Trouble shooting

injection molding
D. Grewell, PhD

Troubleshooting
z Overview of the process
z Mold design
z Parameter settings

The process
z Filling
z Mold closes,
screw rapidly Melt

moves forward,
frozen polymer Clamp force
skin forms at
mold walls

Mold flow

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Preparing shot

The process
z Packing Time
(Holding)
z Cavity filled,
packing begins,
cooling occurring

Moldflow

The process
z Cooling
z Packing complete, gate
freezes off, cooling continues
z Screw moves back and begins
plasticating resin for next shot

z Mold Open
z Cooling completes, mold
opens

Moldflow

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 The process-Pressure

10 ksi Ram

In the mold
P

5 ksi

time

The process steps

Fill Pack Sealed cooling

Ram

In the mold
P

time

The process-Pressure

Material building up in mold Mold totally filled

Ram

In the mold
P

Decrease pressure
as material hardens
Gate freeze
Packing

time

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The switch over time
z Typically the fill pressure is higher than the
pack/hold pressure-to reduce time
z When you drop the pressure this switch over
z It is the time between full filling and actually
dropping the pressure
z No switch over time (Ok for small parts, and long
flow parts)
z Based on time, travel, clamp force
z Best if based on cavity pressure (ejector pen)

Late switch over

Ram

In the mold
P

time

Early switch over

Ram In the mold

time

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Weld lines
z Causes
z Pens/obstructions Flow

Weld line

z Multiple gates
Weld line

Weld lines

weld lines

Part design
(a) Shut-off hole:
no side action required

(b) Latch:
no side action required

(c) Angled Latch:

Side action cam required

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 Part design

Inserts
z Screws
z Bosses
z Metal components
z Other plastics

Trouble shooting
z Hesitation A

2 1

2 1
C

2 1

z Gate Location A - Rib #1 would freeze off as the rest of the part is filled.
May also be some hesitation at rib #2.
z Gate Location B - Marginally better. Rib #2 would still freeze off while the
rest of the part is filled.
z Gate Location C - Solves the hesitation problem by making the thin ribs the
last place to fill.

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Trouble shooting
z Flash
z Too large shot
z Too high pressure
z Clamp force not sufficient
z Residual material on mold face
z Repair parting line. Provide adequate venting and
use correct tool steel for application.
z Correct fit.
z Provide adequate support. Use thicker support
plates and/or incorporate support pillars as needed.
z Use correctly sized vents.

Trouble shooting
z Burning or air entrapment
z Gas entrapment
z Shooting too fast
z Need new vent in mold
z Vent in mold is too small
z Vent in mold needs cleaned

Trouble shooting
z Sinks
z Part design is main problem
z Shot too slow
z Packing pressure is too low
z Shot is too small
z Gate is to small (freezes to fast)
z Add texture surface (common solution!)
z Increase packing time

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Trouble shooting
z Cavity to cavity variations
z This is a major issue with multi-cavity molds
z Runners are not properly balance
z Heat is not balance
z Use hot runners

Trouble shooting
z Warpage
z Part design
z Gate locations
z Cooling is not balanced
z Pressure is too high
z Injection rate is too high
z Increase mold temperature
z Add filler (glass fibers)

Trouble shooting
z Jetting
z Occurs when melt is pushed
through restrictive areas at a high
velocity and does not come in
contact with the mold walls.
z Leads to multiple small scale weld
lines where the melt folds over.
z Surface blemishes.
z Part weakness.
z Gate Designs that help eliminate
jetting:
z Reduce rate!

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Trouble shooting
z Slay: A gas or liquid dispersed over the part surface causing a non-uniform finish.
z Increase back pressure to remove trapped air.
z Change screw type to remove trapped air.
z Reduce melt decompression.
z Reduce melt temperature.
- Reduce cylinder temp.
- Reduce back pressure.
- Reduce injection speed.
z Reduce residence time in barrel.
- Reduce cycle time.
- Use smaller injection unit.
z Reduce humidity in molding environment or increase mold
temperature.
z Dry material.

z Clean mold. Use mold release sparingly or not at all.

Trouble shooting
z Short shot
z Shot too small
z Hesitation
z Increase packing time
z Increase temperature
z Replace check value

The Machine

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