Professional Documents
Culture Documents
Practical Injection Molding
Practical Injection Molding
INJECTION MOLDING
PLASTICS ENGINEERING
Founding Editor
Donald E. Hudgin
Professor
Clernson University
Clernson, South Carolina
Bernie A. Olmsted
Consultant
Springfield, Massachusetts
Martin E. Dauis
Consultant
Prescott, Arizona
m
MARCEL
MARCEL DEKKER,
INC. -
NEWYORK BASEL
D E K K E R
ISBN: 0-8247-0529-7
This book is printed on acid-free paper.
Headquarters
Marcel Dekker, Inc.
270 Madison Avenue, New York, NY 100l6
tel: 2 12-696-9000;fax: 2 12-685-4540
The publisher offers discounts on thls book when ordered In bulk quantities. For more Information,
wrlte to Special SaledProfesslonal Marketing at the headquarters address above.
Nelther this book nor any part may be reproduced or transmitted In any form or by any means, elec-
tronlc or mechanlcal, including photocopying, microfilming, and recording, or by any mformatlon
storage and retrieval system, wlthout permlsslon I n writmg from the publisher.
The authors have kept true to their audience and have touched on
each important aspect without getting into too much detail.
Michael R. Cappelletti
Executive Director
Society of Plastics Engineers
...
111
This Page Intentionally Left Blank
Why read this book?
The mechanics,operatorsandset-uppersonnelinmolding
operations are in key positions to control product quality and improve
operating performance. Unfortunately, many of these people have not had
the benefit of formal training nor the opportunity to attend seminars or
workshops that would enhance their ability to perform job. theirMost have
learned fiom their predecessors who probably had even fewer educational
opportunities.Productqualityandoutputmayimprovedramatically
through the educationof this group of personnel and . . . . . there may even
be increased enlightenmenton the part of their supervisors and managers.
V
v1
This book will deal with each of these factors, and others, in a
manner that is straightforward and easily understood. Case studies from
actual molding experiences will help to enhance the understanding of the
material in someof the chapters. We want this book beto a practical guide
for those involved in injection molding and not a highly technical reference
for those with advanced plastics technology backgrounds or education.
Bernie A. Olmsted
Martin E. Davis
vii
This Page Intentionally Left Blank
Contents
1 Introduction ........................................................................................... 1
1.1 Elements of the Injection Molding Process............................ 1
1.2 Summarizing the Elements ..................................................... 6
2 Plastics.................................................................................................. 8
2.1 Thermoplastics........................................................................ 8
2.2 Thermosets.............................................................................. 9
2.3 Crystalline vs. Amorphous Materials.................................... 10
2.4 How Plastics Affect the Molding Process ............................. 11
2.4.1 Melting Characteristics .......................................... 11
2.4.2 Thermal Conductivity............................................ 12
2.4.3 Shear Sensitivity.................................................... 13
2.4.4 Viscosity (Melt Index)........................................... 14
3 Additives............................................................................................. 16
3.1 Fillers and Reinforcements................................................... 16
3.2 Plasticizers............................................................................ 17
3.3 Stabilizers.............................................................................. 17
3.4 Flame Retardants .................................................................. 18
3.5 Colorants............................................................................... 18
3.6 Adding the Additives ............................................................ 18
4 Loaders and Dryers............................................................................. 21
4.1 Hopper Loaders and Conveying Systems............................. 21
4.2 Dryers.................................................................................... 22
4.2.1 Hot Air Dryers....................................................... 22
4.2.2 Dessicant Dryers .................................................... 23
5 hjection Unit ...................................................................................... 26
5.1 The Barrel ............................................................................. 29
5.2 End Cap and Nozzle .............................................................. 30
5.3 Heater Bands......................................................................... 33
5.4 Non-Return Valve................................................................. 34
5.5 Screw..................................................................................... 38
5.5. I Length-to-Diameter Ratio...................................... 39
1x
X
15.1.15SinkMarks . . . . . . . . . . . . . . . . . . . . . . . . . . 156
15.1.16Splay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
A InjectionMoldingMaterials . . . . . . . . . . . . . . . . . . . . . . . 194
B Properties of Common Plastics . . . . . . . . . . . . . . . . . . . . . 196
C Recommended Plastic Drying Data . . . . . . . . . . . . . . . . . . 199
DUsefulData . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Abbreviations and Symbols . . . . . . . . . . . . . . . . . . . . 200
Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
E Velocity Control on Injection Molding Machines . . . . . . . 203
F Procedure for Application of Bolt Torque on
NozzleAdaptors(EndCaps) . . . . . . . . . . . . . . . . . . 209
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
1 Introduction
This book is intended to provide the hands on injection molding
personnel,themachineoperators,techniciansandmechanics,withan
improved understanding of the basics of injectionmolding.Although
injection molding has been in use in the United States since the1930s, the
operatingpersonnelhavegenerallylearnedtheprocessfromtheir
supervisors,whoeitherlearnedfromtheirpredecessors or gained the
knowledge by trial and error. There have been few seminars, workshops
or books that have offered educational opportunities to the operator withno
college degree or formal training in plastics technology. This book will
explore the elements of the molding process at the most basic levelthe in
hope that it will contribute to the productivity job andsatisfaction of those
hands on personnel. The residual benefit to the managers and owners of
molding operations . . . . improved profitability.
- Injection Unit
-
Plastic
Clamp Unit Mold i I -
Controls Unlt
HPM and various other U.S. and foreign manufacturers. The machine is
illustrated inFigure 2. The diagramshows the clamp unitclosed without
a mold.
The injection unit heats, melts, pumps and injects the plastic into
the mold when the moldis closed. The control unitmonitors and,as the
name implies,controls the functioning of the injection unit andthe clamp
unit. The mold is mounted within the clamp unit and this unit opens the
mold to allow plastic parts to be ejected and holds the mold closed when
melted plastic is being injected. Each of these units will be the subject of
an entire chapter later in the book.
Part
In order to solidify the plastic part in the moldso that it can be removed
(ejected), it isusuallynecessarytocoolthemold. The cooling is
accomplished by circulating cool water through cooling channels that are
machined into the mold itself.The water is cooled by a chiller, which can
either be a free standing unit nearby the pressor by a partof a temperature
controller system that may serve several molds in several injection molding
machines.Temperaturecontrollersmaytaketheform of chillers,as
described, or in other cases, heating units (for thermosets), heat exchangers,
and various typesof water and oil temperature controlling devices.
Moving the plastic from its storage to the pressis the function of the
loader. A loader may be as simple as a vacuum powered unitwith hoses
that pull pellets from a gaylord and deposit them in the hopper.This unit
is called a hopper loader and sits beside the press with hoses that can access
gaylords thatarenearby. A loaderunitmaybeascomplicated as a
pneumatic materialhandlingsystemthatconnectsalargenumber of
injection molding machines to storage silos (large, enclosed metal bins) and
5
After the plastic parts are removed (ejected) from the mold, they
may be droppedontoa conveyor (orremoved by robot) forfurther
transporting to an inspection or packaging area. Conveyors come in all
sizes and shapes and help automate the parts movement throughout the
plant. In addition to conveying parts, they may also convey runner systems
and parts that have defects to a grinder. The grinder is used to grind up
the runners (see next paragraph) and defective parts into a form (typically
flake-like pieces slightly larger in size than pellets) that be
canmixed with
new pellets (referred to as virgin material) in quantities up to 50% (and
sometimes more) for remelting again into plastic parts. The ground-up
material is referred to as regrind.
Thisintroductorydiscussion of injectionmoldingelements is
designed to acquaint the operator with all of the pieces to the molding
puzzle. Each element will be discussed in further detail in a succeeding
chapter of the book. A knowledge of how the elements fit together should
help when the basicsof each element are pursued further.The table on the
next page summarizes these elements for the readers review.
7
I I I
Element I Function I
I I
Plastic Raw material usedto mold parts
I Additives
~~~~
l
~
Colorants, lubricants or other ingredients added
pellets
to the plastic
I
Additive Adds specified quantity of additive (colorant or other additive)
Feeder to the plastic being fedto injection unit
Injection Unit Part of the injection molding machlne that heats, melts and
injects the plastic into the mold
Chiller A type of refrigeration unit that cools the water that circulates
through the moldto speed the solidificationof the plastic part
Grinder Grinds runners and defective parts into a regrind that may be
added to virgin material and recycled
~~
2.1 Thermoplastics
The majorityof thermoplastics are made fiom petroleum and have
the unique physical property of being able to be melted, solidified, and
remelted again without signiscantly changing the chemistry of the material
(provided they are kept clean and not contaminated). By grinding up the
solidified thermoplastic and remelting it, the material can usually be reused,
with or without mixingitwithvirgin (unprocessed)material [l].
Dependinguponhowmanytimesandunderwhat conditions the
thermoplastic material has been melted and solidified (its heat history),
some of its properties may be diminished. As a result, most thermoplastic
that is reused (and referred to as regrind) is mixed with virgin material
where the regrind represents less than 50% of the resulting mixture. There
are some cases, however, where plastic products are molded fiom 100%
regrind. These are instances where the mechanical andor the cosmetic
properties of the resultingparts are not critical.
Polyethylene PE
Polypropylene PP
Polystyrene PS
Acrylonitrile Butadiene Styrene ABS
Polyamide (nylon) PA
Polycarbonate PC
Polymethylmethacrylate (acrylic) PMMA
Polyoxymethylene (acetal) POM
Polyvinylchloride PVC
Styrene Acrylonitrile SAN
Many of the long names begin with poly, which simply means
many or multiple. The smallest repeating unitin the chemical structure of
plastics(which is amolecule) is called a monomer. Whenseveral
monomers are combined or joined, the resulting chemicalstructure is called
apolymer. So it becomes clear that polyethylene, polypropylene and the
others beginningwith the letters polyareplasticsconsisting of a
combination of monomers.A fiuther understanding of the molecular
structure ofplastics is not required, but is available
in several references[3].
2.2 Thermosets
Crystalline Amorphous
2.4.1 MeltingCharacteristics
The first major processing difference between crystalline and
amorphous materials is the way they melt [ 5 ] . As heat is applied, both
types of materials soften somewhat at first, but the amorphous material
continues to soften gradually until it w li flow. The softening point is
referred to as the glass transition temperature (or T, ). Amorphous
materials have no defined melting point.
I 0
0
morphous
have a maximum limiting shear rate, beyond which they will degrade
[7].
material into their bulkstorage tank (silo). After processing with material
from that silo for a few days, the qualityof the melt changed andthe same
colors they had been achieving could notbe maintained. Despite changes
rate became so intolerable that the
in the processing profile, the reject entire
remainder of the material in the silo had to be dumped. This was a very
expensive lesson for an experienced molding operation.
In contrast, the nylon pellet would not visibly soften and, after a
period of heating, it would rather quickly change to a complete melt.
Moreover, if the heat of the skillet was significantly increased, the acrylic
would degrade andburn rather than changing more rapidlyto a fluid state.
It is likely that the nyloncouldsurvive the excessiveheat(unless
unreasonably high) and reach the molten state more quickly.
quite strong, often replacing die cast metal parts. The glass reinforced
material requires special molding considerations and is very abrasive to the
metal surfaces with which they come into As ifthese are not severe
contact.
enough, fibersare also madefiom carbon, graphite, and metal, enhancing
the resulting part strength and even M h e r complicating the molding of the
parts. Some metal fiber reinforcements are added to provide electrical
conductivity. In addition to powder and fiberforms, some reinforcements
are in the form of a flake. These flake reinforcements include those made
fi-om mica (a lightweight mineral),glass and aluminum.
3.2 Plasticizers
3.3 Stabilizers
PVC is a common object ofbothheatstabilizers and UVstabilizers.
If PVC is processed at too high a temperature, degradation wil occur and
may be associated withthe release of hydrochloric acid. This may result in
a lossof properties in the molding process, potential severe damage to the
metal surfaces in the injection unit and the mold and, if excessive heat
occurs, can create a safety problem for the molder. Heat stabilizers are
combined withthe plastic to help prevent degradationfiom excessive heat
in processing. We wil later learnthe importance of the proper control of
heat duringthe molding of all plastics, including PVC.It is also important
that the stabilizersbe compatible withthe resins to which they are added to
avoid chemical or viscosity problems in molding. Uvstabifizers are also
important because they increasethe molecular stabilityof plastics that are
exposed to light. UV stabilizers help increase
the weatherability ofplastics
exposed to sunlight in outdoor environments.
3.4 Flame Retardants
3.5 Colorants
types of feeders and blenders used inthe molding process. Some can mix
and add onlytwo different typesof solid material whileothers may be able
to mix and add up to five types of materials, including pellets, powders,
granulated material and even liquids. Most of these units are mounted
directly on the injectionmoldingmachine,inaddition to the standard
hopper. The more complex units are floor-mounted and use pneumatics to
take the mixed materialto the machine. It is not important for
the reader to
understandhowtheseblendersandfeeders are constructed, it is only
important to understand how they operate and what they are designed to do.
The last example involves a molder who found that the addition of
a colorant to his material required a screw with a mixing device
to achieve
the properly colored part andthe better the mixing device, the less of the
expensive colorant was required.
4.2 Dryers
All plastics used in the molding process, including regrind, are
affected by moisture to some degree.Ifthe moisture is not removedfrom
the plastic, it can cause defects in the molded product, such as splay
marks (streaks) and brittleness. Plastic materials are considered to be
either
hygroscopic or non-hygroscopic. Those considered to be
hygroscopic absorb the moisture within the pellet (or flake) and cause a
molecularbondwith the material.Includedamong the hygroscopic
materials are: ABS, PMMA (acrylic), FEP, PA (nylon), PBT, PC, PET,
PPO,PVC, S A N , PSU and PE1 (see Appendix A for technical names). In
addition to causing part defects, moisture that is allowed
to remain in these
materials can unite with other elements to produce corrosivesat processing
temperatures. The result is a premature corrosive wearon the surfaces of
the injection unit components.This type of wear w ibe discussed in a later
l
chapter.
The lesson is: Be mindfd of the problems that can arise in the
conveying and feeding of material and use additive feeders or other
similar devices that insure a constant
feeding of homogenous material.
5 Injection Unit
(I")
The injection unitof an injection molding machine consists
of the elements shownin the schematic drawing below:
Barrel (
alsoknown as a cylinder) Screw
Non-returnValve Nozzle
EndCap HeaterBands
Hydraulic or Electric Screw Drive Hopper
Non-retum Heater
Vahre
I \
I \
Il I
I
/
Screw Drive &
Nonle End Cap Barrel Screw
Injection Cylinder
The screw also provides some of the heat to melt the plastic pellets,
by squeezing and shearing the pellets againstthe screw flights and the barrel
wall as the pellets move forward. This vital h c t i o n of the screw and how
it is designed to perform this h c t i o n is covered in Section 5.5 of this
chapter.
As the screw turns, the plastic moves forward and becomes a melt
which ultimately reaches the end of the barrel. The melt then proceeds
through the non-return valveand the end cap. For reasons wewill explain
later, the melted plastic cannot move forward through the nozzle. As a
result, the pressure of the melted plastic builds up in front of the screw
and forces the screw backward. The screw drive only indirectly causes
the screw to move backward. Because of the back and forward motion,
some referto the screw as the "reciprocating screw."
The injection unit then completes its primary function. With the
pressurizing of the hydraulic injection cylinder,the screw moves forward,
causing the injection of the plastic forward through the nozzle into the
mold. Although the melted plastic could not moveforward into the mold
during the screw rotation, injection is now possible because the previous
plastic that was in the mold has now been removed (ejected). The mold
ejects the parts &om the prior shot and closes just prior to the injection of
the new shot. Shot is the term applied to the amount of melted plastic that
is injected intothe mold. Theshot sizeis the quantity of melt injected into
the mold, measured in ounces or grams.
The back end of the barrel fits into the casting of the injection
molding machine. It is typically securedin place by one of three methods.
The barrelmay haveaflange with bolt holes which allows the barrel to be
inserted into the casting and then secured by large bolts going through the
flange and into the casting.A second method that is similar to the flange,
is the use of a split ring groove and removable flanges. The barrel is fit into
the casting, the two flanges are placed in the groove and then bolted to the
casting. The third method involves a threaded end on the barrel which is
inserted into andthrough the casting andis secured by a large nut on the
interior of the casting.
Another method used more recently involves sliding the barrel downward
into the casting and securing it with a flange-like piece that fits downon
top ofthe barrel. Most machine manuhcturers use a versionof one of these
methods and it is only important to the reader to be able to recognize the
basic designof each.
Although most barrel shells are made &oman alloy steel in the 4000
series(typically 4140 or 4150) AIS1 designation,there are several
alternative linings available which resist wear. The alternatives maybe
grouped into three types that relate to how the linings are manufactured.
They include:nitrided barrels, cast bimetallic barrels andtool steel-lined
barrels [ 5 ] . An understanding of the metallurgical considerations involved
in each lining type is not withinthe scope of this book. It is important to
remember that the linings of all barrels are not the same and they have a
bearing on the wear life of the barrel before it must berepaired.
Because the screw fits very snugly intothe bore of the barrel, it is
vitalthatboth the screwand the barrel be quitestraight. A lack of
straightness in either of the components can causethem to wear
prematurely.
22,000 psi), the bolt-on end caps typicallyuse 10 to 16 holes with bolts that
are threaded and are rated very strong. When bolting the end cap to the
barrel, it is very important to gradually tighten each bolt using a pattern
which alternates opposite sides of the bolt circle. In addition, a degree of
tightness isusuallyspecifiedby the machine manufacturer that is best
achieved using a torque wrench. Over-tightening is as damaging as not
tightening enough. Damageto the lining of the barrel can occur if the end
cap is tightened too tight.
The second transition point between the barrel and the mold is the
n o d e . The nozzle is a tube which provides a mechanical and thermal
connection fiom the hot barrel to the much colder injection mold with a
minimum pressure and thermal loss [7]. Some nozzles do not have an
interchangeable nozzle tip, as illustrated in Figure 9. But in either case,the
end ofthe nozzle tipor the nozzle(ifno tip is present) typically has a radius
of either % or X. The radiused (rounded) end of the nozzle tip (or
nozzle) fits into a part
of the injection mold referredto as a sprue bushing.
It is very important that the fit between the nozzle tip and the sprue
bushing is correct (See Figure 9).The incorrect fit could allow the nozzle
to back away duringthe high pressureof injection allowing plasticto leak.
Some nozzles have a straight bore and others a tapered bore, depending
upon the requirements of the plastic material being processed.The nozzle
is threaded into the end cap and usually has a thermocouple and a small
heater band to control the temperatureof the plastic at the nozzle.
A majority of the nozzles in use are the first type. Basedon our
experience, there are many pneumatic shut-off nozzles being utilized and
only a few spring-loaded nozzles.
Electrical heater bands are used for heating the injection molding
barrel and the nozzle. The heater bands vary from approximately 1 to 14
I
ormoreinwidth,andmanufacturersofferavarietyofconstruction
variations.Several of thebandsarepositionedaroundthebarreland
respond to pyrometer settings that are based on the readings from the
thermocouples in the barrel. You can usually read the set temperature
and the actual temperatureof the barrel on the control gauges.
Screw Forwsrd in
lnjcd Position
Screw Back In
Rotate Position
(Valve Open]
As you can see, both types of ball check valves requirethe melted
plastic to enter the valve through four ports in the side (at the rear end)of
the valve, making 90"a turn. The plastic must make another 90" turn toward
the front of the valve to proceed forward. In the side discharge valve, the
plastic must make another 90" turn, around the ball, to exit out the four
ports on the side of the valve (near the forward end). The front discharge
valve allows the plasticto move forward, aroundthe ball, and outthe front
end of the valve.
Outlet Port8 Ball Seat Inlet pbrts Screw
In the closed positionfor both types of ball check valves, the ball
shuts off against the conical shaped opening at the rear center of thevalve,
allowing the valve to come forward during injection without allowing any
plastic to flow backward.
5.5 Screw
The screw is housed inside the barrel and consists a shank
of and a
flighted length. The shank is designed to fit into the quicl of the screw
drive, allowing the screw drive
to turn the screw during screwrotation and
causethescrew to goforwardduringinjection.Theflightedlength
approximates 80% of the overall lengthof the screw and isthe portion of
the screw which receivesthe plastic pellets whichare gravity fed through
the feed hole of the barrel. The flighted lengthalso conveys and melts the
plastic as the screwrotates backward.
Referring back to Figure 22, you will note that the helix angle of
a screw is the angle of the screw flight relativeto a plane perpendicularto
the screw axis. It is not important to understand the impact of the helix
angle on the design of the screw. However, the reader should know that
when the helix angleis 17.6568' (asis the case with most screws), it causes
the distance fiom the fiont edge of one flightto the front edgeof the next
flight to be equal to the diameter of the screw. This is referred to as a
square pitch.
Easyflowingmaterialsinjectedintoamoldwiththickwalled
sections may require only 48.3 to 70.0 Mpa (7,000 to 10,000 psi) injection
pressure, while a very high viscosity material being injected into thin
walled sections of a mold with small gates might require more than 138
MPa (20,000 psi), even as high as 345 Mpa (50,000 psi).
43
A fkther discussion of injection pressures in the molding process
wlifollow in later chapters. However, it is important for the reader to
understand that the pressure that is exerted on the melted plastic
in front of
the screw during injectionis considerable. Accordingly, the pressure that
is necessary to hold the mold closed during injection, as discussed in the
next chapter, is also significant.
6 Clamp Unit
The clamp unit of an injection molding machine performs the
following essential functions:(1) holds the mold;(2) closes the mold; (3)
keeps the mold closed under pressure during injection;(4) opens the mold
to allow the parts to be ejected; and(5) accommodates the ejector system
which ejectsthe parts out of the mold. The clamp unit is illustrated inthe
schematic drawing(Figure 13) showing the mold inthe open position with
the moving platenas far to the left as possible.
The clamping mechanism provides the force to keep the mold closed
during the injection and holding-pressure stages of the machine cycle.
Although many variations have existed through the years, there are two
basic types of clamping mechanism used on injection molding machines:
hydraulic and hydro-mechanical. Manyinjectionmoldingmachine
manufacturers offer both hydraulic and hydro-mechanical machines, and
some now providea M y electrical machineas an option. Eachof the two
more common clamping mechanisms will be illustrated and explained.
46
When the mold is nearly closed, the prefill valve closes. The hydraulic
pressure, developedby hydraulic pumps, developsforce a on the main r m
of about 20.7 MPa (3,000 psi). This force is used to achieve the final
clamping of the mold, typically a relativelyshort stroke. Depending upon
the size ofthe mainram,the 20.7 MPa (3,000 psi) cantranslate into a clamp
tonnage of considerable magnitude.
47
Hydraulic
Clamp Cylinder
R a r e I5 Injection molding machine toggle clamp unit
provides the force to the toggle links can be much smaller than on a
hydraulic clampunit of comparable size. The mechanical advantagein the
toggle system can range fiom 25:l to 50:l. This mechanical advantage
reduces the diameter of the hydraulic cylinder requiredto achieve clamp
force. It also permits the use of lower hydraulicpressures and hydraulicoil
requirements. An example for the latest model of a U.S. manufactured
machine:
The toggle clamp unitin the closed positionis shown in Figure 16.
Both hydraulicandtoggleclampsystemshaveadvantagesand
disadvantages and,as a result, some of the larger injection molding machine
manufacturers offer bothtypes of machines. The relative meritof one vs.
the other is not withinthe scope of this book so we w ileave that debate
l to
the molding machine manufacturers themselves.
o- ....I .-..
b - Clamp droks
- ..
c Mmmnnn closed
dayli&t
an the market
It should be noted thatthere are injection molding machines
the mounting of
that are considered tie bar-less machines which facilitate
and access to the mold. Most of these machines are of d e r clamp
tonnages (under 500 tons).
The method of ejecting parts out of the mold invobs bath the
clamp unit and the molditselHydraulic ejectioq is af0ature of
all machines. However, there are some older,kjmliw molding machines
still in service that use mechanical ejectioq.,Bwause mast machinesbuilt
during the last 20-25 years include hydravlic, ejection (except electric
machines), the following explanations w libe limited to that type of system.
01:
0
0
0
0
0
0
0
0
:1
0 0
0 0
0 0
O
@ O 0
0
0 0
O
0
0
0
0
0
a
O
0
O
0
\ Tie Bar Holes
0 0 0 0 0 ~ ~ 0 0 0 0 0
0 0 0 0 0 0 0 0
@ 0 0 0 @ 4
Knock-out Holes
0 0 0 4
0 0 0
0 0 0 0 0 0 oOo 0
Q 0 0 0 0 0 0 0 0
o+- Mold Mounting Holes
0 0 0 0 0 0000 0 0 0
0 0 0 0 0 0 Q 0 0 0 0 0
0 0
0 0
0 0
0
0
0
0 0
figure 18 Platen hole patternfor 500 ton injectionmoldmgmachme
II I
.
The ejector systemshownabove is typical for manymolding
machines. Othertypes of systems are used, involving:(1) a single hydraulic
cylinder, (2) a push-pull action with the ejector bars bolted to the ejector
plate, and(3) floating ejector bars. However, the principles involved in their
operation are similar to thoseillustrated.
54
The lesson is: Do NOT &able machine safeties that affect the
operation ofthe clamp unit, While working aroundthis unit anaYor the
mold, turn the power off andproceed according to the safety rules that
the machine manufacturersupplies.
55
L*
Rere 20 Ttro plate moldin a dosed position
'A" Plate I Holds the cavity inserts. the sprue bushingand runner
system.
~~ ~~~
Part ThespacebetweentheCavrtylnsertandtheCorelnsertthat
is in- with d
e np k t k and then coded and s d i i e d
part.
to form the desired
Core Insert Forms the male side c4 the part. Like the Cavity
Insert, can
be repaired or replaced if requiredwithout replacing the"B'
Plate.
Locdesvlecavrtysidedthemddtothestatiafyplatenof
the machine.
Containsthesprueand,liketheinserts,canbereplaced
without replacing the
"A" Plate.
Runner System Accepts the molten plastic and directs it to the gate
(small
apeningt0thepartspace)whereitenterstoformthepart.
"B" Plate
Similar
the
to "A" Plate. Hokls the
core
inserts and space for
qectorpins.
Ejector Bar 8 Ejector Plate Provides the force to theEjector Plate to push theejector
pins forward to eject the pari off of the core.
Ejector RetainerPlateRetainsthe *
o
r pins so that after ejed~on.they can be
retracted to their original
position.
There are several methods of separating the parts fiom the sprue
and runner system, One is a sprue picker, which is a pneumatic device
similar to a robot, that goes into the mold opening and, before ejection,
clamps onto the sprue and pullsthe sprue and runner system away fiom the
parts, disconnecting at the gate. The other method is a conveyor that is
designed to separate the parts fiomthe runner systemwhile conveying. The
connection at the gate is usually very small and easily snappedOE
59
Ejecto
Pins
Parts
I \m
You also noted the gates in Figure 23. As with runner systems,
gates can take a varietyof forms. They may be a tab gate,fan gate, ring
gate, submarine gate, and others.It is not important thatyou know howor
why these gates are used, but only to know that there is a variety of
methods to gate a part.The gate is always smaller in cross-section than the
runner so that the part may detach cleanly and easily. Because of their
small size, gates also impart some shear to the melted plastic as it enters the
cavity.Excessiveshear is notdesirableand can causecosmeticand
physical imperfections inthe part.
in which the runners are heated by an external means to keep the plastic in
the runner in molten form. These systems involve a different type
of mold
design which is discussed briefly in the next section
of this chapter.
7.2 Types of Molds
Hot runner molds have several advantages over cold runner molds.
First, there is no runner system and sprue molded as a by-product that must
be ground up and reused. Second, sprue pickers or special conveyorsthat
separate the runner system and sprue fi-om the part are not required. Third,
a d o r m melt temperature can be maintained all the way from the nozzle
to the cavity, insuring fewer deviationsin part quality dueto a melt that is
not isothermal. Fourth, the shot capacity and clamp tonnage required thein
injection molding machine are decreased by the size of the sprue and runner
system which, although not a part, must be considered as a molded by-
product [ 1l]. There are some disadvantagesto hot runner molds, including
to purge, making repair
ditficulty in controlling their temperature, inability
a time consuming process, and not being able to change color easily.
The true hot runner ntotd (Figure 25) functions similarly to the
insulated runner mold, however, the runner system is kept byhotheating the
runner plate itselfor by using a heated manifold through which the runner
system moves(hot maniford mold).The distinctionofthe hot runner mold
is the ability to start up cold without intervention by an operator, as
descriid above for insulated runner molds.
+"-U M r
(b) Slide Molds - in this case the mold contains partial plates that
are referred to as slides that move away from the part as the mold is
opening. These slides are used to form a portion of the part that is not
symmetrical. A typical example mightbe a coffee mug where the exterior
of the mug involves a handle that would be sheared off at mold opening.
Instead, a slideon each side of the mug forms the exterior of the mug and
they pull away sideways as the mold opens. This side pull action be can
accomplished withunglepin~~~ that mechanically cause the sliding action
as the mold halves are opened, orcore by pull^'^ that do the same thing but
are activatedbyhydraulicsasthemoldopens,withtheslideplates
remaining closed against the core until the core and cavity plates are open.
The part is ejected off of the core after
the core pulls have completed their
function. Core pulls are used to accomplish the forming of many part
configurations and are essential to most custom molding operations.The
core pulls are activated by the hydraulic system of the injection molding
machine or pneumatics, which are available machine accessory options.
7.3 Ejection
Although the ejection of parts was briefly reviewed in the sections
on the clamp unit and mold components, this subjectis one that warrants
further discussion. The type of ejection discussed in the earlier sections
is
described as hydraulic ejection which uses ejector bars that pass through
holes in the moveable platen and, at a selected time in the cycle, are
activated by machine hydraulics to push against theejector plate. As the
ejector plate moves forward, it causes ejector pinsto contact the part and
push it offof the core, completing the ejectionof the part. Springs maybe
used to return the ejector plate toits begin position or the ejector bars,if
fastened to the ejector plate, can also return it to that position as the mold
closes forthe next shot.
Air cylinder ejection is sometimes usedto blow the part offof the
core. Stack molds which may require ejectionfiom the stationary half of
the mold(which has noejectionmechanism)canuseaircylinders to
accomplish ejection. Syringe bulbs made fiom thermoplastic elastomers(a
rubbery-like plastic that canstretch) can be molded over a knob-shapedcore
and be blown off of the core rather than having to use a more expensive
collapsible core. In some cases, air ejection is usedin addition to hydraulic
ejection to simply facilitatethe removal of the part fiom the mold.
The projected area of a mold isthe area in the mold that will be filled
with plastic at the molds parting line. The parting line of a mold is the
primary opening of the mold where the core and cavity halves separate,
allowing the parts to eject. Theprojectedarea has also been defined as the
area of the shadow castby the molded shot . . . on a plane surface parallel
to the parting line [ 1l]. This includes the runner system. The projected
area of the mold is used to establish the tonnage of an injection molding
machine that is requiredto run a particular mold.
69
Rpt.326 F'rojectedareaforafourca\rilymold
P
!
- 27 Ilhrehation of typicalwriting of a mold cavity
rather than out ofthe system and into the mold. It is importantto remember
that the flow rate of the cooling fluid is probably more importantthan its
temperature. Also it should be noted thatthe cooling liquidmay not be cool
nor water. The coolant circulating through the mold is controlled at a
temperaturerequired to insure the proper formationof the parts, whichmay
be more than 100F(38C). When the desired temperature is above 150F
(66"C), liquids other than water (such as oil) are considered for use. A
coolant that is too cold will potentially causeparts tostick inthe mold and
not eject properly. Alternatively, a coolant that runs too hot can cause
warpage in the parts and allow ejector pins to penetrate the'part causing
ejector marks that are not cosmetically desired.
Too many times we have observed molds that had not been properly
maintained, both on and off the press. Rusty components, hobbed vents and
parting linesthat are nicked or otherwise damaged prevent the successful
continued useof a mold. The observance of simple maintenancetasks help
keep a mold in good condition (in addition to routine mold makerwork),
including cleaning the parting lines and spraying the mold with a rust
inhibitor before removing fiom the press. In addition, ifthe mold is stopped
during production,do not letthe coolant continueto runthrough the mold.
Doing so not only can cause rust forming condensation but, if flowing
through one halfonly, can affectthe fit when restarted, allowing potential
damage to the mold.
The lesson is: Take good careof the molds being used Many of
them may have cost more than $100,000 and should betreated like a
valuableprecision instrument, notjust a large blockof steel.
76
Control
Most of the functions of the injection molding machine have been
discussed in prior chapters, such as the clamp unit, the mold and the
injection unit. In order to cause those functions to perform properly with
any degree of automation, a control system on the machine is required.
Becausetherearemoretypes of controlsthantherearemachine
manufacturers (independent control manufacturers also make them),this
chapter will discuss the types of control elements that are present on most
machines. The information presented will also differentiate between older
types of machines where the controls are more mechanical and rudimentary
and the newer machines where microcomputers are used to automate many
of the control functions. Because controlling and monitoring are both
essential elementsof the control system, each will be discussed separately.
8.1 ProcessingFunctions
m Core Pull - the selection of the core pull sequence and the
positions requiredare determined by this function. Refer back to Chapter
6 to review the use of core pulls in the forming of the part.
8.2 ControlFunctions
All of the injection molding machines manufactured today include
a controller that is essentially a microcomputer. The control settings are
usually accomplishedby pushing buttons on a computer screen rather than
78
Automatic mode - where all machine limits are preset and the
machine cycles repeatedly unless stopped by a safety conditionor by the
operator.
Hold prassure( S t a g e 2) Manual hydraulic relid VahR control setting (%, psibar) on CS
Hold time (Stage 2) Manual timer(sec) Control setting(sec) on CS
> Mold Open - when the machine is in the manual mode, this
actuator opens the mold. It is used when mounting a mold,at start up and
at other times whenthe mold needs to be opened for incidental work to the
Gees of the mold halves.
> Mold Close - this actuator closes the mold for use during setup,
shut down or other times whenthe machine is inthe manual mode.
> Heats OnlOff - this actuator turns the heater band heatcontrols
on at whatever settings are provided on the controller. To activate the
heaters for the oil in the hydraulic system, a separate setting must be
activated on the controller.
> Inject Forward - also used during purging and at shut down,
after purging is complete, the screw is left
in the forward position.
> Eject Retract - used in the same hctions as Eject Forward and
to ready the machine to commence operation on cycle.
> Core Pull In/Out - this activates the core pull mechanism that
allows cores to be retracted or pulled in during setup.
Setting the mold close speed too high causing the mold to hit
hard upon closing, causing damageto the mold face
The lesson is: Study carefully, go slowly and ifyou dont know
the result ofa change in oneor more of the controls, ask someone who
knows.
83
9.1 Robotics
In Chapter6, the use of sprue pickerswas described as a method
of retrieving the runner system and sprue fiom the mold to facilitate part
separation and movement. Quite often the sprue picker drops the runner
system and sprue intoa nearby granulator while theparts can proceedto
the next station on a conveying system. A form of robotics, the sprue
picker is typically mounted to the stationary platen of the machine and,
usingpneumatically operated cylinders to providethepower,utilizes
extension arms and a gripping device thatenters the open mold andgrabs
the runner system, removesthe runner out of the platen area, pivots and
drops the runner in a specified place.
9.2 Granulators
10 Getting Started
Getting started in the injection molding process includes Mold
Setup, ProcessSetup, Mold Start-up and Process Documentation. Each
of these steps is important, including
the documentation of the process after
it has been optimized. Although these steps should be performed by an
experienced Process Engineer, the information presented below should give
you a good guideline toward understanding what is involved in Getting
Started in molding.
The objectiveof injection molding isto fill a mold with hot molten
plastic and then
cool the plastic to solidrfjr to the desired shapeofthe part(s)
being produced. As we have learned, the mold contains a space between
the cavitiesand cores that forms the shape of the product,plus the
necessary runners and gates to direct the flow of the molten plastic into this
space during injection.
The size of the mold depends on the size and shapeof the parts to
be produced. However,the size of a mold that w lifit into a given machine
depends uponthe space betweenthe tie barsof the machine. For example,
a machine with a rated 200tons of clamp forcemay have a platen size of 28
inches by 28 inches (71 1 mm), but the space between the tiebars may be
only 20 inches by 20 inches (508 mm), allowing a maximum mold size of
19%by 28 inches (495 by 71 1 mm). In this instance, the number of mold
cavities will depend on the size of the mold, the projected area, and the
weight of the parts and runner system. Total weight cannot exceed the
maximum shot size of molten plastic capable of being produced by the
injection unitof the machine.
the replacement mold. The ejector bars that connect theejector plate of the
mold to the machine ejector plate mustalso be changed. This process can
be time consuming. Although down time is costly, it is not as costly as
expensive mold repairsifthe changing processis not done properly. There
are many automated mold changing systems being offered today that can
pay for themselves in saved production time.
The key steps involved inMold Setup for a new mold (rather than
changing a mold that has been run previously) may be summarized as
follows:
1. Make sure that the mold size will jii the machine to be used.
Nothing is more embarrassing than to have the mold lifted above the
machine and find that it will not fit!
3. Procure the proper ejector bars and checkto determine that they
are of e q w f length. Ejector barsof unequal lengthwill cause uneven mold
ejection, hang-ups of molded parts, and unnecessary wear of the ejector
plate bushings and guide rods.
5. Using the hoist, lower the mold into the open platen space
(avoiding hitting the tie bars). If the mold is horizontal and cannot be
loweredthrough the tiebarspacingfromthetop,itmustbemoved
horizontally. In this case, a fork truck or crane will support the mold as it
is moved to engage the locating ring. Molds suspended in the air tend to
swing as they are being moved. Always maintain control of the mold and
do not allow itto sway!
After the mold has been securely clamped to the platens, the safety
straps maybe removed and the hoist maybe unhooked.
8. Open the mold to the desired daylight and set the mold open
and closed controls,making sure that the settings will not permit a banging
of the mold. Continue to fine tune these controls until the proper settings
have been achieved.
89
As the screw comes forward with an air shot, examine the melt,
looking closely for any signs of unmelt. Observe how the screw moves
94
backward during rotation (steadily without pauses) and review the heater
band controls for proper cycling with no heat overrides.
If no problems are
apparent, you are ready to cycle.
5 . Adjust shot size and transferpoint so that the fill stage (first
stage) achieves nearly allof the fill. You can tell thisby watching for any
forward movement ofthe screw during packing.If any movement occurs,
the first stage is not filling the mold. Continue to adjust until shot size,
transfer point, fill rate and fill pressure are at desired levels. Fill pressure
should be raised to 100 psi above the actual pressure required to fill the
mold. At that pressure,any resistance to flow that mightoccur wil not call
for pressures that could damage the mold.
8. Next retract the carriage and take an air shot into a pan
in order
to check the melt temperature. Having heated the probe tipof a hand-held
pyrometer (to atemperature 30-50F hotter than the expected melt
temperature) just before the airshot, quickly insert the probe intothe shot
and determine if the melt temperatureis at the desiredleveL
10. After the heat controls are stabilized, the proper melt
temperature is achieved and the SRP indicates a proper balance of heat
energy source, change to the automatic mode and review the molding
performance for several cycles. I f there are no problems, the cycle is
optimized andthe processing setup should be documented as described in
the next sectionof this chapter.
Also note thattwo machines, runningthe same mold design and the
same plastic material may not result in the same processing parametersor
part quality. Differences may result fiom the conditions described above.
Although each machine should have aSet Up Sheet for each application,
theyshould all be based on the sameplasticvariables.Deviations in
performance need to be corrected by maintenance to the machine and its
components.
97
During the time that the part is cooling, the screw begins to rotate
and, as plastic melts and moves forward through the non-return valve,i i h g
the chamber in front of the screw, the resulting pressure pushesthe rotating
screw backward until enough melted plastic residesin fiont of the screw
(between the end of the valve andthe end cap) to make the next part. This
overlap of machine functions, as well as the entire molding cycle, is best
understood by reviewing a molding cycle diagram. See Figure 30 on the
next page.
In today's molding environment,the machine desirablyoperates in
the automatic mode, allowing one cycle to follow another withthe parts
being ejectedonto a conveying system that takes them to another stationfor
subsequent operations, inspecting andor packaging. In some cases,a robot
picks the part(s) out ofthe mold, also allowing automatic cycling. During
automatic cycling, the operatoronly intervenes when there is a problem. It
is commonto have an alarm system which calls the operator tothe machine
where the problem exists. If only one cycle is to be performed, or an
operator is required to open thesafety gate, retrievethe molded parts and
close the gate tostart the next cycle, we have learned that
the machine is in
its semiautomatic mode.Now is a good time to refresh your memory by
referring to Chapter 8 for a review of thethree types operating modes.
Example: Using a 300 ton, 30 ounce shot capacity machine. The mold
is a four-cavity mold with a hot runner system. Parts weigh 71
grams with total shot size of 284 grams or 10 ounces.
I
-
n g E w == 14,000 14,000
Tdal casts 75,190
Profit for the month $3,800 $6,880
~~ ~ ~~
As you can see fiom the illustration, the profitfiom operating the
machine forone month witha one second improvement in cycle time can
nearly double the profitability. The importance of cycle time cannot be
overstated!!
~~
The operation was studied and althoughthe machine was new and
was using new components, itwas believed thatthe screw was inadequate
to the color mixing task. A new screw was designed and installed with
the
following results:
The screw RPM was reduced fiom 75 RPM to 50 RPM and the
screw drive motor pressure required also
was reduced itom
1,900 psito 800 psi, which reduced energy requirements
A better solutionis to check the vents to make sure that they are
not filled with dirt and debris or, over time, have not become hobbed
(made more shallow by constant clamping of the mold), decreasing their
efficiency. Clogged or hobbed vents can easily cause the burns, voids and
weld lines thatmay be occurring. Cleaning out vents and makingsure they
are the properdepth should be a routine mold maintenance activity.
This is fkequently the problem with mold vents. Assume the vents
in the mold are 1/4 inch wide and.008 inch deep. If the lengthof this vent
is 2 inches to the edgeof the mold,there would be a large pressuredrop and
it would take higher injection pressureto overcome this resistance. If the
vent length were shortened to 1/2 inch, there would be less resistance,
allowing the use of a more rapid injection rate. Improved part quality
(fewer burns or voids) and increased production should result. Please refer
back to Chapter 7 on Mold Venting fora fhther discussion of the subject.
As plastic flows into the mold, the material that touches the cold
mold surface wil immediately start to solid^ as it slows andstops
moving. The molten plastic continues to flow by and through the
portion that has solidified. This process usually requires that even
more heat be added to the mold or the melt to keep the material
fluid long enoughto fill the mold cavities. It also requires a faster
injection speedto fill the cavities before the flowis completely shut
off by the cooledplastic.With colder mold surfaces,higher
injection pressures and/or speed be required which, inturn, may
will
require increased clamp tonnage to prevent flashing.If the vents are
not properly designed, the higher clamp pressure can reduce venting
capacity, whichfirther aggravates the filling process. You cansee
why decreasing the temperature of the coolant(water) may be self-
defeating!
In Chapter 5, we learned that all screws are not alike. They may
differ in the following ways(see Figure 31 below):
I
Secondary Flight
M
\
\
\
\
I pCnrsEelineMaterial
Amorp-- I
------
\
SCREWDESIGNGUIDELINES
Due to the mechanics of design, ball check valves shut off with
greater efficiency and speedthan ring valves. However, ball check valves
also create greater shear of the melted plastic and a pressure drop as it
moves through the valve. Moreover,if greater shearis caused by the valve,
the melted plastic will havean elevated heatas it goes through the nozzle
and enters the mold. Because most of the heat mustbe removed from the
plastic in the mold in order that solid parts may result, a hotter melt wl
i
produce a longer required cooling time. . . and a longer cycle. This same
undesirable shear can be caused by ring valves that are worn or are not
designed to be as free-flow as possible, where the opening through the
valve is restrictive.
Setting the barrel heat profdeis one of the least understood and
mst importantfixtors in injection molding.The proper heat profile plays
a major role in moldingparts that possess their intended physicalproperties,
are fiee fiom degradation, heat splay, andstreaks and insure trouble-fiee
continuous operation. Improper heat profiles often result in rejected parts,
low production rates, and premature wear of barrels, screws and valves.
not go up, but instead go down. Why? Because the uncontrollable shear
heat is reduced to permit a balance of shear heat and controllable conductive
heat. The softening of the plastic by the heater band heat in the zone
preceding the overriding zone reduces the shear heat in the zone indicating
an override. The heater bandsin the override zone should again begin to
cycle. If this technique does not work, it indicates that: (1) the heater
bands, whose settings were increased, do not have sufficient wattage to
accomplish the objective, or (2) the screwdesignis too aggressive
(transition zone too short and/or compression ratio to high), or (3) there
may be excessive screw and barrel wear that is causinga level of shear heat
too great to overcome.
L-TargdsdMeltTwnperaturs
3 . Balancing the Heat Sources- after setting the heater bands, the
sources of the heat energy should be balanced. To do this involves an
understanding of the hydraulic pressure requiredto rotate the screw.
Pressures greater than 1,200 to 1,300 psi indicatesthat the screw is working
hard, creating potentially excessive shear. Readings under 800 psi suggest
that too little shear energyis being used indicating that the process may be
experiencing long residence times, long cycles, or abnormally high melt
temperatures.
nor
Shot
Qw=nY
2 minutes
Ascending
Suggested by Average affront Desired mett
amore I
resin mfr Brearmnes I
temoerature
25% or
less bsthan2 Flat Desiredmett Desiredmett Desiredmel
minutes temDeratUre temmre temperature
2 minutes Flat Desiredmett Desiredmelt Desiredmett
ormore temperature temperature temperature
c%$ ~essthan2
minutes
H- sugptedby
resin mfr
miredmelt
temp+30F
Midmett
temperature
2minutes Hunp Suggestedby Desiredmett Desiredmelt
amore resin mfr temp + 30 O F temperature
%
%$ Lessthan2 Rewse Desiredmelt Awagedfront Desiredmett
minutes temp+40F &rearzones temperature
More 2minutes Rewse Desiredmett Awageoffront Desiredmett
m&% amore ~ ~ ~ ~~~
temp+40F &rearzones temperature
Lessthan2 Reverse Desriedmetl Averageoffront Desiredmett
minutes temp+ 5oF 8 rearzones temperature
SRP is within the desired range.If the S W is too low, reverse the process,
lowering the zones, one at a time, by 5 OF and check.
Disadvantages - backpressureincreasesmelttemperature,
restricts the recovery of the screw and can lengthen
both recovery and cycle
times.Because the screw works harder,moreenergy isconsumed
increasing the cost of production. Excessive back pressure w liresult in
increased wear of barrels, screws and valves and, if used with glass-
reinforced resins, may cause the breakageof the glass fibers, reducing the
mechanical properties of the parts.
Stage l (the first part ofthe injection stroke) may then be set relative
to injection speed (in inchedsecond) and % ofthe injection stroke distance.
Hence, the screw mightbe set to move 2.00 idsec until the screw reaches
a point where 80% of thestroke remains.
portion (say 20%) of the stroke. At that point, the transfer position is
reached, which changes the screw actionfrom injection to pack (or hold).
Part ofa control screen for setting the Injection Velocity Profile
for one injection molding machineis illustrated in Figure 35.
I INJECTION VELOCITY
Cushion Pm]
mow
(54 + 1.05) x 1.25 x (18 + 20) x 1.20 = 69.43 ounces (say69 oz)
12.9 PerformanceMeasurement
The Process Sheet contains all ofthe processing parameters that are
carellly developed when a particular mold is first set up to run. The
processsheet sets forth the drying time, barrelheat profile, mold
temperatures,clamptonnage,injectionrate, filling andholding
pressures, back pressure and all of the times that are included in the
overall determinationof cycle time. Included are the times forfill,pack,
holri, cooling, screw recovery and total cycle time. These times,together
with the other set points in the process, constitute the plan that has been
made to effectively and profitably produceparts from the mold.
This report not only indicatesthe number and percentageof parts that are
rejectedbutalsoshows the number that wereactuallyproduced as
compared with the number that should have been produced.
M8Cbk
No.
This report (Figure 37) can be the basii for a varietyof corrective action.
If the cycle time is slowerthan the original setup, it may bedue to excessive
recovery, SU, or cooling times or other causes. A deteriorationin recovery
time couldbe the first indicator that a valve,screw or barrel is worn.
13 Thermoset Molding
Injection molding thermoset materials is quite similar to molding
thermoplastic materials. The changes required to mold thermoset materials
are caused by the differences in the materials themselves. Thermplastic
materials can be melted, molded and solidified into parts and those parts
can be ground up, remelted and remolded intodserent parts. There is no
chemical change that takes place in molding thermoplastics. In contrast,
thermoset materialsundergo achemicaZ change or polymerization during
which the molten materialcures (or cross-links) as itsolidljiws. This curing
process occurs within a specifiedtemperaturerangewhichshould be
achieved just after the melt enters the mold. Premature curing of the
material can leaveit solidified inthe barrel and its removal is a very difficult
process. Once cured, thermoset material will not melt again. If exposed
to intense heat, the cured material may burn, scorch or disintegrate, but
never melt.
Aminos are very hard and have abrasion resistant surfaces. They
can also be processed to have a wide range of colors that are retained.
Aminos were originally used in the manufacture of dinnerware. These
materials are most often compression rather than injection molded.
8 Screws and smear tips are mQdefrom wear resistant tool steels
or aretungsten carbide coated to prevent excessive wear.
14 Safety
As stated in the booklet Omrators Handbook for Plastic Iniection
Molding, producedby the SPI Molders Division and published by the S.P.I.,
Injection molding machines are lightning fast, tremendously powerful,
blisteringly hot and run by electricity. The pressures, temperatures and
electrical currents are more than suflicient to severely injure an
operator or
helper. These hazards have resulted in crushed or amputated fingers,
hands, arms, legs and have, in some cases, terminated human life.
platen
closing core action
injectionforward ejectormovement
screw rotation
4. A rear guard covers the same spaceon the back of the machine
(opposite the operator) as does the operators gate on the fiont. This is not
an operating gate and is equipped with a mechanical latch that has two
interlocks that separately interrupt
the control circuit andthe power circuit,
preventing all IMM movements fi the guardis open or removed.
139
7. Guards that relate to areas other than the mold (platen) area
are also required. Theareas covered by these guards include:
feed
openings purging protection safety
signs
electricalsystems injectionbarrel covers vent covers
injection unit swivel interlocks
15.1.lBrittleness of Parts
Brittleness in parts can be recognized by physically examining them,
but moreoften, parts that are presumed to have impact and tensile strength
are subjected to laboratory tests which will confirm the presence
or absence
of the required properties.
144
Causes:
Potential Solutwm:
Causes:
Potential Solutions:
Causes:
Dieselingorthebuming of theplasticcausedby the
compressed, heated air in the cavities, results in black, charred
surface bums in the part. Excessive melt temperatures causedby
shear, long residence times, incorrect heat profile or malfunctioning
heater bands.
Potential Solutions:
Cleanand/oraddtheventsinthemoldandrunner
system. Also clean the ejector pins.
Causes:
Contamination of the resinor the useof too much regrind.
Lack of proper or desired mold finish. Stressing of the material
during the molding process.
147
Potential Solutwm:
15.1.5 Drool
Drool is the oozing of melt (failure of the melt to fi-eeze off
either at the nozzle or at the gate in a hot runner system). Drooling can
cause soliditied materialto be introduced into the nexf part which causes
surface defects. It may also interfere with theflow of the material and/or
the mechanical properties of the parts.
Causes:
Potential Soluiions:
15.1.6 Flash
Flash is the ragged edge of the part occurringat the parting line.
Causes:
Potential Solutions:
Causes:
Potential Solutions:
Causes:
Potential Solutions:
Causes:
Potential Solutions:
15.1.l0 Jetting
Jetting appearsas worm tracks or squiggly markson the wall of the
finished part. The problem gets its name fiom the cause rather than the
resulting condition or appearance.
Causes:
Potential Solutions:
Causes:
Potential Solutions:
15.1.l
2 Part Deformation
A part maybe deformed if it stickson the cavity-half of the mold.
Deformation also occurs during ejection and may result from improper
ejection and can include ejector markson the part.
Causes:
Potential Solutions:
Causes:
Potential Solutions:
Minimizebackpressureandavoidusinghighback
pressure as a substitute for good screw design.
Causes:
Potential Solutions:
Causes:
Potential Solutions:
15.1.l6 Splay
Splay is the term applied to silver streaks in the part surface or
through the part thickness in thin-walledparts.
Causes:
Potential Solutions:
Causes:
Potential Solutions:
Causes:
Potential Solutions:
Heater band settings that are too low in the feed and
transition zones can cause excessive shear, also resulting
in
adhesive and abrasive wear. Use heater band settings to
achieve 50% of the heat energy from conductive heat rather
than shear. Consider hump and reverse heat profiles.
Be sure to check all of the heater bands to determine that
they are hctioning properly.
,CheckraSidencetilTl!
BUMICE, a voids - Inadequate ventingofmdd . Clean 8 increase venting
or runner system . Reduce i n @ i fill speed
-Excessiisuckbackormelt . Reduce Clamp ton- PreSSUre
decam pe
rs
sh .Decrease melt decompression 8 reduce
nozzletemperature
.Use taper or shutoff nanle
Burned Material - Excessive shear .Clean 8 increase venting
-LOngreSidencetime .Reduce injectionfill speed
-lncorredheatprofile .Increase gate size
- Malfunctioning heeter bands .Confirm use d praper screw design
- Check valw for too much restriction
- Review heat profile 8 check heater bands
- Resin contamination - Determine proper purgingd prior mat&&
- Using too muchregrind -Checkfortoohigha%ofregrind
- Improper mdd finish -Checkcores&cavitiesforproperfinish
- Stressing of material - Assure that melt temperature is correct
- Determine thatfill rate is not too s l w
- check mokl for proper temperature
- Improper nanle design - Checkdrying procedures
-lnadeqwteheatcontrolat -Useteversetaperorshutoffnanle
drod location -LawertemperatureddrodSWrce
- Inadequateyl dried material - Increasemelt decompression
- Reduce back
- lnjectian tW high - Reduce injedion pressureused for
- Incorrect heat prafile packing and/or filling
- Improper clamp tonnage -checkheatprofileandcheckmelt
e
tmperau
trempyranee
tr
- Increase clamp tonnage,if mailable
-coreorcavity" - Check mold for blemishes
" ~ r e t W C d d -Increasemelttenperature&checkwith
- Mold temperature toocold PF-w
- Improperfill rate - Increase Inold temperature
-Decressein~ficmrate&increase
packing and/or hold pressureor time
- Repair gades and/or increasegate size
-Checkspruecddwellforpmpersize
- Reduce injection fill rate (VelOCny)
-chedcmelttemperaturemwrandera
increesefrontzone8nanleseitingif
t w low
163
16 Terminology
The following pages include terminology that is commonly used in
the plastics industry and more specifically, in injection molding. Reference
ismade to glossariesalreadypublished,such as those in the Plastics
Engineering Handbook, Fifth Edition; The Kayeness Practical Rheology
Handbook; and in the RecommendedGuidelineNomenclature for
Machinery Components by the Machinery Division of the S.P.I. In all
cases, those definitions have been simplified
to facilitate their usefulness.
accumulator - an awclliarycylinderequippedwithaplungerthatis
mounted on an injectionmoldingmachine (or blowmolding
machine) to provide a fast delivery of melt. The accumulator is
f l e d between shots with melt comingfiom the main barrel. It can
aid in injection speed butdoes not add injection pressure.
adhesive wear - wear resultingfiom two metals rubbing against each other,
such as the screw flights and valve rings coming intocontact with
the lining of the barrel during injection molding operation.
automatic mold - an injectionmold (or other type ofmold) that permits the
entire molding cycleto be repeated, time after time (untilstopped)
without human assistance.
barrel - a cylindrical housing in which the screw rotates, including the inner
surface lining material,or replaceable liner,ifused. Also commonly
referred to as a cylinder.
barrel shell - the outer thick wall of the barrel made froma strong metal
backing material (suchas chrome-molybdenum alloy steel, 4 140 or
167
carbon black - a very black pigment usedas a filler because of its useful
protection against ultraviolet light andenhances the life of plastic
products intended for outside weathering applications.
cavity - the part of the injection moldthat usually forms theouter surface
of the molded part. Molds are fkequently identified by the number
of cavities they contain (such as a sixteen cavity mold) and as a
group (multi-cavity mold).
check ring - the cylindrically shaped component that moves back forth and
along the axial lengthof a non-return ring valve. During injection,
the ring shuts off against the rear seatof the valve, preventing melt
fkom flowing backwardtoward the meter endof the screw. During
screw recovery, the ring rests against the fiont seat (or stud in a
three-piece valve), allowing melt to flow forwardthrough the valve
into the discharge end of the barrel.
169
chrome plating - a process that deposits a hard film of chrome onto wear
surfaces involved in injection molding, such as screws, end caps and
mold cores and cavities. Typically the plating thickness ranges from
.001 (.0025cm) to .005 (.0127cm).
cold slug - the first material to enter an injection mold (in a mold
other than
a hot runner mold) which is typically cooled below the effective
molding temperatureas it passes through the sprue orifice. The cold
slug ends up in a space provided directly oppositethe sprue opening
called a cold slug well.
core (in a screw) - an internal hole extending down the center line of a
portion of a screw used to circulate a coolant
or heating mediumto
better control the temperature of the screw.
core pin - a pin that is included in an injection mold that is used to mold a
hole in the molded part.
counterbore - the recessed area in the discharge end of a barrel (or screw)
which acts as a pilot to ensurethe concentric fit and sealingof the
end cap (or valve) to the barrel (or screw).
daylight (in molds) - the distance between the stationary and moving
platens of a molding machine when they as arefar retracted (open)
as possible, without an ejector box
or any spacers.
ejector pins - rods or pins that push a molded partoff of the core or out
of a cavity during ejection. The pins are usually attached to an
ejector bar or plate that can be actuated by the ejection systemof
the machine. Ejector sleeves can be used instead of pins to eject
parts (especially round parts).
end cap - the steel component that bolts to the discharge end
of an injection
barrel andalso adapts (holds) the injection nozzle.
family mold- a multi-cavity mold where each of the cavities forms oneof
the component parts of the assembled finished object. Theterm is
also applied to molds whereeach of the cavities produce a different
part in the interests of economic production.
feed opening - the hole through the feed section of the barrel through
which the unmelted plastic feedstock (such as pellets or powder) is
introduced. It is also referred to as the feed hole or feed port.
173
feed section(or feed zone of the screw)- the part of the screw
that extends
under the feed opening andreceives the materialto be processed.
The feed section (in injection molding) normally has a constant
channel depth andconveys the material to the transition (or
compression) sectionof the screw.
filler - material addedto the plastic feedstock for the purpose of improving
its physicalproperties (such as strength) or its process ability (such
as a plasticizer or heat stabilizer), or to reduce the cost of the
material.
fines - very small particles (commonly under 200 mesh) that accompany
largerparticles (or pellets)ofplasticfeed stock. Finesoccur
especially in regrind materials.
fisheye - a pellet of plastic that has survived the molding process without
being completely melted.
flash - extra plastic attached to the molded part along the parting line
which, under most conditions, is a defect and must be removed
before the parts are acceptable.
flight - the helical metal thread-like, raised portion of the screw which
defines the screw channel.
flow line - a line in a molded part caused by the joining of two melt flow
fionts during injection. Also called a weld Zine or knit Zine.
1 74
gas assist - the term used to refer to the introduction of a gas (such as
nitrogen), under pressure, into the melted resin, eitherat the nozzle
or the mold, to cause the molded part to have a hollow, gas-filled
center thus requiring less plasticto mold the desired part.
gate - the small, short and usually restricted section of a runner at the
entrance to the cavity of an injection mold. The molten plastic
enters the cavity through the gate during injection. Gates have
various shapes and forms, depending upon the design of the partto
be molded.
guide pins - large pinsin a mold that maintainthe proper alignment of the
core and cavity halvesofthe mold when it closes.Also called leader
pins.
heater bands - electrically powered heating elements that fit around the
outside diameter of a barrelto control the conductive heat used to
helpmelt the plastic.They are commonlymade fiom mica or
ceramic and are connected to machine controls that permit the
desired heat settings forthe various heating zonesof the barrel.
helix angle - the angle of the flight of a screw relative to a plane that is
perpendicular to the axis of the screw. The most common helix
angle is 17.6568' which forms a square pitch.
hygroscopic - the term that refers to resins indicating that they absorb
moisture fiom the air.
injection pressure - the pressure exertedon the melted plasticby the screw
and valve to cause the plastic to be injected into the mold. The
pressure is expressed in psi.
injection rate - is the calculated rate, expressedin cubic inches per second
(cubiccentimeterspersecond), at whichthescrew(andvalve
assembly)injectsmeltedplasticintothemoldattheinjection
pressure specified.
inlay - the hard surfaceportion of a flight that does not extend completely
across the widthof the flight.
insert - a part made of metal or other material that is molded into the
plastic part (or pressed into the part) as the molding cycle is being
completed.
lining - the wear resistant portion of an injection barrel that forms the
inside diameter. The lining may be metallurgically bonded to the
inside diameterof the barrel shell or may be removable linersthat
are press or shrink fit into the barrel shell.
locating ring- a metal ring located on the backof the stationary half
of an
injection mold that helps alignthe mold to the machine platen and
the nozzle of the injection barrel with the entrance of the sprue
bushing.
meter section - the portion of the screw at the forward (discharge) end
which has screw channels of a constant depth and a length of at
least one turn of the flight.
mixing section- a sectionof the screw (usually less than 3 diameters long)
that has special geometry designed to enhance distributive andor
dispersive mixingof the melted resin.
mold base - the assemblyof all parts of an injection mold, other thanthe
cores, cavities and pins. Standard mold bases of various sizes may
be purchased from manufacturers to expedite the mold making
process for more simple molds.
nitriding (gas) - the hardeningof the surface of certain alloy steels caused
by heating the steel in an atmosphere of nitrogen (ammonia gas) at
approximately925F(496C) to 950F ( 5 10C). The resulting
surface is very hard (70 RCor higher) with wear resistant hardness
(50 RC or higher) extending to a depthof .007" (.018cm) to .015"
(.038cm). The processis commonly used to provide wear resistance
to the surfaces of screws, valves and the inside diameterof barrels.
nozzle - a device that threads into the end cap and adapts the discharge end
of the nozzle (and nozzle tip)to the sprue bushing in the mold.
olefins - the term applied to a group of hydrocarbons which are the basis
for certain polymers, most notably polyethylene and polypropylene.
part - the term that is applied to the product of the injection molding
process. For example,a molded cup, container, toyor other object
is referred to as a part.
parting line - the term applied to the line on an injection mold (and as
evidenced in the molded part) where the halvesof the mold met in
closing.
pitch - the distance, measured parallelto the axis of the screw, fkom one
edge of the top of a flight to the same edge of the next adjacent
flight. In the case of a multi-flighted screw,the pitch is less than the
lead.
179
pocket (in screws) - the location where a screw flightis initiated. Most
commonly, the feed pocket is located at the intersection of the
bearing of the screw drive and
the beginning of the first flightof the
screw.
purging - the cleaning out of the injection unit (barrel, screw, valve, end
cap and nozzle)of all plastic that might remain tiom the immediately
precedingprocessing. If changingcolor or shuttingdowntlie
machine, a differentplastic may be forced through the unit
(sometimes with the nozzle withdrawn from the wold). Purging
materials are also available. Purging sbudalways occur before
shutting down the machine.
rear radius (of screw flights) - the radiusat the intersectionof the rear or
trailing side of the screw flight and the screw root. Usually this
radius is larger than the fiont radius and may change fi-om one
portion of the screwto another.
regrind - ground up scrap that may be added to the "virgin" plastic feed
stock and remolded. See scrap.
root (in screws) - the surface of the screw betweenthe flights, usuallyof
a cylindrical or conical shape thathas a diameter smaller than the
outside diameterof the flights.
runner - the channel that connects the sprue with
the gates in a mold. Also
refers to the molded form connecting the sprue witha molded part.
scrap - any productof the injection moldingoperation that is not partof the
primaryproduct. Scrap may include flash, short shots, runner
systems, rejected parts and sprues,all of which may be ground up
and added to "virgin" material to be remolded. The ground scrap
is referred to as regrind.
screw speed - the speed with which the screw rotates as expressed in
revolutions per minute(RPM).
shank - the rear, non-flightedportion of the screw thatfits into the quillof
the injection molding machine at the drive end. Also sometimes
referred to as the screw drive.
shelf life - the periodof time thata molding compoundor plastic feedstock
can be stored withoutlosing any of its physical or molding
properties.
shot - the yield fiom one complete injection molding cycle, including
the
parts, runner systems (unlessa runnerless mold) and flash.
sprue - the primary openingin the mold that accepts the melted plastic for
further distributionthrough a runner systemor hot runner system.
stripper plate - a plate in the injection mold thatstrips the molded part(s)
from the cores.
transition section (zone) - the portion of a screw between the feed and
meter sections where the flightdepth decreases from deep(at the
end of the feed section) to shallow (at the beginning of the meter
section). This area is also referred to as the compression section.
184
-
vented processing the use of a barrel with a vent port and a two-stage
screw to accomplish the removal of volatiles (gases and water
vapor) fromthe material being processed.
vent bleed - the unplanned escapeof melt through the vent port (vent hole)
during the operation of vented barrel processing.
vent port - an opening through the barrel wall, usually located just forward
of the center of the barrel, to permit the removal of air,gases, water
vapor and volatilesfiom the material being processed.
vent stack (or chute) - a device surrounding a portion of the vent port
designed to preventanymeltedplasticthatmightescape fiom
collecting on the barrel, heater bandsor wiring.
virgin material- plastic feedstock that has not been processed previously
in an injection molding operation.
185
You have seen coffee mugs that have a white interior and colored
exterior that have obviously been injection molded. Also, keyboards on
phones andcomputersare in two colors, but it is clear that the numbers and
letters have not been paintedon the keys. The answer is that two different
colored plastics have been injected into the same cavity, at butthenot
same
time. There are several ways to achieve two color molding. The most
commonly observed approach involves two injection units, each havinga
different color feed stock. The mold, which might have two cavity inserts
in the cavity plate, is equipped so that the entire cavity plate indexes180"
allowing a second color fromthe second injection unit to inject over the
first color. Let's illustrate:
1 87
The core and cavity sets for positions A and B form the white
interior of the coffee mug, with that interior being retainedthe on
core (and
not ejected). The core plate of the mold indexes 180" and the cores with
B and A, allowing the
the molded interior now sit in slightly larger cavities
second injection unit to inject the dark colored material the around
smaller
interior part that sits on the core. The molded interior actually becomes
part of the core for the molded exterior.
With thetwo color part now complete, the mold opens the andtwo
colored partis ejected, andthe process begins again.It is obvious that the
cavities for the darker exterior must shut off accurately to prevent the
darker material from covering some portion of the interior maythat
not be
desired.
This illustration is quite simple but even the most complex two
color molds allow the first colorto become either part of the core or form
the cavity for the second injectionoperation.
Step 1 Step 2
The interior color (white) IS injected into After rotation, the second darker color
cavities A and B. The part stays on the is injected over and around the light
cores as the plate indexes. interior color, formingthe exterior of the cup.
1
Figure 38
188
Moving Platen
Block
Figure 39
189
The third step is the sintering process where the parts are placed
into an oven set at rather high temperatures, such as 2,200F (1,200C) for
metals, where the part is completed and now in usable form. Because of
the three steps, there is a significant shrinkage fiom the original injection
molded partto the completed sinteredpart, often as much as 2530%. The
shrinkage is simply calculated and allowances made the during
design of the
completed part andthe mold.
Step 1 I
Step 2 l Step 3
Injection mold the Place the partinto an Transfer the partto
part with powdered oven at about 93OOF to an oven at about
material added to plastic carrier 2,20OoFto complete remove the
polyolefin the sintering process
The authors have seen parts made from powdered metal that had
perfectly squarecorners and various holes and ribs in the parts. Suchparts
would have otherwise had to be machined fiom a metal block, requiring
several steps and considerable time.We have also viewed ceramic parts to
be used as insulators in electrical applications that were producedin the
powder injection molding process. There is a drawback to the process,
however, the molding ofthese materials simplyeats up barrels and screws
and other parts of the injection unit, plusthe mold cavities and cores. All
must be made fiom special, wear resistant materials.
191
17.1.5IntrusionMolding
There are cases where the molder desiresto make a part thathas a
greater volume of plastic than the maximum capacity of the machines
injection unit. In such instances, the moldera combination
uses of injection
and extrusion to completely fill the cavity with the desired volume of
plastic. This process is called intrusion molding.
APPENDIX A
INJECTION MOLDING MATERIALS
THERMOPLASTICS GROUP Density gm/&
I cellulosi: I I I
Cellulose Acetate CA Crystalline* 446Tm 1.14 1.22
FlUWopdymers:
APPENDIX A
polyethylenes:
Linear LW Denslty LLDPE Crystalline 250Tm .70 .93
polystyrenes:
~~ ~~
Vinyls:
APPENDIX D
Useful Data
Abbreviations andSymbok:
APPENDIX D
Calculations:
Conversions: APPENDIX D
To Convert I
One I To One I Calculation
in mm in x 25.4
mm in mm x .03937
in in x 2.54 cm
cm in cm x .3937
in2 mm2 n
i2 x 645.16
in2 mm2 mmz x .W155
in3 mm5 in3 x 16,387.06
in3 cm3 in3 x 16.387
cm3 in3 cm3 x B6102
oz 9 oz x 28.35
9 oz g x .0353
Ib kg Ib x .45359
kg Ib kg x 2.2046
oz/in3 @cm3 oz/ina x 1.7307
@cm3 din3 oz/in3 x.5778
Ib/in3 @cm3 Ib/in3 x 27.6799
@cms Ib/in3 @cm3x .03613
foot-pound N-m orJ foot-pound x 1.3558
N-m or J foot-pound N-m or J x .73756
N-m J N-m x 1.000
Mm2 Pa Nlm2 x 1.000
N/m2 bar N/m2 x .00001
bar Pa bar x 100,OOO
bar MPa bar x 1,000,000
psi Pa psi x 6,895
psi N/m2 psi x 6,895
Pa psi Pa x .OW145
MPa Psi MPa x 145
hp W hp x .W134
W hp wx746
W-S J W-S x l.m0
kwh hphour kwh x 1.34
203
APPENDIX E
Introduction:
developing a stable process. Know what the part looks like at the end of
first stage.
The next question is: Howto keep fill time constantwhile running
an injection molding machine? Most hydraulic machines have some of type
valve to control flow of oil to the hydraulic ram. This can be a manual
valve, servo-valve, proportional, cartridge, etc. These valves are adjusted
manually or electrically, closed-loop or open-loop, to regulate the flow of
oil to the ram. For these valves to function correctly they require one
common variable to be set correctly: A pressure differential (delta P)
across the valve. That is, first stage pressure must be set higher than the
maximum pressure required to push the plasticto fill the part 99% full. If
first stage set pressureon the pump side ever nearsor equals the pressure
in the hydraulic ramthe injection speed will slow down. If the ram slows
down then the viscosity or the plastic will change(get stiffer) andwe begin
a stairstep effect. If the plastic gets harder to push thenthe ram will slow
some more until we havea short shot.Bottom line: for velocitycontrol you
must operate your machine with a delta P across the flow control device and
with abundant pressureon the pump side.
cavities worth of plastic into onlythree cavities. If there were slides inthe
mold,wemayflash them and damage the tool on the next shot. This
presents a dilemma. No delta P; no process control on fill and parts w li
vary dueto all viscosity changes (temperature, lots, colors,% regrind etc.).
Too much pressure and werun the risk of over packing the mold and we
may damage it. The ram must be taken off cruise control before the last
area to fill fills out. Otherwise the mold will likely flash. Its like driving a
boat into a dock, you mustcut the power before you hitthe dock. A well
built mold should be able to withstand a certain amount of excess pressure.
Over pressurizing the mold is likely to happen for a number of reasons
throughout its We. The question is how much extra or abundant pressure
is needed to gain velocitycontrol yet not potentially damage the mold. The
machine should not be setto full system pressure for all molds.
Figure 1:
Typical Plastic
Maintain a W -
Use abundant pressure
209
APPENDIX F
Procedure for Applicationof Bolt
Torque on Nozzle Adaptors (End Caps1
Step 1 Align component parts and clamp together with hold down.
Step2Lubricatestud(orbolt)threads in areaofnut(orforgedring
engagement. Also lubricate face of nuts (or bolt head) using a suitable
lubricant.
Step 5 Apply torque (using torque wrench) in 20% steps of required torque.
Loading all bolts at each step before proceeding to next step.
Step 6 Tighten bolts in sequential order (see chart) at each step until final
torque is reached.
Step 7 Tighten bolts in rotational order ( s e e chart) until all bolts are stable at
final torque level. (Two complete times around is usually required.)
Injection Unit Size Torque (Ft Lbs) InjectionUnit Size Torque (Ft Lbs)
30 mm 22 75 mm 150
35 mm 27 80 mm 195
40 mm 34 90 mm 301
50 mm 64 105 mm 512
57 mm 83 115 mm 886
65 mm 98 135 mm 1,110
70 mm 146 155 mm 1,750
10BdtPattem
12BotPattsm
14 Bdt P a t m
Sequential
Order
Sequential
Order
Sequential
Order
1 - 2 1 - 2
3 - 4
5 - 6 5 - 6 5 - 6
7 - 8
9 - 10 9 - 10 9 - 10
11 - 12 11 - 12
13 - 14
Rotational
Order
Rotational
Order
Rotational
Order
1 - 12- 2 1 - 2
5 -56 - 6 . 5 - 6
9 - 10 9 - 10 9 -10
3 -3 4- 4 3 - 4
7 - 8 7 - 8 11 - 12
11 12 - 7-8
13 - 14
Index
APlate,mold 57 Benchmark96
Abrasivewear
165 Bimetallic
167
Accumulator
165 Blenders
18
Actuators 78, 80 Blister
ring
167
Adaptor
31 Blow
molding 167
Additivefeeders 18 Bore 167
Additives 1, 2,16,165 Brittleness of parts143
Adhesive wear
165 Bubbler
72
Air shots 93,95, 165 Bubbles 144
Allyls, thermoset
133 Bulkratio41,167
Ambient temperature 165 Burned material
145
Aminos, thermoset133 Calciumcarbonate 16, 168
Amorphous materials 10,108, Carbon black 16,19,168
166 Carbon fiber
168
Anglepins
66 Carriage forwardhack 80
Anneal
166 Castbimetallic,barrel30
ANSI B151.1 137 Cavity 3,55,168
Ascendingheatprofile 115 Ceramic insulated heater
Atactic
166 bands34
Autoclave
166 Channel
168
Automatic control mode78 Channel depth ratio 40
Automatic mold 166 Channeldepth,screw38,106
Axis (screw or barrel)166 Channel width168
BPlate,mold 57 Checkring
168
Backpressure28, 119,166 Chiller
169
Baflle
72 Chrome plating
169
Ballcheckvalves 36,37, 166 Clampforce (tonnage) 49,169
Barrel 26,29, 3 1, 166 Clamp stroke 50
Barrel
shell
166 clamp unit 1,2,3,45
Barrier
flight
167 Clamp unit control 76
Bayonet adaptor 167 Clearance (screwharrel) 169
Bearingsurface
167 Cloudy parts 146
Bell
end 167
213
Slug
well 61 Titaniumdioxide
19
Smear tips 134,182 Toggleclampsystem 47,48
Smoke suppressants
18 Toggle links 47,48
Solidschannel182 Toolsteel-linedbarrel 30
Splay
157,182 Top guard139
Splines
42 Torque wrench 32
Splitringgroove29 Transfer point (position) 92, 123
Sprue 55,182 Transition section, screw38, 39,
Spruebushing 32,58 40,183
Spruepicker 58, 83 Troubleshooting processing
Sprue puller 58 problems
162
Square pitch41,182 Turret molding 188
Stabilizers
16 Twocolormolding186
Stack molds 67 Two stage screw184
Start (hydraulicpumps) 80 Two-plate mold 56,62
Stationary half,mold 55 Ultrasonic
welding184
Stationary platen
182 Unscrewing molds
66
Stop (hydraulicpumps) 80 UV stabilizers17
Stripper plate53,183 Velocity control 90
Stripperplatemolds66 Vent grooves 71
Stroke 27 Vent
stack
184
Talc 16,183 Ventedprocessing184
Temperature control 77 Venting,molds70
Temperature controller 1,4,7 1 Vents71,102,184
Ten Keys to Successful Molding Virginmaterial 5 , 184
102, 131 Viscosity
14
Terminology165 Voids
144
Thermalconductivity12,108 Warped parts 158
Thermocouples 27,30, 183 Water jackets 134
Thermoplastics 8, 183 Window
185
Thermosets 9,132,183
Threadedend,barrel29
Three-plate molds62
Tie
bars 45,50
Tie rods 50
183
TIR