INJECTION MOULDING

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 Parts of Injection Moulding Machine

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 Historical Background

 A single-action hydraulic injection machine was designed in the U.S.A. in

1870 by Hyatt . The history of plastic injection molding begins in 1868 when
inventor John W. Hyatt patented the process of creating celluloid, a material
originally intended to replace the ivory used in billiard balls. In 1872, Hyatt
and his brother Isaiah patented the first injection molding machine, which
used a simple plunger mechanism to push celluloid through a heated
cylinder and into a mold. The device led to the development of a booming
manufacturing industry that produced buttons, combs, collar stays, and
other items from celluloid.
 Heating-cylinder design was first recognised in a patent issued to Adam
Gastron in 1932
 Large-scale development of injection moulding machinery design towards
the machines we know today did not occur until the 1950's in Germany

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 Historical Background

 In 1946, James Watson Hendry’s extrusion screw injection

machine revolutionized the modern plastic injection molding
field. The machine’s rotating screw gave the operator better
control over the production process, resulting in significant
improvements to the quality of the injection-molded parts.
Hendry also pioneered the gas-assisted injection molding
process, which made it possible to manufacture long and
complex hollow parts.

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 What is Injection Moulding Process

Defination Process

Injection molding is a process in

which a thermoplastic polymer is
heated above its melting point,
resulting in the conversion of the
solid polymer to a molten fluid with
a reasonably low viscosity. This
melt is mechanically forced, that
is, injected, into a mold in the
shape of the desired final object.
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 MOULD

Injection Mould Injection Mould

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 Injection Mould Description

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 Injection Mould Description

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 Type of Injection Moulding Machine

 Hand Injection Moulding M/C

 Plunger type Injection Moulding M/C

 Reciprocating Screw Type Injection Moulding M/C

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 Hand Injection Moulding Machine

vertical machine consists of Barrel, Plunger, Band Heaters

along with energy regulator, Rack & Pinion system for
Injecting the material by the plunger, a torpedo and nozzle.

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 Plunger Type Injection Moulding M/C

Vertical & Horizontal Plunger Type Injection Moulding Machine

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 The Reciprocating Screw Moulding M/C

The Reciprocating Screw Moulding M/C consists of

•The feeding zone
•The compressing (or transition) zone
•The metering zone

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Reciprocating Screw Machine components

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 Injection Moulding Process

 Plasticizes the material by reciprocating Screw.

 Injects the molten material to a closed mould
via a channel system of gates and runners.
 Cools the Mould in order to solidify molten plastic
 Refills the material for the next cycle.
 Ejects the Product.
 Closes the Mould for further cycle.

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 Injection Moulding Applications

 Electronic Housings
 Computer Components
 Containers
 Bottle Caps
 Automotive Interiors, under Hood, Exteriors Bumpers,
Mirror housing, Door latch assembly, Lamps, fenders etc
 Lenses
 Brackets
 Fasteners
 Top and Bottom Covers
 Toys

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 Injection Moulded Components

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 Injection Moulded Components

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 Injection Moulded Components

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Advantages of Injection Moulding Process

 Parts can be produced at high production rates.

 Large volume production is possible.
 Relatively low labour cost per unit is obtainable.
 Process is highly susceptible to automation.
 Parts require little or no finishing.
 Many different surfaces, colours, and finishes are
available.
 Good decoration is possible.
 For many shapes this process is the most economical
way to fabricate.
 Process permits the manufacture of very small parts
which are almost impossible to fabricate in quantities
by other methods.

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Advantages of Injection Moulding Process

 Minimal scrap loss result as runners, gates, and rejects

can be reground and reused.
 Same items can be moulded in different materials,
without changing the machine or mould in some cases.
 Close dimensional tolerances can be maintained.
 Parts can be moulded with metallic and non-metallic
inserts.
 Parts can be moulded in a combination of plastic and
such fillers as glass, asbestos, talc and carbon.
 The inherent properties of the material give many
advantages such as high strength-weight rates,
corrosion resistance, strength and clarity.

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 Limitations of Injection Moulding

 Intense industry competition often results in low profit

margins.

 Mould costs are high.

 Moulding machinery and auxiliary equipment costs are

high.

 Lack of knowledge about the fundamentals of the

process causes problems.

 Lack of knowledge about the long term properties of

the materials may result in long-term failures.

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 KEY FACTORS IN INJECTION MOULDING

 Temperature: it includes barrel temperature, material

melt temperature, mold temperature, material dried
temperature.
 Pressure: it includes injection pressure, holding pressure,
back pack pressure, clamping force.
 Time: it includes injection time, holding time, cooling
time, material dried time.
 Speed: it includes injection speeds, back pack speed,
mold close and open speed.
 Position: it includes gauge position, Injection position,
Hold Position, ejection position, mold close & open
position.

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 Injection Moulding Process

 Material enters the barrel

 Material melts and mixes
 Volume of material (Shot sizes in barrel is created)
 Mold closes
 Injection of the plastic into the mold cavity
 Molten material cooled (during this process, steps 1-
3 are preparing for next cycle)
 Mold opens
 Part ejects
 Return to Step 4 for the next cycle

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How to Calculate an Injection Moulding Cycle

 Cycle = Mo+Mc+I+C
 Mc = Time to close the mold (this is the time it takes
to actually close the tool)
 I = Time to inject material into the mold
 C = Cooling Time (Time to solidify molten material)
 Mo = Time to open a mold and eject the part (these
can overlap and together make up total open time)

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 INJECTION MOULDING PROCESS

STEP 1: THE MOLD CLOSES

Hydraulic or electric toggles close the mold halves and press them
together with hundreds of tons of pressure to prevent mould open
under influence of filled material cavity pressure

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 INJECTION

 STEP 2: INJECTION
The screw pushes the molten plastic into the mold cavity. This completely
packs the molten plastic with adequate holding pressure. The heated
plastic is injected into the mold. As the melt enters the mold, the displaced
air escapes through vents in the injection pins and along the parting line.
Runner, gate and vent design are important to insure the mold is properly
filled

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 COOLING

 STEP 3: COOLING:
Once the mold is filled the part is allowed to cool for the exact amount of time
needed to harden the material. Cooling time is dependent on the type of resin
used and the thickness of the part. Each mold is designed with internal cooling
or heating lines where water is cycled through the mold to maintain a constant
temperature

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 PLASTICIZING THE RESIN

 STEP 4: PLASTICIZING THE RESIN

While the part cools, the barrel screw retracts and draws new plastic resin into
the barrel from the material hopper. The heater bands maintain the needed
barrel temperature for the type of resin being used.

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 EJECTION

 STEP 5: EJECTION
The mold opens and the ejector rod moves the ejector pins forward. The
part falls and is captured in a bin located below the mold. The mold will
then reclose to repeat the process.

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REMOVING THE RUNNER AND PACKAGING

 STEP 6: REMOVING THE RUNNER AND

PACKAGING
Although the injection molding machine’s cycle ends on Step 5, the
process continues. The machine operators, or robots separate the
usable parts from the left over runner.

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Different types of Injection Moulding Process

 In-mould Decoration and In-Mould Lamination

 Insert Moulding
 Low-Pressure Moulding
 Micro Moulding
 Multi-Component (Over-moulding)
 Family Moulds
 Thin-Wall Moulding
 Rubber Injection Moulding
 Liquid Silicone Rubber Moulding

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Additive Function Examples
Filler increase bulk density calcium carbonate,
talc, limestone

Plasticizer improve processability, phthalate esters,

reduce product brittleness phosphate esters

Antioxidant prevent polymer oxidation phenols, aromatic

amines

Colorant provide desired part oil-soluble dyes,

application colour organic pigments

Flame reduce polymer flammability antimony trioxide

retardant

Stabilizer stabilize polymer against carbon black,

heat or UV light hydroxybenzophenone

Reinforcement improve strength E-glass, S-glass,

carbon, Kevlar fibers
 Auxiliaries used in Injection Moulding

 Cooling Towers

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 Auxiliaries used in Injection Moulding

 Chiller System  Mould Temp Controller

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 Auxiliaries used in Injection Moulding

 Compressor  HOPPER DRYER

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 Auxiliaries used in Injection Moulding

 Blenders  Over head Cranes

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 Auxiliaries used in Injection Moulding

 ROBOTS FOR AUTOMATION

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 Mould Clamp

 Mould Clamp

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 Accessories needed in Injection Moulding
 Mould Clamps  Quick Mould change
System

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 Accessories needed in Injection Moulding

 Quick release couplings Hose pipes & Pneumatic Tubings

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 Thanks for watching the Presentation!

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