Injection Molding- Injection Molding

Process Description
ver. 1
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
1
Overview
Equipment
Process
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
2
Equipment Equipment
Cl M ld B l Clamp Mold
Hopper
Barrel
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
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Equipment Equipment
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
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KrausMaffei at Ford 4000 tonnes KrausMaffei at Ford - 4000 tonnes
5 ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
Machine schematic
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
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Mold
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
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Mold Mold
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
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Modular molds Modular molds
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
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Mold schematic
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
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Mold
sprue
runner
cavity
gate
sprue nozzle p
side
front
ejection
pin
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
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pin
Process
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
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Process Process
Pellets placed in hopper Pellets placed in hopper
Pellets fall into barrel through throat
P ll t k d t f lid b d Pellets packed to form solid bed
air forced out through hopper
Pellets melted by mechanical shear
between barrel and screw
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
13
Process Process
Melted plastic forms shot in front of Melted plastic forms shot in front of
screw
b k l ti screw moves back as plastic moves
forward (reciprocating screw)
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
14
Process
Screw moves forward to inject plastic j p
into mold cavity
P t l d lidifi Part cools and solidifies
next shot is made
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
15
Process Process
Mold opens Mold opens
Ejection pins move forward to eject part
Mold closes
Process starts again Process starts again
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
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Solid bed Solid bed
Pellets crushed together Pellets crushed together
Air ejected
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
17
Melting zone Melting zone
Solid bed melted by mechanical shear Solid bed melted by mechanical shear
barrel barrel
screwflight
solid bed
secondary
mixing flow
screw flight
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
18
Homogenization zone Homogenization zone
Melted polymer is homogenized
thermally and color-wise. y
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
19
Injection pressure Injection pressure
Typically 15,000 psi
Ranges from3 000 to 40 000 psi Ranges from 3,000 to 40,000 psi
Hydraulic pressure is about 10x less
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
20
Process time
Close mold
Injection
Open and eject
part
j
p
1
5
33
35
Part cooling
Pack and hold
15
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
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Pressure historyy
Mold closed time
Cycle time
50
j
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c
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Cooling
Mold closed time
2
s
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Pack
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25
F
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33 35 15 5 0
0
Time (s)
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
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Time (s)
Temperature history Temperature history
Cooling
200
j
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part
100
s
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Pack
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gate
F
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33 35 15 5 0
0
Time (s)
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
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Time (s)
Gates and freeze off Gates and freeze-off
Filling &
Packing
Cooling
ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering
Prof. J .S. Colton GIT 2009
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