HOW TO MAKE

SETTING PARAMETER
By : Anggun Huda P.
R&D Dept.
Parameters to be discussed is :
I. Clamping Force
II. Charging parameter
a. Charging Speed
b. Back Presssure
c. Metering Position
III. Inject Parameter
a. Inject Position & Transfer (V/P) Position
b. Inject Speed
c. Inject Pressure
IV. Holding Parameter
V. Cooling Time
VI. Barrel (zone) Temperature

1
I. CLAMPING FORCE

2
Example for part 2453

Projected Area

Clamping force = Total projected area X Inj. Peak pressure

𝐹 = 𝐴 𝑥P
𝐹 = 2𝑥3. 104 10−6 𝑚2 𝑥 40. 106 𝑁𝑚−2
𝐹 = 240 . 104 N
𝐹 = 240 . 103 Kg
𝐹 = 240 Ton ≈ 250 Ton

3
Setting clamping force in the machine
According to information from Haitian technicians, the MA6000 machine
can reach clamping force 600 Ton when maximum pressure is reached.
The maximum pressure from machine is 140 bar (2030 Psi)
So to get clamping force 250 Ton, we set the pressure when clamping
at 850 Psi

4
II. Charging Parameter
F4
#1 #2 #3 #4
Suck II.a. Charging speed
Purging/Charging Back
Position MM 20 30 50 75 8 According to PDS (processing data sheet) from BASF,
For PA66 material,
Pressur Setting 80 80 80 80 40
Suggested Peripheral screw speed is ≤ 0,3 𝑚/𝑠
e Mpa Tolerance ±5 ±5 ±5 ±5 ±5
𝜋. 𝐷. 𝑛
Speed Setting 40 40 40 40 25 𝑣=
60 V = peripheral speed (m/s)
% Tolerance ±5 ±5 ±5 ±5 ±5 D = screw diameter (m)
60. 𝑣 n = screw rpm (Rpm)
Back Pressure Mpa 6 6 6 6 / 𝑛=
𝜋. 𝐷

Example in MA6000 machine

60 . 0,3
𝑛=
3,14 . 0,08 Suggested peripheral screw speed is ≤ 72 rpm.
by setting the speed value 40%,
18
𝑛= = 72 𝑅𝑝𝑚 we get the screw rpm is 65 rpm.
0,25

7
II.b. Back Pressure

Back Pressure is the pressure that works on the injection cylinder

To hold back motion from the screw during charging process.

Back pressure serves to maintain the density of material in the metering

zone area (the material is ready to inject).
The bigger the back pressure, the better the material density.
But if the back pressure is too large, it will cause charging time longer than
the time it should.
In this case more material will slip inside the barrel.

8
 Back
Raw Back Pressure Raw
Pressure
Material (Mpa) Material
(Mpa)
ASA 9.5 ~ 15 ABS 9.0 ~ 18
BDS 3.0 ~ 10 SAN 5.0 ~ 15
HIPS 5.0 ~ 10 GPPS 5.0 ~ 10
PP 6.0 ~ 14 HDPE 7.0 ~18
LDPE 7.0 ~ 18 PA6 2.0 ~ 8.0
PA66 2.0 ~ 8.0 PC 6.0 ~ 15
PBT 5.0 ~ 10 PEI 5.0 ~ 18
PET 5.0 ~ 10 PMMA 13 ~ 28
POM 5.0 ~ 10 PPS 3.0 ~ 15
PSU 5.0 ~ 12 TPU/PUR 1.0 ~ 5.0
MA6000 PVC 4.0 ~ 8.0 ABS+PC 5.0 ~ 12
*Back pressure for common plasics
Piston : 210,0 mm
Rod : 90,0 mm
Screw : 80,0 mm F4 Purging/Charging #1 #2 #3 #4 Suck Back

Position MM 20 30 50 75 8
Inject cylinder area : 56548,7 mm2
Pressure Setting 80 80 80 80 40
Screw area : 5026,5 mm2 Mpa Tolerance ±5 ±5 ±5 ±5 ±5

BACKPRESSURE Setting 40 40 40 40 25
Speed %
Backpress setting : 6,0 bar Tolerance ±5 ±5 ±5 ±5 ±5

Backpress shot Back Pressure Mpa 6 6 6 6 /

6,8 Mpa
metering :
II. Charging Parameter II.c. Metering position
F4 Suck
#1 #2 #3 #4
Purging/Charging Back
Position MM 20 30 50 75 8

Pressur Setting 80 80 80 80 40
e Mpa Tolerance ±5 ±5 ±5 ±5 ±5

Speed Setting 40 40 40 40 25
% Tolerance ±5 ±5 ±5 ±5 ±5

Back Pressure Mpa 6 6 6 6 / Position = (Sx10) + 10

Example for part 2453
333,6
𝑆= Position = (6,53 x 10) + 10
Weight 1 shot (Part+Runner) = 333,6 gr 3,14 . 82
𝑥1,13𝑥0,9 = 75 mm
Screw diameter (MA6000) = 80 mm = 8 cm 4
Density PA66 = 1,13 gr/cm3 333,6
Inj. Effisiensi = 0,9 𝑆=
50,24𝑥1,13𝑥0,9
𝑆 = 6,53 cm
6
Example for part 2453, shoot metering length
Berat 1 shot
Specific vol. : 1,042 𝑐𝑚3 /𝑔 (part&runner)= 333,6 gr
PA 66
Density = 1 1,042 333,6
1,042 𝑆=
= 0,959 𝑔/𝑐𝑚3 3,14 . 82
𝑥0,959
4
333,6
𝑆=
50,24𝑥0,959
𝑆 = 6,92 cm = 69,2 mm

F4 Purging/Charging #1 #2 #3 #4 Suck Back

Position MM 20 30 50 75 8

Setting 80 80 80 80 40
Pressure
Mpa
Tolerance ±5 ±5 ±5 ±5 ±5

Setting 40 40 40 40 25
Speed %
Tolerance ±5 ±5 ±5 ±5 ±5

Back Pressure Mpa 6 6 6 6 /

Actual shot metering length needed :

75 – 5,4 = 69,6 mm
285-290
example Charging time calculation in MA5300 machine Charging Animation : * Screw’s area
* Charging process

A
*screw dimension in MA5300
Suck
F4 Purging/Charging #1 #2 #3 #4
Back
Screw rpm : 80 rpm = 1,33 rot/s Charging volume (V)
Position MM 10 20 30 60 8 Screw pitch : 70,8 mm
Pressure Setting 80 80 80 80 40 Linear screw speed (v): 70,8 x 1,33 = 94,1 mm/s
Mpa Tolerance ±5 ±5 ±5 ±5 ±5 A area:
Setting 50 50 50 50 40
Speed %
Tolerance ±5 ±5 ±5 ±5 ±5

Back Pressure Mpa 4 4 4 4 / Charging time : V/Q

𝐴 = 1122,35 − 57,32 = 1065 𝑚𝑚2
Material debit (Q)= A x v
Q = 1065 x 94,1
Q = 100216,5 mm³/s
9
: 301440 / 100216,5
: 3,0 s
Actual Chg.time is 4,23 s.
Difference 1.23s with
Theoretical calculations. So that
Slip material is just about
1.6 rounds of screw
III. Inject Parameter

Explanation: 上图显示填充动画，按 “Shift+ F5” 键可以播放动画。The picture above shows the filling animation, Press
结果说明 "Shift + F5" to play the animation.

10
III.a. Inject position
Part volume in injection step 1 :
Step 1 1,404
𝑥100% = 80%
1,755
80
Part weight : 100 𝑥 333,6 𝑔𝑟 = 266,9 𝑔𝑟

Step length in step 1 :

266,9 Position step 1 :
𝑆=
3,14 . 82 Charging pos. – step length
𝑥1,13𝑥0,9
4
P1 = 75-52 = 23
266,9
𝑆=
50,24𝑥1,13𝑥0,9
𝑆 = 5,2 cm = 52 mm
F3 Injection #6 #5 #4 #3 #2 #1
Position MM / / / / 12 23
Pressure Setting / / / / 45 90
Mpa Tolerance / / / / ±5 ±5
Setting / / / / 20 39
Speed %
Tolerance / / / / ±3 ±3

Time (s) Position MM Pressure Mpa

Transfer Position
Setting Tolerance Setting Tolerance Setting Tolerance
11
5 ±1 12 ±1
III.a. Inject position
Part volume in injection step 2 :
Step 2 1,700
𝑥100% = 96,8%
1,755
96,8
Part weight : 100 𝑥 333,6 𝑔𝑟 = 322,9 𝑔𝑟

Step length in step 2 :

322,9 Position step 2 :
𝑆=
3,14 . 82 Charging pos. – step length
𝑥1,13𝑥0,9
4
P2 = 75-63 = 12
322,9
𝑆=
50,24𝑥1,13𝑥0,9
𝑆 = 6,3 cm = 63 mm
F3 Injection #6 #5 #4 #3 #2 #1
Position MM / / / / 12 23
Pressure Setting / / / / 45 90
Mpa Tolerance / / / / ±5 ±5
Setting / / / / 20 39
Speed %
Tolerance / / / / ±3 ±3

Time (s) Position MM Pressure Mpa

Transfer Position
Setting Tolerance Setting Tolerance Setting Tolerance
12
5 ±1 12 ±1
III.a. Transfer position

6.5 Set condition F3 Injection #6 #5 #4 #3 #2 #1

6.5.1 Gradually increase injection speed until product Position MM / / / / 12 23
reachs 90% full.
Pressur Setting / / / / 45 80
6.5.2 Check injection curve on the screen, read pressure
e Mpa Tolerance / / / / ±5 ±5
peak value.
6.5.3 Add about 5%~10% to pressure peak value as the Speed Setting / / / / 20 39
set value for injection pressure. E.g.: If add 10%, and peak % Tolerance / / / / ±3 ±3
value is 50MPa, then injection pressure should set as
Time (s) Position MM Pressure Mpa
55MPa=50+50*0.1.
6.5.4 Decrease transfer position value to ensure product Transfer Position Setting Tolerance Setting Tolerance Setting Tolerance

filling amount is among 95%~ 98%. 5 ±1 12 ±1

13
III.b. Inject speed
Step length in step 1 + suckback = 52+8=60 mm (S)
Step 1 Wanted time = 1,404 s (t)
𝑆
𝑣1 =
𝑡
60
𝑣1 = = 42,7 𝑚𝑚/𝑠
1,404
42,7
𝑣1 = 𝑥100% = 39%
110,2

Injection speed standard : F3 Injection #6 #5 #4 #3 #2 #1

Position MM / / / / 12 23
MA1600II/540e Injection speed : 87.7 mm/s
Pressure Setting / / / / 45 90
MA2500II/1000e Injection speed : 91.7 mm/s Mpa Tolerance / / / / ±5 ±5
Setting / / / / 20 39
MA2800II/1350e Injection speed : 107.6 mm/s Speed %
Tolerance / / / / ±3 ±3
MA3800II/2250e Injection speed : 100.7 mm/s Time (s) Position MM Pressure Mpa
MA5300II/4000e Injection speed : 97.7 mm/s Transfer Position
Setting Tolerance Setting Tolerance Setting Tolerance

MA6000II/4500 Injection speed : 110.2 mm/s 5 ±1 12 ±1

percentage value 0 ~ 99% = 0 ~ 87.7 mm/s

for MA1600II/540e 14
III.b. Inject speed
Position step 1 – step 2 = 11 mm (S)
Step 2 Wanted time = 0,5 s (t)
𝑆
𝑣2 =
𝑡
11
𝑣2 = = 22 𝑚𝑚/𝑠
0,5
22
𝑣2 = 𝑥100% = 20%
110,2

Injection speed standard :

F3 Injection #6 #5 #4 #3 #2 #1
MA1600II/540e Injection speed : 87.7 mm/s Position MM / / / / 12 23
Pressure Setting / / / / 45 90
MA2500II/1000e Injection speed : 91.7 mm/s Mpa Tolerance / / / / ±5 ±5
MA2800II/1350e Injection speed : 107.6 mm/s Setting / / / / 20 39
Speed %
Tolerance / / / / ±3 ±3
MA3800II/2250e Injection speed : 100.7 mm/s
Time (s) Position MM Pressure Mpa
MA5300II/4000e Injection speed : 97.7 mm/s Transfer Position
Setting Tolerance Setting Tolerance Setting Tolerance
MA6000II/4500 Injection speed : 110.2 mm/s 5 ±1 12 ±1

percentage value 0 ~ 99% = 0 ~ 87.7 mm/s

for MA1600II/540e 15
III.c. Inject Pressure

Injection Pressure is basically the pressure works in the injection cylinder

to produce a thrust force, so that the injection speed we set can be achieved.

Theoretically the inject pressure is obtained by taking into account the

pressure drop in the nozzle, runner, gate, + cavity pressure

16
example pressure drop calculation

suppose known family mold 2 cavity with cross section runner.

- weight part 1 = 15gr, part weight 2 = 40gr
- density= 1 gr/cm3
- injection time = 5 seconds
- sprue diameter = 5 mm, sprue length = 30 mm
- channel length 1 = 80 mm, channel diameter 1 = 5 mm
- channel length 2 = 30 mm
Determine the channel diameter 2 and the pressure before the sprue !

17
example pressure drop calculation

Answer :
Rheology calculation with

18
example pressure drop calculation

19
example pressure drop calculation

20
III.c. Inject Pressure

MA6000

Piston : 210,0 mm
Rod : 90,0 mm F3 Injection #6 #5 #4 #3 #2 #1
Screw : 80,0 mm Position MM / / / / 12 23
Pressure Setting / / / / 45 90
Inject cylinder area : 56548,7 mm2 Mpa Tolerance / / / / ±5 ±5
Setting / / / / 20 39
Screw area : 5026,5 mm2 Speed %
Tolerance / / / / ±3 ±3

INJECT RESSURE Time (s) Position MM Pressure Mpa

Transfer Position
Pressure setting : 86,0 bar Setting Tolerance Setting Tolerance Setting Tolerance

Pressure shot 5 ±1 12 ±1
96,7 Mpa
metering :
IV. Holding Parameter
6.5.5 Input initial holding pressure parameter:
a.Holding pressure: 50%~60% of injection pressure peak value;
b.Holding speed: 10~20%;
c.Holding time:1~2S(please refer to form 4);

表格1：型腔内树脂压力表 Form 1: Resin Pressure inside the Cavity

外装件
序号 材料名称 普通成型
Exterior Decorative
精密件 F3 Hold stress #5 #4 #3 #2 #1
No. Material Name Normal Molding Precision Parts
Part
1 PVC（ 硬 hard） 30（ 300） 40（ 400） 50（ 500） Pressure Setting / / / / 45
2 PVC（ 软 soft） 25（ 250） 35（ 350） 45（ 450） Mpa Tolerance / / / / ±5
3 PP 25（ 250） 35（ 350） 45（ 450）
Setting / / / / 15
4 PE 25（ 250） 35（ 350） 45（ 450） Speed %
5 PA-6 35（ 350） 45（ 450） 60（ 600） Tolerance / / / / ±5
6 PA-66 40（ 400） 50（ 500） 65（ 650） Setting / / / / 1.5
7 POM 35（ 350） 50（ 500） 65（ 650） Time (s)
Tolerance / / / / ±0.5
8 PBT 35（ 350） 50（ 500） 65（ 650）

2
注：模腔内平均树脂压力单位是MPa，（）内的单位是kgf/cm
Note: measuri ng uni t for average resi n pressure i nsi de the cavity i s Mpa, uni t of val ue i nsi de （） i s kgf/cm 2

表格4：保压时间与壁厚和材料关系表
Form 4: Correlation chart between holding pressure time and wall thickness & material

产 品 壁 厚 Product 0.75 1 1.5 1.75 2 2.5 3 3.5 4 单位/Unit：mm

Wall Thickness
PP 0.5 0.8 1.8 2.4 3.2 5 7.1 9.7 12.7
单位/Unit:S
PA 0.3 0.5 1.1 1.5 1.9 3 4.3 5.8 7.6

23
V. Cooling time
表格3：冷却时间与壁厚和材料关系表
Form 3: Correlation chart between cooling time and wall thickness & material

产 品 壁 厚Product 0.75 1 1.5 1.75 2 2.5 3 3.5 4 单位/Unit：mm

Wall Thickness
材 料 Material
PP 1.2 2.3 5.1 7 9 14.1 20.4 27.8 36.3
单位/Unit:S
PA 1 1.9 4.3 5.8 7.6 11.9 17.1 23.4 30.5

24
V. Cooling time calculation Tabel Thermal Diffusity
Example for PA66 material :
General thicknes= 1.5 mm

𝑊𝑇𝑚2
𝑡𝑐 =
𝛼
1.52
𝑡𝑐 =
0.1069
𝑡𝑐 = 21 𝑠

25
VI. Barrel (zone) Temperature
The basic for determining the temperature of a barrel (zone) is the material type and volume of material required at
shot metering area (front zone).

Semi-crystaline material requires more energy to reach its melting point, than amorphus material
It's easier to reach the melting point. In this case semi-crystaline material will take longer time
To reach the melting point.

Material in the shot metering area and behind (material for charging)
Must be at the melting point condition.

To minimize material degradation due to prolonged melting point position,

Temperature behind the charging area can be lowered
10-20 ° C under melting temperature.

26
Heating Band dimension for Haitian machine
from Nozzle, End Cap, Barrel
MA1600II Ø 36 x 40 Ø 60 x 30 Ø 120 x 50 -
MA2500II Ø 36 x 40 Ø 80 x 48 Ø 170 x 55 -
MA2800II Ø 36 x 40 Ø 80 x 48 Ø 150 x 75 Ø 200 x 60
MA3800II Ø 42 x 35 Ø 90 x 55 Ø 170 x 75 Ø 225 x 60
MA5300II Ø 42 x 35 Ø 70 x 48 Ø 210 x 82
MA6000II Ø 42 x 35 Ø 70 x 48 Ø 210 x 82

*The arrangement of MA6000 machine heating band

27
 example charging length for part 2453

Ø 80

75 353,8

shot metering volume :

1
𝑉 = 𝜋𝐷2 𝑥 𝑆
4
1
𝑉 = . 3,14. 802 . 75
4 𝐴 = 1122,35 − 57,32 = 1065 𝑚𝑚2
𝑉 = 376800 𝑚𝑚3 A
Charging length :
F4 Suck 𝑉
Purging/Charging
#1 #2 #3 #4
Back 𝑆=
𝐴
Position MM 20 30 50 75 8
376800
Pressure Setting 80 80 80 80 40 𝑆= = 353,8 𝑚𝑚
Mpa 1065
Tolerance ±5 ±5 ±5 ±5 ±5
Setting 40 40 40 40 25
Speed %
Tolerance ±5 ±5 ±5 ±5 ±5

Back Pressure Mpa 6 6 6 6 / 28

Example for part 2453, PA66 material

F8 Temperature℃ F4 Suck Ready inject material

#1 #2 #3 #4
Parameter Setting℃ Tolerance Purging/Charging Back

#1 290 ±10 Position MM 20 30 50 75 8 Material for charging

#2 290 ±10 Pressure Setting 80 80 80 80 40
Mpa Tolerance ±5 ±5 ±5 ±5 ±5
#3 280 ±10
Setting 40 40 40 40 25
#4 275 ±10 Speed %
Tolerance ±5 ±5 ±5 ±5 ±5
#5 275 ±10
Back Pressure Mpa 6 6 6 6 /
#6 270 ±10 29
POWER CALCULATION
FOR ENERGY SAVING

By : Anggun Huda P.
R&D Dept.
Check injection Pressure & speed part 2453

Injection peak pressure untuk mencapai
Speed 30% adalah sekitar 76 bar.
Sehingga pressure step 1 dapat dirubah
Dari 95 bar menjadi 85 bar
Saat menggunakan 3 gate, Dengan speed yang sama,
inject peak pressure yang dibutuhkan mencapai 88 bar
1
Actual condition
Total inject time + Holding = 3,89 – 3,92 s
Holding time = 1,2 s
Inject time = 2,69 – 2,72 s Injection speed mesin standard :

MA1600II/540e Injection speed : 87.7 mm/s

Theoretical calculation
MA2500II/1000e Injection speed : 91.7 mm/s
step 1 speed = 30%
30 MA2800II/1350e Injection speed : 107.6 mm/s
= 100 𝑥 110.2 = 33.06 𝑚𝑚/𝑠
MA3800II/2250e Injection speed : 100.7 mm/s
step 1 length = 83-20 = 63 mm
MA5300II/4000e Injection speed : 97.7 mm/s
𝑆1 63
𝑡1 = = = 1,91 𝑠 MA6000II/4500 Injection speed : 110.2 mm/s
𝑣1 33,06
Persentase nilai 0 ~ 99% = 0 ~ 87.7 mm/s untuk
step 2 speed = 20% type MA1600II/540e
20
= 100 𝑥 110.2 = 22.04 𝑚𝑚/𝑠
step 2 length = 20-10 = 10 mm Inject time = t1 + t2
𝑆2 10 = 1,91 + 0,45
𝑡2 = = = 0,45 𝑠 = 2,36 s
𝑣2 22,04
2
 Q=Axv
𝑚𝑚
Q = 56548 𝑚𝑚2 x 33,06
𝑠
6 𝑚𝑚3
Q = 1,87 . 10
𝑠
−3 𝑚3
Q = 1,87 . 10
𝑠

*ilustrasi injection unit MA6000

Injection Cylinder mesin standard :

MA1600II/540e. Piston Ø 115 Rod Ø 50 Luas penampang silinder untuk
stroke maju = 28274 𝑚𝑚2
MA2500II/1000e. Piston Ø 145 Rod Ø 65 Total luas penampang =
MA2800II/1350e. Piston Ø 160 Rod Ø 70 2 x 28274 = 56548 𝑚𝑚2

MA3800II/2250e. Piston Ø 185 Rod Ø 80

−3 𝑚3
MA5300II/4000e. Piston Ø 210 Rod Ø 90 Kesimpulan : Mesin MA6000 menggunakan debit 1,87 . 10 ,
𝑠
MA6000II/4500. Piston Ø 210 Rod Ø 90 Untuk mencapai speed 30% (33,06 mm/s)
3
 Power = Pressure X Debit
𝑉𝑜𝑙𝑢𝑚𝑒
𝑊𝑎𝑡𝑡 = 𝑃𝑎𝑠𝑐𝑎𝑙 𝑋
𝑊𝑎𝑘𝑡𝑢
𝐸𝑛𝑒𝑟𝑔𝑖 𝐺𝑎𝑦𝑎 𝑉𝑜𝑙𝑢𝑚𝑒
(𝑊𝑎𝑡𝑡) = 𝑋
𝑊𝑎𝑘𝑡𝑢 𝐿𝑢𝑎𝑠 𝑊𝑎𝑘𝑡𝑢

𝐽𝑜𝑢𝑙𝑒 (𝐺𝑎𝑦𝑎 𝑋 𝐽𝑎𝑟𝑎𝑘) 𝐺𝑎𝑦𝑎 𝑉𝑜𝑙𝑢𝑚𝑒

= 𝑋
𝑊𝑎𝑘𝑡𝑢 𝐿𝑢𝑎𝑠 𝑊𝑎𝑘𝑡𝑢
𝑁 .𝑚 𝑁 𝑚3
= 2𝑋
𝑠 𝑚 𝑠
𝑁 .𝑚 𝑁. 𝑚
=
𝑠 𝑠
 Perbedaan power saat mesin menggunakan pressure 88 bar & 76 bar

Power = Pressure X Debit (Q) Power = Pressure X Debit (Q)

3 −3 𝑚3
−3 𝑚 Power = 76 bar X 1,87 . 10
Power = 88 bar X 1,87 . 10 𝑠
𝑠
3 𝑁 𝑚3
Power = 88. 5 𝑁
10 2 X 1,87 . 10 −3 𝑚 Power = 76. 105 2 X 1,87 . 10 −3
𝑚 𝑠 𝑚 𝑠
𝑁 3 6 𝑁 −3 𝑚3
−3 𝑚 10 2 10
Power = 8,8 106 2 X 1,87 . 10 Power = 7,6
𝑚
X 1,87 .
𝑠
𝑚 𝑠
Power = 16,456 . 103 Watt Power = 14,212 . 103 Watt
Power = 16,456 kW Power = 14,212 kW

Berdasarkan perhitungan teoritis, selisih power yang digunakan oleh mesin saat menggunakan pressure
88 bar & 76 bar adalah 16,456 – 14,212 = 2,244 kW

4
Berdasarkan grafik diatas, waktu yang dipakai untuk mencapai peak pressure
Adalah sekitar 1,9 detik (0,00053 jam)

Sehingga dalam 1 siklus injeksi ada perbedaan energi (pressure 88 bar & 76 bar) sebesar =
2,244 x 0,00053 = 0,0012 kWh

CT part 2453 adalah 47 detik, sehingga dalam 1 hari (24 jam) produksi ada ± 1800 siklus injeksi.
Sehingga energi yang dihemat dalam 1 hari = 0,0012 x 1800 = 2,16 kWh

Misal harga listrik per 1 kWh adalah Rp 10.000 (asumsi), maka cost yang dapat dihemat dalam 1 hari =
2,16 x Rp 10.000 = Rp 21.600,00 5
Problem Sharing :
1. Bubbles
There are 3 possibility why the bubbles can happen in the part :
- Material drying process is not good
If the drying process is not properly, it will cause the water concentration in the material is still high. The water will be
Vapour when the material is melted in the barrel. So, make sure the drying process run properly according to the standard.
- Cavitation in the barrel (when charging process) *cavitation video
When the charging RPM speed is too high & the difference between theoritical chg.time and actual chg.time is too big,
It will may be cause the cavitation. That’s why BASF give us refference for peripherall screw speed is < 0,3 m/s.
So, we have to make chg. Parameter with speed is below that limit (depend on screw diameter).
And the difference between theoritical & actual chg.time is not too big.

- Gas trap in the mold during injection process

During the injection process, there is a transfer of air volume inside the cavity that is driven by the flow of plastic material.
If the air that comes out does not fluently through the gasvent, then this will cause bubbles.
So, make sure the gasvent in the mold is enough (minimal 30% of PL perimeter). And make sure the gasvent works normally,
There is no dirt covering the gasvent.
Problem Sharing :
2. Burnmark
Burnmark is also caused by trapped gas.

P . V . T Laws (pressure, volume, temperature)

From shot step above, we can know the burnmak is the final
filling area of material flow from 3 gates. When the material
Flows, it will push the air to final filling. When the air is compressed,
The temperature will increase and cause burnmark. If the volume smaller (V2), then the presseure (P2)
And temperature (T2) will increase
Solution : improve setting parameter, make the injection speed
Slower when the position already near with final filling position.
To give chance the air flows out through gasvent. or
Add more gasvent by make new insert
Problem Sharing : Improve sinkmark
We can improve sinkmark condition by add the step in holding parameter.
In this case, we make the holding from 1 step become 2 step.
At 2nd step, we add the holding time 1 s. From injection graph, we can see.
Actually, the material flow is stopped after the holding run for 0,3 s.
We can consider it as cooling time start (when 2nd holding run,
Cooling process also run). So, we can reduce cooling time parameter -1 s
Before After To keep the cycle time is still the same.

Box 1: record before improve, Box 2 : record after improve

1
Problem Sharing : Gate burn in 2468
Gate burn, Conclusion : if the flow speed is too high, it will cause
greater friction. As a result of the friction, the temperature
in mold 2468
at the friction area will increase. Regardless of the quality
of gate material is good or not, we already have a reference
that if the flow speed reach 95000 mm/s, it will cause burn in gate.
Screw speed : 45 mm/s So, we have to decrease injection speed. Or change gate design
Ø Barrel : 65 mm
1
A barrel : 𝜋𝐷2
4
1
: . 3,14 . 652 = 3316,6 𝑚𝑚2
4
Q in barrel : v x A
: 45 x 3316,6 = 149247 𝑚𝑚3 /s
Ø gate : 1 mm
∅1 1
A gate : 𝜋𝐷2
4
1
: . 3,14 . 12 = 0,785 𝑚𝑚2
4
A total : 2 x 0,785 = 1,57 𝑚𝑚2
Material flow speed at gate position :
𝑄 149247
𝑣= = = 95062 𝑚𝑚/𝑠
𝐴 1,57
Problem Sharing :

0191 Cavity Broken

Analysis
By : Anggun Huda P.
R&D Dept.
*side section_mold 0191
We usually set the clamping pressure 1000 – 1500 Psi.
So when we set in 1000 Psi, the clamping force is about 140 Ton
 Fy from clamping

In ideal conditions received Fy by insert section

is (the cross-section of the insert is divided all over
Cross-section of the PL) x clamping force.
If at the time of clamping, the insert area touching first
than in other PL areas, the insert area will
receive Fy force as big as clamping force. Fx
Fx
Because there is a slope L
in the contact area,
So there is a reaction
force in the direction of
X axis

The Fx force multiplied by L distance, will give rise to a bending moment.

This bending moment will cause a bending strain in the insert.
If the bending strain that occurs exceeds the bending strain of the material,
Then the insert will break
Bending Strain F.L
b 
b = Bending strain Wb
F = Force strain I
Wb = Resistance moment Wb 
0.5b
ℎ. 𝑏 3
F 𝐼𝑦 =
h
12

L
 Mb
Fy = 140 Ton b 
Wb
= 140000 x 9.8
= 1372000 N 3,35.106
b 
Fx = Fy . tan 10° 106,2
= 1372000 x 0,176
= 241472 N  b  31544 𝑁/𝑚𝑚2
Mb = Fx . L
= 241472 . 13,89 Conclusion:
= 3,35. 106 𝑁𝑚𝑚 The insert area receives a bending strain
Much bigger than the bending strain
of the permit allowable material.
So the insert after receiving the recurring force,
It will break.
ℎ. 𝑏 3 𝐼𝑦
𝐼𝑦 = 𝑊𝑏 =
12 0,5𝑏
371,6
13. 73 𝑊𝑏 =
𝐼𝑦 = 0,5 . 7
12
𝑊𝑏 = 106,2 𝑚𝑚3
𝐼𝑦 = 371,6 𝑚𝑚4
Material strain table
Tabel 1-01
Kekuatan Bahan untuk Baja (N/mm2)
Tegangan Tegangan Tegangan Tegangan Tegangan Tegangan
Modulus Modulus Resistan Resistan
tarik tarik bengkok bengkok puntir puntir
Elastisitas Geser Max extension
Bahan berulang berganti berulang berganti berulang berganti

E G Rm Re t.ul t.gt b.ul b.gt p.ul p.gt

St 37 210,000 80,000 370 240 240 175 340 200 170 140
St 42 210,000 80,000 420 260 260 190 360 220 180 150
St 50 210,000 80,000 500 300 300 230 420 260 210 180

St 52 210,000 80,000 520 320 320 240 430 280 220 190
St 60 210,000 80,000 600 340 340 270 470 300 230 210
St 70 210,000 80,000 700 370 370 320 520 340 260 240

50 Cr Mo4 210,000 80,000 900 860 500 940 540 630 370
20 Mn Cr 5 210,000 80,000 700 700 540 980 600 490 340
 0194 & 2452 MOLD
SPRING FORCE TOO BIG
By : Anggun Huda P.
R&D Dept.
Eject Bwd Problem_MA2800
Eject backward movement
So fast, although in setting
parameter already set
Zero “0” (pressure & speed).
The ejector also move back.
Although eject backward button
Is not pressed.

There are 2 possibility cause :

- Machine (flow control valve)
- Mold spring (too big force)
0194 MOLD_SPRING CONFIGURATION

*there are 6 yellow spring *spring dimension

*spring technical data

 X1 = 94,26 – 80,92 = 13,34 mm

*Before thightening EP plate *After thightening EP plate

Ejector Forward Ejector Forward Ejector Backward Ejector Backward X2 = 33 mm

F5 Ejector #1 #2 #1 #2
Total X = 13,34 + 33 = 46,34 mm
Position MM 15 33 1 10

Pressure Mpa 45 45 25 25

Speed % 10 15 15 15

*Eject parameter in 0194

 REACTION FORCE IN SPRING AT MAX. EJECT POSITION

Known : k = 56,4 N/mm Conclusion : The spring reaction force in mold 0194 is about 15,6 kN.
X = 46,34 mm Another mold (2274) that run in same machine, use 4 yellow spring.
n = 6 springs It’s mean the reaction force is about (4/6) x 15,6 = 10,4kN.
And there’s no problem in mold 2274.
It’s too big force, only to push the EP plate back in the normal position.
Calculation : So we can change the spring in mold 0194 with same dimension, but
Σ F = n.k.x With lower spring constant.

F = 6 . 56,4 . 46,34 𝐹
𝑘=
F = 15681 N 𝑛.𝑥
10000
𝑘=
6 . 46,34
𝑘 = 36 𝑁/𝑚𝑚
Problem Sharing :

Injection process not stable

In MA6000

By : Anggun Huda P.
R&D Dept
Part problem in MA6000:
2482 2453 2484

The part problems in MA6000

Is more than 10.000 ppm
With the same charging parameters, the transfer position (V / P change) that happens is always changing.
In inject parameter (F3), the transfer position (V / P change) is setted at position 10. From the record above
there are several shots Holding position occurs at position up to 13.4 (difference of 3.4 with setting).
All holding position above 10, inject time is definitely 6. Means when the process of inject before until position 10,
the product volume is full. So the screw can not move forward again (to get to position 10). But actually the machine
will keep trying to push the screw to reach point 10, Until the inject time limit is reached (5 seconds).
Then after that V / P change (holding) run for 1 second.
So it can be concluded that the density in the shot metering area is not always stable.
With the same charging parameters, actual charging time is always changing (up and down). The cushion is also up and down.
This constantly changing cushion indicates the density of the material produced in shot metering area is unstable.
The interesting thing is when the cushion is low (meaning the step length is greater), The actual inject time that happens
is even faster. In other words injection speed increases when the cushion happens is lower (material density smaller).
This is very logical, with the same inject pressure, if the load / resistance (when the inject process) is smaller,
then the resulting speed will be bigger.
Which affects the charging process:
1. Speed (Rpm) screw
2. Pressure
3. Backpressure
4. Material suply
5. Screw and barrel condition
6. .....????
*charging graph in MA6000 *charging graph in MA3800

From the graph above, the most striking difference is the purple line (backpressure graph). In the MA3800 machine,
Backpressure tends to be more stable. While in the MA6000 machine, backpressure tends to be unstable (up and down).

Backpressure is the most influential parameter to the density generated in the shot metering area.
So it can be concluded that the problem in the MA6000 machine is
Possible in the part of the system that regulate backpressure
 This is a Flow control valve circuit diagram
in Haitian machine.
The function of flow control valve
is to set the hydraulic oil flow.
One of them is during the charging process,
Flow control valve will inhibit
Outflow of oil from inside
Hydraulic cylinder (backpressure).
So this resistance force will make
density in the shot metering area increases.

Conclusion :
Valve number 10.1, 10.2, 10.3
*hydraulic circuit Haitian machine
Is possible problem.
So it needs to be checked
Production Trial Run 2453 in MA5300
We already try to run production
Part 2453 in MA5300 machine,
For 2 shift production.
And the result is good.
The process is also stable.
After Haitian’s Service
Haitian technicians already check the MA6000 machine. And try to improve setting parameter.
BEFORE BEFORE BEFORE
F8 Temperature℃ F4 Suck F3 Injection #6 #5 #4 #3 #2 #1
#1 #2 #3 #4 #5
Parameter Setting℃ Tolerance Purging/Charging Back Position MM 10 20
#1 285 ±10 Position MM 20 30 62 / / 7 Setting / / / / 40 75
Pressure
#2 290 ±10 Pressure Setting 80 80 80 / / 40 Mpa Tolerance / / / / ±5 ±5
#3 285 ±10 Mpa Tolerance ±5 ±5 ±5 / / ±5
Setting / / / / 7 25
#4 285 ±10 Setting 40 40 40 / / 40 Speed %
Speed % Tolerance / / / / ±3 ±3
#5 280 ±10 Tolerance ±5 ±5 ±5 / / ±5
Time (s) Position MM Pressure Mpa
#6 280 ±10 Back Pressure Mpa 6 6 6 / / / Toleran Toleran Toleran
Transfer Position Setting Setting Setting
ce ce ce
5,0 ±1 10 ±1

AFTER AFTER AFTER

F8 Temperature℃ F4 Suck F3 Injection #6 #5 #4 #3 #2 #1
#1 #2 #3 #4 #5
Parameter Setting℃ Tolerance Purging/Charging Back Position MM 8 18
#1 280 ±10 Position MM 20 58 64 / / 8 Setting / / / / 55 75
Pressure
#2 285 ±10 Pressure Setting 80 80 80 / / 40 Mpa Tolerance / / / / ±5 ±5
#3 285 ±10 Mpa Tolerance ±5 ±5 ±5 / / ±5
Setting / / / / 7 25
#4 280 ±10 Setting 40 40 40 / / 40 Speed %
Speed % Tolerance / / / / ±3 ±3
#5 270 ±10 Tolerance ±5 ±5 ±5 / / ±5
Time (s) Position MM Pressure Mpa
#6 260 ±10 Back Pressure Mpa 7 7 5 / / / Toleran Toleran Toleran
Transfer Position Setting Setting Setting
ce ce ce
5,0 ±1 8 ±1
Machine record After Haitian’s Service

Haitian’s technician already try to improve

The setting parameter.
But the actual chg.time is still unstable
AFTER CHECKING
THE CHECK VALVE & TORPEDO
Our maintenance team already open the barrel.
There is a lump of material inside the check valve.
This lump of material blocks the flow of material
when charging process run.
So the charging time is unstable.
This lump of material also blocks
the movement of check valve to close when injecting.
So that the back flow occurs and the cushion is unstable
Machine record after clean the torpedo & check valve

BEFORE AFTER