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Trouble Shooting For Injection Moulding 2014 PDF
Trouble Shooting For Injection Moulding 2014 PDF
TROUBLE SHOOTING
GUIDE
Your trusted partner for
Plastic Injection Moulding
A pro-active approach to PRODUCTION PROBLEM
SOLVING….
Trouble Shooting Guide - Index
Page No Description
Questions
CONSISTENT DEFECTS
This will usually indicate a problem in the injection nozzle, the hot
runner system or shape and design of the cold runner feed and
gate.
IRREGULAR DEFECTS
Look at compounding factors such as low melt temperature,
backpressure, screw speed and retraction can also be important
here.
DISTORTION Solutions:
Distortion is perhaps the 1. Aim for uniform packing of
prevalent problem for the the mould.
moulding industry today and is
normally caused by differences 2. Experiment with different
in cooling, shrinkage or mould temperatures.
orientation from one area of the 3. Ensure balanced filling of
part to another. the mould.
Distortion concentrated in the 4. Increase the injection
corners is often due to poor speed.
cooling, parts incorporating a 5. Ensure uniform and
variable wall thickness profile symmetrical cooling of the
can exhibit distortion due to moulding.
differential shrinkage.
6. Choose a more free-flowing
As a general rule crystalline plastic material.
materials usually exhibit 7. Consider changing to a
relatively high shrinkage and material with lower
are more susceptible to
shrinkage.
distortion particularly where
variable mould surface 8. Reduce differences in wall
temperatures and or variations
in wall thickness occur.
Fibre filled compounds often
show distortion and reinforced
crystalline grades tend to show See Appendix 1 for
a greater level of distortion Material
than amorphous grades due to
higher natural shrinkage of the Selection Guide and a list
base polymer. of Crystalline &
Amorphous materials.
Check shrinkage due to
differential fibre orientation.
Your trusted partner for
Plastic Injection Moulding
Trouble Shooting Guide for Injection Moulding
FLASH Solutions
Example of
Flash Your trusted partner for
Plastic Injection Moulding
Trouble Shooting Guide for Injection Moulding
Burn marks. Air and gasses in 1. Check tool faces are clean
front of the flow front can not 2. Reduced injection speed.
escape due to insufficient venting 3. Reduce injection pressure.
and are compressed to the point of 4. Improve venting in the area of
ignition. the burn mark.
5. Decrease the melt temperature
in case of degradation.
6. Check thermocouples and
check band heaters.
7. Reduce clamping force if
possible
Delamination/Splay Solutions
6. Consider adding a
hemispherical gate well
opposite the gate to
reduce shear and stress
Delamination in the immediate area.
Discolouration Solutions
Inconsistent Melts
Solutions:
Jetting Solutions
Example of Jetting