A05-01-007 Introduction To Machine and Process Conditions: August, 2019

A05-01-007
Introduction to Machine and Process

Conditions
August, 2019
CoreTech System Co., Ltd. www.moldex3d.com

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please contact mail@moldex3d.com .
2
What to learn
> Learning objectives

– How to set the Flow and Pack inject properties
– How to control cooing time
> Moldex3D version

– All Moldex3D product
> Recommended user

– All Moldex3D user
3
Outline
> Introduction to Injection Molding Machine

– Function and classification
– Different units
> Introduction to Process Conditions

– How to specify the process conditions
• Filling and switchover conditions
• Packing conditions
• Cooling conditions
4
Introduction to Injection Molding
Machine

Injection machine
Injection unit
Mold unit
Hydraulic unit
Clamping unit
Control unit
6
Function
> Functions of injection molding machine

– Move mold
– compose mold's closing compression
– Inject material into mold
– Plasticize new batch.
> Different types of injection molding machines
– Mechanical
– Hydraulic
– Electric-hydraulic
– Electric
7
Classification
> The injection molding machine can be classified into

clamping force, injection pressure, screw size and
injection capacity.
> The ranges of these classifications are typically:
– Clamping force: 200 – 100,000 kN
– Injection pressure: 120 - 250 MPa
– Screw diameter: f18 - f120 mm
– Injection Capacity: 0.5 -5Kg
8
Control Unit
> It is the medium of machine control and settings. It can

control the closing unit to close mold and injection unit to
inject melt at a correct time & amount. Controlling unit
can also monitors injection process parameters.
– Temperature
– Pressure
– Injection speed
– Screw speed and position
9
Injection unit
> Function:
– To melt the plastic materials and then inject the resin into
mold
> Units:
– Barrel
– Screw
– Nozzle
– Heating coils
– Hopper
10
Clamping unit
> A clamping unit moves mold halves toward and further

each other. It also composes the clamping force.
> Clamping units are divided in mechanical, hydraulic and
hydraulic-mechanical units. Clamping unit is the biggest
part of an injection molding machine.
Mechanical Hydraulic
11
Clamping Force
> Clamping force is the maximum force of machine to keep the

mold closed against the cavity pressure during injection.
> It should be greater than the cavity force in the mold. The cavity
force depends on injection pressure and projected area of
molded part.
Clamping force = Projected area X Injection pressure
> Projected area = Surface area = 10 in x 10 in = 100 in2 injection
– Injection Pressure = 15,000 psi
– Tonnage required to keep mold closed is
100 in2 x 15,000 psi= 1,500,000 lbs = 750 tons
12
Mold unit
> Function:
– To form the parts with molten plastics
> Units:
– Runner
Runner & gate Cooling channels
– Gate
Cavity
– Cavity (female mold)
– Plates
– Cooling channels
– Insert
• Part insert
• Mold insert
Please refer to Mold design chapter.
Core (male mold) Parting line
13
Introduction to Process Conditions

Factors Affecting Injection Molding
Material Selection
Mold Design
Machine and Process Setting
> Productivity and Quality of Molding Product Design
15
Injection Molding Cycle
Cooling stage Mold opening and Part Ejection

(Plasticating for next shot)
Mold Closing
Injection Unit Forward
Filling stage
Packing/Holding stage
Nozzle Disengage Injection Unit Backward
16
Indirectly Quality Control for
Injection Molding Process
Controlling Plastic Processing Conditions
Molding Machine Plastic Processing

Controls Molded Part Properties
Conditions
• Barrel temps. • Temperature • Dimensions

• Mold temps. • Flow • Impact
• Fill rates • Pressure • Tensile
• Transfer set pt. • Cooling • Chemical
• Packing pr. • Optical
• Packing timer
• Holding pr.
• Holding timer
• Cooling time
Source: Paulson training material

17
Questions
> Before to get in detail, what do we need to know.

> How to setup the suitable process conditions, so we can
obtain good quality of product through the stable
processing?
– What should be for melt temperature?
– What should be mold temperature?
– What should be for filling time, flow rate, and injection
pressure?
– What should be packing pressure, and packing time?
– What should be the cooling time?
18
What do we need to know
Response and Machine Setting
> The difference between the machine setting and its
response
> Stability of process
> The environment variation
Green: speed setting
> Human issue Blue: true response
19
Process Condition Specify
20
Process Condition Specify (Cont’d)
21
Setup of Melt Temperature
> Melt Temperature (Processing Temperature)

– The temperature of the polymer melt as it enters the mold
– May be different from the barrel temperature setting
Tb
barrel
temperature
Temperature rise: melt

viscous concentrates in the temperature
(nozzle)
Tb + T
22
Simulation Method and Procedures:
ScrewPlus
Injection Molding Process Screw Process
Quality of Injected ScrewPlus*

products History of Pre- Process
* ScrewPlus simulator is developed by Compuplast international In.

23
Melting Profile at exit of Screw: ABS
Melt temperature is affected by

the primary channel depths.
240
Tip temperature: the melt
average temperature at the T (melt)
Temperature, oC
exit of screw. 235
T (Tip)
Melt temperature: the 230

melt temperature at the
entrance of injected
cavity system. 225
1 1.5 2 2.5 3 3.5
Gap of metering section, mm
24
Mold Temperature
> Mold Temperature Type of Material Mold Temperature (℃)

– It is necessary to set mold AS 40-70
temperature as high as
ABS 40-75
possible, and it is desirable to
fill the resin rapidly into the GPPS 50-70
cavity and cool the resin HIPS 55-75
uniformly. That is, increasing PP 40-70
the mold temperature lowers
PE 35-55
the resin flow resistance,
makes orientation small, but it PMMA 55-75
will be extended the cooling PVC 40-60
time and the cycle time.
PC 70-95
PA 60-90
POM 60-80
PSF 85-140
PBT 50-70
CA 50-85
PPO 60-80
25 PET 90-120
Setup of Fill Time
Flow Rate (g/sec)

Flow Rate
V part
Q  P
t Fill
tFill = 1 sec
Q  Qmax
Time (sec)
Flow Rate (g/sec)

Flow Rate (g/sec)
tFill = 2 sec tFill = 4 sec
Time (sec) Time (sec)
26
Setup of Fill Time
> Faster filling speed (shorter fill time)

– Reduce the cycle time
– Higher viscous heating and higher shear rate
– Higher pressure drop and injection pressure required
> Limits to the injection speed (fill time)
– Machine capability
– Type of plastics
– Product design and Mold design
27
Setup of Fill Time
> Fill Time-Pressure Curve
Pmax
Injection Pressure (Loss)
Suggested Fill Time

(Minimum injection pressure)
Viscous Flow Heat Transfer Control

Control
28
Fill Time
Setup of Flow Rate Profile
Q4 = V4 A4
Q2
Q3 = V3 A3
fast filling
Q3
Flow Rate
Q1 Q4
Q2 = V2 A2 avoid pressure overshoot

avoid jetting and help air venting
Q1 = V1 A1 Time or Section
in general, A1 ,A4  A2 ,A3
Constant profile: Q = V1  A1 = V2  A2 = V3  A3 = V4  A4
V1 ,V4  V2 ,V3
Variable profile: Q1 ,Q4  Q2 ,Q3
29
Setup of Flow Rate Profile
in general, A1 << A2  A3 < A4

Constant profile: Q = V1  A1 = V2  A2 = V3  A3 = V4  A4
V1 >> V2  V3 > V4
Q1 Variable profile: Q1 < Q2  Q3 > Q4
Q2
Q3
Q4
Q3
Q1 = V1  A1
Q2 = V2  A2
Q2
Q3 = V3  A3
Flow Rate
Q4 = V4  A4
flow rate is regulated
Q1 according to the flow area
Q4
avoid pressure overshoot

avoid jetting
and help air venting
30
Time or Section
Setup of Injection Pressure
> Injection Pressure

– The pressure exerted on the melt in front of the screw tip
during the injection stage, with the screw acting as a
plunger.
– Affects both the speed of screw ram and filling process in
the mold cavity.
Pinject  Pinject,max
Phydraulic Ahydraulic
Pinject,max  Phydraulic ~ (7 −10 ) Phydraulic
Abarrel
31
Setup of Machine Conditions
> Maximum Machine Pressure

– Maximum injection pressure available
– ~10 maximum hydraulic pressure available
injection pressure, Pi
hydraulic pressure,
Ph
A  barrel area, Ab
piston area, Ah
Pi =  h  Ph = (7 ~ 10 ) Ph
 Ab 
32
Setup of Packing Time
> Effective Packing Time=Gate Freeze Time
Shot Weight
packing around
gate only
gate freeze time
Effective
Packing Time
Packing Time
33
Setup of Packing Time
> Setup of Packing Time

– Depends on part thickness, gate dimension, cavity pressure
build up, etc.
– Typical value: 3~10 sec (for thickness<3mm, mold
temperature < 60 oC )
tpack<tfreeze, backflow occurs
34
Setup of Packing Pressure
> Packing Pressure

– The pressure exerted on the melt entrance during the
packing/holding stage.
– Affects the dimensional accuracy and cosmetic quality of
the molded part
Ppack
pressure-control mode
35
Setup of Packing Pressure
Pressure Level
Packing
End of Filling
Filling
Flow Length
36
Setup of Packing Pressure Profile
P1
P2
P3
t1 t2 t3
Usually, tpack=3~10 sec (thickness<3 mm, Tmold<60 oC)

>t1=1/2 tpack, t2=1/3 tpack , t3=1/6 tpack (or t1=2/3 tpack, t2=1/3 tpack )
>P1,P2,P3 depends on cooling rate (cavity pressure reduction rate)
37
Setup of Switchover Percentage
> Switchover Percentage

– Ensures a smooth transition from the filling (flow-rate
control) stage to the packing (pressure-control) stage.
– Volume percentage: 0%~100%
– Default value: 98% (switchover during filling stage)
Screw holding
filling packing
Ram
Position
switch-over point
Cavity (Mold)
Pressure
Hydraulic
Pressure
38
Time
Setup of Switchover Percentage
Correct switchover Switchover too Late

•Smooth transition •pressure peak
Cavity Pressure
Cavity Pressure
•After volumetric filling •Backflow of melt
Time Time
Without switchover Switchover too Early
•Filling under packing pressure
Cavity Pressure
•pressure spike
Cavity Pressure
•Pressure and flow rate loss

•Switch-over marks
Time
39
Time
Setup of Cooling Time
> Theoretical Minimum Cooling Time (TMCT)

– Estimation of minimum cooling
time required Thermal
Material Diffusivity
(x10-3cm2/sec)
ABS 1.334
Acetal 1.268
h2  8 TP − TM 
t c = 2 ln 2  Acrylic 1.5483
  p   TE − TM  Epoxy 3.670
Nylon, PA 1.106
, thermal diffusivity, cm 2 / sec 
k PA 66 1.10
p 
C P Phenylene Oxide 1.543
k = thermal conductivity,  erg / sec - cm - o C  PP 0.706
 = density,  g / cm 3  PC 1.050
CP = heat capacity, erg / g - o C  Polyester 1.359
h = maximum part thickness,  cm  LDPE 1.70
TP = polymer melt temperature,  C o HDPE 2.00

PS 0.867
TM = mold wall temperature,  C  o
Vinyl, PVC 1.081
TE = ejection temperature,  C  o
POM 0.92
40
Setup of Cooling Time
Plastics Cooling Time Required (sec) for Part with Thickness (mm)
0.5 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 3.00 3.75 4.50 5.00 5.50 6.25
ABS - 1.8 2.9 4.1 5.7 7.4 9.3 11.5 13.7 18.8 28.5 40.1 49.0 58.3 75.0
PA - 2.5 3.8 5.3 7.0 8.9 11.2 13.4 15.9 21.5 32.0 44.5 53.9 63.9 80.8
HDPE 1.8 3.0 4.5 6.2 8.0 10.0 12.5 14.7 17.5 23.5 34.5 47.7 57.5 67.9 85.0
LDPE - 2.3 3.5 4.9 6.6 8.4 10.6 12.8 15.2 20.7 30.9 43.2 52.4 62.1 79.0
PP 1.8 3.0 4.5 6.2 8.0 10.0 12.5 14.7 17.5 23.5 34.5 47.7 57.5 67.9 85.0
PS 1.0 1.8 2.9 4.1 5.7 7.4 9.3 11.5 13.7 18.9 28.5 40.3 49.0 58.3 75.0
PVC - 2.1 3.3 4.6 6.3 8.1 10.1 12.3 14.7 20.0 30.0 42.2 51.1 60.7 77.5
Empirical cooling time equation
 h  (1 + 2h ), for part thickness h < 4 mm, mold temperature < 60o C

tc = 
1 . 3  h  (1 + 2 h ), for part thick ness h < 4 mm, mold temperatu re > 60 o
C
41
Setup of Ejection Temperature
> Ejection Temperature

– Temperature at which part can be ejected without damage
– Determines the cooling time required (if CoolTime=0)
– Lower than transition temperature, higher than mold
temperature
TE
1atm curve
Tmold Tm or Tg
42
Setup of Air Temperature
> Air Temperature

– the ambient air temperature surrounding the mold
– may influence final part temperature distribution
Heat to air
(<30%)
43
Setup of Coolant Temperature
> Coolant Temperature

– Default temperature of coolant in the cooling channels
– Water (10~80oC), Mineral Oil (0~200oC)
– Influences thermal properties of coolant, as coolant
temperature increases
• viscosity and density is reduced
• heat capacity and thermal conductivity increases
• usually heat transfer coefficient increases
– Influences heat transfer efficiency of the cooling channels
44
Setup of Coolant Flow Rate
> Coolant Flow Rate

– Default value for each cooling channel
– The greater the coolant flow rate (velocity), the better the
heat transfer effect
4Q
Re  Reynolds Number Re<2100
D Laminar Flow
Poor HT
D = diameter of cooling Re>4000

channel, [cm] Turbulent Flow
Better HT
 = coolant density, [g / cm 3 ] Re>10,000

 = coolant viscosity, [poise] Complete
Turbulence
Q=coolant flow rate, [cc / sec]
Excellent HT
45
Setup of Coolant Flow Rate
Diameter of Cooling Channel Flow Rate for Water Flow Rate for Mineral Oil
D (mm) Q (cc/sec) Q (cc/sec)
5 16 46
8 26 74
10 32 92
12 38 110
14 45 129
15 48 138
20 64 184
25 80 230
30 96 276
for Re  4000 or
1000D  3.2 D for water
Q  Q in cc/sec, D in mm
 9.2 D for oil
46

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A05-01-007

Introduction to Machine and Process

CoreTech System Co., Ltd. www.moldex3d.com

The following content is provided for educational purposes by CoreTech

Copyright for the following material is primarily held by the CoreTech

> Learning objectives

– How to control cooing time

> Moldex3D version

> Recommended user

> Introduction to Injection Molding Machine

> Introduction to Process Conditions

• Filling and switchover conditions

CoreTech System Co., Ltd. www.moldex3d.com

> Functions of injection molding machine

> The injection molding machine can be classified into

> It is the medium of machine control and settings. It can

> A clamping unit moves mold halves toward and further

> Clamping force is the maximum force of machine to keep the

> Projected area = Surface area = 10 in x 10 in = 100 in2 injection

– Injection Pressure = 15,000 psi

– Tonnage required to keep mold closed is

100 in2 x 15,000 psi= 1,500,000 lbs = 750 tons

Core (male mold) Parting line

CoreTech System Co., Ltd. www.moldex3d.com

Machine and Process Setting

> Productivity and Quality of Molding Product Design

Cooling stage Mold opening and Part Ejection

Injection Unit Forward

Nozzle Disengage Injection Unit Backward

Controlling Plastic Processing Conditions

Molding Machine Plastic Processing

• Barrel temps. • Temperature • Dimensions

Source: Paulson training material

> Before to get in detail, what do we need to know.

> Melt Temperature (Processing Temperature)

Temperature rise: melt

Injection Molding Process Screw Process

Quality of Injected ScrewPlus*

* ScrewPlus simulator is developed by Compuplast international In.

Melt temperature is affected by

Melt temperature: the 230

> Mold Temperature Type of Material Mold Temperature (℃)

Flow Rate (g/sec)

Flow Rate (g/sec)

tFill = 2 sec tFill = 4 sec

Time (sec) Time (sec)

> Faster filling speed (shorter fill time)

> Fill Time-Pressure Curve

Suggested Fill Time

Viscous Flow Heat Transfer Control

Q2 = V2 A2 avoid pressure overshoot

in general, A1 << A2  A3 < A4

avoid pressure overshoot

> Injection Pressure

> Maximum Machine Pressure

> Effective Packing Time=Gate Freeze Time

gate freeze time

> Setup of Packing Time

tpack<tfreeze, backflow occurs

> Packing Pressure

Usually, tpack=3~10 sec (thickness<3 mm, Tmold<60 oC)

> Switchover Percentage

Correct switchover Switchover too Late