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Injection Molding
Injection Molding
Injection Molding
Injection Molding
Injection Molding
Plastics Manufacturing
PROCESSE S
THERMOSETS THERMO PLASTICS
COMPRESSION MOULDING SHEET MOLDING COMPONENT (SMC) BULK MOLDED COMPONENT (BMC) THERMOSET INJECTION MOULDING
INJECTION MOULDING VACUUM FORMING / THERMOFORMING PRESSURE FORMING BLOW MOULDING ROTATIONAL MOULDING / ROTO MOULDING EXTRUSION STRUCTURAL FOAM RIM (REACTION INJECTION MOULDING)
Injection Molding
Injection Molding
Characteristic features
1. 2. 3. 4. 5. 6. 7. 8. High volume. Production of intricate parts. Tight tolerance parts. Good dimensional stability. Automated process. Low scrap. No/ Minimum secondary operations required. Good surface finish.
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Injection Molding
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Injection Molding
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Injection Molding
Material
Tooling
GOOD PART
Processing
Design
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Injection Molding
Processing
Design
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Injection Molding
The Equipment
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Injection Molding
Machine details
Molding
Once the plastic is feed into the mold, through the nozzle and sprue. After cooling cycle, mold starts opening. The moveable half of the mold is actuated by the hydraulic cylinder for opening the mold.
Conveyer
The screw is surrounded by heating coils. Material inside the screw is heated gradually. Ram forces material to flow through the nozzle.
Feeding
Plastic pallets is feed into the hopper. Once material is heated, starts flowing through the screw.
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Injection Molding
Hydraulic System
Mold System Clamping System Control System
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Injection Molding
Injection System
Hopper Hopper
The Barrel
The Reciprocating Screw
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Injection Molding
Injection System
Heaters
Nozzle
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Injection Molding
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Injection Molding
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Injection Molding
Screw Rotation Feeds and Shears Material Into a Melt. Melt Collects Into Front of Barrel, Forcing Screw Back
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Injection Molding
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Injection Molding
Cushion
Packing Pressure
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Injection Molding
Hydraulic System
Open and close the mold Build and hold the clamping tonnage Turn the reciprocating screw Drive the reciprocating screw
A typical hydraulic system include pumps, valves, hydraulic motors, hydraulic fittings, hydraulic tubing, and hydraulic reservoirs
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Injection Molding
Mold System
Tie bars Stationary and moving platens Molding plates (bases) Tie Bars Moving Platen
Stationary Platen
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Injection Molding
Mold System
Injection Molding
Mold System
Door closed and part molded Part
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Injection Molding
Clamping System
Open and close the mold
Supports and carries the constituent parts of the mold Generates sufficient force to prevent the mold from opening Clamping force can be generated by Mechanical (toggle) lock Hydraulic lock
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Injection Molding
Clamping System
Clamping Mechanisms Hydraulic Clamping System
Hydraulic Cylinder
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Injection Molding
Clamping System
Clamping Mechanisms Single Toggle Clamping System
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Injection Molding
Control System
Provide consistency and repeatability in machine operation It monitors and controls the processing parameters, including the
Injection Molding
1. Plasticising
Molding Cycle
2. Injection
3. Cooling
4. Ejection
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Injection Molding
Gate Component
Runner Sprue
Gate Components
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Injection Molding
Components
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Injection Molding
Components
Feed System
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Injection Molding
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Injection Molding
Injection Molding
Molding Defects
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Injection Molding
Short Mouldings
Description
Molding formed incompletely
Causes
Insufficient material Inadequate flow Melt cooling too rapidly
Solutions
Check for material inside the barrel Increase the injection pressure Increase the barrel temperature Increase the gate size
Injection Molding
Warping or Shrinkage
Description
Distortion in one or more planes
Causes
Less cooling time. During ejection
Solutions
Increase in cooling time. Check for ejection system design.
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Injection Molding
Sinks
Description
Depressions over the surface of the molding
Causes
Insufficient material in mold to allow for contraction on cooling.
Solutions
Increase Packing inside the mould. Ensure that there is sufficient material inside the barrel to maintain pressure during dwell time.
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Injection Molding
Voids
Description
Vacuum bubbles within the molding
Causes
Sink marks. Gas trapped inside the cavity.
Solutions
Increase Venting
Increase injection pressure Packing correct material inside.
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Injection Molding
Flash
Description
Excess material attached with the molding
Causes
More injection pressure
Solutions
Reduce the Injection pressure Increase the clamping tonnage. Reduce the barrel temperature
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Injection Molding
Spot Burning
Description
Discolored or Charred sections in molding
Causes
Due the compressed air inside the mould. More Injection pressure.
Solutions
Improve mold venting Reduce the injection speed Reduce the melt temperature
Injection Molding
Causes
Less melt temperature Less injection pressure
Solutions
Increase Injection pressure
Increase melt temperature
Injection Molding
Flow lines
Description
Mark visible on the finished parts that indicate the direction of flow
Causes
Improper flow of material in to the mold Inadequate temperature
Solutions
Increase the material temperature Increase the gate size Increase injection pressure
Injection Molding
Contamination
Description
Material is filled with foreign particles
Causes
Improper cleaning of material
Solutions
Proper cleaning of materials or granules
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Injection Molding
Exercise
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Injection Molding
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Injection Molding
http://www.youtube.com/watch?v=u5rul_ELwy8&feature=related http://www.youtube.com/watch?v=6yVkNUYVe-4&feature=related http://www.youtube.com/watch?v=wScUAoCciGo&feature=related http://www.youtube.com/watch?v=SovjCTtBY4Q&feature=related Molding Side core and others Mold construction Material processing
http://www.youtube.com/watch?v=l1jNrmpx-Rw&feature=rellist&playnext=1&list=PL5A5C802C347EC661-Molding machine basics http://www.youtube.com/watch?v=hiPO8w7NlcI&feature=BFa&list=PL5A5C802C347EC661&lf=rellist--angled pin http://www.youtube.com/watch?NR=1&v=k14n9sVusvc--Multi color molding http://www.youtube.com/watch?v=V49wSbnRpsY--2 shot hot runner
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