Sink Marks

Physical cause
Sink marks occur during the cooling process, if the thermal contraction
(shrinkage) of the plastic cannot be compensated in certain areas. If the
outside walls of the moulded part are not stable enough, due to insufficient
cooling, the outer layer is drawn inside by cooling stresses as shown in
Figure 9.1.
There are three fundamental cases:
Solidification too slow
Effective holding pressure time too short
Not enough holding pressure transfer; because flow resistances in the
mould are too high.
nguyn nhn vt l
du chm xy ra trong qu trnh lm mt, nu s co li nhit (co) ca nha
khng th c bi thng cc khu vc nht nh. Nu cc bc tng
bn ngoi ca mt phn c l khng n nh, do khng lm mt,
lp ngoi c v bn trong ca ng sut lm mt nh th hin trong hnh
9.1.
C ba trng hp c bn:
ng rn qu chm
Hiu qu p lc thi gian nm gi qu ngn
Khng chuyn p lc nm gi ; v khng c dng chy trong khun
qu cao.
Note: For optimum holding pressure transfer the moulded part should be

gated to the largest cross- section. In order to avoid premature solidification

of the sprue and gate system, sufficient dimensioning is necessary.
Lu : i vi truyn p lc nm gi ti u phn c nn c gated vi
mt ct ngang ln nht. trnh ng rn sm ca u rt v h thng
cng, o kch thc l cn thit.
Sinkmarksappearforexamplenearmaterialaccumulationsasdepressionsonthe
surfaceofthemouldedpart,ifthethermalcontraction(shrinkage)cannotbe
compensated
duchmxuthinvdnhtrongstchlyvtliunhhtrnbmtca
phnc,nuscolinhit(cort)khngthcbithng
Streaks
Streakscausedbyburning,moistureoraircanlookverysimilarmaking
classificationdifficultifnotimpossible.Thesignslistedheredonothaveto
appear,theyonlygivereasontosuspectacertaintypeofstreak
Vt gy ra bi s t chy, m, khng kh c th trng rt ging nhau
phn loi lm kh khn nu khng phi khng th. Cc du hiu c lit
k y khng c xut hin, h ch a ra l do nghi ng mt loi nht
nh ca vt
Signs for burnt streaks

Thestreakappearsperiodically

Thestreakappearsbehindnarrowcrosssections(shearpoints)orsharpedgesin
themould

Themelttemperatureisneartheupperprocessinglimit

Loweringthescrewadvancespeedhasapositiveimpactonthedefect

Loweringthemelttemperaturehasapositiveimpactonthedefect

Longresidencetimeintheplasticisingunitorthespaceinfrontofthescrew(due
to,e.g.,cyclebreaksorlowshotvolumes)

Highreclaimcontent,orapartofthematerialhasalreadybeenmeltedseveral

timesbefore

Themouldisequippedwithahotrunner

Themouldisequippedwithashutoffnozzle.
Duhiuchovtchy
Ccvtxuthintheonhk
Ccvtxuthinphasauhpmtct(imct)hoccnhscnttrongkhun
Nhitnngchylgngiihnxltrn
Gimtcvttrccmttcngtchccncckhimkhuyt
Hthpnhitnngchyctcngtchccncckhimkhuyt
thigiandictrticcnvdohoccckhnggianphatrccatrc
vt(do,vd,phvchutrnhhockhilngbnthp)
hmlngilicao,hocmtphncavtchtbtanchynhiulntrc
Khunctrangbvimthunng
Khunctrangbmtviphunngtt
Topleft:Burntstreaksduetoexcessiveresidencetimeintheplasticising
cylinder

.
.

Topright:Burntstreaksduetohighshearingheatinthegate
.

Bottomleft:Burntstreaksduetoexcessiveresidencetimeintheplasticising
cylinder

Whenslowlyinjectingintotheair,themeltshowsblistersand/orissteaming

Thesolidifiedflowfrontofapartialfillingshowscraterlikestructures

Themoisturecontentofthematerialbeforetheprocessingisveryhigh.
Khittphunvokhngkh,tanchychothyvtphngrpv/hocchi
nc
Mttrcdngchyharncamtinmtphnchothycutrcmingh
gingnh
Mcmcavtliutrckhichbinlrtcao.

Themoisturecontentintheenvironmentisveryhigh(especiallyin
combinationwithcoldmouldsandcoldgranules)

Thedefectbecomessmallerwithlowerdecompression

Thedefectbecomessmallerwithlowerscrewadvancespeed

Blistersarevisibleintheinjectedmaterial

Thesolidifiedfrontflowofapartialfillingshowscraterlikestructures.
mtrongmitrnglrtcao(cbitlkhikthpvikhunlnhvcc
htlnh)
Cckhimkhuyttrnnnhhnvigiinnthp
Cckhimkhuyttrnnnhhnvitctinvtthp
Vtphnggipcthnhnthytrongvtliubm
Dngchyphatrcharncamtinmtphnchothycutrcming
nilanhthno.

Topleft:Airstreakbehindawallthicknessvariation

Topright:Airstreak(nearthesprue)duetosuckedinairduring
decompression

Bottom:Airstreakduetoentrainedandstretchedairnearrib

nLntrnbntri:streakAirngsaumtbctnngdyvariation?

Trnbnphi:Airvt(gnurt)dohttrongkhngkhtrongqutrnhgiinn

Bottom:vtAirdobcuntheovcngkhngkhgnxngsn

Burnt Streaks (Brown or Silver)

Physical cause

Burntstreaksarecausedbythermaldamagetothemelt.Theresultcan
beadecreaseofthelengthofthemoleculechain(silverydiscoloration)
orachangeofthemacromolecules(brownishdiscoloration).

Possiblecausesforthermaldamage:

Temperaturetoohighorresidencetimetoolongduringpredrying

Melttemperaturetoohigh

Shearingintheplasticisingunittoohigh(e.g.,screwspeedtoohigh)

Residencetimeintheplasticisingunittoolong

Shearinginthemouldtoohigh(e.g.,injectionratetoohigh).
nguyn nhn vt l
vt chy l do thit hi nhit tan chy. Kt qu c th gim di ca
cc chui phn t (bc i mu) hoc mt s thay i ca cc i phn t
(nu i mu).
Nguyn nhn c th thit hi nhit:
Nhit qu cao hoc thi gian c tr qu di trong predrying
tan nhit qu cao
Ct trong n v do qu cao (v d, vt tc qu cao)
Thi gian c tr trong n v do qu di
Ct trong khun qu cao (v d, t l tim qu cao).

Note:Injectintotheairinordertocheckthemelttemperature.
Measuretemperaturewithaneedlethermometer.Thermaldegradation
oftheplastichasanegativeimpactonitsmechanicalproperties,evenif
nodamageisvisibleonthesurface.
Lu : Tim 'vo khng kh' kim tra nhit nng chy. o nhit
bng nhit k kim. phn hy nhit ca nha c mt tc ng tiu cc n
tnh cht c hc ca n, ngay c khi khng c thit hi c th nhn thy
trn b mt.

Moisture Streaks
nguyn nhn vt l
Trong thi gian lu trgia cng, m c hp th bi cc ht, to thnh
hi nc trong tan chy. Do vn tc pha trc dng chy, bt kh c
y ln b mt ca s tan chy nh th hin trong hnh 9.7. V h mun b
p nhng p lc, nhng mn nc b v, b bin dng bi pha trc
dng chy di chuyn v ng bng cc bc tng mc. ng rn thnh
khun
.

Possiblecausesformoisturestreaks:(1)Moistureonthemouldsurface
leakymouldtemperaturecontrolsystemcondensationwateronthe
mouldwalls(2)Moisturein/onthegranulesinsufficientpredryingof
thematerialwrongstorageofthematerial
Nguynnhncthchovtm:
(1)mtrnbmtkhun
Hthngiukhinnhitkhunbrr
ncngngttrntngkhun
(2)mtrong/trnccht
sykhng
lutrsaicavtliu

Colour Streaks
Physical cause

Duringpigmentation,pigmentagglomerationscanleadtodifferences
intheconcentration.Tosomeextentthiscanbemitigatedbyan
increaseinshearingasshowninFigure9.8andincreasesinback
pressurecanbeappliedduringtheplasticationstagetoincreasemixing.
Thiskindofpoordistributioncanbecausedbytheplastic,the
processingparameters,adhesivesandotheradditives.Withinplant
colouringusingdyes,thedefectcanoccurduetouncompletedsolution

ofthedyeparticlesinthemelt.
nguyn nhn vt l
Trong sc t mu, s tch t sc t c th dn n s khc bit v nng
. mt mc no iu ny c th c gim thiu bng tng x
nh th hin trong hnh 9.8 v tng p lc ngc c th c p dng
trong giai on plastication tng trn. y l loi phn phi ngho c th
c gy ra bi cc nha, cc thng s x l, cht kt dnh v ph gia
khc. Vi trong nh my nhum bng thuc nhum, cc li c th xy ra
do gii php d dang ca cc ht thuc nhum trong tan chy.

Similartothermoplastics,pigmentsanddyesaresensitivetoexcessive
processingtemperatureandresidencetimes.Ifthermaldamageisthe
reasonforcolourstreaks,theyshouldbeconsideredasburntstreaks.
Extensivestressorwarpagecanalsocausecolourdifferences.The
deformedareasbreakthelightinadifferentmannerthanotherareas.
Note:Ifusingmasterbatchesforcolouring,makesurethesubstrateis
compatiblewiththeplastictobecoloured.Theeffectoftheuseofan
incompatiblemasterbatch
Tng t nh nha nhit do, bt mu v thuc nhum rt nhy cm vi
nhit x l v c tr thi gian qu mc. Nu thit hi nhit l l do cho
nhng vt mu, h cn c xem xt nh nhng vt chy.
ng sut nhiu hoc warpage cng c th gy ra s khc bit mu sc.
Cc khu vc b bin dng ph v nh sng mt cch khc nhau hn so vi
cc khu vc khc.
Lu : Nu s dng cc l tng th mu, m bo cht nn tng thch vi
nha c mu. Hiu qu ca vic s dng mt masterbatch khng tng
thch

Left:Colourstreaksduetoanincompatiblemasterbatch
Right:Orientationofmetaleffectpigmentscausedbytheflownh

hngcaccsctkimloihiunggyrabidngchy
Air Streaks/Air Hooks

Airwhichcannotescapeintimeduringthemouldfilling,isdrawnto
thesurfaceandstretchedinthedirectionoftheflow.Especiallynear
writings,ribs,domesanddepressions,theaircanberolledoverand
thusentrappedbythemeltasshowninFigure9.10.Theresultisthe
formationofairstreaksorairhooks.
Khngkhmkhngththotratrongthigiantrongvicinvokhun,cvln
bmtvtriditheohngdngchy.cbitlgncctcphm,xngsn,mi
vmvsuythoi,khngkhcthcquayvngvdoktbistanchynhth
hintronghnh9.10.Ktqulshnhthnhccvtkhhocccmckhngkh.
Ifairissuckedintotheareainfrontofthescrewduringdecompression,airstreakswill
appearnearthegate.Here,airistransportedintothecavityduringtheinjection,andis
thenpushedtowardsthemouldwallwhereitfreezes.

Nukhngkhchtvocckhuvcphatrccatrcvttrong
giinn,vtkhsxuthingncng.y,khngkhcvn
chuynvohctrongkhitim,vsaucyvphabctng
khunmnbngbng.
Glass Fibre Streaks
Physical cause

Duetotheirlength,glassfibresorientatethemselvesinthedirectionof
flowduringinjection.Ifthemeltsuddenlyfreezeswhentouchingthe
mouldwall,theglassfibresmaynotyetbesufficientlysurroundedwith
melt.
Inadditiontothat,thesurfacecanturnroughbecauseofthebig
differencesinshrinkage(glassfibre:plastic=1:200).Theglassfibres
impedeshrinkageofthecoolingplastic,especiallyinthelongitudinal
directionofthefibre,thusproducinganunevensurface
nguyn nhn vt l

Do chiu di ca h, si thy tinh t nh hng theo hng ca dng

chy trong khi tim. Nu nhit nng chy t nhin b ng bng khi
chm vo tng mc, cc si thy tinh c th cha c bao quanh vi
nng chy.
Bn cnh , b mt c th chuyn th do s khc bit ln trong co rt
(si thy tinh: nha = 1: 200). Cc si thy tinh cn tr co rt ca nha lm
mt, c bit l theo hng dc ca si, do to ra mt b mt khng
ng u
Gloss/Gloss Differences

Theglossofamouldedpartistheappearanceofitssurfacewhen
exposedtolight.
Ifarayoflighthitsthesurface,itsdirectionwillchange(refractionof
light).Whileonepartofthelightwillbereflectedonthesurface,
anotherpartwillreflectinsidethepartorpenetrateitwithdifferent
intensities.Theimpressionofglossisatanoptimum,thelowerthe
surfaceroughness.Toachievethis,apolishedmouldwallshouldbeas
goodaspossible,atexturedmouldwallwouldnot.Thisisillustratedin
Figure9.13.Glossdifferencesarecausedbydifferentprojection
behavioursoftheplasticatthemouldwall,duetodifferentcooling
conditionsandshrinkagedifferences.
Cc bng ca mt phn c l s xut hin ca b mt ca n khi tip xc
vi nh sng.
Nu mt tia nh sng chm vo b mt, hng i ca n s thay i (khc
x ca nh sng). Trong khi mt phn ca nh sng s c phn nh
trn b mt, mt phn khc s phn chiu trong mt phn hoc thm nhp
n vi cng khc nhau. nn ca bng l mt ti u, thp hn b mt
g gh. t c iu ny, mt bc tng khun nh bng nn cng
tt cng tt, mt bc tng khun kt cu s khng c. iu ny c
minh ha trong hnh 9.13. khc bit Gloss c gy ra bi hnh vi d bo
khc nhau ca nha vo bc tng mc, do iu kin lm mt khc nhau
v khc nhau co rt.

Veryglossyimpressionduetoreflectiononthepolishedsurface
(b)Onlyslightlyglossyimpressionduetoreflectiononaroughsurface
andonfillermaterialsnhinthChhibngdophnxtrnbmt
thrpvtrnccvtliuchtn
Stretching of already cooled areas (e.g., due to warpage) can be another
reason for gloss differences. Various examples of gloss related defectsTri
di ca khu vc c lm ngui (v d, do warpage) c th l mt l do
cho s khc bit c bng. v d khc nhau ca cc khuyt tt lin quan
n bng

Topleft:GlossdifferencesnearweldlinesTopright:Gloss
differencesduetowallthicknessvariationsBottomleft:Glass
differencesnearribs
Weld Line (Visible Notch or Colour Change) Physical cause
Weld lines are created when two or more melt flows meet. The rounded
flow fronts of the melt streams are flattened and bonded when touching
each other. This is shown in Figures 9.15 and 9.16 This process requires
stretching of the already highly viscous flow fronts. If temperature and
pressure are not high enough, the corners of the flow fronts will not
completely develop, creating a notch. Furthermore, the flow fronts no
longer melt together homogeneously, possibly producing an optical and
mechanical weak spot as shown in Figure 9.17. If moulding compounds
containing additives (e.g., colour pigments) are used, strong orientations of
these additives near the weld line are possible. This can lead to colour
changes near the weld line. Notches are particularly visible on dark or
transparent parts with smooth, highly polished surfaces. Colour changes
are particularly visible on parts with metallic pigments. note: significant
improvements can only be reached by high mould wall temperatures.
Increasing the mould wall temperature increases the cycle time by
approximately 2% per C.
nguyn nhn vt l ng hn c to ra khi hai hay nhiu dng nng
chy gp nhau. Cc mt dng chy trn ca cc dng nng chy c san

phng v gn khi chm vo nhau. iu ny c th hin trong hnh 9.15

v 9.16 Qu trnh ny i hi phi ko di ca mt trn lu lng c
nht cao. Nu nhit v p sut khng cao, cc gc ca mt trn
dng chy s khng hon ton pht trin, to ra mt khe. Hn na, cc
mt trn dng chy khng cn c nng chy cng nhau ng nht, c th
sn xut mt im yu quang hc v c hc nh th hin trong hnh 9.17.
Nu hp cht c c cha cht ph gia (v d, cc sc t mu) c s
dng, nh hng mnh m ca cc cht ph gia gn ng hn l c th.
iu ny c th dn n nhng thay i mu sc gn ng hn. khe c
bit bt mt trn phn ti hoc trong sut mn mng, b mt c bng
cao. thay i mu sc c bit bt mt trn cc b phn vi cc sc t kim
loi. u : nhng ci thin ng k ch c th t c nhit tng
khun cao. Tng nhit tng khun lm tng thi gian chu k khong
2% mi C.
Jetting
Physical cause

Jettingiscausedbyanundevelopedfrontalflowofmeltinthecavity.
Ameltstrandisdevelopedwhich,startingatthegate,entersthecavity
withuncontrolledmovements.Duringthisphasethemeltstrandhas
cooleddowntosuchadegreethatitcannotbefusedhomogeneously
withtherestofthemouldingcompound.Thisoftenhappenswith
discontinuouslyincreasingcrosssectionsofthemouldingpartin
conjunctionwithhighinjectionspeeds.JettingisillustratedinFigures
9.18and9.19.Oftenjettingcausesdifferencesincolourandgloss.In
somecasestherearesimilaritiestotherecordgrooveseffect.Note:
jettingcanalsobeinfluencedbythepositionofthemould.Inorderto
avoiddefects,thecavityshouldnotbefilledfromtoptobottom.
Bn vt c gy ra bi mt dng chy pha trc cha pht trin chy
trong hc. Mt nng chy chui c pht trin , bt u cng, i vo
hc bng vic di chuyn khng kim sot c. Trong giai on ny nhit
nng chy chui ngui xung n mt mc nh vy m n khng
th c hp nht ng nht vi phn cn li ca hp cht c. iu ny

thng xy ra vi khng lin tc tng qua cc phn ca mt phn c kt

hp vi tc phun cao. Phun c minh ha trong hnh 9.18 v 9.19.
Thng jetting nguyn nhn khc bit v mu sc v bng. Trong mt
s trng hp c nhng im tng ng vi cc hiu ng cc ng
rnh k lc. Lu : phun cng c th b nh hng bi v tr ca khun.
trnh cc khuyt tt, cc hc khng nn in t trn xung di.
Diesel Effect (Burns)
Physical cause
The diesel effect is a pure venting problem. It can occur near blind holes,
fillets, the end of flow paths and near points where several flow fronts fuse.
It happens whenever the air cannot escape or not quick enough via
commissures, venting channels or ejector fits. Towards the end of the
injection process, the air is compressed and thus heated to a high degree.
The result is very high temperatures which can cause burn marks on the
plastic as shown in Figures 9.20 and 9.21.
Note: Due to the burning of the plastic, aggressive decomposition products
may be created, which often attack the mould surface, leading to
destruction.
nguyn nhn vt l
Cc hiu ng ng c diesel l mt vn thng gi tinh khit. N c th
xy ra gn l m, phil, kt thc ca ng dn dng chy v gn cc
im m nhiu mt trn dng chy nng chy. N s xy ra bt c khi no
khng kh khng th thot ra hoc khng nhanh qua commissures,
thng hi knh hoc ph hp ejector. n cui ca qu trnh tim, khng
kh nn v do un nng n mt mc cao. Kt qu l nhit rt
cao c th gy ra cc vt chy trn nha nh th hin trong hnh 9.20 v
9.21.
Lu : Do vic t nha, cc sn phm phn hy mnh c th c to ra,
thng tn cng cc b mt khun, dn n s hy dit.

Record Grooves Effect

Inthiseffectveryfinegroovesshowuponthemouldedpart,whichare
verysimilartothoseofrecords.Concentricringsappearnearpinpoint
gates,whilemarkingsareparalleltowardstheendoftheflowpath
and/orbehindthegate.
Trong thc t ny rnh rt tt hin th trn phn c, l rt tng t nh
h s. vng trn ng tm xut hin gn cng pin-point, trong khi du
song song v pha cui ca flowpath v / hoc pha sau cnh cng.
Physical cause

Highcoolingvelocity

Melttemperaturetoolow

Injectionspeedtoolow
Mouldwalltemperaturetoolow.Wheninjectingthemoulding
compoundintoacoldmould,asolidifiedperipherallayerwillbe
formedbehindtheflowfrontduetothehighcoolingrate.Thecooling
oftheperipherallayeralsocausescoolingofflowfrontareasnearthe
mouldwall.Ifthiscoolingisveryhigh(especiallywithlowinjection
speeds)theseveryhighviscosityorfrozenflowfrontareascanimpede
thedirectfrontalflowofthemelttothewall.Thusthefollowinghot
meltwillnotbepushedtowardsthewallasusual,butitwillcausean
elongationoftheflowfrontinthemiddle.Fromacertainpressurethe
flowfrontwillagaintouchthewall.Thecooleddownperipheralareas
oftheflowfronthavenocontactwiththewall
nguyn nhn vt l
tc lm mt cao
tan nhit qu thp
Tc phun qu thp

 Nhit Khun tng qu thp.

Khi tim hp cht c vo mt khun lnh, mt lp ngoi vi(ngoi
bin, chu vi) ha rn s c hnh thnh pha sau pha trc dng chy
do tc lm mt cao. Vic lm mt ca cc lp ngoi vi cng gy ra
lm mt ca khu vc pha trc dng chy gn tng mc. Nu lm
mt ny l rt cao (c bit l vi tc phun thp) cc nht rt cao
hoc khu vc pha trc dng chy ng lnh c th cn tr dng chy
trn trc tip ca nhit nng chy vo tng. Do , nng chy sau
y s khng c y v pha bc tng nh bnh thng, nhng n
s gy ra mt s ko di ca mt trc dng chy gia. T mt p
sut nht nh pha trc dng chy s mt ln na chm vo tng.
Cc khu vc ngoi vi(ngoi bin, chu vi) h nhit ca mt trc dng
chy khng c lin h vi cc bc tng
Stress Whitening/Stress Cracks
Physical cause Stresswhiteningorstresscracksoccurwhenexceeding

themaximumdeformation(e.g.,duetoexternalstressorwarpage).The
maximumdeformationdependsonthetypeofmaterialused,the
molecularstructure,theprocessingandthesurroundingclimateofthe
mouldedpart.Thestrengthagainstexternalandinternalstressescanbe
drasticallyreducedthroughphysicalprocessesdependingontimeand
temperature.Inthiscase,thelinkageforcesofthemoleculesare
reducedthroughwetting,diffusionandswellingprocesses.Thismay
especiallyfavourstresscracks.Besidesinternalcoolingstressesand
stressesduetoflow,internalstressesduetoexpansionareanothermain
reasonforinternalstresses.Externalexpansionstressiscreatedby
demouldingunderresidualpressure,whenthemouldedpartsuddenly
shiftsfromresidualpressuretoatmosphericpressure.Thustheinner
layersofthemouldedpartputstressontheouterlayers.Themain
reasonsfordemouldingunderresidualpressureareinsufficiently
dimensionedmouldsand/orhighcavitypressures.Theformationof
stressisshowninFigure9.26andthephysicalmanifestationsonthe
mouldinginFigure9.27.Note:ifaggressivesubstancesareused(e.g.,
alkalisolutions,grease,etc.)stresswhiteningandstresscracksoften
appearafteraverylongtimeofoperation.

Vtlnguynnhnngsutlmtrnghocntngsutxyrakhivtqusbin
dngtia(vd,dongsutbnngoihocwarpage).Ccbindngtiaphthuc
voloivtliucsdng,cutrcphnt,vicxlvkhhuquanhccphn
c.Cngchnglingsutbnngoivnibcthcgimngkthng
quaccqutrnhvtlphthucvothigianvnhit.Trongtrnghpny,cc
lclnglinktcaccphntcgimthngqualmt,khuchtnvsngquy
trnh.iunycthcbitclichoccvtntstress.Bncnhngsutlmmt
bntrongvngsutdodngchy,ngsutnibdosginnlmtldochnhcho
ngsutnib ngsutmrngbnngoictorabidemouldingdiplccn
stli,khimtphnctnhinchuyntplcdnpsutkhquyn.Vvy,
cclpbntrongcaphnctcngthngtrnlpbnngoi.Nhngldochnhcho
demouldingdiplcdlkhngkhunmukchthctngv/hocplchc
cao.Shnhthnhcascngthngcthhintronghnh9.26vccbiuhinvt
ltrnkhuntronghnh9.27.Lu:nuccchtxmcsdng(vd,ccgii
phpkim,dum,vv)ngsutlmtrngvccvtntngsutthngxuthinsau
mtthigianrtdihotng.

Unstressed,feltedmoleculestructure;(b)Orientationofmoleculesdue
toforce;(c)DestroyedmoleculesduetoadditionalforceKhngc
nhnmnh,cutrcphntton;(B)nhhngcaccphntdo
buc;(C)phhyccphntdolclngbsung
e
Left:Stresswhiteningonanintegralhinge?
Right:Stresscracksonsaladservers(damagevisibleseveralweeksafterpurchase)Left:
Stresslmtrngtrnmthingekhngthtchri
vtntngsuttrnccmychxlch(nhnthyhhngmtvitunsaukhimua):

Incompletely Filled Parts

Injectionmouldedpartswithincompletelydevelopedouterprofilesare
calledincompletelyfilledparts(orshortshots).Anexampleisshown
inFigure9.28.Thiskindofdefectoftenappearsfarfromthegateif
therearelongflowdistances,oronthinwalls(e.g.,ribsasshownin
Figure9.29).Duetoinsufficientmouldventing,thisdefectcanalso
occurinotherareas.
Tim c ph tng vi h s khng y bn ngoi pht trin c gi l
phn khng y in (shots ngn). Mt v d c th hin trong hnh
9.28. y l loi khuyt tt thng xut hin xa cng nu c khong cch
dng chy di, hoc trn cc bc tng mng (v d, xng sn nh th

hin trong hnh 9.29). Do khng thng hi khun li ny cng c th xy

ra cc khu vc khc.

Figure9.28HousingwithincompletelydemouldedlatticeHnh9.28
Nhvimngtinhthkhngyra
Physical cause
Figure 9.29 Filling problems near thin ribs
There are several physical causes for incomplete filling:
Injected compound volume too small (e.g., shot volume too small)
Melt flow impeded due to venting problems
Injection pressure not sufficient
Premature freezing of a channel cross-section (e.g., low injection speed
or wrong temperature
control in the mould).
Note: Incomplete filling due to venting problems does not necessarily
cause the diesel effect (Section 9.2.8). Therefore the cause for the defect
is often hard to determine.
nguyn nhn vt l
Figure 9.29 vn in gn xng sn mng
C mt s nguyn nhn vt l in khng y :
Tim khi lng hp cht qu nh (v d, bn khi lng qu nh)
tan chy dng chy b cn tr do vn thng hi
p lc phun khng
ng bng sm ca mt knh ct ngang (v d, tc phun thp hoc

kim sot nhit sai trong cc khun).

Lu : in khng y do cc vn thng hi khng nht thit gy ra
cc tc dng ng c diesel (mc 9.2.8). V vy nguyn nhn cho s
khim khuyt thng rt kh xc nh.
Oversprayed Parts (Flashes)

Flashesareoftencreatednearsealingfaces,ventingchannelsor
ejectors.Theylooklikeamoreorlessdevelopedfilmlikeplasticedge.
Fineflashesarenotoftenimmediatelyvisible.Largeareathickflashes
ontheotherhandsometimesstickoutseveralcentimetresoverthe
nominalprofile Nhythngctoragnknkhunmt,thnghiknhhoc

ejectors.HtrnggingnhmtcnhnhaFilmgingnhnhiuhnhoctphttrin.
chpMnhthngkhngngaylptcnhnthyc.Dintchlnchpdymtkhc
ikhidnhravicmsovihsdanhngha

Figure9.30Largeareaoverspraying(flash)
Physical cause Thedifferentpossibilitiescanbedividedintofourmain
groups:
Allowedgapwidthsexceeded(mouldtightnessinsufficient,production
tolerancestoolargeordamagedsealingfaces)
Clampingforceofthemachineinsufficientorsettoolow(mould
openingforcehigherthanclampingforce,mouldcannotbekeptclosed;
clampingforcedeformsplatensandmould)
Internalmouldpressurestoohigh(shapingpressureatthegapisso
highthatthemeltispushedevenintoverysmallgaps)
viscosityofmouldingcompoundtoolow(highinternalmould
pressuresandlowflowresistancefavourflashformation).
Note:Flashformationcanveryquickly(fewcycles)anddamagethe
sealingfaces(partingsurface).
nguynnhnvtlCckhnngkhcnhaucthcchiathnhbnnhmchnh:

chnhlchchophprngvtqu(khunknkhng,dungsaisnxutquln
hocbhhngkhunmtbtkn)
Lckpcamykhnghocquthp(lclngmkhuncaohnlckp,nm
mckhngthgikn;lckpbindngaunvkhun)
scpkhunNiqucao(hnhplckhongcchlqucaomnhitnngchy
cythmchvonhngkhongtrngrtnh)nhtcasnphmcchtqu
thp(plckhuncaonibvlulngchngclishnhthnhFlashthp).
Lu:hnhFlashcthrtnhanh(vichuk),lmhhng(bmtchiatay)mtnim
phong.

Visible Ejector Marks

Ejector marks are depressions or elevations on the ejector side of the
moulded part surface. These wall thickness variations can cause gloss
differences and depressions on the visible surface of the moulding as
shown in Figure 9.31.
du Ejector l p thp hoc cao pha ejector ca b mt phn c.
Nhng bin th dy tng c th gy ra s khc bit c bng v suy
thoi trn b mt nhn thy cc khun nh trong hnh 9.31.
Physical cause

Thedifferentpossibilitiescanbedividedintofourmaingroups:

Processrelatedcauses(e.g.,prematuredemouldingorhighdemoulding
forcesduetounfavourablemachinesettings)

Geometriccauses(e.g.,wrongfittingorwrongejectorlength)

Mechanicalorstrengthrelated(e.g.,faultydimensioninganddesignof
themould,themouldedpartorthedemouldingsystem)

Thermalcauses(hightemperaturedifferencesbetweenejectorand
mouldwall,e.g.,
nguyn nhn vt l

Cc kh nng khc nhau c th c chia thnh bn nhm chnh:

(lc lng v d, demoulding non hoc demoulding cao do ci t my khng
thun li) cc nguyn nhn lin quan n qu trnh
nguyn nhn hnh hc (v d, sai khp hay sai chiu di ejector)
C hoc bn lin quan (v d, kch thc b li v thit k khun, phn c
hoc h thng demoulding)
nguyn nhn nhit (chnh lch nhit cao gia ejector v tng khun v d,
Deformation During Demoulding

Dependingonthedegreeofdamagethereisaclassificationinto
extractionmarking,cracks,fractures,overstretchedareasanddeeply
depressedejectors.Criticalaremouldedpartswithundercuts,whichare
demouldedwithoutmovableparts(e.g.,slides).Examplesoftwo
defectivemouldingsareshowninFigure9.33.
Ty thuc vo mc thit hi c mt phn loi vo chit tch nh du,
vt nt, gy xng, cc khu vc qu mt v ejectors trm cm su sc.
Quan trng c c cc b phn vi ct xn, c ra m khng c b
phn chuyn ng (v d, trnh by). V d v hai khun li c th hin
trong hnh 9.33.
Physical cause

Figure9.33Deformationduringdemoulding
Left:Demouldinggroovesonatexturedsurface
Right:Defomationduetoforceddemouldingatanundercut
Thecausesofdeformationscanbeclassifiedasfollows:
Theforcesnecessaryfordemouldingcannotbeappliedtothemoulded
partwithoutdamagingit

Thedemouldingmovementisdisturbed.Theamountofdemoulding
forceappliedisacrucialcriterionandshouldthusbekeptsmall.Beside
otherfactorstheshrinkageofthemouldedparthasadirectimpacton
thedemouldingforces.Shrinkageanddemouldingforcecanbe
influencedconsiderablybyvaryingtheprocessparameters.Itistobe
consideredthoughthatthegeometryofthemouldedpartisavery
importantinfluencingfactor
Cclclngcnthitchodemouldingkhngthcpdngcho
ccphncmkhnglmhngnCcdichuyndemouldingbxo
trn.Lngdemouldinglclngpdnglmttiuchrtquan
trngvdonncgimcnh.Bncnhccyutkhcsco
rtcaccphncctcngtrctipvocclclng
demoulding.Congtvdemouldinglclngcthbnhhng
ngkbngcchthayiccthngsqutrnh.Nccoilmc
drnghnhhccaphnclmtyutnhhngrtquantrng
Ingeneral,lowshrinkageisdesirableforsleeveandboxshapedparts,
sincethesepartstendtoshrinkontothecore(==>increaseholding
pressureorreducecoolingtime).Nearribs,theshrinkageretroactson
thedemouldingforce,becausetheribsarebeingdetachedfromthe
mouldwalls(==>decreaseholdingpressureorincreasecoolingtime).
Nichung,cothplmongmunchotayvccbphnhnhhp,vnhngbphn
nycxuhngcolivoli(==>plcgiatngnmgihocgimthigianlm
mt).Gnxngsn,retroactscortvlcdemoulding,bivccxngsnc
tchratccbctngkhun(==>plcgikhitnghocgimthigianlmmt).

Flaking of the Surface Layer

Thelayersofmaterialarenothomogeneouslyjoinedtogetherandstart
flaking.Thiscanoccuratthegateoronthemouldedpart,andcanbe
eitherlargeorverysmallandthin,dependingontheintensity.
ExamplesofbothareshowninFigure9.34.
Cc lp vt liu khng ng nht kt hp vi nhau v bt u bong. iu
ny c th xy ra cng, hoc mt phn c, v c th l ln hoc rt nh
v mng, ty thuc vo cng . Cc v d ca c hai c th hin
trong hnh 9.34.

Physical cause

Figure9.34Flaking
Flakingofsurfacelayersisduetoinsufficientbondingofadjacent
surfacelayers.Thedifferentlayersareformedbydifferentfloweffects
andcoolingconditionsoverthecrosssection.Shearstressesand
inhomogeneitiescanreducethebondingoftheselayerstosucha
degreethatsinglesurfacelayersstartflakingoffBongcclpbmtl
dothiulinktcalpbmtlink.Cclpkhcnhauchnh
thnhbicctcdngdngkhcnhauviukinlmmttrnmt
ctngang.ngsutctvkhngngnhtcthlmgimktdnh
cacclpmtmcnhvymlpbmtnbtubongra
Highshearstressesandthermaldamagecanbecausedby:

Highinjectionspeeds

Highmelttemperatures.Inhomogeneitiescanbecausedby:

Impuritiesorothermaterialsamongthegranules

Incompatibledyeormasterbatch

Moisturein/onthegranules

Poorlymeltedmouldingcompound.
ngsutctcaovthithinhitcthcgyrabi:
Tcphuncao
caonngchynhit.
Khngngnhtcthcgyrabi:
Cctpchthocccvtliukhcgiaccht
thucnhumkhngtngthchhochnglotch
mtrong/trnccht

kmnngchychpcht.

Cold Slugs/Cold Flow Lines

Physical cause Coldslugsareformedwhenmeltsolidifiesinthegateor

inthenozzle,beforethecompoundisinjected,andistransportedinto
themouldwiththefollowingshotsequence.Ifthecoldslugsdonot
meltagain,theywillcausemarkingswhichlooklikecomettails.They
canbespreadalloverthemouldedpart.Thecoldslugcanalsojama
runner,forcingthemelttopart.Theresultsaresurfacedefectssimilar
toweldlines.AnexampleisshowninFigure9.36.Coldslugsareoften
causedbyawrongnozzletemperatureorbelatedretractionofthe
plasticisingunit.Smallnozzlediameterscanalsohaveanegative
effect.Anillustrationofthemechanism
nguyn nhn vt l
sn lnh c hnh thnh khi nng chy ha rn cng, hoc trong cc
vi phun, trc khi cc hp cht c tim vo, v c vn chuyn vo
khun vi cc trnh t bn sau y. Nu sn lnh khng nng chy mt ln
na, h s gy ra du m trng ging nh ui sao chi. Chng c th
c tri rng trn tt c cc phn c. Sn lnh cng c th gi mt
hu, lc nhit nng chy n phn. Kt qu l b mt khuyt tt tng
t n dng hn. Mt v d c th hin trong hnh 9.36. sn lnh thng
gy ra bi nhit vi phun sai hoc tr co rt li n v do. ng
knh ng ht nh cng c th c mt tc ng tiu cc. Mt minh ha v
c ch
reception of the cold slug by runner holding gate tip tn/ tip nhn ca
sn lnh bng cng gi runner
Entrapped Air (Blister Formation)
Physical cause

Duringtheinjection,airisentrappedinthemeltandappearsasa
hollow(airblister)onthemouldedpart.Primarilytherearetwofactors
responsibleforthisdefect:

Decompressiontoohighortoofast
Plasticisingperformancetoolow.Note:Therearetwotypesof
hollows,entrappedairandvoids.Voidsarevacuolehollows,formedby
theshrinkageofthemouldingcompound(seesinkmarks).
Distinguishingbetweenthetwoisveryhard,becauseoftheirsimilar
appearance.Thefollowinghintsmightbehelpful:
Whenopeningthehollowinafluid,avoid(vacuum)showsnogaseous
bubblesnguynnhnvtl
Trongkhitim,khngkhangkttrongnngchyvxuthinnh
mtcl(vkhngkh)trnphnc.Chyuchaiyutchu
trchnhimcholiny:
Giinnqucaohocqunhanh
Dohiusutquthp.Lu:Chailoihc,ktkhngkhv
khongtrng.Khongtrnglhckhngbo,hnhthnhbiscort
cachpcht(xem'nhduchm').Phnbitgiahailrtkh,
vvbngoitngtcah.Nhnggisauycthhuch:
Khimcltrongmtchtlng,mtkhongtrngkhng(chn
khng)chothykhngcbongbngkh
Entrappedairdefectscanbereducedbyusingnodecompression
Changingtheholdingpressureortheholdingpressuretimehasno
effectonthesizeofthehollows.Mouldedpartswithhollowsare
usuallynotasstrongaspartswithout.Nontransparentpartsshouldbe
randomlytestedbyrandomlyopeningthem,ifsuspicious
khim khuyt khng kh kt c th c gim bng cch s dng khng gii nn
Thay i p lc nm gi hoc nhng p lc thi gian gi khng nh hng n kch
thc ca cc hc.
phn Moulded vi hc thng khng mnh nh cc b phn m khng c. phn khng
minh bch cn c kim tra ngu nhin bng cch m ngu nhin , nu nghi ng

Dark Spots
Physical cause

Blackordarkspotsappearonthesurfaceduetowear,thermaldamage
ordirt.Differentfactorscancausetheformationofdarkspotsor
speckledparts:
Processrelatedcauses,e.g.,melttemperaturetoohighorresidence
timeintheplasticisingunittoolong.Wrongtemperatureprofileinthe
hotrunnersystem.
Mouldrelatedcauses,e.g.,dirtygatesystemorwear(deadedges)in
thehotrunnersystem.
Machinerelatedcauses,e.g.,dirtyplasticisingunitorwornscrewand
cylinder.
Causedbypolymerordyeing,e.g.,impuritiesinthegranule,high
reclaimcontentorunsuitabledye/masterbatch.Figure9.39showsdark
spotsresultingfromthermaldamagetothepolymer.
nguyn nhn vt l
m en hoc sm xut hin trn b mt do mc, thit hi nhit hoc
bi bn. cc yu t khc nhau c th gy ra s hnh thnh ca cc m
en hoc cc b phn c m:
nguyn nhn qu trnh lin quan, v d, lm tan nhit qu cao hoc
ni c tr thi gian trong cc n v do qu di. cu hnh nhit sai
trong h thng hu nng.
nguyn nhn Khun mu lin quan, v d, h thng bn ca hoc eo
(cnh cht) trong h thng hu nng.
My lin quan n nguyn nhn, v d, n v do bn hoc vt mn v
xi lanh.

Do polymer hoc nhum, v d, cc tp cht trong ht, hm lng i

li cao hoc khng ph hp thuc nhum / masterbatch. Hnh 9.39 cho
thy cc m en do thit hi nhit vi polyme.
Figure9.39Darkspotsduetothermaldamage
Dull Spots Near the Sprue
Physical cause

Dullspotsnearthespruearemainlycausedby:

Smallgates
Highinjectionspeeds.Duetohighinjectionspeeds,smallgatecross
sectionsandbypassesbehindthegate,extremelystrongorientationsof
themoleculechainsareformedduringinjection.Thereisnotenough
relaxationtimedirectlybehindthegate,sotheperipherallayersofthe
meltarefrozenwhilestillstronglyoriented.Suchperipherallayerscan
onlybestretchedtoaminimumdegreeandcrackundertheimpactof
thehighshearstresses.Thehotmeltinsideflowstothemouldwalland
formsverysmallnotchesasshowninFigure9.40.Thedullappearance
iscausedbythewidespreadreflectioninthisarea.
nguynnhnvtl
imDullgnurtchyuldo:
canh
Tcphuncao.
Dotcphuncao,nhcngctngangviquaphasaucnhcng,
nhhngcckmnhmcaccchuiphntchnhthnh
trongqutrnhphun.Khngcthigianthgintrctipphasau
cnhcng,vvycclpngoivicanhitnngchycng
lnhtrongkhivntheonhhngmnhm.lpngoivi(ngoibin,
chuvi)nhvychcthckodinmtmctithiuv

crackditcngcangsutctcao.
Ccnngchybntrongchyvotngkhunvcchnhthcrnh
rtnhnhtronghnh9.40.Sxuthinmgyrabisphnchiu
phbinrngritronglnhvcny.
micronotch
Blister As the name says, this is a part defect which
appears as a small bubble or blister on the surface of a
part and it generally created by improper heating or
cooling of by gas or air bubbles.
Blowmolding The process follows the basic steps found
in glass blowing. A parison (heated plastic mass,
generally a tube) is inflated by air. The air pushes the
plastic against the mold cavity to form the desired
shape. Once cooled, the plastic is ejected. This method
is used to make plastic bottles.
Bridgetool An injection mold that makes parts until the
final tool is completed. These molds or tools are not
meant to be production tools.
Bubbles Similar to blisters, gas pockets, or voids that
have formed inside the plastic.
V - Nh tn gi ca n, y l mt khim khuyt mt phn xut hin
nh mt bong bng nh hoc v trn b mt ca mt phn v n thng
c to ra bi gia nhit hoc lm mt bng kh hoc khng kh bong
bng khng ng.
Thi c - Qu trnh sau cc bc c bn c tm thy trong thi thy
tinh. Mt s so (khi lng nha nng, thng l mt ng) c bm
bng kh. Khng kh y nha chng khoang khun to thnh hnh
dng mong mun. Khi ngui, nha c y ra. Phng php ny c
s dng lm cho chai nha.

cng c cu - Mt khun p m lm cho cc b phn cho n khi cng

c cui cng c hon thnh. Nhng khun mu hoc cc cng c
ny khng c ngha l nhng cng c sn xut.
Bubbles - Tng t nh mn nc, ti kh, hoc khong trng c
hnh thnh bn trong nha.
Core- A protrusion or set of matching protrusions, which
form the
inner surface of a plastic part.
Corepull A device that retracts a core in a direction that
is not parallel to the opening direction of the mold. Often
referred to as a side action, this functionality assists in
the manufacture of more complex parts.
Cure The process of allowing a plastic to harden or
stabilize.
CoreMtcdnglihocthitlpccphhpvinhngchlilm,tothnh
bmtbntrongcamtphnnha.
LikoMtthitbthulimtctlitrongmthngmkhngcsongsongvi
hngmkhun.Thngcgilmthnhngph,chcnngnyhtrtrong
vicsnxutccbphnphctphn.
CureQutrnhchophpmtloinhacnglihocnnh.

Cushion A space between the screw and the nozzle that

provides a pressure pathway to enabling packing out the
part.
Ejectionpin Metal rods in the mold which push the parts
from the mold.

Hotrunnermold Hot runner molds consist of 2 plates

that are heated with a manifold system. The
manifold sends the melted plastic to nozzles which
fill the part cavities.

CushionMtkhnggiangiacccvtvccviphuncungcpmtconngplc
chophpngramtphn.
Phngpinthanhkimloivokhunmyphntkhun.
Hotrunnerkhunkhunhunngbaogm2tmcunnngvimththng
adng.Vicadngginhanngchyviphunminvocckhoangph

Hottocoldmold- Using a hot runner system to gate

into a cold runner which in turn feeds each cavity.
This configuration can be used when full cold runner
molds aren't viable and full hot runner molds are cost
prohibitive.
Machineshotcapacity The maximum volume of resin which
can be injected in a single stroke. Masterbatch A solid or
liquid additive for plastic used for coloring plastics or
imparting other properties to plastics.
NngkhunlnhSdngmththnghunngncathnhhulnhm
lnltnmihc.Cuhnhnycthcsdngkhiykhunhulnhkhng
philkhunhunnghuhiuvycachiph.
MycngsutbnKhilngtiacaloinhacthctimvomtntduy
nht.
MasterbatchMtphrnhoclngchonhacsdngnhummunhahoc
truynttnhchtkhcchochtdo.

Orangepeel A patchy rough surface defect caused by

moisture in the mold cavity, or by incomplete pack-out.
Partingline A line on a part formed when the two sides of
the mold come together. Pinpointgate A very small gate,
used in hot runner molds, to control the flow of material.
Prototypetool Also called a soft tool, a preliminary mold
built to produce prototype parts and used to make
adjustments to the final production tool.
VcamMtthkhimkhuytbmtkhngngudomtronghckhunhoc
khngygira.

dngngnraMtdngtrnmtphnhnhthnhkhihaibncakhunnvinhau.
PinpointcngMtcngrtnh,csdngtrongcckhunhunng,kim
sotdngchycavtliu.
cngcthnghimCngcgilmtcngcphnmm,mtkhunsbc
xydngsnxutphtngnguynmuvsdngthchiniuchnhcccng
csnxutcuicng.

Purging The process of cleaning the injection machine of

remnant color or materials prior to running a new part.
Ram A plunger-like part which pushes the melted
material into the mold.
Sideaction,slideorcam- a mechanical, pneumatic or
hydraulic action within the mold that forms a plastic part
detail that is not in the line of draw of the mold.
Spruebushing This part seals tightly against the nozzle of
the injection barrel of the molding machine to allow
molten plastic to flow from the barrel into the mold.
TyQutrnhlmschmyphunmucnlihocvtliutrckhichymtphn
mi.
RamMtphnpttngnh,yvtchtnngchyvokhun.
Sidehnhng,slidehoccammttcngchc,khnnhocthylctrongkhun
hnhthnhmtchititphnnhamkhngctrongccdngcartcakhun.
urtbcnphnnycgnchtviccviphuncathngphuncamyp
chophpnhanngchytthngvokhun.

Thermoset A material, which when heated, is pressed or

molded into a shape. The heating process changes the
structure of these materials, and for this reason they
cannot by re-heated.
Tiebars- Bars which provide structural support to the
mold in the press. The spacing between the tie bars
dictates the size of the mold that can be placed into the
injection machine. The mold opens and closes riding on

the tie bars.

NhitrnMtloivtliu,mkhibnungnng,cphoccthnhmthnh
dng.Qutrnhgianhitlmthayicutrccacctiliuny,vvldony,hc
thkhngphibitiunnng.
TiethanhBarsmhtrcutrcnkhuntrnboch.Khongcchgiaccthanh
tieralnhkchthccakhuncthctvomyphun.Khunmravngli
citrnccthanhging.

Toggle A mechanism that is used to mechanically close

the mold, as opposed to hydraulic clamping. Tool The
mold used to form plastic parts in an injection machine.
Undercut Can be a design flaw that results in an
indentation or protrusion that inhibits the ejection of the
part from the mold. Other times undercuts are designed
into a mold to ensure a part holds onto the correct side
of the mold.
Chuyn i - Mt c ch c s dng mc ng khun nh tri
ngc vi kp thy lc. Cng c - Khun dng to thnh b phn
bng nha trong my phun.
Ct xn - C th l mt l hng thit k m kt qu trong mt li lm
hoc c dng li c ch s phng ca phn khi khun. Nhng ln
khc, ct xn c thit k thnh mt khun mu m bo mt phn
nm gi ln pha ng ca khun.