Machine Manual Injection Molding-SY200 I Polymers Lab

Machine #:4
A- Description:

Name: SY200-I Plastic Injection Molding Machine

Machine dimensions: 1.95*0.55*1.25 m

Technical Parameters:

o Injection Pressure: 185 MPa

o Max. Working Pressure: 14 MPa
o Motor Power: 2.2 KW
o Working temperature: 200OC

B- Application:

This machine applies the injection molding processing of various kinds of thermoplastics (e.g.
polystyrene, such as ABS; polythene, polypropylene, PVC, polycarbonate..etc). It produces plastic
products of no more than 20 grams in weight. It applies especially to produce the small sized
precise plastic parts in the industrial meters.

C- Sample output:

Dimensions: (mm)

Department of Material science and Manufacturing

Machine Manual Injection Molding-SY200 I Polymers Lab

D- Machines Structure:

It consists of the injection unit and the clamping unit

Components:
1- Injection unit
o Hopper

Its a conical cylinder, which feeds the used raw material into the injectiong unit. The feeding
happens normally with gravimetric forces .

o Heaters
 In plunger type injection molding machine, a measured quantity of raw material is fed into the
cylinder where the plastic material is heated with the help of the two heating zones to soften. In
this type, the function of the plunger is to push the plasticized plastic material into the closed
mold that is fed from the hopper to the cylinder

Department of Material science and Manufacturing

Machine Manual Injection Molding-SY200 I Polymers Lab

2- Clamping unit

The main functions of the clamping unit in the injection molding machine are to open and close
the mold, to close the mold tightly to avoid flash during filling and to hold up the injection
molding cycle

o Mold Section
 Clamping unit consist of stationary platen, movable platen and tie bars. Locating ring side of the
mold is clamped at the stationary platen and the ejection side of the mold is clamped at
movable platen. The movable platen is moved towards stationary platen, until the two mold
halves meet. Plastic material is injected from the stationary platen side through sprue bush to
cavities. This unit clamps the mold halves by toggle until the injected plastic part is solidified.

o Control unit
o Motor

E- Machines Cycle:

1. Clamping/Mold closing
2. Injection/mold filling
3. Holding pressure
4. Injection unit back
5. unclamping
6. Mold open/ejection

1. Clamping/mold 2.Injection /mold

closing filling

6. Mold 3.Holding pressure

open/Ejection (4min)

5.unclamping 4.Injection unit back

Department of Material science and Manufacturing

Machine Manual Injection Molding-SY200 I Polymers Lab

The Machine is labeled clearly in the laboratory to assist in operation

F- Preparation before starting operation:

 The hydraulic oil should be filled in the oil box. The filling quantity should be over half
the oil level indicator.
 Every oil site should be lubricated and check for moving surfaces cleanliness (e.g. tie-bar).
 Check the cooling water drainage.
 Make sure the exhaust is working.
 Make sure the safety gate is properly closed before operation

G- Start-up to Run in:

 Start the motor

 Turn on the heating switch and check whether the two heat bands (zones) are heated
at the same time. When the heating temperature reaches the set point ( 200 Oc), the
power switch will be turned on automatically and cluck sound will be made.

Modes of operation:

There are three operational modes available:

*manual: in one working period, every motion is controlled by the operator with
pressing the manual operation switches. Press the ejector button after clamping is done.

*Semi-Automatic: the machine can finish all the motions in one working period, but
when the period is over, the operator must open the safety gate to take the work piece.
Only after the safety gate is closed, the machine can carry over the next period.

*Full-Automatic: the machine can finish all the motions in one working period and the
workpiece is ejected automatically.

- During start, please choose the manual mode then choose either the semi or full
automatic modes of operation.
 Turn the operation mode switch to the manual position (green knob) and close the
safety gate , then press clamping ,injection, close mold, unclamping and ejecting.
 Check pressure to be 7 MPa
 Then collect the sample
 Afterwards, the mode could be changed to either semi or full automatic.

Department of Material science and Manufacturing

Machine Manual Injection Molding-SY200 I Polymers Lab

H- Safe Operation:

 For safety purposes, the operators of this machine must be trained before operating the
machine
 Safety gate must be closed during operation, if opened the mold wouldn’t close and
hence the machine wouldn’t work.
 Never touch the heat bands while the machine is working it is very hot.
 Always keep the machine clean and lubricated.

Department of Material science and Manufacturing