PLASTIC INJECTION TECHNOLOGY 2

INJECTION MOULDING MACHINE

INJECTION MOULDING
Injection Molding is the most widely used technique for fabricating thermoplastic materials because it can
mass produce parts for relatively low costs.
Melted plastic is pressurized and forced into a prefabricated mold. There, it is allowed to cool and will take
the shape of the mold as it solidifies.
Concept is simple
- Melt plastic, flow into mold and take part shape, cool, demold
Injection molding makes parts in discrete (discontinuous) process
More injection molding machines used for plastic processing than any other equipment
Almost all thermoplastic and some thermosets materials can be injection molded
Process is automated and highly repeatable parts
Injection molding parts are finished with little post molding operations
Very complex parts can be made
Machines and molds are expensive
a. Characteristics
Favorable material
Lower energy consumption for molding due to lower processing temperatures
Direct route from raw material to end product (single-stage operation, less secondary finishing)
Part shape can be very complex & has no specific limitation
Part size is not limited
Short cycle times
Very good dimensional stability
Very good visual quality
Integration of post processing method is possible

Factors that Affect Injection Moulding

1. MAN Motivation, qualification, flexibility, experience....
2. INJECTION MOULDING MACHINE Ergonomics, efficiency, accuracy, reliability, correct design, monitoring
options....
3. MOULD Plastics-oriented component & gate design, rigidity, maintenance....
4. MATERIAL Correct choice, purity, pre-drying, only minor batch operations....
5. PERIPHERALS/ AUXILIARY EQUIPMENT Temperature control units, hot runner control....
6. ENVIRONMENT Safety, environment influences....

MAN
Man is the only influencing factor with the ability to learn and to react. This places him in a prominent
position, and with the injection moulding process growing increasingly complex he needs more and more
support.
Responsibility of Injection Moulding Personnel is to Maintain the following:
1. optical cycle time for maximum productivity
2. dimensional control of the parts
3. aesthetic quality of the parts

Peripheral/Auxiliary Equipment
1. Mould temperature controller 3. Granulator 5. Mixer 7. Robot
2. Chiller 4. Hopper Loaders 6. Conveyor
INJECTION MOULDING MACHINE

Three Major Types of IMM

1. Hydraulic
2. Electric
3. Hybrid

Major Components of Hydraulic Machine

- Electric Motor - Valves
- Pump - Hydraulic System
- Hydraulic Motor - Pressure/Stoke Sensor
- Analogue pressure gauge - CPU Terminal

Advantages of Hydraulic Machine

1. Cheaper Machine 3. High Injection Speed
2. Popular Concept 4. Cost-effective

Disadvantages of Hydraulic Machine

1. not ideal for clean-room environment 3. Not environmental friendly
2. need for hydraulic oil

Major Components of Electric Machine

- Electric motor - Pressure and Stroke Sensor
- Pump - CPU
- Belt/Pulley/Chain System
Advantages of Electric Machine
1. High degree of precision 3. No need for hydraulic oil
2. Ideal for clean-room environment
Disadvantages of Electric Machine
1. Higher cost (20%) 2. Low Injection Speed (>800mm/s)

Advantages of Hydraulic Machine

1. combines best of worlds concept
2. ideal for all processes

Disadvantages of Hydraulic Machine

1. costs (generally most expensive)
 Types of Clamping Unit
1. Toggle (Three Platen)
2. Fully Hydraulic (Three platen Platen)
3. Hydrostatic (Two Platen)
Types Injection Unit
1. Vertical
2. Horizontal
3. Multiplug
Types of Control on Injection Process
1. closed loop
2. closed speed control

Why is closed-loop speed control important?

1. a must for processes involving very slow injection speeds (>2
mm/s)
2. higher degree of precision due to double closed loop
monitoring
3. preserves overshoot of injection speeds
4. a selling point which people are usually confused between closed-loop control and closed-loop speed control

MACHINE MAINTENNACE (IMPORTANT NOTES AND REMINDERS)

To prevent injuries, it is important for all personnel maintaining or operating the machines to abide by the
companys safety standards and rules and regulations, to fully understand the content and to follow the
safety procedures detailed in the instruction manuals of the injection machine and other peripheral
equipment.
Read the instruction manual thoroughly
To prevent injuries, it is important for all personnel maintaining or operating the machines to abide by the
companys safety standards and rules and regulations, to fully understand the content and to follow the
safety procedures detailed in the instruction manuals of the injection machine and other peripheral
equipment.
MACHINE USERS
1. Operator defined as the person who operates the machine. An operator should not carry out the following
maintenance work: a. any work that requires removing the fixed cover using tools; b. machine installation,
relocation, et.
2. Maintenance Technician defined as the person performs the maintenance work on the machine. He should
possess good mechanical and electrical knowledge.
3. Serviceman defined as the person who carries out more difficult or higher level maintenance operations. He
should be recognized by Machine Makers or received a similar level of education and training. They should carry
out the machine installation and machine repair (replacement of mechl or electl parts requiring
setting/adjustment after replacement).

SPECIAL INJECTION MOLDING PROCESSES

Coinjection Molding (two separate screws, two different material selection-color, strength, flexibility)
Flow-controlled injection processes sometimes called scorim
Gas Injection Molding employs gas to create hollow parts
Injection Compression Molding parts were made with the same mold. The only difference between the
two parts is the used of the compression cycle.