges may require longer LIN consumption. The estimated
deflashing cycle time and will result LIN Transfer Piping and LIN consumption and part loading
in increased LIN consumption. Usage Variables density for various part compounds
Molded Part Loading. Optimum The type, size, length, can be seen in table 3.
LIN consumption is achieved when configuration and usage pattern To accurately project LIN
the equipment is loaded to its rated of the cryogenic liquid transfer consumption, deflashing trials
capacity and when part load density piping system will determine the should be conducted. Trials should
is high. The weight of the additional amount of heat leak losses incurred utilize the appropriate deflashing
parts offsets the fixed heat load of in the piping system. A poorly equipment with optimum parts
CRYOGENIC SYSTEMS

Cryogenic Deflashing Using Liquid Nitrogen

Vent

Controls
Classifier
LIN

Liquid
Nitrogen Cyclone
LIN

Parts Drum
Throw
Wheel

Scrap Flash
Media
Drum
Collection

Scrap Fines
Dust
Drum

This schematic depicts a cryogenic deflashing process using liquid nitrogen. Using the very low temperature of cryogens like
liquid nitrogen, cryogenic deflashing temporarily embrittles residual material for removal when subjected to stress applied
though tumbling and media blasting.

loading for the given equipment after tumbling, the part was under- the same batch. It is best to evaluate
size. Consideration also must be embrittled and temperature should the initial results and then adjust the
made for deflashing quality relating be lowered. If the part is damaged or next new cycle accordingly.
to flash thickness, part geometry broken, it likely was over-embrittled,
and mold condition. The following and the temperature should be Ongoing Process
parameters are also important for raised. Management and
conducting cryogenic deflashing Throw Wheel Speed. The throw Optimization
trials: wheel is the impeller wheel that Changes will occur over time.
accelerates the blast media. If the It is a part of every operation. It
• Media selection. geometry of the part is thin, a lower is important to re-evaluate your
• Temperature. wheel speed should be used. On the approach when new parts are
• Throw wheel speed. contrary, if the geometry of the part introduced or when your process
• Process/blast time. is thick, use a higher wheel speed. begins to experience unexpected
The presence of sharp, delicate edges issues from known or unknown
Media Selection. Proper selection dictates using a lower wheel speed. changes. Optimization of the
of media type is based on the Process/Blast Time. cryogenic deflashing process may
geometry of the part/product. Recommended process/blast time is include:
Temperature. If the flash is still two to three minutes, but additional
present on the part and is flexible time and cycle may be needed on • Changes to the liquid nitrogen inlet
 Estimated LIN Consumption and Part Loading Density
for Various Part Compounds
Load Density Deflashing Liquid Nitrogen Ratio
Compound (lb/ft3) Temperature (°F) (lb of LIN/lb of parts)

Neoprene High -100 0.75 to 1.0

Neoprene Low -100 1.0 to 1.5
Nitrile High -100 0.75 to 1.0
Nitrile Low -120 1.0 to 1.5
Butyl High -140 1.0 to 1.5
Butyl Low -150 1.5 to 2.0
SBR High -150 1.0 to 1.75
SBR Low -160 1.75 to 2.5
EPDM High -150 1.0 to 1.75
EPDM Low -160 1.75 to 2.5
Silicone High -175 to -225 1.75 to 3.0
Silicone Low -180 to -250 2.0 to 5.0

Load density: High ≥ 30lb/ft3 Low ≤ 5 lb/ft3

TABLE 3. A poorly designed piping system will cause excessive two-phase flow, resulting in erratic process control, longer
operating cycle time and increased LIN consumption. The estimated LIN consumption and part loading density for various part
compounds are shown.

nozzle to adjust spray pattern and Cryogenic deflashing of identify the type of equipment best
flow rate. molded or machined parts has suited for a deflashing operation
• Thermocouple maintenance to become an increasingly important as well as test a variety of process
ensure that the temperature and option for meeting the strict parameters to help optimize
liquid nitrogen flow are tolerances and intricate finishes productivity. PC
controlled correctly. of high performance materials
• Mechanical checks to make sure used in today’s growing markets Joe Tittermary is the senior applications
that the throw wheel and material such automotive and electronic engineer for the chemicals processing
control cages are oriented components. Using the very low industry at Air Products. The
correctly and continue to operate temperature of cryogens like liquid Allentown, Pa.-based company can be
properly. nitrogen, cryogenic deflashing reached at 800-654-4567 or visit
• Deflashing recipe re-evaluation temporarily embrittles residual www.airproducts.com/cryogenics
to optimize the duration and material for removal when subjected
liquid nitrogen usage for each to stress applied though tumbling
different and media blasting. By employing
part material and geometry. this method, manufacturers can
• Liquid nitrogen supply piping benefit from consistently high
checks to avoid the unnecessary production rates and product finish
loss of liquid nitrogen to venting quality, resulting in lower labor
or piping that has lost its and operating costs. A cryogenic
insulation value over time. gases application specialist can help

Reprinted with permission from Process Cooling, January 2018 © 2018, BNP Media. 312-18-005-US