:‫أوال سنبدا باخذ نظرة عامة وجانب نظري عن الماكينة واجزائها‬

Machine components

1. Injection system

The injection system consists of a hopper, a reciprocating screw and barrel assembly, and an injection
nozzle, as shown in Figure 1. This system confines and transports the plastic as it progresses through the
feeding, compressing, degassing, melting, injection, and packing stages.

Figure 1 A single screw injection molding machine for thermoplastics, showing the plasticizing screw, a barrel,band
heaters to heat the barrel, a stationary platen, and a movable platen.

2. The hopper

Thermoplastic material is supplied to molders in the form of small pellets. The hopper on the injection
molding machine holds these pellets. The pellets are gravity-fed from the hopper through the hopper
throat into the barrel and screw assembly.

3. The barrel

As shown in Figure 1, the barrel of the injection molding machine supports the reciprocating
plasticizing screw. It is heated by the electric heater bands.

4. The reciprocating screw

The reciprocating screw is used to compress, melt, and convey the material. The reciprocating screw
consists of three zones (illustrated below):
the feeding zone
the compressing (or transition) zone
the metering zone
While the outside diameter of the screw remains constant, the depth of the flights on the reciprocating
screw decreases from the feed zone to the beginning of the metering zone. These flights compress the
material against the inside diameter of the barrel, which creates viscous (shear) heat. This shear heat is
mainly responsible for melting the material. The heater bands outside the barrel help maintain the material in
the molten state. Typically, a molding machine can have three or more heater bands or zones with different
temperature settings.
 Figure 2 A reciprocating screw, showing the feeding zone, compressing (or transition) zone, and metering zone.

5. The nozzle
The nozzle connects the barrel to the sprue bushing of the mold and forms a seal between the
barrel and the mold. The temperature of the nozzle should be set to the material's melt temperature
or just below it, depending on the recommendation of the material supplier. When the barrel is in its
full forward processing position, the radius of the nozzle should nest and seal in the concave radius
in the sprue bushing with a locating ring. During purging of the barrel, the barrel backs out from the
sprue, so the purging compound can free fall from the nozzle. These two-barrel positions are
illustrated below.

Figure 3 (a) Nozzle with barrel in processing position. (b) Nozzle with barrel backed out for purging

6. Mold system

The mold system consists of tie bars, stationary and moving platens, as well as molding plates
(bases)that house the cavity, sprue and runner systems, ejector pins, and cooling channels, as shown in
Figure 4.The mold is essentially a heat exchanger in which the molten thermoplastic solidifies to the
desired shape and dimensional details defined by the cavity.

Figure 4 A typical (three-plate) molding system.

An mold system is an assembly of platens and molding plates typically made of tool steel. The mold
system shapes the plastics inside the mold cavity (or matrix of cavities) and ejects the molded part(s).

The stationary platen is attached to the barrel side of the machine and is connected to the moving platen
by the tie bars. The cavity plate is generally mounted on the stationary platen and houses the injection
nozzle. The core plate moves with the moving platen guided by the tie bars. Occasionally, the cavity
plate is mounted to the moving platen and the core plate and a hydraulic knock-out (ejector) system is
mounted to the stationary platen.

Two-plate mold

The vast majority of molds consist essentially of two halves, as shown below. This kind of mold is used
for parts that are typically gated on or around their edge, with the runner in the same mold plate as the
cavity

Three-plate mold

The three-plate mold is typically used for parts that are gated away from their edge. The runner is in two
plates, separate from the cavity and core, as shown in Figure 5 below.

Figure 5 (Left) A two-plate mold. (Right) A three-plate mold.

7. Cooling channels (circuits)

Cooling channels are passageways located within the body of a mold, through which a cooling
medium (typically water, steam, or oil) circulates. Their function is the regulation of temperature on
the mold surface. Cooling channels can also be combined with other temperature control devices, like
bafflers, bubblers, and thermal pins or heat pipes.

8. Hydraulic system

The hydraulic system on the injection molding machine provides the power to open and close the
mold, build and hold the clamping tonnage, turn the reciprocating screw, drive the reciprocating
screw, and energize ejector pins and moving mold cores. A number of hydraulic components are
required to provide this power, which include pumps, valves, hydraulic motors, hydraulic fittings,
hydraulic tubing, and hydraulic reservoirs.

9. Control system
The control system provides consistency and repeatability in machine operation. It monitors and
controls the processing parameters, including the temperature, pressure, injection speed, screw
 speed and position, and hydraulic position. The process control has a direct impact on the final part
quality and the economics of the process. Process control systems can range from a simple relay
on/off control to an extremely sophisticated microprocessor-based, closed-loop control.

10. Clamping system

The clamping system opens and closes the mold, supports and carries the constituent parts of the
mold, and generates sufficient force to prevent the mold from opening. Clamping force can be
generated by a mechanical (toggle) lock, hydraulic lock, or a combination of the two basic types.

11. Molded system

A typical molded system consists of the delivery system and the molded part(s), as shown in Figure 6

Figure 6 The molded system includes a delivery system and molded parts.

12. The delivery system

The delivery system, which provides passage for the molten plastic from the machine nozzle to the part
cavity, generally includes:
• a sprue
• cold slug wells
• a main runner
• branch runners
• gates
The delivery system design has a great influence on the filling pattern and thus the quality of the molded
part.

- Cold runners
After molding, the cold-runner delivery system is trimmed off and recycled. Therefore, the delivery
system is normally designed to consume minimum material, while maintaining the function of
delivering molten plastic to the cavity in a desirable pattern.
- Hot runners

The hot-runner (or runnerless) molding process keeps the runners hot in order to maintain the
plastic in a molten state at all times. Since the hot-runner system is not removed from the mold with
the molded part, it saves material and eliminates the secondary trimming process.
 ‫كيف نختار نوع او تصميم الماكينة المطلوبة‪:‬‬
‫المعلومات ماخوذة من يوتيوبر مصري )‪(538‬إزاى تشترى ماكينة حقن بالستيك‪- YouTube‬‬

‫يستخدم ال‪ reciprocating plunger‬مع الضغوطات الصغيرة طبعا تصميم ال ‪ plunger‬يختلف نوعا ما عن ‪piston‬‬
‫النه محيطه يحتوي على مجاري لعبور البالستيك‬
‫اما ال ‪ screw‬الدوراني مع الضغوطات العالية‬

‫بالنسبة للماكينة العامودية تستخدم في حالة كان اإلنتاج بطئ واما الماكينة االفقية تستخدم لإلنتاج بسعة كبيرة وسرعة عالية‬
‫لذا فانه النوع األكثر انتشارا واستخداما‬

‫هناك مصطلح هام ومتداول في األسواق عند شرائك لماكينة (الطن) او بمفهوم علمي (السعة ‪ ) capacity‬هذا معناه ال‬ ‫‪-‬‬
‫‪ clamping force‬وهي القوة االالزمة الغالق القالب ويجب ان تكون هذه القوة متساوية مع مقدار السعة ولكن باتجاه معاكس حتى‬
‫يتسنى للماكينة بان تقاوم هذه القوة وتعمل على اغالق محكم للقالب فاذا اعطاك ‪ Model: EA160‬معناه ان ال ‪clamping‬‬
‫‪force 160 ton‬‬
‫‪ Shot weigth‬وزن الشوط وهذا معناه وزن البالستيك الذي سيتم دفعه خالل النوززل في الشوط الواحد ويجب ان يكون اكبر من‬ ‫‪-‬‬
‫وزن القطعة المراد انتاجها‬
‫يجب االنتباه الى المسافة بين ‪ tie bar‬عشان نعرف كم اقل قيمة للطول واالرتفاع للقالب الذي سيتم تركيبه وكم ‪mold‬‬ ‫‪-‬‬
‫‪ thickness‬عشان نعمل باالنتباه العرض الالزم للقالب وأيضا يجب معرفة ال ‪ stroke‬للفتح واالغالق قبل التصميم الكلي‬
‫يجب معرفة معدل العجن ‪ plasticizing capacity‬يعني كم جرام تعجن من ال بالستيك في الثانية الواحدة وهذا يتحدد من قطر‬ ‫‪-‬‬
‫ال ‪barrier‬‬
 ‫مالحظات تذكرها‪:‬‬
‫يمكن استخدام ‪ gearbox‬حق المترات او شراء جيربوكس جاهز او يمكن عمل جيربوكس من سلسلة السيكل كما هو موضح في‬ ‫‪-‬‬
‫الفيديو الروسي ‪(538) Экструдер прутка для 3D-принтера из доступных компонентов - YouTube‬‬
‫في هذا الموقع يحتوي على شرح تفصيلي بالفيديوهات لماكينة مصغرة ويمكن عملها تابعه لشركة عالمية‬ ‫‪-‬‬
‫‪ Digg Benchtop Injection Molding Machine - RobotDigg‬ويمكن تحميل ‪ user manual‬لمعرفة المعلومات عنها‬
‫واجزائها وفلوتشارت الواجهة المستخدمة ومعلومات المتحكمة وغيرها‬
‫‪RobotDigg Benchtop Injection Machine Manual.pdf - Google Drive‬‬
‫وتوجد قائمة تشغيل لسلسلة من الفيديوهات لشرح معظم األجزاء من نفس الشركة ‪(538) Extrusion n Molding - YouTube‬‬

‫موقع ‪ APSX‬يعرض نوع مصغر ورائع يصل سعرها ل‪ 12500‬دوالر ويحتوي الموقع على معلومات ليست وافية لكن يمكن‬ ‫‪-‬‬
‫استنباط األفكار منه '‪APSX Machines. Products tagged with 'injection molding‬‬
‫قائمة مكونة من فيديوهات اثنين يشرحان جزء الهيكل وجزء ال ‪ screw‬وبشكل عملي قابل للتطبيق ‪(538) Injection Molding‬‬ ‫‪-‬‬
‫‪Machine - YouTube‬‬
 Specifications of Injection Moulding Machine

:‫قبل البدء في تصميم ماكينة الحقن يجب معرفة المواصفات الخاصة بالماكينة المطلوبة‬

INJECTION UNIT To understand the meanings

Maximum swept volume cc / max. shot weight

gr. calculation of max. shot (‫ )اطالق او الحقنة من البالستيك‬weight for a material

‫االعتماد على جودة الذوبان التساق القولبة‬

Maximum metering stroke in mm. dependance of quality of melt for consistency of moulding.

how it ensurs melt to spread through out when in fluid condition-

Maximum injection speed g/s or cc/s before it freezes. Its relationship with freezing time.

how it overcomes resistance to flow during filling and; pressure phase

Maximum injection pressure Kg/cm2 on account of flow ratio and; viscosity.

how it takes care of difficulty in filing for thinner walled and high
Maximum Injection Power.Kgcm/sec. flow ratio parts.‫االهتمام بصعوبات تعبئة االجدرة الرقيقة ونسب التدفق العالية‬

Plasticizing rate g/s or Kg/hr. how it influences cycle time.

INJECTION UNIT To understand the meanings

CLAMPING UNIT To understand the meanings

Clearance between Tie bars and platen size mm x how it accomodates mould.
mm

Maximum daylight mm and mould open stroke mm its significance for ejection of deep parts.
The daylight in injection molding machine is space
or distance between fixed platen and moving platen
during open and close clamping on a injection
molding machine.

Minimum mould height its relationship with mould open stroke and daylight.

its dependance on cavity pressure and method to compute cavity

Clamping force pressure.

The minimum and maximum daylight in injection molding machine determines the sizes of the items it
can make.
The maximum daylight has to accommodate height of moving half of mound, height of moulded part,
minimum and enough clearance for removal of moulded part and height of fixed half of mould.

Formula to calculate the day light of the toggle injection molding machines:
Maximum daylight = Maximum mould height + mould open stroke.
Minimum daylight = Minimum mould height + mould open stroke.
 With Hydraulic clamp machine, Maximum daylight = Minimum mould height + mould open stroke.
If shut mould height is more than minimum mould height of machine then the mould open stroke is reduced to the
extent of difference in shut mould height of mould and minimum mould height of machine.

MAXIMUM DAYLIGHT
The shut mould height of the mould should be less than 1/3rd of maximum daylight so that there should be enough
room for the ejection of part when mould platen is fully opened. If it is closer to 1/3rd of maximum daylight then
the clearance between core and cavity of mould in fully open position should be verified on the drawing board.

The maximum daylight has to accommodate height of moving half of mould, height of moulded part, minimum and
enough clearance for removal of moulded part and height of fixed half of mould.

In case of Toggle machine, Maximum daylight = Maximum mould height + Mould open stroke. Mould open stroke
remains constant in toggle machine.

MAXIMUM DAYLIGHT AND MOULD OPEN STROKE

Maximum daylight as well as mould open stroke depends on toggle geometry whereas hydraulic clamp machine
can be built easily for larger daylight by simply providing longer cylinder and longer tie bars. The longer mould open
stroke can be provided by using longer clamp cylinder and ram. Therefor it is easier to satisfy special requirements
of customers.

In hydraulic clamp machine

Mould open stroke = Maximum day-light minus Closed mould height

HYDROMOTOR To understand the meanings

Torque Kgm and rpm torque requirement for -viscosity of- melt.

*Specifications of Injection Moulding Machine Hydro motor.

DRIVE POWER To understand the meanings

Power supply frequency 60 or 50 Hz. its influence on speeds.

Pump-motor rating. kW to match the application – usage of machine.

*Specifications of Injection Moulding Machine Drive Power.

CONTROLS To understand the meanings

Controls • Conventional / Proportional and Cartridge valve Hydraulic Controls

• Electrical / solid state / microprocessor controls
• Open loop or closed loop controls

*Specifications of Injection Moulding Machine Controls Unit.

NO LOAD CYCLE TIME To understand the meanings

Cycle Time It indicates the time for non processing part of the cycle time

*Specifications of Injection Moulding Machine Cycle Time.