LABORATORY REPORT OF

POLYMER PROCESSING DESIGN LAB

DEPARTMENT OF POLYMER AND PROCESS ENGINEERING

6th Semester

Batch 2015-2019

Submitted to: Submitted by: Group#6

Dr. Farhan Saeed Hafiz Tanveer Ashraf 2015-PE-20

University of Engineering and Technology Lahore

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Polymer Processing Design Lab

Table of Contents:
5.1: Objective:..................................................................................................................................3
5.2: Abstract:....................................................................................................................................3
5.3: Introduction:.............................................................................................................................3
5.4: Experimentation:......................................................................................................................4
5.5: Results and Discussion:............................................................................................................5
5.6: Questionnaire:...........................................................................................................................6
5.7: Conclusion:...............................................................................................................................8
5.8: References:...............................................................................................................................8
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Polymer Processing Design Lab

Experiment #5: Horizontal Injection Molding

5.1: Objective:
 To learn processing techniques associated with injection molding.
 To introduce the plastics injection moulding conversion process.
 To examine the influence of some process variables on the process efficiency and some

Hopper

Motor

Clamping
section
Mold

properties of moulded high density polyethylene.

Figure 5.1: Horizontal Injection Molding Machine

5.2: Abstract:
Injection Moulding (IM) is one of the most prominent processes for mass production of plastic
products. One of the biggest challenges facing injection moulders today, is to determine the
proper settings for the IM process variables. Selecting the proper settings for an IM process is
crucial because the behaviour of the polymeric material during shaping is highly influenced by
the process variables. In this report we have study that how the process. In this report, the
demonstration of working principle and process of injection molding are observed with HDPE as
the processing resin. In addition, the influence of some process variables on process efficiency is
studied.

5.3: Introduction:
Injection molding is considered one of the most common plastic part manufacturing processes. It
can be used for producing parts from both thermoplastic and thermoset polymers. The process
usually begins with taking the polymers in the form of pellets or granules and heating them to the
molten state. The melt is then injected/forced into a chamber formed by a split-die mold. The
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Polymer Processing Design Lab

melt remains in the mold and is either chilled down to solidify (thermoplastics) or heated up to
cure (thermosets). The mold is then opened and the part is ejected. Despite the relatively
expensive tooling cost, injection molding remains the most popular manufacturing process for
plastic materials in mass production, thanks to its low operational cost, high throughput, and the
flexibility to make parts with complex shapes.

Figure 5.2: Schematic of Injection Molding Machine

5.4: Experimentation:
5.4.1: Apparatus:
 Horizontal Injection moulding machine
 Vernier calliper
 Cutting tools
 Scrapper
 Weight balance
5.4.2: Materials:
HDPE
5.4.3: Procedure:
 Turn on the injection molding machine and fill the hopper with the material to be processed.
 Here we will be using injection grade of HDPE, so the hopper will be filled with HDPE
pellets.
 Adjust the temperature and other required parameters according to the type of material being
processed.
 When the required temperatures are attained, switch the machine to semi-auto mode to check
that all the material inside the barrel has melted.
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Polymer Processing Design Lab

 Before starting experiment, switch the machine to become neutral.

 First attach screw unit to mold manually then switch to semi auto mode and window
operation will start.
 Injection unit will move forward. Then move the window in close position, clamping unit
(moveable platen) will move forward and the material will enter the mold.
 Backward movement of clamping unit will indicate the formulation of product. Whole cycle
will take approximately 22 to 23 seconds.
 Repeat the process to get more products.

Figure 5.3: Sample with flash Figure 5.4: Deflashed sample

5.5: Results and Discussion:

5.5.1: Results:
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Polymer Processing Design Lab

No. of sample Weight (g) Defects

Flow Sinking Surface Mold Short Voids
mark roughness flashin shots
s g
1. 7.65 Yes No No Yes No No
2. 7.67 Yes No No Yes Yes No
3. 7.65 Yes Yes No Yes No No
4. 7.64 Yes No No Yes No No
5. 7.67 No No No Yes No No
Table 5.1: Weights and Visual defects of different samples

5.7: Conclusion:
In conclusion, injection molding is an extremely useful tool for mass-producing polymer parts
once the parameters for its ideal operation have been ascertained. This lab was useful in
exploring and understanding how different effects on a desired characteristic for a part. Using
design expert, it was shown how some control variables have a strong effect on a specified
characteristic, while others have little effect. Through design expert it was found that the
variables affecting the final weight of the plastic mold injected part the most, were pressure and
flow weight. Each of these factors had a larger impact than the nozzle temperature and dwell
time combined. Even though this experiment was a half factorial, a lot of useful data was
collected about the different factors and how they interact with each other. Finally, we conclude
that plastic injection molding is very helpful in making all necessary basic goods like tumblers,
body of the brush etc which attract people with snazzy colours as well as shining and their
smoothness.

5.8: References:
1. Injection Molding, Springer Reference. Really Fast Custom Parts. (n.d.). Retrieved
November 7, 2015.
2. InjectionMolding.com - The latest injection molding news and information on start-ups.
(n.d.). Retrieved November 7, 2015.
3. Tobin, W. (1989). Basic injection molding (2nd (rev.) ed.). Los Angeles, CA: T/C Press,
Division of Technology Conferences.
4. InjectionMolding.com - The latest injection molding news and information on start-ups.
(n.d.). Retrieved April 26, 2016, from http://www.injectionmolding.com