PLASTIC INJECTION

MOLDING

SUBMITTED BY: - SUBMITTED TO:-

SOURABH KR TOMAR RAKESH KUMAR
ENRL. NO.- 020513004 (ASST.PROFF.)
MECHANICAL DEPT.
 Plastic Injection Molding
Itis a manufacturing technique for making parts
from thermoplastic and thermoset materials
In contrast to the extrusion (which makes
continuous parts of constant cross section),
injection molding make discrete parts (with
complex and variable cross section)
Molten plastic is injected at high pressure into a
mold, which is the inverse of the desired shape.
The mold is made from metal, usually either
steel or aluminium
Widely used for manufacturing a variety of
parts, from the smallest component to entire
body panels of cars
 Injection Molding

3 Major Functional Units: Injection, Mold, Clamping

 Injection Unit
Purpose:to liquify the
plastic materials and
then inject the liquid
into mold
Resin is introduced through
hopper
Some machines can have
several hoppers (to fed filler,
colorants, other additives)-
Injection molding act as mixer
However, due to limited size of
barrel, mixing capability is
poor
Injection Unit

Important measure of the size of an injection

molding is weight of resin that can be injected,
called shot size
Typical shot size range from 20g to 20 kg
Since shot size depends on the density of the
plastic, PS has been chosed as the standard for
rating the machine
Reciprocating Screw Injection Molding
Machine
Resin is melt by mechanical shear and thermal
energy from heaters
The molten resin is conveyed to a space at the
end of the screw- collects in a pool
Here, the mold is closed
Reciprocating Screw Injection Molding
Machine
The entire screw move forward and pushes the
molten resin out through the end of barrel
To ensure the resin does not flow backward, a
check valve or nonreturn valve is attached to the
end of screw
Normally the screw will stay in the forward
position, until resin began to harden in the mold
Reciprocating Screw Injection Molding
Machine
Retraction of the screw, create space at the end of
the screw
Cooling of the part in the mold, until it can be
removed
While the part is cooling, the screw turns and melts
additional resin
Reciprocating Screw Injection Molding
Machine

Advantages
More uniform melting
Improved mixing or additives and dispersion
throughout the resin
Lower injection pressure
Fewer stresses in the part
Faster total cycle
Ram Injection- Injection Molding Machine
In this type of injection molding, the resin is fed
from a hopper into the barrel, and heated through
thermal energy from the heaters
The molten resin is collect in a pool in a barrel
celled injection chamber
The molten resin is then push forward by the
action of plunger (ram or piston)
To five better mixing, the molten resin is pushed
past a torpedo/spreader, impart shear to the melt
Clamping Unit
Prior to the injection of the molten plastic into the mold, the two
halves of the mold must first be securely closed by the
clamping unit. When the mold is attached to the injection
molding machine, each half is fixed to a large plate, called a
platen. The front half of the mold, called the mold cavity, is
mounted to a stationary platen and aligns with the nozzle of the
injection unit. The rear half of the mold, called the mold core, is
mounted to a movable platen, which slides along the tie bars.
The hydraulically powered clamping motor actuates clamping
bars that push the moveable platen towards the stationary
platen and exert sufficient force to keep the mold securely
closed while the material is injected and subsequently cools.
After the required cooling time, the mold is then opened by the
clamping motor. An ejection system, which is attached to the
rear half of the mold, is actuated by the ejector bar and pushes
the solidified part out of the open cavity.
Lubrication and Cooling

Obviously, the mold must be cooled in order for the

production to take place. Because of the heat capacity,
inexpensiveness, and availability of water, water is used
as the primary cooling agent. To cool the mold, water
can be channeled through the mold to account for quick
cooling times. Usually a colder mold is more efficient
because this allows for faster cycle times. However, this
is not always true because crystalline materials require
the opposite: a warmer mold and lengthier cycle time.
 Thekey to success in injection molding are
to have:

Proper machine for good melting and injecting of the resin

The proper resin to appropriate part performance
A good mold for part definition and removal
Proper operation for efficient molding cycle (mold cycle
depends on the design of the mold and manufacturing
parameters)
Themost commonly used thermoplastic
materials are:
Polystyrene (low-cost, lacking the strength and longevity of
other materials)
Nylon (chemically resistant, heat-resistant, tough and flexible -
used for combs)
Polypropylene (tough and flexible - used for containers
PVC (more common in extrusions as used for pipes, window
frames, or as the insulation on wiring where it is rendered
flexible by the inclusion of a high proportion of plasticiser).
QUALITY CHECK
General Plastic Injection Molding
Applications
Aerospace components
Automotive components
Avionics components
Cable assemblies
Computer electronics
Electronics components
Encapsulations
New product design &development
R&D labs Test specimens
Engineering prototypes
Geophysics
Instrumentation
Marketing samples
Material quality testing
Medical & dental products
Medical laboratories
Model shops, toys, hobby
Conclusion

Injection molding is one of the most important

processes for plastics and it has a very wide list
of kinds of products it can produce, which makes
it very versatile.
THANK YOU