CENTRAL INSTITUTE OF PLASTICS ENGINEERING AND TECHNOLOGY

BY
R.T. NAGARALLI

INJECTION MOULDING PROCESS RESOURCES

MATERIAL MACHINE MOULD MAN POWER

MATERIAL
PLASATIC MATERIAL

THERMOPLASTIC MATERIAL

THERMOSET MATERIAL

THERMPLASTIC MATERIAL

HEAT

SOFT

COOL PRESS.

SOLID

IT CAN BE RECYCLED

THERMOSET MATERIAL

HEAT

SOFT

HEAT PRESS.

SOLID CHARCOAL

IT CAN NOT BE RECYCLED

MACHINE
HEATING PRESURISING AND CONVEYING MOULD CLAMPING

MOULD
THE MOLD HAS 4 MAIN FUNCTIONS
RECEIVE & DISTRIBUTE THE MATERIAL SHAPE FORMING

COOLING(Water & oil)

DISPOSAL

MANPOWER
TO SET UP A PROCESS

TO MONITOR AND TROUBLE SHOOT

TO OPARATE MACHINE

TYPES OF INJECTION MOULDING MACHINES

PLUNGER TYPE

PLUNGERPLUNGER TYPE

SCREW PLUNGER TYPE

IN LINE RESIPROCATING SCREW TYPE

Screw Rotation

The rotation of the screw produces frictional and shear together with the heat input from heater bands around the barrel cause the material to melt. These two sources of heat , combined with the mixing effect of the screw , provide a homogenous melt

Screw Speed

It is important that the speed the screw is kept constant from cycle to cycle. If the speed of rotation of the screw is increased, or if takes longer to refill the amount of sheer put in to melt will be increased.

Screw stroke:
The return stroke of the injection is determined by the amount of material to be injected ( shot weight). The longer the stroke larger the volume.

Injection Pressure and Hold on Pressure

MELT TEMPARATURE
CAN BE CHANGED BY
BARREL TEMPARATURE BACK PRESSURE SCREW RPM CYCLE TIME

PRESSURE PROFILE IN CAVITY

NOZZLE
It provides thermal&mechanical connection from hot cylinder to cold injection mold TYPES
An open channel with no mechanical valve An internal check - valve held closed by spring A shut off valve

Standard / Open Channel nozzle

Reverse tapered / Nylon nozzle

Needle type shut off nozzle

Non-return valve

Ring type

Ball Type

Standard Type

P.V.C Purpose

SCREW-TYPES
GENERAL PURPOSE SCREW ENTED SCREW BARRIER SCREW SCREW FOR THERMOSET

Screw nomenclature

SCREW-L/D RATIO
The flighted length of screw to the dia. Of screw Generally L/D ratio varies 20:1 to 30:1 Generally L/D ratio for PVC is 16:1 The larger the L/D ratio greater the opportunity for mixing,resulting in better homogeneity of melt Greater the resident time of the plastic in the barrel permitting faster cycles of larger shots & more output

SCREW- VARIOUS ZONES IN SCREW FEED ZONE: Promotes pumping/output rate adequately-It can be 50 to 60% of L COMPRESSION ZONE: Promotes shearing and hence melting of polymers at the output rate of feed zone-It can be 20 to 25% of L METERING ZONE: Promotes homogenization of entire melt stream emerging from compression zone- It can be 20 to 25% of L

SCREW
SIGNIFICANCE OF LENGTH OF EACH ZONE
Longer feed zone creates greater potential throughput Longer compression zone results in less shear heat and more to compress and melt the plastic Longer meter zone allows screw to develop more pumping pressure and greater opportunity to homogenize Shorter meter zone allows less time to assure uniform melt temperature and viscosity

SCREW-CHANNEL DEPTH
Higher channel depth in feed zone conveys more material and hence more torque is required to rotate.Shallow channel depth screw requires higher rpm and lower torque for a given output rate.Shear rate is lower on the polymer in screws with deeper channel depth at lower rpm.Hence it is preferred for shear sensitive polymers A shallow screw channel Increases the exposure of plastic to the heated barrel wall Increases the shear heat imparted to the polymer Reduces potential throughput of the screw

COMPRESSION RATIO
IT IS THE RATIO OF THE VOLUME OF FIRST TURN OF SCREW TO VOLUME OF LAST TURN OF THE SCREW IT IS NORMALLY BETWEEN 1.5 to 4.5 FOR GENERAL PURPOSE SCREW LOWER CR SUITS LOW VISCOCITY MELTS AND HIGHER CR SUITS HIGHER VISCOCITY MELTS HIGHER THE CR,GREATER THE RESULLTING

Shear heat imparted to the polymer Heat uniformity of melt Potential for creating stresses in some polymers Energy consumption

CLAMPPING-TYPES
MAJORLY OF TWO TYPES
HYDAULIC CLAMPING TOGGLE CLAMPING

Hydraulic Clamping

Toggle Clamping

HYDRAULIC Vs TOGGLE-COMPARISION
Much higher original cost Higher horse power needed.Therefore more expensive to run Unlimited stroke potential Direct readout of clamp force Lower original cost Lower horse power needed.More economical to run Limited stroke potential No Direct readout of clamp force

HYDRAULIC Vs TOGGLE-COMPARISION

Easy adjustment of clamp force Easy mold setup Varies stroke to mold height Clamp speed easily controlled or stopped at any point Low maintenance as parts are self lubricated

More difficult More involvement in mold setup Constant mold stroke Clamp speed more difficult to control and stop Higher maintenance cost

MACHINE SELECTION
INJECTION UNIT
Maximum swept volume,cc
Max.Inj.Speed, gm/sec or cc/sec Max.Inj.Pressure,Kg/cm2

TO UNDERSTAND
Shot weight for a material
How it ensures melt to spread throughout when in fluid conditionbefore it freezes How it overcomes to flow during filling on account of flow ratio and viscosity How it influences cycle time

Max.Plasticizing rate,gm/sec or Kg/hr

Max.Injection power, Kg-cm/sec

How it takes care of difficulty in filling of thinner walled and high flow ratio parts

MACHINE SELECTION
CLAMPING UNIT
Clearance between tie bar and platen size

TO UNDERSTAD
How it accommodates mold
Max.day light =

Max.day light and mold open stroke

mold open stroke + min.day light (it`s significance for ejection of deep parts)

Clamping force in tons

Depends on cavity pressure

HYDROMOTOR

MACHINE SELECTION
DRIVE POWER
Power supply frequency 60 or 50 hz Pump-motor raring,Kw

TO UNDERSTAND
Its influence on speeds

To match the application-usage of machine Conventional/Proportional valve hydraulic controls Electrical/microprocessor controls Open/closed loop controls It indicates the time for non processing part of the cycle time

Controlls

No load cycle time

MACHINE SELECTION
Force on melt (F1)= Force in Hydraulic cylinder ( F2) Pm As = Ph Ah Ph D2h Pm = _------------D2s

INJECTION MOULDING PROCESS

MATERIAL PREPARATIOIN PLASTICIZING INJECTION COOLING EJECTION PACKING

Elements of the Injection Moulding Cycle

POLYMER MATERIAL
Nylon-6 Nylon-6 with GF Nylon-66 Nylon11 Polysulphon LDPE LLDPE HDPE EVA copolymer PP homopolymer PP,20% Talc PP,copolymer PP,20% glass GPPS GPPS with GF HIPS SAN ABS

TEMP.RANGE 0 C
230-260 230-280 270-290 210-240 33-400 160-240 200-280 160-220 160-230 220-280 200-280 170-230 220-280 170-280 210-280 190-260 200-280 240-280

MOLD TEPMP.
80-90 70-90 80-90 30-60 100-160 30-50 30-50 30-50 30-50 20-70 20-70 20-60 20-80 20-70 60-80 50-80 30-80 40-80

POLYMER MATERIAL
PVC,Rigid PVC,Soft Acrylic PET PET,Not reinforced PBT,30%GF PET/PBT copolymer PC PC 40% GF PPS POM copolymer PPO modified with GF PPS/PS PUR

TEMP.RANGE 0 C
190-220 140-200 220-250 280-295 235-280 235-280 235-280 280-310 270-310 300-360 180-230 250-280 270-300 170-220

MOLD TEPMP.
30-60 20-40 60-90 5-15 20-70 20-90 20-90 80-120 80-120 120-180 60-120 110-13 70-110 10-30

THREMOSET INJECTION MOULDING PROCESS

ADVANCED INJECTION MOULDING PROCESS

VENTED BARREL TYPE

SCREW COOLING TYPE

REACTION INJECTION MOULDING PROCESS

TWO COLOR MOULDING

MULTI COLORED MOULDING

GAS ASSISTED INJECTION

MOULDING
PROCESS

CLOSED LOOP CONTROLS SYSTEM

In closed loop controls the effect of disturbances in the process is eliminated by counter acting or by opposing the effects of disturbance by automatically triggering certain reaction The above is done in response of feedback which is compared with the set value to take the required corrective action

OPEN-LOOP CONTROLS SYSTEM

Set process parameters in open loop control influences the process. But does not make correction by providing the feedback, if there is any disturbance is effecting the process . In open loop controls the effect of disturbances in the process is eliminated or held constant to ensure the uniformity in the process

SRUCTURAL FOAM MOULDING

( SANDWHICH )

THANK YOU