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6.2.

2017 MOULDINGPROBLEMSMould,MachineandMaterialrelated:(Table1702)

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MOULDINGPROBLEMSMould,MachineandMaterial
related

MOULDING MOULDrelated MACHINErelated


PROBLEMS
IN Unequalshrinkagedue Holdonpressureand
CONSISTENT tovariationinmould holdontime
CRITICAL surfacetemperature. influencesthe
DIMENSIONS shrinkage.High
Coolingcircuitdesign pressureandtime
related. reducestheshrinkage.
Lowerpressureand
Coreandcavity timeincreasesthe
dimensionrelated. shrinkageofthepart.
Correctshrinkageis
notconsideredfor shrinkageinthe
core/cavity directionoforientation
dimension. ismore.

dimensionscouldbe
controlledby
controllingcooling
rateindifferentareas
ofthemouldwhen
wallthicknessisnot
constant.Coolingrate
couldbeincreasedby
usingBaCuinsertin
themould.
SINKMARKS Partdesignrelatednon Injectionspeed
uniformityofwall profileandhold
thickness. onpressure
profilecan
minimisetosome
extent.
Gasinjection
Moulding
techniquecanbe
considered.

WARP Usetechniqueto ...


improvepartstiffness
withpartdesign.
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6.2.2017 MOULDINGPROBLEMSMould,MachineandMaterialrelated:(Table1702)

Randomdistributionof
mouldsurface
temperature.Cooling
circuitdesignrelated.

WEAKWELD Partdesignrelated. Injectionspeedcan


LINES influence.
DEGRADATION Checkdimensionsofrunner ExcessiveResidence
systemforexcessive timeduetouseof
shearing. oversizedinjection
unit.

Loweringbarrel
temperatureand
injectionspeedcan
havesomeinfluence
EJECTION Partdesignrelated ...
DIFFICULTY Unbalancedmeltflow.Use
flowleadertoreduce
unbalanceinflow.
POORIMPACT Radiusatprojectionsand ...
strength sharpcornersasitactlike
notchfromwherecrack
propagates.
IN ... %ageutilisationof
CONSISTENT shotcapacityiscloser
WEIGHT. to90%resultingin
inconsistentmelt
qualityifmetering
strokeismorethan3
timesscrewdiameter.
Borderlinecasefor
shotweight.
IN Increasegatesizetoreduce Availablemaximum
CONSISTENT pressuredropacrossthe injectionrateisnot
FILLING gate. adequateforflow
ratioofpartbeing
moulded.Borderline
caseforinjection
rate.
STRESS Meltflowisunbalanced. Overpackedpart.Set
CRACKING Partdesignrelated. correctpressureprofile
duringpressurephase.

... MATERIALRELATEDPROBLEMS
SINKMARKS Filledpolymercanreducesinkmark.
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6.2.2017
SINKMARKS MOULDINGPROBLEMSMould,MachineandMaterialrelated:(Table1702)
Filledpolymercanreducesinkmark.

POOR Considerhighmolecularweightpolymers.
MECHANICAL
STRENGTH Considerfilledpolymers.Preheatpolymerin
dehumidifierifrequiredforpolymeras
recommendedforpolymer.
DIMENSIONAL Checkshrinkagecharacteristicsofmaterial.
VARIATION
DEGRADATION Check thermal stability of polymer as well as
OFMELT pigments and other additives if any used with
material.
DIFFICULTYIN ConsiderpolymerofhigherMFI
FILLING

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andqualityinperformance

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Polymers Mould
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Machine Process proces curve
pvtdiagram Thermalstability BalancingmeltFlow Balancing Freezing Quality
Heat Problems
ThreeBalances MouldedinStress Shrinkage Inconsistent Sinkmark Weldlines
Dimension
Moulding CYCLETIME PlasticsPartDesign Flow .. ..
Problems Analysis

Engineering Glossaryoftechnical Glossaryoftechnical Myth UnderstandingMould Ideal


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