SHAPING PROCESSES FOR PLASTICS

Chapter 13- Part 2

Injection Molding

Manufacturing Processes, 1311

Dr Simin Nasseri
Southern Polytechnic State University

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SHAPING PROCESSES FOR PLASTICS
 Properties of Polymer Melts
 Extrusion
 Production of Sheet, Film, and Filaments
 Coating Processes
 Injection Molding
 Other Molding Processes
 Thermoforming
 Casting
 Polymer Foam Processing and Forming
 Product Design Considerations

Manufacturing Processes
Prof Simin Nasseri
Injection Molding
13.6

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 Injection Molding
Similar to hot-chamber die casting.
• Pellets fed into heated chamber.
• Melt forced into split die chamber.
• 10,000 to 50,000 psi.
• Mold is water cooled.
• Part is ejected.
Manufacturing Processes
Prof Simin Nasseri
 Polymer is heated to a highly
plastic state and forced to flow
under high pressure into a
mold cavity where it solidifies
and the molding is then
removed from cavity.
 Produces discrete components
almost always to net shape.
 Typical cycle time 10 to 30
sec, but cycles of one minute
or more are not uncommon.
 Mold may contain multiple
cavities, so multiple moldings
are produced each cycle.
Injection Molded Parts
 Complex and intricate shapes are possible
 Shape limitations:
 Capability to fabricate a mold whose cavity
is the same geometry as part
 Shape must allow for part removal from
mold
 Part size from  50 g (2 oz) up to  25 kg
(more than 50 lb), e.g., automobile bumpers
 Injection molding is economical only for large
production quantities due to high cost of mold

Manufacturing Processes
Prof Simin Nasseri
 Polymers for Injection Molding
 Injection molding is the most widely used molding
process for thermoplastics.
 Some thermosets and elastomers are injection molded
 Modifications in equipment and operating parameters
must be made to avoid premature cross-linking of these
materials before injection.

Parts manufactured by
injection molding

Manufacturing Processes
Prof Simin Nasseri
 Injection Molding Machine
Figure 13.21 Diagram of an injection molding machine, reciprocating
screw type (some mechanical details are simplified).

- Melts and delivers - Opens and

polymer melt closes mold each
- Operates much like an injection cycle
extruder Two principal components
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Prof Simin Nasseri
 Injection Molding Cycle

Figure 13.22 Typical molding cycle: (1) mold is closed. (2) melt is injected into
cavity. (3) screw is retracted. (4) mold opens and part is ejected.

Manufacturing Processes
Prof Simin Nasseri
Injection Unit of Molding Machine
Consists of barrel fed from one end by a
hopper containing supply of plastic
pellets.
Inside the barrel is a screw which:
1. Rotates for mixing and heating
polymer.
2. Acts as a ram (i.e., plunger) to
inject molten plastic into mold.
 Non-return valve near tip of
screw prevents melt flowing
backward along screw threads.
 Later in molding cycle ram
retracts to its former position.

Manufacturing Processes
Prof Simin Nasseri
Clamping Unit of Molding Machine
Functions:
1. Holds two halves of mold in
proper alignment with each
other.
2. Keeps mold closed during
injection by applying a
clamping force sufficient to
resist injection force.
3. Opens and closes mold at
the appropriate times in
molding cycle.

Manufacturing Processes
Prof Simin Nasseri
Injection Molding Machines
Injection molding machines differ in both injection unit and
clamping unit

Name of injection molding machine is based on the type of

injection unit used
 Reciprocating-screw injection molding machine
 Plunger-type injection molding machine

Several clamping designs

 Mechanical (toggle)
 Hydraulic

Manufacturing Processes
Prof Simin Nasseri
Shrinkage
Reduction in linear size during cooling from molding to
room temperature.
Polymers have high thermal expansion coefficients, so
significant shrinkage occurs during solidification and cooling
in mold.

Manufacturing Processes
Prof Simin Nasseri
Shrinkage Factors
Shrinkage decreases if the following quantities increase:

 Fillers in the plastic tend to reduce shrinkage

 Injection pressure – higher pressures force more

material into mold cavity to reduce shrinkage

 Compaction time - similar effect – longer time forces

more material into cavity to reduce shrinkage

 Molding temperature - higher temperatures lower

polymer melt viscosity, allowing more material to be
packed into mold to reduce shrinkage

Manufacturing Processes
Prof Simin Nasseri
Reaction Injection Molding (RIM)
A processing technique for the
formation of polymer parts by
direct polymerization in the mold
through a mixing activated
reaction.

Two highly reactive liquid ingredients

are mixed and immediately
injected into a mold cavity where
chemical reactions leading to
solidification occur

Manufacturing Processes
Prof Simin Nasseri
Reaction Injection Molding (RIM)
RIM was developed with
polyurethane to
produce large
automotive parts such
as bumpers and
fenders.

RIM polyurethane parts

possess a foam internal
structure surrounded by
a dense outer skin.

Manufacturing Processes
Prof Simin Nasseri
Compression Molding
A method of molding in which the
molding material, generally
preheated, is first placed in an
open, heated mold cavity.

The mold is closed with a top

force or plug member,
pressure is applied to force the
material into contact with all
mold areas, and heat and
pressure are maintained until
the molding material has
cured.

Manufacturing Processes
Prof Simin Nasseri
Compression Molding
A widely used molding process for thermosetting plastics.

Also used for rubber tires and polymer matrix composite

parts.

Molding compound available in several forms: powders or

pellets, or liquid.

Manufacturing Processes
Prof Simin Nasseri