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Historical Background
A single-action hydraulic injection machine was
designed in the U.S.A. in 1870 by Hyatt
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
Machine components
Advantages of Injection
Moulding Process
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.
The cavity cools as the gate freezes off and the screw begins to
retract to plasticize material for the next shot.
Injection Mould
Mould system
A typical (three-plate) moulding system
A two-plate mould.
A three-plate mould.
The screw has three zones with a ring-plunger assembly. The Feed Zone,
where the plastic first enters the screw and is conveyed along a constant
root diameter; the Transition Zone, where the plastic is conveyed,
compressed and melted along a root diameter that increases with a constant
taper; and the Metering Zone, where the melting of the plastic is completed
and the melt is conveyed forward along a constant root diameter reaching a
temperature and viscosity to form parts.
L/D RATIO
The L/D ratio is the ratio of the flighted length (Effective
Length) of the screw to its outside diameter.
Most injection screws use a 20:1 L/D ratio. But it may
range from 18:1 to 24:1
In the case of Thermoset it may range from 12:1 to 16:1.
Cushion
The cushion is the difference in the final forward position
of the screw and its maximum allowable forward
position.
More Cushion results more residence time, some time
degrades.
If the screw were allowed to travel its full stroke and stop
mechanically against the nozzle, the cushion would be
zero.
With zero Cushion no hold on works.
Typically a cushion of 3 to 6 mm is used.
Newtonian Plastic
During Refilling
During Injection
Additive
Function
Examples
Filler
calcium carbonate,
talc, limestone
Plasticizer
improve processability,
reduce product brittleness
phthalate esters,
phosphate esters
Antioxidant
phenols, aromatic
amines
Colorant
oil-soluble dyes,
organic pigments
Flame
retardant
antimony trioxide
Stabilizer
carbon black,
hydroxybenzophenone
Reinforcement
improve strength
E-glass, S-glass,
carbon, Kevlar fibers
DISADVANTAGE
Do not read the clamp force.
Clamping is more difficult.
Higher maintenance as lubricant is provided.
HYDRAULIC CLAMPING
A clamping unit actuated by hydraulic cylinder, which is
directly connected to the moving, closed the mould. In
this case ram of hydraulic system is attached to moving
platen. There are two halves in hydraulic cylinder, which
is actually inlet and outlet of oil.
When oil goes to the cylinder with pressure oil pushes
the ram to forward direction by which moving platen
moves and mould closed and when oil comes from the
cylinder the ram come back and mould is open.
HYDRAULIC CLAMPING
HYDRAULIC CLAMPING
ADVANTAGE
DISADVANTAGE
Theoretical Calculation
Example 7: The same GPPS cup has a flow path length of 104 mm. Find
a more accurate clamping force needed.
Flow path to thickness ratio (L/T Ratio) = 104 / 0.6 = 173. From Figure 2,
at 0.6 mm wall thickness, the cavity pressure is 550 bar.
1 bar = 1.02 kg/cm2. The clamping force = 550 * 1.02 * 49 = 27,500 kg =
27.5 tonnes.
The above calculation has not accounted for viscosity. It turns out to be
still correct as the viscosity factor for GPPS is 1.0.
Example 8: The same cup as in the above example is to be made out of
ABS. Find the clamping force needed.
Using the viscosity factor of 1.5, the clamping force needed = 1.5 * 27.5
tonnes = 41.3 tonnes.
Plastic flow
where
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Material Parameters
Geometry Parameters
Manufacturing Parameters
Fill Time
Packing Pressure Level
Mold Temperature
Melt Temperature
Residual stress
Process Controls
Injection Moulding cycle can be broken down into four
phases:
Fill,
Pack,
Hold, and
Cooling/plastication
These phases can be controlled by following variables:
Injection Speed,
Plastic Temperature,
Plastic Pressure,
Cooling Temperature and Time.
Heat inserting
Chrome Plating
In Mould Insert Moulding
Post Mould Inserting
Drilling
Polishing
Assembly
Secondary operations
Bonding
Welding
Inserting
Staking
Swaging
Assembling with fasteners
Secondary operations
Appliqu: a surface covering applied by heat and
pressure
Printing: a process of making a mark or impression onto
a substrate for decorative or informational purposes.
Painting
Hard coating
Metallizing/shielding
Surface treatment
Annealing
Machining
Chrome Plating
Drilling
The drilling of parts is used to remove any
unnecessary polymer that may have been
necessary in the moulding process. By
removing this extra material in house it
means a ready-to-assemble moulding can
be provided to the customer, or the part can
be assembled with other mouldings.
Polishing
For products that have a high quality gloss finish a
post moulding polishing operation is often a useful
extra process. Even though the finish produced by
the moulding tool may be of a very high quality, a
polishing operation to remove any dust from the
product before final packaging gives a part the
high gloss finish that will have been specified..
Polishing operations are carried out on a softpolishing wheel with high quality wax to ensure
that a part is polished to a perfect finish without
leaving any marks.
Assembly
For products that require assembly we are able to
carry out this operation in our assembly facility. We
can demonstrate examples of assemblies where
we mould all the separate components in house
and assemble the parts either as a whole in the
assembly facility or as a step by step process on
the press as each part is produced. By carrying out
assembly in house we can reduce costs for our
customers while still producing products to a high
standard.
Sink Marks
Depression in a moulded part caused
by shrinking or collapsing of the resin
during cooling.
Jetting
Turbulence in the resin melt flow caused
by undersized gate, abrupt change in
cavity volume, or too high injection
pressure.
Jetting - Problems
Obstruction in nozzle.
Screw rpm too high.
Back pressure too low.
Melt temperature too
high.
Nozzle too hot.
Nozzle too small.
Gates too small.
Sprue too small.
Insufficient venting.
Blush
Discoloration generally appearing at
gates, around inserts, or other
obstructions along the flow path. Usually
indicates weak points.
Blush - Problems
Burn Marks
Black marks or scorch marks on surface
moulded part; usually on the side of the
part opposite the gate or in a deep cavity.
Faulty temperature
controllers.
Frictional burring--gates too
small
Dead material hung up on
screw or nozzle.
Melt stock temperature too
high or too low.
Nozzle diameter too small
Over-heated heater band
Incorrect screw rpm.
Voids (Bubbles)
An unfilled space of such size that it
scatters radiant energy such as light.
Voids - Problems
Delamination (Skinning)
Surface of the finished part separates or
appears to be composed of layer of
solidified resin. Strata or fish scale type
appearance where the layers may be
separated.
Delamination - Problems
Contamination of resin by additives or other
foreign materials.
Resin temperature too low.
Non-uniformity of resin temperature.
Wrong mould temperature.
Excessive material moisture.
Inadequate injection speed.
Sharp corners at gate.
Incompatible polymers.
Excessive Warpage/
Shrinkage
Excessive dimensional change in a part
after processing, or the excessive
decrease in dimension in a part through
cooling.
Black Specks
Particles in the surface of an opaque part
and visible throughout a transparent part.
Brittleness
Tendency of a moulded part to break,
crack, shatter, etc. under conditions which
it would not normally do so.
Brittleness - Problems
Brittleness - Problems
Flash
Excess plastic around the area of the
mould parting line on a moulded
part.
Flash - Problems
mould parting surfaces do not seal properly.
Injection pressure too high.
Clamp pressure set too low or projected area
or item too large for clamp pressure of the
machine.
Injection temperature too high.
Feed needs adjustment.
Hold time too long.
Inadequate mould supports.
Oversize vents.
Blister
Defect on the surface of a moulded part
caused by gases trapped within the part
during curing.
Blister - Problems
Crazing
Fine cracks in part surface. May
extend in a network over the surface
or through the part.
Crazing - Problems
Insufficient drying of the material.
Contamination.
Injection temperature too high (crazing
accompanied by dis-coloring or yellowing).
mould surface contaminated
Inadequate injection speed.
Inefficient injection forward time.
Excessive injection pressure.
mould temperature too low.
Gate too large.
Cracking
Fracture of the plastic material in an
area around a boss, projection, or
moulded insert.
Cracking - Problems
Parts cool too quickly
moulded-in stress
Wall thickness too heavy for compound.
Low Gloss
Surface roughness resulting from high
speed fill which causes surface wrinkling
as the polymer melt flows along the wall of
the mould.
Inadequate flow.
Contamination
Resin excessively moist
Sprue, runners, and/or gate size too
small.
Pigment agglomerates.
Oil or grease on knockout pins.
Short Shot
Injection of insufficient material
to fill the mould.
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