Screw operation

Overview

The reciprocating screw is used to plasticize the plastic pellets using various RPMs, inject the molten
plastics as a plunger at various speeds and shot volumes, and control the pressure level in the molten
plastic charge in front of the screw. Several of its operations are discussed in this document.

Back pressure
Back pressure is the amount of pressure exerted on the material volume ahead of the screw, as the screw is pushed
back in preparation for the next shot.

Setting the maximum back pressure

Typically, all machines have an adjustment for the maximum back pressure. This "screw-back" stage stops when
the screw reaches a preset position. The stop position is manually set, based on the amount of material required to
fill the mold's cavity and runner system. When the machine is ready to inject the shot, the screw then plunges the
material ahead of the screw forward, injecting it into the mold. While the injected material is cooled in the mold
after the injection, the screw-back stage is re-initiated and the molding cycle repeated.

Injection speed
The injection speed (or ram speed) is the forward speed of the screw during its injection operation.

Setting the injection speed

For most engineering resins, the ram speed should be set to the fastest setting that the part design and process will
allow for technical and economic reasons. However, slower injection speed at the beginning of injection may be
necessary to avoid turbulent flow and Jetting, as material passes through the restrictive areas such as the gates. The
injection speed should be reduced again toward the end of injection to avoid flashing at the end of stroke, and to
enhance the formation of homogenous weld lines after a divided flow.

Screw rotation speed

The screw rotation speed (RPM) is the rate at which the plasticizing screw rotates. The faster the screw rotates, the
faster the material is compressed by the screw flights, increasing the amount of shear heating.

Cushion
The cushion is the difference in the final forward position of the screw and its maximum allowable forward
position. If the screw were allowed to travel its full stroke and stop mechanically against the nozzle, the cushion
would be zero. Typically a cushion of 3 to 6 mm (1/8 to 1/4 inches) is used.