Scientific Troubleshooting of Common Injection Molding Defects

Scientific Troubleshooting
of Common Injection
Molding Defects
presented by:
www.traininteractive.com | (tel) 978.957.0700

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Intelligent Molder
in·tel·li·gent
According to Encarta:
1 : the ability to learn facts and skills and

apply them, especially when this ability
is highly developed
Intelligent Molder
According to the New York

Times… Intelligence is defined
as problem solving ability
This is the basis of this presentation
FREE 10-Day Online Training Offer
Intelligent Molder Series: Process Evaluation

• In-Mold Rheology Test
• Gate Seal Worksheet
• Decoupled II Process Worksheet
• More Details at the End of the Presentation
of Common Defects
• Real-Life Troubleshooting Scenarios
• Who is a Scientific Troubleshooter?
• Process Documentation
• Causes for Common Defects
• Troubleshooting Methods
• FREE Training Offer
• Q & A Session
Real-Life Troubleshooting Scenarios
Case #1 – Material Issue - Problem

• Scenario:
– Connector Mold
– New Material Supplier with “Identical Material”
– Could Not Maintain Desired Cycle Times
– 13.9 seconds vs. 11.2 seconds
Case #1 – Material Issue – Solution

• Process, machine, & mold – identical
• What changed… Material
– Internal lubricant was not the same
– Internal lubricant not at the same percentages
• Established:
– Correct internal lubricant
– Correct percentages of lubricant
• Resulting in a cycle time under 9 seconds!
Case #2 – Part Design Issue - Problem

• Scenario:
– Kitchen shelving support
– Operating at 17.2 second cycle time
– Needed to maintain critical dimensions
– Wanted to optimize process
Case #2 – Part Design Issue – Solution

• Design Change
– Added 0.25º draft angle
• Resulting in a cycle time under 12 seconds!
Case #3 – Machine Issue - Problem

• Scenario:
– 3 plate mold replaced with hot runner mold
– 6 second capable automation added
– New machine could not plasticize fast enough
– New machine could not move all machine
functions at simultaneously
Case #3 – Machine Issue – Solution

• Specified new machine with:
– Better screw design
– Independent machine functions
• Resulting in cycle time under 4 seconds!
• Machine could outrun the automation!
Case #4 – Mold Issue - Problem

• Scenario:
– Theft protection tag
– 3 plate mold has slow process
– Cycle time above 23 seconds
– High scrap rate ~35%
Case #4 – Mold Issue – Solution

• Specified mold with hot runner system
• Significantly reduced scrap
• Resulting in cycle time under 10 seconds!
Case #5 – Technology Issue - Problem

• Scenario:
– Tubular coat hanger
– Intermittent short shots
– Due to viscosity variations in off-spec materials
Case #5 – Technology Issue – Solution

• Specified process monitoring system with:
– Cavity pressure transducer
– Integration to boost cutoff
• Resulting in elimination of short shots
• Variations in material viscosity had little to
no change in process
Who is a Scientific Troubleshooter?
trou· ble· shoot· er

According to Merriam-Webster:
1 : a skilled worker employed to locate

trouble and make repairs in machinery
and technical equipment
A Typical Troubleshooter:
• acts upon learned behavior
• makes multiple changes at one time
• rarely documents anything
• often blames the tool or material
• avoids speaking in specifics
sci· ence
According to Merriam-Webster:
1 : the state of knowing : knowledge as

distinguished from ignorance or
misunderstanding
sci· ence + trou· ble· shoot· er =

'a skilled worker who acts from a
state of knowing'
A Scientific Troubleshooter:
• knows the history of the process, mold,
machine, material, technology
• determines what has changed
• acts on knowledge
• verifies the results of any change
Process Documentation
Machine Inputs
vs.
Process Outputs
Setup Technicians Typically Document:

• machine-dependent inputs
• speed settings
• time settings
• temperature settings
• pressure settings
• tonnage settings
Scientific Troubleshooters Document:

• machine-independent process outputs
– temperatures
– times
– plastic pressures
– weights
– additional data
Process Outputs - Temperatures:

• plastic melt temperature
• coolant temperature in
• coolant temperature out
Process Outputs - Times:

• fill time
• pack time
• hold time
• gate seal time
• cycle time
• recovery time
Process Outputs - Plastic Pressures:

• back pressure
• pressure at transfer
– and/or peak pressure
• pack pressure
• hold pressure
Process Outputs - Weights:

• fill weight
• pack weight
• final weight
Process Outputs - Additional Data:

• cavity measurements
• quality measurements
• clamp tonnage
• photographs
• observations
• cavity balance
The Scientific Troubleshooter Uses

Documentation To:
• know how the process ran
• determine what changed
• act on knowledge
• verify the results
Causes/Symptoms for Common Defects
The Typical Troubleshooter Asks:
'what buttons do I push

to correct the defect?’
they often rely on learned behavior & troubleshooting guides
The Scientific Troubleshooter Asks:
‘what change occurred

to cause this defect?’
process documentation is crucial for these people
Flash
Flash
What Changed:
– high melt temperature or degradation
Causes:
– reduced melt viscosity
– more material enters cavity during fill
Symptom:
– flash anywhere on part
– decreased plastic pressure at transfer
• or peak pressure during fill
– increased fill weight
– change in screw recovery time
Flash
What Changed:
– low melt temperature
Causes:
– high melt viscosity
– more pressure is required to fill mold
Symptom:
– flash near gate or center of mold
– increased plastic pressure at transfer
– decreased fill weight
Flash
What Changed:
– decreased fill time due to high flow rate
Causes:
– lower viscosity due to shear thinning
– excessive material enters mold during fill
Symptom:
– decreased fill time
– increased pressure at transfer
Flash
What Changed:
– increased fill time due to a low transfer setpoint
Causes:
– excessive material enters mold during fill
Symptom:
– increased fill time
Flash
What Changed:
– increased pack and hold pressure
Causes:
– excessive pressure within mold
Symptom:
– increased pack weight
– increased final weight
Flash
What Changed:
– low clamp tonnage
Causes:
– insufficient tonnage to hold mold closed
Symptom:
– little change in outputs
– increased pack weight
Flash
What Changed:
– high cavity imbalance
Causes:
– excessive material enters during fill
Symptom:
– not all cavities may flash
– intermittent shorts
– intermittent flash
– incorrect fill time
Flash
What Changed:
– inconsistent check ring
Causes:
– inconsistent material during fill
Symptom:
– intermittent shorts
– intermittent flash
– inconsistent fill time
Flash
What Changed:
– excessive mold and platen deflection
Causes:
– inconsistent tonnage across parting line
Symptom:
– flash near center of the mold
Flash
What Changed:
– mold damage or wear
Causes:
– wear or damage occurs
Symptom:
– flash in a unique area
– flash near a moving component
Sinks and Voids
Sinks and Voids
What Changed:
– high melt temperature
Causes:
– excessive shrinkage occurs
Symptom:
– shrinkage anywhere on the part
– decreased pressure at transfer
Sinks and Voids
What Changed:
Causes:
– excessive pressure loss occurs
Symptom:
– shrinkage near the end of fill
Sinks and Voids
What Changed:
– increased fill time due to low flow rate
Causes:
Symptom:
– decrease pressure at transfer
– change in fill weight
Sinks and Voids
What Changed:
– decreased fill time due to a high transfer
setpoint
Causes:
– insufficient material enters mold during fill
Symptom:
– decrease in fill weight
Sinks and Voids
What Changed:
– decreased pack and hold pressure
Causes:
– inadequate pressure within mold
Symptom:
– shrinkage anywhere on part
– decreased pack weight
– decreased final weight
Sinks and Voids
What Changed:
– poor gate seal due to a low hold time
Causes:
– material exits the cavity through the gate
Symptom:
– shrinkage near the gate
Sinks and Voids
What Changed:
– high mold temperature
Causes:
– excessive shrinkage occurs
Symptom:
– shrinkage anywhere on the part
– decreased pressure at transfer
Voids
What Changed:
– low mold temperature
Causes:
– polymer freezes to mold surface as part shrinks
Symptom:
– voids anywhere on the part
Short Shots
Short Shots
What Changed:
Causes:
Symptom:
Short Shots
What Changed:
– increased fill time due to low flow rate
Causes:
Symptom:
– change in fill weight
Short Shots
What Changed:
– decreased fill time due to a high transfer
setpoint
Causes:
– insufficient material enters mold during fill
Symptom:
– decrease in fill weight
Short Shots
What Changed:
– decreased pack pressure
Causes:
– inadequate pressure to complete mold filling
after transfer
Symptom:
Jetting
Jetting
What Changed:
Causes:
– high viscosity prevents fountain flow
Symptom:
– increase pressure at transfer
Jetting
What Changed:
– decreased fill time due to high flow rate
Causes:
– high flow rate prevents fountain flow
Symptom:
– increase pressure at transfer
– decreased fill time
Jetting
What Changed:
– low mold temperature
Causes:
– poor adhesion to mold surface prevents
fountain flow
Symptom:
as you can see…
if the process is documented,

the scientific troubleshooter can
quickly identify what changed
Troubleshooting Methods
Again… A Scientific Troubleshooter:

• knows the history of the process, mold,
machine, material, and technology
• determines what has changed
• acts on knowledge (intelligence)
• verifies the results of any change
Step 1: Examine the Part to Ensure:

• proper diagnosis
• no other defects are present
Step 2: Rule Out Obvious Causes:

• check the simple causes
– where applicable
Step 3: Compare with Documented

Process Outputs
• focus on related outputs
• process of elimination
Step 4: Return Process to Documented

Standard
• change one parameter at a time
• allow each change time to affect the
process
Step 5: Verify Other Process Outputs

• verify any relevant parameters
• a full verification may be necessary
• if cause not found, check the mold,
machine, & material
Step 6: Document Any Changes Made

• record actions and causes
• ensures others can follow
In conclusion: it is not only about

troubleshooting a process…
All factors such as material, mold,

machine, part design and
technology must be documented.
Intelligent Molder Series: Process Evaluation

• In-Mold Rheology Test
• Gate Seal Worksheet
• Decoupled II Process Worksheet
Follow-Up Email Will Contain:

• Instructions to Download Worksheets
• Instructions to Receive Free Trial
• Webinar Notes & Special Offer
of Common Defects
Q&A
Session

Scientific Troubleshooting of Common Injection Molding Defects

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Scientific Troubleshooting

www.traininteractive.com | (tel) 978.957.0700

Please visit: www.IDES.com

Please visit: www.traininteractive.com

2009 Upcoming Webinars

Part Design for

2009 Upcoming Webinars

2009 Upcoming Webinars

10 Easy Ways to Analyze

2009 Upcoming Webinars

April 15, 2009

2009 Upcoming Webinars

1 : the ability to learn facts and skills and

According to the New York

This is the basis of this presentation

Intelligent Molder Series: Process Evaluation

Case #1 – Material Issue - Problem

Case #1 – Material Issue – Solution

Case #2 – Part Design Issue - Problem

Case #2 – Part Design Issue – Solution

Case #3 – Machine Issue - Problem

Case #3 – Machine Issue – Solution

Case #4 – Mold Issue - Problem

Case #4 – Mold Issue – Solution

Case #5 – Technology Issue - Problem

Case #5 – Technology Issue – Solution

trou· ble· shoot· er

1 : a skilled worker employed to locate

1 : the state of knowing : knowledge as

sci· ence + trou· ble· shoot· er =

Setup Technicians Typically Document:

Scientific Troubleshooters Document:

Process Outputs - Temperatures:

Process Outputs - Times:

Process Outputs - Plastic Pressures:

Process Outputs - Weights:

Process Outputs - Additional Data:

The Scientific Troubleshooter Uses

The Typical Troubleshooter Asks:

'what buttons do I push

they often rely on learned behavior & troubleshooting guides

The Scientific Troubleshooter Asks:

‘what change occurred

process documentation is crucial for these people

as you can see…

if the process is documented,

Again… A Scientific Troubleshooter:

Step 1: Examine the Part to Ensure:

Step 2: Rule Out Obvious Causes:

Step 3: Compare with Documented

Step 4: Return Process to Documented

Step 5: Verify Other Process Outputs

Step 6: Document Any Changes Made

In conclusion: it is not only about

All factors such as material, mold,

Intelligent Molder Series: Process Evaluation

Follow-Up Email Will Contain:

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