Injection Molding-

Molding
Process Description

ver. 1

ME 4210: Manufacturing Processes and Engineering 1

Prof. J.S. Colton © GIT 2009
 Overview
• Equipment
• Process

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 Equipment

Cl
Clamp M ld
Mold B
Barrel
l
Hopper

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Prof. J.S. Colton © GIT 2009
 Equipment

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Prof. J.S. Colton © GIT 2009
KrausMaffei at Ford - 4000 tonnes

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Machine schematic

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 Mold

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 Mold

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 Modular molds

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 Mold schematic

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 Mold
runner sprue
cavity
gate

sprue
p nozzle

front ejection side

pin
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Prof. J.S. Colton © GIT 2009
 Process

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Prof. J.S. Colton © GIT 2009
 Process

• Pellets placed in hopper

• Pellets fall into barrel through throat
• Pellets
P ll t packedk d tto fform solid
lid b
bed
d
– air forced out through hopper
• Pellets melted by mechanical shear
between barrel and screw

ME 4210: Manufacturing Processes and Engineering 13

Prof. J.S. Colton © GIT 2009
 Process

• Melted plastic forms shot in front of

screw
– screw moves back
b k as plastic
l ti moves
forward (reciprocating screw)

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Prof. J.S. Colton © GIT 2009
 Process

• Screw moves forward to inject

j p
plastic
into mold cavity

• Part
P t cools
l and
d solidifies
lidifi
– next shot is made

ME 4210: Manufacturing Processes and Engineering 15

Prof. J.S. Colton © GIT 2009
 Process

• Mold opens
• Ejection pins move forward to eject part

• Mold closes
• Process starts again

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 Solid bed

• Pellets crushed together

• Air ejected

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 Melting zone

• Solid bed melted by mechanical shear

barrel

screw flight
secondary
mixing flow solid bed

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 Homogenization zone

• Melted polymer is homogenized

thermally
y and color-wise.

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Prof. J.S. Colton © GIT 2009
 Injection pressure

• Typically 15,000 psi

• Ranges from 3 3,000
000 to 40
40,000
000 psi
• Hydraulic pressure is about 10x less

ME 4210: Manufacturing Processes and Engineering 20

Prof. J.S. Colton © GIT 2009
 Process time
Open and eject Close mold
part
p Injection
j
1
33
35 5

Pack and hold

Part cooling
15

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Prof. J.S. Colton © GIT 2009
 Pressure historyy
Cycle time

Mold closed time

Part ejjection
Cooling
50
Injection
Fasst closing

Gate freezze off

Pack

2
25

0
0 5 15 33 35
Time (s)

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Prof. J.S. Colton © GIT 2009
 Temperature history
Cooling

200

Part ejjection
part
p
Fasst closing

Injection
gate

Gate freezze off

100 Pack

0
0 5 15 33 35
Time (s)

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Prof. J.S. Colton © GIT 2009
 Gates and freeze
freeze-off
off

Filling &
Packing

Cooling

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ME 4210: Manufacturing Processes and Engineering 25
Prof. J.S. Colton © GIT 2009