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    Injection Molding

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    gunawan_ub
    Injection molding uses equipment including a clamp, mold, barrel, and hopper to melt plastic pellets and inject the melted plastic into a mold cavity. The process involves feeding pellets into the barrel where they are melted by friction from a reciprocating screw. The melted plastic is then injected into the mold under high pressure to form the desired part geometry before the part solidifies and is ejected.

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    Injection Molding

    Uploaded by

    gunawan_ub
    697 views24 pages
    Injection molding uses equipment including a clamp, mold, barrel, and hopper to melt plastic pellets and inject the melted plastic into a mold cavity. The process involves feeding pellets into the barrel where they are melted by friction from a reciprocating screw. The melted plastic is then injected into the mold under high pressure to form the desired part geometry before the part solidifies and is ejected.

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    Injection molding uses equipment including a clamp, mold, barrel, and hopper to melt plastic pellets and inject the melted plastic into a mold cavity. The process involves feeding pellets into the barrel where they are melted by friction from a reciprocating screw. The melted plastic is then injected into the mold under high pressure to form the desired part geometry before the part solidifies and is ejected.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as pdf or txt
    697 views24 pages

    Injection Molding

    Uploaded by

    gunawan_ub
    Injection molding uses equipment including a clamp, mold, barrel, and hopper to melt plastic pellets and inject the melted plastic into a mold cavity. The process involves feeding pellets into the barrel where they are melted by friction from a reciprocating screw. The melted plastic is then injected into the mold under high pressure to form the desired part geometry before the part solidifies and is ejected.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
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    of 24

    Injection Molding-

    Process Description

    ver. 1

    ME 4210: Manufacturing Processes and Engineering 1


    Prof. J.S. Colton
    Overview
    • Equipment
    • Process

    ME 4210: Manufacturing Processes and Engineering 2


    Prof. J.S. Colton
    Equipment

    Clamp Mold Barrel


    Hopper

    ME 4210: Manufacturing Processes and Engineering 3


    Prof. J.S. Colton
    Equipment

    ME 4210: Manufacturing Processes and Engineering 4


    Prof. J.S. Colton
    Machine schematic

    ME 4210: Manufacturing Processes and Engineering 5


    Prof. J.S. Colton
    Mold

    ME 4210: Manufacturing Processes and Engineering 6


    Prof. J.S. Colton
    Mold

    ME 4210: Manufacturing Processes and Engineering 7


    Prof. J.S. Colton
    Modular molds

    ME 4210: Manufacturing Processes and Engineering 8


    Prof. J.S. Colton
    Mold schematic

    ME 4210: Manufacturing Processes and Engineering 9


    Prof. J.S. Colton
    Mold
    runner sprue
    cavity
    gate

    sprue nozzle

    front ejection side


    pin
    ME 4210: Manufacturing Processes and Engineering 10
    Prof. J.S. Colton
    Process

    ME 4210: Manufacturing Processes and Engineering 11


    Prof. J.S. Colton
    Process

    • Pellets placed in hopper


    • Pellets fall into barrel through throat
    • Pellets packed to form solid bed
    – air forced out through hopper
    • Pellets melted by mechanical shear
    between barrel and screw

    ME 4210: Manufacturing Processes and Engineering 12


    Prof. J.S. Colton
    Process

    • Melted plastic forms shot in front of


    screw
    – screw moves back as plastic moves
    forward (reciprocating screw)

    ME 4210: Manufacturing Processes and Engineering 13


    Prof. J.S. Colton
    Process

    • Screw moves forward to inject plastic


    into mold cavity

    • Part cools and solidifies


    – next shot is made

    ME 4210: Manufacturing Processes and Engineering 14


    Prof. J.S. Colton
    Process

    • Mold opens
    • Ejection pins move forward to eject part

    • Mold closes
    • Process starts again

    ME 4210: Manufacturing Processes and Engineering 15


    Prof. J.S. Colton
    Solid bed

    • Pellets crushed together


    • Air ejected

    ME 4210: Manufacturing Processes and Engineering 16


    Prof. J.S. Colton
    Melting zone

    • Solid bed melted by mechanical shear

    barrel

    screw flight
    secondary
    mixing flow solid bed

    ME 4210: Manufacturing Processes and Engineering 17


    Prof. J.S. Colton
    Homogenization zone

    • Melted polymer is homogenized


    thermally and color-wise.

    ME 4210: Manufacturing Processes and Engineering 18


    Prof. J.S. Colton
    Injection pressure

    • Typically 15,000 psi


    • Ranges from 3,000 to 40,000 psi
    • Hydraulic pressure is about 10x less

    ME 4210: Manufacturing Processes and Engineering 19


    Prof. J.S. Colton
    Process time
    Open and eject Close mold
    part Injection
    1
    33
    35 5

    Pack and hold

    Part cooling
    15

    ME 4210: Manufacturing Processes and Engineering 20


    Prof. J.S. Colton
    Pressure history
    Cycle time

    Mold closed time

    Part ejection
    Cooling
    Cavity pressure (MPa)

    50
    Fast closing

    Injection

    Gate freeze off


    Pack

    25

    0
    0 5 15 33 35
    Time (s)

    ME 4210: Manufacturing Processes and Engineering 21


    Prof. J.S. Colton
    Temperature history
    Cooling

    200

    Part ejection
    part
    Temperature (oC)

    Fast closing

    Injection
    gate

    Gate freeze off


    100 Pack

    0
    0 5 15 33 35
    Time (s)

    ME 4210: Manufacturing Processes and Engineering 22


    Prof. J.S. Colton
    Gates and freeze-off

    Filling &
    Packing

    Cooling

    ME 4210: Manufacturing Processes and Engineering 23


    Prof. J.S. Colton
    ME 4210: Manufacturing Processes and Engineering 24
    Prof. J.S. Colton

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