Supplemental worksheets for the following presentation:

In this presentation, a highly effective scientific approach to

troubleshooting will be discussed. These supplemental worksheets are provided
in both Metric and Imperial format to help participants better understand the
type of process documentation which is discussed in the webinar.

The worksheets provided in this cover worksheets for properly

documenting In-Mold Rheology, Gate Seal, and a Robust Decoupled II Process.
Enclosed are three of the nine worksheets covered in the Intelligent Molder
Series of training provided by A. Routsis Associates, Inc.

If you have any questions, please feel free to contact Andy Routsis at
978.957.0700 or e-mail him at andyr@traininteractive.com.
 IN-MOLD RHEOLOGY TEST Machine #
Mold #
# of Cavities
1. Set-up a first stage short shot using a fast injection speed
Material Type
2. Mold a part and record: Fill Time
Pressure at Transfer Cycle Time
3. Reduce injection speed and repeat until table is complete
4. Calculate and plot data Name
5. Choose a recommended fill time in the flattened region Date

1st Stage Fill Time Transfer Pressure Shear Rate Effective Viscosity
Shot Weight (t) ( psi ) (1÷t) ( t × psi )

Melt Temp. 1
2
3
4
5
SHOT

High (stiff)
6
7
8
9
10
VISCOSITY ( t × psi )

Low (easy)
0

Slow Fast
0
SHEAR RATE ( 1 ÷ t )

Recommended 1st Stage Fill Time seconds

 IN-MOLD RHEOLOGY TEST Machine #
Mold #
# of Cavities
1. Set-up a first stage short shot using a fast injection speed
Material Type
2. Mold a part and record: Fill Time
Pressure at Transfer Cycle Time
3. Reduce injection speed and repeat until table is complete
4. Calculate and plot data Name
5. Choose a recommended fill time in the flattened region Date

1st Stage Fill Time Transfer Pressure Shear Rate Effective Viscosity
Shot Weight (t) ( bar ) (1÷t) ( t × bar )

Melt Temp. 1
2
3
4
5
SHOT

High (stiff)
6
7
8
9
10
VISCOSITY ( t × bar )

Low (easy)
0

Slow Fast
0
SHEAR RATE ( 1 ÷ t )

Recommended 1st Stage Fill Time seconds

 GATE SEAL WORKSHEET Machine #
Mold #
# of Cavities
PURPOSE: Material Type
To determine adequate second stage time
Cycle Time
EQUIPMENT NEEDED:
Name
• molding machine and mold
• part weighing scale Date

PROCEDURE: Part Weight 2nd Stage Time

1. Set up machine to run a standard Decoupled II process 1
2. Begin with little or no 2nd Stage Time 2
3. Mold a part and record: 3
Part Weight ( no gate or runner )
4
2nd Stage Time ( pack + hold )
5

SHOT
4. Repeat with increasing 2nd Stage Time beyond gate seal
5. Plot on chart 6
6. Determine the time frame during which the gate seals 7
7. Determine the optimal 2nd Stage Time 8
9
10
Part Weight (grams)

0
2nd Stage Time (seconds)

The gate sealed between and seconds

Final Second Stage Time seconds
Decoupled II Machine #
Mold #
2-stage DECOUPLED MOLDING SM # of Cavities

PROCESS SHEET Material Type

Name
Date

Template Name ( optional ) :

Plastic Temperature

Melt Temp ( ºF or ºC ) Plastic Back Pressure ( ppsi )

Plastic Flow Rate

Fill Time ( s ) Fill Only Part(s) Weight ( g )

 Plastic Pressure at Transfer 

Mold Shot ( ppsi ) (or Peak Injection Pressure ) Air Shot ( ppsi )

Plastic Pressure

Pack Time ( s ) Plastic Pack Pressure ( ppsi ) Fill & Pack Part Weight ( g )

Hold Time ( s ) Plastic Hold Pressure ( ppsi ) Final Part Weight ( g )

Gate Seal Time ( s )

Plastic Cooling

Cooling Timer ( s )

Coolant Temp. IN ( ºF or ºC ) Coolant Temp. OUT ( ºF or ºC ) Coolant Flow

Clamp

Clamp Force Clamp Type Cycle Time ( s )

Decoupled II Machine #
Mold #
2-stage DECOUPLED MOLDING SM # of Cavities

PROCESS SHEET Material Type

Name
Date

Template Name ( optional ) :

Plastic Temperature

Melt Temp ( ºC ) Plastic Back Pressure ( pbar )

Plastic Flow Rate

Fill Time ( s ) Fill Only Part(s) Weight ( g )

 Plastic Pressure at Transfer 

Mold Shot ( pbar ) (or Peak Injection Pressure ) Air Shot ( pbar )

Plastic Pressure

Pack Time ( s ) Plastic Pack Pressure ( pbar ) Fill & Pack Part Weight ( g )

Hold Time ( s ) Plastic Hold Pressure ( pbar ) Final Part Weight ( g )

Gate Seal Time ( s )

Plastic Cooling

Cooling Timer ( s )

Coolant Temp. IN ( ºC ) Coolant Temp. OUT ( ºC ) Coolant Flow

Clamp

Clamp Force Clamp Type Cycle Time ( s )