Plastic Processing

Author : Krishnamoorthy Narasimhan

Version : 01
Date : 22 August 2013
Training Material Owner Details
Name : Krishnamoorthy Narasimhan

Designation : Technical Manager - Plastics

Email: krishnamoorthy.narasimhan@valeo.com

Contact Details :
R&D Center

Valeo India Private Limited

Block - A, 4th Floor, TECCI Park,
No.173, Rajiv Gandhi Salai, Sholinganallur,
Chennai - 600 119, India
Tel: + 914466235089

Valeo Work Experience : 2 Years

Total Work Experience : 16 Years

Domain Expertise : Plastic product design, Tool engineering, Processing, Materials and
Moldflow analysis

Property of Valeo Duplication prohibited

2
Other Trainer Details
Name : Kulandaivel Palanisamy

Designation : Senior Engineer - Moldflow

Email: kulandaivel.palanisamy@valeo.com

Contact Details :
R&D Center

Valeo India Private Limited

Block - A, 4th Floor, TECCI Park,
No.173, Rajiv Gandhi Salai, Sholinganallur,
Chennai - 600 119, India
Tel: +914466235029

Valeo Work Experience : 3 Years

Total Work Experience : 10 Years

Domain Expertise : Plastic product design, Tool engineering, Processing, Materials

and Moldflow analysis

Property of Valeo Duplication prohibited

3
Change History

Version
Date Modification Description Sections / Pages Modified
Number

1.0 22-Aug-13 New Document - First release -

Copyright © VIPL R&D Center – Strictly COFIDENTIAL, Un-authorized use or duplication is prohibited.
This document is the exclusive property of VIPL R&D Center. It cannot be used or divulged to anybody
without previous written authorization. The changes to this document shall be done only by the document
owner and approved by designated persons. Un-authorized changes or modifications to this document by
anyone else is strictly prohibited.

Property of Valeo Duplication prohibited

4
Training Data
Training duration : 2 Hours

Minimum Number of Participants : 8

Maximum no of participants : 14

Pre-requisites to attend this Training :

☞ Current Role : Engineers / Sr. Engr..

☞ Métier : CAD / CAE /

☞ Work experience : 0 Years

☞ Any other training to be completed before this training : NA
Who should attend this Training :

☞New Joiners, Anyone from Design, CAE, Process

Property of Valeo Duplication prohibited

5
Infrastructure Required

☞ Attendance sheet - Yes

☞ License availability- NA
☞ Work station availability-NA
☞ Training room availability - Yes
☞ Training material printout - Yes
☞ Product examples – NA
☞ Training certificate - Yes
☞ Feedback sheet - Yes

Property of Valeo Duplication prohibited

6
Training Evaluation Sheet

Property of Valeo Duplication prohibited

7
Objectives

☞ Improve knowledge of Valeo engineers on Plastic materials

☞ This training provides an introduction to the different plastic

processing techniques and details about the injection molding
machine.

Property of Valeo Duplication prohibited

8
Contents
 Plastic Processing Techniques

 Process Selector

 Compression Molding

 Blow Molding

 Injection Blow Molding

 Stretch Blow Molding

 Vacuum Thermoforming

 Pressure Thermoforming

 Introduction to Injection Molding Machine

Property of Valeo Duplication prohibited

9
Plastic Processing Techniques
Injection Molding Process
Gas Assisted Injection Molding / Co-injection molding / Structural Foam Molding

Compression Molding
Open Flash type / Positive & Semi-positive mold

Transfer Molding

Property of Valeo Duplication prohibited

10
Plastic Processing Techniques
Blow Molding
Injection Blow Molding /

Extrusion Blow Molding /

Stretch Blow Molding

Extrusion
Blow film Extrusion

Sheet Extrusion

Pipe or profile Extrusion

Property of Valeo Duplication prohibited

11
Plastic Processing Techniques
Rotational Molding
Vacuum Thermoforming /

Pressure (blow) Forming / Mechanical Forming

Thermoforming
Vacuum Thermoforming /

Pressure (blow) Forming / Mechanical Forming

Property of Valeo Duplication prohibited

12
Process Selector

Property of Valeo Duplication prohibited

13
Compression Molding

Property of Valeo Duplication prohibited

14
Blow Molding

Property of Valeo Duplication prohibited

15
Injection Blow Molding

Property of Valeo Duplication prohibited

16
Stretch Blow Molding

Property of Valeo Duplication prohibited

17
Vacuum Thermoforming

Property of Valeo Duplication prohibited

18
Vacuum Thermoforming

Property of Valeo Duplication prohibited

19
Pressure Thermoforming

Property of Valeo Duplication prohibited

20
Introduction to Injection Molding Machine

 Injection molding is the most commonly used manufacturing process for the fabrication of plastic
parts.
 A wide variety of products are manufactured using injection molding, which vary greatly in their
size, complexity, and application.
 The injection molding process requires the use of an injection molding machine, raw plastic
material, and a mold.
 The plastic is melted in the injection molding machine and then injected into the mold, where it
cools and solidifies into the final part.

Property of Valeo Duplication prohibited

21
Injection Molding

Property of Valeo Duplication prohibited

22
Injection Molding Cycle

Property of Valeo Duplication prohibited

23
Injection Molding Machine

Property of Valeo Duplication prohibited

24
Injection Molding Machine

Property of Valeo Duplication prohibited

25
Injection Molding Machine - Manufacturers

Some of the Injection molding machine manufacturers are listed below

 Arburg
 APM – Supermaster (SM)
 Battenfeld
 DGP Windsor
 Demag
 Engel
 Ferromatik Milacron
 Husky
 L&T
 Mitsubishi
 Milacron
 Sumitomo
 Toshiba

Property of Valeo Duplication prohibited

26
Injection Molding Machine - Specification

Property of Valeo Duplication prohibited

27
Injection Molding Machine: Overview

Property of Valeo Duplication prohibited

28
Injection Molding Machine: Overview

Property of Valeo Duplication prohibited

29
Injection Molding Machine: Injection Unit

Property of Valeo Duplication prohibited

30
Injection Molding Machine: Clamping unit

Property of Valeo Duplication prohibited

31
Injection Molding Machine: Injection Mold

Property of Valeo Duplication prohibited

32
Common Injection Molding Defects
Molding Defects Alternative Descriptions Causes
Name

Raised or layered Tool or material is too hot, often caused

Blister Blistering zone on surface of the by a lack of cooling around the tool or a
Plastic part faulty heater

Black or brown burnt

Air Burn/Gas areas on the plastic Tool lacks venting, injection speed is too
Burn marks
Burn part located at furthest high
points from gate
Plastic material and colorant isn't mixing
Localized change of properly, or the material has run out and
Color streaks (US)
color it's starting to come through as natural
only
Contamination of the material e.g. PP
mixed with ABS, very dangerous if the
Thin mica like layers part is being used for a safety critical
Delamination
formed in part wall application as the material has very little
strength when delaminated as the
materials cannot bond
Tool damage, too much injection
Excess material in thin
speed/material injected, clamping force
Flash Burrs layer exceeding
too low. Can also be caused by dirt and
normal part geometry
contaminants around tooling surfaces.

Property of Valeo Duplication prohibited

33
Common Molding Defects
Molding Defects Alternative Descriptions Causes
Name

Particles on the tool surface,

Foreign particle (burnt
Embedded Embedded contaminated material or foreign debris
material or other)
contaminates particulates in the barrel, or too much shear heat
embedded in the part
burning the material prior to injection

Injection speeds too slow (the plastic

has cooled down too much during
Directionally "off tone"
Flow marks Flow lines injection, injection speeds must be set
wavy lines or patterns
as fast as you can get away with at all
times)

Deformed part by
Poor tool design, gate position or runner.
Jetting turbulent flow of
Injection speed set too high.
material

Polymer polymer breakdown Excess water in the granules, excessive

degradation from oxidation, etc. temperatures in barrel
Holding time/pressure too low, cooling
Localized depression time too short, with sprueless hot
Sink marks
(In thicker zones) runners this can also be caused by the
gate temperature being set too high

Non-Fill/Short Lack of material, injection speed or

Short shot Partial part
Mold pressure too low

Property of Valeo Duplication prohibited

34
Common Molding Defects
Molding Defects Alternative Descriptions Causes
Name

Splash Circular pattern around

Splay marks/ Silver Moisture in the material, usually when
Mark/Silver gate caused by hot
streaks resins are dried improperly
Streaks gas

String like remain from

Nozzle temperature too high. Gate
Stringiness Stringing previous shot transfer
hasn't frozen off
in new shot
Lack of holding pressure (holding
pressure is used to pack out the part
Empty space within
during the holding time). Also mold may
Voids part
be out of registration (when the two
(Air pocket)
halves don't center properly and part
walls are not the same thickness).
Mold/material temperatures set too low
Knit Line/Meld Discolored line where
Weld line (the material is cold when they meet, so
Line two flow fronts meet
they don't bond)
Cooling is too short, material is too hot,
lack of cooling around the tool, incorrect
Warping Twisting Part Distorted part
water temperatures (the parts bow
inwards towards the hot side of the tool)

Property of Valeo Duplication prohibited

35
References

Plastic Materials – J A Brydson, Butterworth-Heinemann, 1999

Injection Molding Handbook Dominick V. Rosato, Donald V.

Rosato, Marlene G. Rosato

http://www.solvay.com/

http://www.sabic-ip.com/gep/en/Home/Home/home.html

http://www.custompartnet.com/wu/InjectionMolding

Property of Valeo Duplication prohibited

36
 Property of Valeo Duplication prohibited
37