Injection Molding Basics Part-1 (Machine)

Introduction

 Welcome to injection molding basics.

 This training Series will provide participants with an overview of the three major aspects of
injection molding
o The machine,
o The process
o And the mold.
 Using standard industry terms and practices with an emphasis on safety, this Series will
enhance the knowledge base of all production personnel, program one entitled machine
covers
o Important safety precautions for working around injection molding machines
o An introduction to the injection molding process
o The types of injection molding machines
o And their modes of operation
o The components of the injection molding machine in their respective functions
o And the general procedures for starting up and shutting down a molding machine.
 Throughout the basic Series, you'll encounter the terms plastic and polymer. These words
have the same meeting and are used interchangeably.
 The terms mold, tool and die are also used interchangeably in the injection molding industry
and throughout these training programs.

Basic Molding Machine Function

 The following sequence illustrates the basic functions of an injection molding machine and
the process by which plastic pellets are transformed into molded parts pellets.
o Air fed into the hopper
o A screw conveys and melts the pellets within the barrel
o Melted polymer is forced into the closed mold.
o The parts are formed the polymer is cooled within the mold
o The mold is opened
o The part is ejected or removed from the mold
o And the next cycle begins.

Machine Type Industry Tip 1

 All machines function under the same principles, even though we may not show your
particular brand of molding machine. The concepts outlined in these programs cover all
machines.

Molding Machine Type

 Molding machines are either hydraulic, electric or a combination of both.

 Hydraulic molding machines use the hydraulic pump to provide pressure to each
component.
  Hydraulic valves air used to control moving components such as the injection cylinders,
screw clamp and ejection.
 The accuracy and repeatability of these machines is dependent on the quality of its
components and the condition of the hydraulic fluid.
 Most plants have the hydraulic fluid tested by a lab on a regular basis to ensure that the oil is
not contaminated.
 Electric molding machines use individual servo motors to operate each machine component.
 Electric molding machines are energy efficient and are generally more accurate and
consistent than hydraulic molding machines.
 An injection molding machine is rated by its maximum tonnage and shot size.
 Tonnage is a measure of the clamping force used to hold the Platen is closed and typically
ranges from 1 ton to 10,000 tons.
 The shot size is the maximum amount of plastic that could be injected during one cycle.
 This standard measurement is given in grams or ounces of polystyrene.

Machine Type Industry Tip 2

 A machine shot sizes measured in ounces or grams of polystyrene.

 There are two reasons why
o Polystyrene was one of the first plastics to be injection molded.
o Second polystyrene has a specific gravity of one, which means it has the same
density as water.

Modes of Operation

 An injection molding machine has three modes of operation manual, semi automatic and
automatic.
 The manual mode allows the operator to control each individual machine function.
 This mode is used when the machine is either starting up, shutting down, temporarily
paused or when adjustments are being made to the mold.
 Manual mode is also used when purging material from the barrel.
 Most modern machines are equipped with an auto purge function specific functions such as
opening and closing.
 The mold can be controlled using buttons or switches on the control panel while in manual
mode.
 The set up or mold set option can also be activated in the manual mode. This setting allows
for the fine tuning of mold parameters using significantly lower speeds and pressures.
 Mold set up and maintenance personnel use this option to help prevent damage during
mold changes.
 When placed in the semi automatic mode, the machine runs one cycle and then stops.
 The semi automatic mode is used when parts need to be manually removed from the mold
during the start up process and when troubleshooting defective parts.
 After the mold opens, the cycle stops. The operator then opens the safety gate, removes the
part and closes the gate.
 Most machines will then begin the next cycle. Yet some machines may require the operator
to press the start button while in the semi automatic mode.
  When the machine is placed in the automatic mode, parts are molded continuously. This
mode is used for molds equipped with ejection and for processes that use robotics.
 It is recommended to use the automatic mode whenever possible since minimal operator
attention is needed.

Injection Molding Machine Base

 The base injection unit Clamping Unit and Control panel are considered to be the four major
components of an injection molding machine.
 The base of the machine is made of high strength steel and is designed to support the
weight of both the injection and clamping units.
 Hydraulic molding machines utilize the base, to house most of the hydraulic components,
including the pump and reservoir.
 The base of electric machines is used solely for the electrical cabinets.
 The entire base rests upon adjustable pads called feet. These are used to adjust the height
and levelness of the machine.
 Smaller molding machines have an opening underneath the clamping unit so that parts
could be collected using conveyors or boxes.
 Larger molding machines have short bases and require parts to be removed from either the
top or side.

Injection Unit Barrel

 The injection unit is comprised of the hopper barrel screw and nozzle.
 The injection unit’s largest component is the barrel, which houses the screw sensors called
thermo. Couples are mounted within the barrel so its temperature can be monitored at all
times.
 Heater bands surround the barrel to help maintain a consistent barrel temperature and
provide the initial heat required during start-up.
 Plastic pellets have poured into the hopper either manually from a bag or through the use of
a vacuum loader.
 After funnelling down the hopper, the material then enters the barrel at the feed throat.
 Water jackets around and cool the feed throat to prevent the premature melting and
sticking of pellets known as bridging.
 If the feed throat becomes too warm and bridging does occur, there are several rules to
follow.
 First, never look directly into the feed throat when servicing. Pressure can build up within
the barrel and unexpectedly blow the material back out, causing serious injury.
 Second, never use any steel objects to remove the bridging, since they could damage both
the screw and the wall of the feed throat.
 Use tools made of softer materials like wood or plastic to dislodge any bridge material.

Injection Unit Screw Intro

 The screw is used to melt and convey the polymer to the nozzle and ultimately to inject the
material into the mold.
  The general purpose screw is the most common type of screw used, although a variety of
specialized screws exist such as the barrier and the PVC.
 Screws are specified using an L over D ratio and a compression ratio. The L over D ratio is
simply the length of the screw divided by its diameter.
 General purpose screws typically have L over D ratios ranging between 20:1 and 30:1.
 Higher L over D ratio screws are better at melting pellets and mixing additives.
 The ratio of the flight depth at the beginning of the screw divided by the flight depth at the
end of the screw is known as the compression ratio. This ratio is commonly between 3:1 and
4:1.
 Screws with higher compression ratios are better suited for materials that are difficult to
melt.

Injection Unit Screw Details

 The screw is rotated by the screw motor and has moved forward by either an electric motor
or hydraulic cylinders.
 The screw contains flights of varying depths. It could be separated into three sections.
o The Feed Zone
o Transition Zone
o And Metering Zone.
 The feed zone has the deepest flights and is used to convey the pellets from the feed throat
to the transition zone.
 The depth of the flights decrease throughout the transition zone until reaching the metering
zone.
 The flights convey the material along the screw while compressing and melting the polymer.
 Shear forces result from the compression of the melted polymer and the friction of the
screws rotation.
 These forces produce 70 to 90% of the heat required to melt the plastic pellets. The
remaining 10 to 30% of the heat is supplied by the barrels heater bands.
 As the screw rotates during recovery to melt the polymer, the meeting zone conveys the
material to the end of the screw. As it builds up, the screw is pushed back until the desired
amount of material is collected. This is referred to as the shot size.

Machine Components Industry Tip 1

 Heater Bands air used to control the temperature of the polymer melt and during machine
start-up.
 70 to 90% of the heat required to melt the pellets actually comes from the shear forces
between the screw and the barrel.

Screw Check Valve and Nozzle

 A check valve is located at the end of the screw. This valve allows material to pass during
screw recovery and prevents material from flowing backward during injection.
 The two common types of check valves are the check ring valve and the ball check valve.
  The check ring is the most widely used check valve and consists of inaccurately machine ring
that seals with the barrel. This ring is pushed forward during screw recovery and seats
against the screw during injection to prevent backflow.
 Another common type is the ball check valve. The perimeter of the ball check valves seals
against the barrel and uses a center ball to control material flow.
 The ball moves forward during screw recovery to allow material to flow through to prevent
backflow during injection, the ball slides back and seals the tip of the screw.
 If the check valve becomes damaged or blocked, the screw will typically drift all the way
forward during injection. The machine may also take too long to build the next shot during
screw recovery.
 The last section of the injection unit is the nozzle mounted to the end of the barrel, the
nozzle transfers the polymer melt to the mold. The nozzle in the screw bushing must have
the same radius to create a proper seal.

Clamping Unit

 When looking at the front of the machine, the clamping unit is mounted above the base on
the left.
 Large steel plates called platinum’s are used to support the extremely high forces required
toe hold the mold closed during injection.
 The two mold halves are mounted to the Platen, using either bolts or clamps. The mold
should take up a least two thirds of the Platen surface to help prevent the Platen size from
deflecting.
 The right platon does not move. It is referred to as the stationary Platon. The hole in the
center of this Platon is used to position the mold with locating ring.
 The locating ring is precision ground around the screw bushing on the mold. This ring is used
to ensure that the screw bushing and the nozzle are properly aligned when the mold is
mounted to the Platen.
 The left Platon is referred to as the movable Platon and slides on steel guides called foot
plates.
 The movement of the Platen is guided by the four large steel bars known as tie bars.
 The three most common types of clamping units are hydraulic, toggle and hydro mechanical.
 A hydraulic clamp uses a large hydraulic cylinder to move the Platen and to apply tonnage.
 A toggle clamp uses a series of linkages to move the Platen and to apply tonnage.
 The movement of the toggle languages is controlled using hydraulic cylinder or electric servo
motor.
 The hydro mechanical clamp uses toggle languages to open and close the mold and a
hydraulic cylinder to apply tonnage.

Mechanical Controls

 The control panel is typically located on the side of the stationary Platon or on the front of
the base.
 The control panel is used to manage virtually every function of the injection molding
machine.
  The control of older injection molding machines consists of limit switches, proximity
switches, timers and pressure valves. These controls require manual adjustment and are less
accurate and repeatable than those of new machines.
 Modern machines use linear potentiometer and optical encoders to more accurately
measure the position of each machine component.
 The operator interfaces with an LCD screen, and a computer is used to adjust and control
the molding machine functions.

Machine Start Up Procedure

 The following general procedures apply to most injection molding machines.

 We strongly recommend reviewing your plants procedures with the supervisor.
 If the molding machine has been down for more than an hour, it's referred to as cold.
 The machine in its auxiliary equipment must be warmed up before any parts could be
produced. This is called a cold start and typically takes 1 to 2 hours.
 The first step is to turn on the barrel heaters and mold temperature controllers. If using a
hydraulic molding machine, the hydraulic pump must be turned on to heat up the oil.
 Once barrel temperatures, air reached the barrel must soak. Soaking allows the barrel to
remain at a stable temperature for 10 to 20 minutes, ensuring the polymer within the barrel
is fully melted before the screw is started.
 This is extremely important as an unsold barrel may cause the screw or screw tip to break is
it turns.
 The machine could be started up once the barrel mold and hydraulic fluid have reached their
respective desired temperatures and have been soaked.
 Begin by placing the machine in manual mode. Next, perform a safety check on the machine
according to your plants procedures.
 This safety check should include the gates safety switches, the purge shield as well as the
emergency stop button.
 Open and close the mold slowly to ensure proper alignment of the mold half’s, then dry
cycle the machine. This refers to cycling the mold without injecting any material.
 Next, back the barrel away from the stationary Platon. Purge the material by running screw
recovery and injecting material out of the barrel. Repeat the process until the material
comes out with an even consistency, and then build the first shot.
 Remove any material from the end of the nozzle and then bring the barrel up to the
stationary Platon.
 Place the machine in semi automatic mode and start the cycle.
 Check the parts and mold for any inconsistencies or unusual damage, such as metal in the
part or flash on the mold.
 Mold a few cycles in semiautomatic until the part quality stabilizes. Place the machine into
the automatic mode if automated part removal is being used.
 Once the process is running, wait a few minutes for the process to become stable before
making any changes.
Machine Shutdown Procedure

 Before shutting down the machine, Stop the material from entering the feed throat and
continue processing the remaining material.
 Once the material runs out, switch the machine into manual mode. Back the barrel off of the
screw bushing and purge out all of the material while leaving the screw in the forward
position.
 When shutting down the machine. Closed the mold, but do not apply clamp tonnage.
 Turn off the barrel heater's temperature controllers and power down all pumps and motors.
 Be sure to turn off all self powered auxiliary equipment.
 Lastly, the pressurized and turn off all waterlines connected to the machine to prevent any
leaks.

Molding Environment Safety

 Since an injection molding environment contains many dangers, all safety rules and
regulations that your plants should be taken very seriously and must be followed by all
personnel at all times.
 Each state, region or country has governing bodies such as OSHA to determine which specific
safety precautions are necessary.
 Be sure that these regulations and guidelines air fully understood before working near
injection molding equipment.
 It is important that all plant personnel are prepared to handle an emergency situation.
 This includes knowing the location of all emergency exits, eyewash stations and first aid kits
as well as whom to contact in case of emergency.

Safety Industry Tip 1

Safety should be the main priority of every plant. Remember, when it comes to safety, no question is
a stupid question.

General Safety Precautions

 Here are some general safety precautions that apply to all molding facilities.
 Always ensure that the area around the molding machine is clean and free of obstructions.
 Leaking oil or water, as well as spilled pellets are severe hazards and should be cleaned up
immediately.
 Never touch the source of a fluid leak. High pressures can inject fluid under the skin, creating
a serious health problem.
 Become familiar with the location of the emergency stop buttons For all of the equipment in
the plant, these buttons should be labelled and are colored red.
 Always wear the appropriate safety Apparel. Safety glasses should be worn before entering
any molding area.
 These areas should be clearly designated by signs to prevent any confusion.
 Ear protection may also be necessary in certain areas. Pay strict attention to all warning
signs. They're there for your protection.
  No where forklifts and other moving equipment travel. Be sure to ask your supervisor if
something is unclear.

Machine Safety Guards and Shields

 Molding machines produced plastic parts using extraordinary speeds, pressures and
temperatures.
 Each machine is equipped with safety guards to protect personnel from these risks and must
not be operated if any guard has been removed.
 If a process incorporates auxiliary devices such as automation, robots, Stamper or conveyor
belts and then guards should be placed around this equipment as well.
 Extreme forces air used to open and close the injection mold. Both front and rear safety
gates are located on the machine to protect personnel from injury.
 When a gate is opened, safety or proximity switches air triggered to prevent moving
components from operating. These switches air literally lifesavers and should be checked at
the start of each shift.

Safety Industry Tip 2

 Every machine has a mechanical and an electrical safety switch on each safety gate to
protect you from the closing platon.
 Hydraulic molding machines are also equipped with a hydraulic safety switch.

Machine Purging and Shutdown

 The polymers, used in injection molding, reach temperatures of 700 degrees Fahrenheit, or
370 degrees Celsius and can cause serious burns during barrel purging hot plastic materials
forced out of the barrel onto the machine.
 Since purged polymer can remain hot for over an hour, leave the material on the machine
until it has cooled or placed the purged material into a bucket of cool water.
 This hot material should not be touched as a protective measure, a purge shield is placed
around the machine nozzle. This shield is equipped with a safety switch that prevents
purging went open.
 For extra protection from the hot polymer, heat resistant gloves and a face shield should be
worn when working around the barrel or nozzle.
 An operator is also susceptible. Tow hot polymer when cleaning vents or removing a stock
runner when performing. Such tasks always back the injection unit away from the clamping
unit to prevent the material from being pressurized and injecting.
 A heat shield surrounds both the machine barrel and the heater bands. Heat shields can
become very hot and remain hot for hours after the molding machine has been shut down.
 High voltage components are enclosed within electrical cabinets and are typically located on
the front side of the molding machine.
 An electrical safety switch located in the cabinets prevents the machine from operating,
while the doors are open.
 Anyone working on electrical machinery should be fully versed in the plants lockout and tag
out procedures. Such procedures prevent power from reaching machinery while being
serviced.
Safety Industry Tip 3

It is critical that you back the injection unit away when servicing the mold.

The melted plastic can cause serious injury if it comes in contact with your skin.

Conclusion

 After successfully completing program, one participant should be familiar with

o Important safety precautions for working around injection molding machines
o An introduction to the injection molding process
o The types of injection molding machines
o And their modes of operation
o The components of the injection molding machine in their respective functions
o And the general procedures for starting up and shutting down a molding machine.
 You should next participate in the second of three courses in the injection molding basic
Series entitled "Process".

Injection Molding Basics Part 2 - Process

 Process is the second of three programs in the injection molding basic Series.
 This interactive training course begins with an overview of
o The injection molding process and covers the classification of polymers
o Material preparation and the use of additives
o In-depth look at each phase of the molding process.
o General processing guidelines,
o The importance of maintaining a process log
o And an introduction to troubleshooting common defects

Plastics Manufacturing Process

 Plastics are being used for just about everything these days, from cars and household goods
to clothing and medical supplies.
 Billions of pounds of plastics a processed every year. Over 30% of that plastic is injection
molded into parts, making it the world's most widely used plastics process.
 The other major processes being extrusion, compounding, thermo forming, blow molding
and rotational molding.
 Injection molding is often a one step process, and in many cases a plastic part like a
container is usable once molded.
 In other cases, gate trimming, painting or assembly is required before parts are deemed
finished.
Polymer Classification

 In the industry, plastics are often referred to as polymers and the actual plastic pellets air
commonly referred to as resin or raw material.
 A polymer is classified using different criteria it is considered to be either
o Natural or synthetic,
o Thermo set or thermoplastic
o And amorphous or semi crystalline.
 Natural polymers of those found in nature, such as rubber, cotton and silk .
 Injection molding calls for the use of manmade synthetic polymers the most common being
polyester, polyethylene and nylon.
 Polymers get their strength from a process called polymerization. During polymerization,
small molecules called monomers combined to form long polymer chains. Thermo sets are
polymerizing during processing, while thermo plastics are polymerized before being
processed.
 During processing, the polymer chains fused together or cross link. Once thermosets
crosslink’s, they undergo a chemical change, which prevents them from being melted and
reprocessed.
 An egg is an example of a natural polymer, which thermo sets. Once the egg is heated, it
solidifies and cannot be melted again.
 Thermal plastics Air long polymer chains that air fully polymerized when shipped by the resin
manufacturer, thermal plastics can be re ground melted and reprocessed while retaining
most of their original properties.
 An example of a natural thermoplastic material is wax. It could be melted and formed. Once
cooled, the hardened wax could be melted and formed again.
 Unlike thermo sets, most plastic companies prefer thermoplastic materials because they can
be reprocessed and recycled.

Polymer Industrial Tip 1

Both thermoplastic and thermosets undergo a physical change during processing.

Thermo-sets also undergo a chemical change that prevents them from being reprocessed. For this
same reason, thermostats cannot easily be recycled.

Thermoplastic Polymers

 Thermoplastic polymers can be categorized in two types

o Amorphous
o Semi crystalline
 Amorphous polymers melt gradually when heated. During cooling, amorphous polymer
chains solidify slowly in a random orientation. By the end of the cooling phase, they shrink
about 0.5%.
 Common amorphous polymers include ABS, polystyrene, polycarbonate and PVC.
 Semi crystalline polymers melt quickly, once heated to their melting temperature. The
rapidly melting polymer is easy to process compared to amorphous polymers.
  As semi crystalline material cools, some of the polymer chains remain in a random state.
While others orient into compact structures called crystalline sites.
 These crystalline sites increased the strength and rigidity of the polymer.
 During cooling, semi crystalline polymers shrink up to 3% much more than amorphous
polymers.
 Semi crystalline polymers include acetal, nylon, polyester, polyethylene and polypropylene.

Polymer Industry Tip

 Many of the plastics that are cloudy or opaque are semi crystalline.
 While, all of the clear plastics are amorphous.

Material Preparation

 Plastic resins often require preparation before being processed.

 This preparation starts by regularly inspecting both the plastic pellets and the material
handling equipment for contamination.
 Always ensure that the material is stored in a temperature controlled environment and is
properly marked with the polymer brand type and lot number.
 In most molding applications, the base polymer being used does not have all the final parts
desired properties and requires the use of additives.
 Common polymer additives include
o Impact Modifiers
o Fillers
o Flame Retardants
o Mold Release Agents
o Antioxidants
o Plasticizers
o Reinforcements
o Heat Stabilizers
o Lubricants
o Coloring Agents
 Plastic from the sprue, runner and ejector parts can be re-ground and processed.
 Depending on the application, this re ground material can either be mixed as an additive
with unprocessed or virgin material or processed by itself.
 Nylon acrylics and most other high strength polymers must be placed into material dryers
before being processed.
 Without drying the pellets, moisture can cause the polymer to break down and results in
brittle parts or parts, exhibiting flash or splay.
 Desiccant dryers air more effective than circulating air dryers and should be used for all
applications featuring moisture sensitive materials.
 Dew meters are used to measure the moisture content within the dryer. Lower dew points
in the dryer indicate less moisture left in the pellets.
 Appropriate drying temperatures, times and dew points should be referenced from the
Material Suppliers Processing guide.
Material Preparation Industry Tip 1

 Never process PVC and acetal in the same injection molding machine.
 This combination produces a highly toxic gas and is a serious safety hazard.

Material Preparation Industry Tip 2

 Many plastic pellets look alike, so always check the polymer brand, type and lot number on
the containers.
 To be sure that you do not accidentally mixed different materials together.

Injection Molding Phases

 The injection molding process has three main phases

o Injection
o Cooling
o And an Ejection.
 The injection phase consists of the filling, packing and holding of the mold cavities.
 Each cycle begins with the screw moving forward to force material out of the nozzle.
 The screw channels the material from the machine nozzle to the center of the mold.
 From there, the runner system channels the material to the gates of each mold cavity.
 The gate is a small passageway machine into the mold, which connects the runner and
cavity.
 Once the polymer in the gate solidifies or freezes the polymer flow to the cavity, stops.
 If the gate freezes too early or not, enough material fills the mold. The final part will not be
full. This defect is known as a short shot.
 If excessive material is used during filling, the mold will be forced open by the high injection
pressure and polymer will flow outside the cavity. This defect is known as flash.

Filling Injection Phases

 The fill could be adjusted by altering

 The Injection Speed
 The Injection Pressure
 The Injection Time or The Transfer Position.
 The injection speed is the speed at which the screw moves forward and is measured in IPS
(in/sec) or CPS (cm/sec).
 To maintain the desired injection speed, most modern molding machines will automatically
make adjustments to the injection pressure.
 The pressure used to force the material into the mold is the injection pressure.
 Modern machines set a maximum limit on this to avoid excessive pressures that may cause
mold or machine damage.
 The injection time begins at the start of injection and lasts until the mold cavities are filled.
 Filling ends and packing starts when the screw reaches the transfer position as it travels
forward, this reference point is measured in either in or cm.
 If the screw reaches the transfer position too early, a sink or short shot may be produced.
 Conversely, if the transfer position is too low, the part may exhibit flash.
Packing Injection Phase

 During packing force is applied to the screw so that additional material is forced into the
mold cavities.
 This additional material compensates for material shrinkage that takes place during part
Cooling.
 The parameters that affect packing are the packing pressure and the packing time.
 The packing pressure is typically set to a value between 1/2 to 2/3 of the injection pressure.
 Insufficient packing pressure can result in depressions in the part called sinks.
 Excessive packing pressure can result in flash or can cause the part to stick to the mold.
 Insufficient packing time can result in sinks, while excessive packing time will only increase
the cycle time.

Holding Injection Phase

 The last stage of injection is referred to as holding. Hold applies pressure on the cavity until
the gate has enough time to freeze off.
 The two parameters that affect hold are the amount of pressure used and how long the
pressure is applied.
 The whole pressure set point typically starts at a value equal to 2/3 of the packing pressure.
 Yet it must be enough to prevent sinks near the gate.
 Excessive hold time has little effect on the part quality, but is a waste of both energy and
material and increases the overall cycle time.
 Proper hold time could be determined by graphing it against part weight and should be kept
as short as possible.
 The point where additional hold time does not affect part weight is the ideal amount of
time.

Cooling Phase

 The second stage of the molding process is the cooling of the part.
 During the cooling stage, screw recovery takes place to get the material ready for the next
shot.
 Cooling typically consumes more than half of the overall cycle time.
 Water is the most common form of coolant. Though high temperature molds may require
the use of oil.
 The coolant flows throughout the injection molding machine channels called cooling lines.
 As the formed part cools, shrinkage causes the part dimensions to be smaller than the
dimensions of the mold cavity.
 The longer it takes for a formed part to cool, the more the part will shrink.
 Cooling is controlled using to process parameters, mold temperature and cooling time.
 The mold temperature controller adjusts the temperature of the coolant to maintain the
desired mold temperature.
 Lower mold temperatures cool the parts quickly, while hotter molds typically have longer
cooling times.
 Another factor of cooling is part thickness. Thin sections of the part require less cooling than
thicker sections.
  The cooling time starts at the end of third stage time and lasts until part removal begins.
 The ideal cooling time used should be the lowest amount of time that consistently produces
good parts.

Cooling Phase Screw Recovery

 As with cooling, screw recovery takes place during the second phase of the molding process.
 As the screw rotates, pellets enter the barrel through the feed throat.
 The deep flights in the feed zone are used to convey the pellets to the transition zone of the
screw.
 As the polymer reaches the transition zone, the depth of the screw flights decrease and
compressing in melting the polymer.
 Between 70 and 90% of the heat required to melt the pellets, comes from the frictional
shear forces within the barrel.
 The melted polymer then reaches the metering zone, where it is conveyed to the end of the
screw.
 A check valve on the end of the screw performs two functions. It allows the polymer to flow
and fill the barrel during screw recovery and blocks flow during injection.
 As the polymer reaches the end of the barrel, it pushes the screw back until the desired shot
size is achieved.
 The faster the screw recovery, the quicker the polymer is ready for the next cycle.
 Unfortunately, a screw recovery that is too fast can break up the polymer chains and cause
material degradation.

Screw Recovery Parameters

 The processing parameters used to control screw recovery are

o The Barrel Temperatures
o Screw Speed
o Back Pressure
o And Shot Size
 The barrels heater bands only provide 10 to 30% of the heat required to melt the polymer,
but play a large role in maintaining a consistent melt temperature.
 The heater bands have multiple temperature zones, most often referred to as the rear,
center, front and nozzle.
 The barrel temperatures should be set to the lowest recommended settings provided by the
material supplier and increased only when necessary.
 Materials such as polyethylene, polypropylene and ABS which melted lower temperatures,
will use a normal profile. Where, the meeting zone temperature is higher than the feed
zone.
 Materials with a higher melt temperature PET, PBT and acetal will use a straight profile
where all the barrel temperatures are equal.
 Semi crystalline polymers such as nylon will use a reverse profile where the feed zone
temperature is higher than the metering zone temperature.
 The screw speed is the rate at which the screw rotates and is measured in revolutions per
minute or rpm's.
  Increased screw speeds build up the shot Quicker. Decreased screw speeds place much less
stress on the material, which lessens the chance of material degradation.
 Ideally, screw recovery time should be approximately 80% of the overall cooling time.
 Back pressure is applied to the screw during screw recovery to slow the building of the next
shot and to improve both the melting of the material and the mixing of additives.
 The back pressure setting should only be increased when inconsistencies in mixing or screw
recovery time exists.
 The position in which the screw stops at the end of recovery is the shot size.
 The shot size indicates the maximum amount of material available for injection during a
given cycle and is measured in either in or mm.

Ejection Phase

 The third phase of the molding process is ejection. This phase starts when the mold begins
to open and ends when the mold is clamped shot to accept the next shot.
 The parameters that affect pot removal are the mold open speed and the mold open
position.
 Since parts constrict as the mold opens, the mold should open as fast assed possible without
risking damage to the mold or part.
 The mold open position should be set to the minimum amount of distance necessary to
properly eject the part.
 In order for an application to be successful a uniformed force must be applied to the part
during ejection. This could be accomplished using multiple ejection components, such as a
number of ejector pins, blades or sleeves.
 Large plates called stripper plates push on the entire perimeter of the part and are the best
form of ejection for achieving a uniformed force.
 The parameters that affect part ejection are
o The Ejection Forward Speed
o Ejection Forward Position
o Ejection Returned Speed
o And The Number of Ejection Cycles
 It is recommended to use the fastest ejection forward speed that does not jeopardize part
quality or damage mold components.
 The ejection forward should travel far enough to eject the part from the mold, but should
not bottom out the ejection system.
 The ejection returned speed should be quick so that the mold could begin closing as soon as
possible.
 Ejection cycles air used to ensure that all the parts have been ejected from the mold before
the mold begins to close.
 Although most processes require the ejection to cycle only once some old require multiple
ejection cycles
 The number of cycles should be kept to a minimum, since each additional ejection cycle
increases the overall cycle time.
 The parameters that control mold closing are the mold close speed, mold protect position,
mold protect force and clamp force.
  The mold Closed speed should be swift unless there are components such as gears and slides
on the mold that can be damaged.
 As the mold closes, mold protect takes over and finishes closing the mold slowly. Under a
lower force, mold protect begins when the mold reaches a set position. This point is typically
equal to the thickness of the part.
 The mold protect can also start at a position where mold components such as the stripper
plate, assembly meat
 The mold, protect force or pressure should be set to the lowest value necessary to close the
mold.
 When set properly, the machine will alarm when the mold tries to close on a stuck part.
Applying full tonnage only when the two mold halves touch
 The clamping force should be set to the minimum tonnage required to mold an acceptable
part.
 Excessive tonnage can compress or damage mold components.

General Processing Guidelines

 When operating an injection molding machine, it is important to only change the process
when necessary.
 To maintain consistent part quality part should be inspected regularly. This includes
weighing the parts, checking dimensions and visually inspecting them.
 One way to ensure a consistent process is by verifying part weight. A consistent part weight
indicates that the same amount of material is being injected into the mold cavity each cycle.
 Any fluctuation in part dimensions can indicate the different amounts of packing or
shrinkage are occurring during processing.
 Checking the parts for visible defects can be one of the most difficult aspects of molding,
because it requires personal judgment
 The operator is often left to determine what a certain defect is and whether the parts are
acceptable or not.
 Samples of good and bad parts should be present at all inspection stations, so guesswork is
eliminated.

Process Log

 Once a stable molding process has been established, it is important to document all changes
in the process log.
 This log should detail information such as the time, reason and results of each parameter
change.
 The process log should also include any changes in material repairs to the machine or
modifications of molding equipment that occur while in application is active.
 Here are two extremely important rules to follow when processing
 First only adjust one process parameter at a time
 And second, always maintain an accurate and complete process log to document these
changes.
 Adjusting multiple parameters at once can quickly lead to an out of control process and poor
documentation can make it extremely difficult to troubleshoot and get things back on track.
Troubleshooting

 When troubleshooting, be aware that a particular molding defect can have a variety of
possible causes.
 Therefore, a systematic approach must be taken before any changes are made.
 The first step taken should always be to identify and understand the present defect.
 This ensures that you don't adjust the process for the wrong defect.
 Keep in mind that some defects may be acceptable depending on the application. For
instance, gate blush, maybe okay on the inside of a part if it will not be seen.
 The second step is to examine the part to see if multiple defects exist. If multiple defects are
detected, it may change how the process is fixed.
 Determining when the defect or defects began by examining previously molded parts is the
third step in troubleshooting.
 Without examining previously molded parts, it is more difficult to determine the cause.
 The defect may have only occurred on one or two parts, and in many cases is not a reason
for making process changes.
 In other cases, a defect could have been present for days, which may require extensive
evaluation.
 The last troubleshooting step that should be taken before correcting a defect is to examine
the process log.
 The start of a defect will often coincide with a process, material or equipment change and
will serve as a logical starting point.
 By completing these steps, personnel are better prepared to fix both current and future
problems in a logical manner.
 When parameters are being changed to fix a defect, only one parameter should be changed
at a time. This eliminates confusion and keeps things from getting worse.
 Additional changes should not be made until the full effect of a changes realized and
documented.
 For example, changes in pressure and speed can take only a few shots to be seen, while
temperature changes to the barrel or mold can take a couple of hours.
 For this reason, temperature changes air, often the last resort when making process
adjustments.

Common Defects Definitions

 It is important that production personnel are able to recognize common molding defects.
 Excessive unwanted material located on the edge of a part, is referred to as flash. This is a
result of material passing between mold components usually the parting line.
 Flash most commonly results from high injection and packing pressures or low clamp
tonnage.
 The incomplete filling of a mold cavity is called a short shot, increasing the amount of plastic
entering the mold during injection or cleaning the mold vents usually corrects this issue.
 Sinks are indentations on the part surface and are often located opposite a rib, a thick
section or around the gate.
 Sinks are most often the result of insufficient packing and can usually be eliminated by
increasing packing or holding pressure.
  Voids are sections in the center of the part where materials shrinks away from itself and
leaves a small hole within the part.
 Although they often appear to be air bubbles, there actually vacuums within the part where
no gas is present.
 An increase in packing or holding pressure usually corrects this.
 Dimensional variations exist when parts are out of specification due to increased or
decreased size.
 If the part is too small, it could be enlarged by using additional packing pressure or lowering
the barrel or mold temperatures.
 Conversely, a large part can be reduced by decreasing packing pressure or increasing the
mold and barrel temperatures.
 Streaks on the surface of a part in the direction of flow indicates splay. This defect is
commonly caused by water being present within the polymer.
 Check the dew point of the material in the hopper to ensure that it is properly dried and
inspect the mold for leaking water lines.
 Burning or dieseling occurs when gas becomes trapped in front of the polymer flow within
the mold, lowering the injection speed and cleaning the vents often corrects this.
 Jetting or warming occurs when the polymer enters the cavity too fast, resulting in a stream.
This is most often improved by lowering the injection speed.
 Brittleness is the reduced strength or toughness of a molded part. This is commonly caused
by moisture being present within the polymer. Check the dew point of the material to
ensure that it is properly dried.

Conclusion

 After successfully completing program 2, participants should be familiar with

o The injection molding process and covers the classification of polymers
o Material preparation and the use of additives
o In-depth look at each phase of the molding process.
o General processing guidelines,
o The importance of maintaining a process log
o And an introduction to troubleshooting common defects
 You should next participate in the third and final program of the injection molding basic
Series - ."Mold".

Injection Molding Basics - Part3

 Mold is the third and final program in the injection molding basic Series.
 Before participating in this course, you should already successfully completed the first two
programs entitled Machine and Process.
 This program covers the following topics
o The specific functions that an injection mold performs
o The machining methods used to construct a mold
 o The three common mold configurations used in the industry
o Common runner shapes common gate types
o And an overview of mold maintenance

Mold Definition

 As stated previously, the terms mold, tool and die have essentially the same meeting and are
used interchangeably within the industry.
 An injection mold consists of a series of metal plates. Group together to create two half’s,
the A half and the B half.
 This half’s are pressed together or closed in order to form melted plastic into a given shape.
 The plastic cools and the mold is opened, allowing the final part to be ejected.
 The location where the mold halves meet is referred to as the parting line.
 Be aware that injection molds may have multiple parting lines if floating plates are used.
 Molds are typically made of steel or aluminum and are constructed using a combination of
machining methods.
 An optimal mold is one that produces plastic parts in an efficient and repeatable manner.
 An injection mold is responsible for performing four major functions
o It must first provide a conduit to transfer the polymer from the machine nozzle to
the mold cavity.
o The mold must then form the part
o Cool the polymer
o And ultimately eject the part without distorting it.

Mold Quality Industry Tip 1

 A well designed and maintained mold is more important in achieving part quality than a
newer molding machine.
 Other words, a brand new molding machine cannot compensate for an inadequate mold.

Material Transfer

 First, an injection mold must successfully transfer the melted pellets from the molding
machine nozzle to the mold cavity, using a network of channels to direct polymer flow.
 These channels air called a runner system runner systems air typically classified as being
either cold or hot.
 In a cold runner system, material passes through a screw a runner and a gate before
reaching the mold cavity.
 A cold runner system ejects from the mold with apart and must be separated.
 After being separated from the part, the runners either ground up and reused or thrown
away.
 Hot runner system uses a heated or insulated channel. Unlike cold runners, the molten
plastic travels directly from this hot runner channel to the mold cavity.
 The runner channel remains hot during all phases of processing and is not ejected with
apart.
 Therefore, hot runner systems do not produce the runner scrap found in cold runner
systems.
Part Forming and Cooling

 Part forming takes place once the mold cavity has been filled with the melted polymer.
 The material is then packed using high pressures to achieve the desired dimensions of the
final part.
 Extreme clamp forces air used to keep the mold shut and to counter the injection and
packing pressures applied to the mold.
 The third function that a mold must perform is to cool the part.
 Cooling channels air machine into each mold half so that colon conf low around the part to
remove heat.
 Proper cooling is essential to the dimensional accuracy and stability of the final molded part.
 During injection, polymer temperatures can exceed 700 degrees Fahrenheit or 370 degrees
Celsius.
 By the time ejection takes place, the part must be cool to at least 200 F, or approximately 90
degrees Celsius.
 Water is the most widely used form of coolant. The oil is needed for higher temperature
applications since water's boiling point is 212 degrees Fahrenheit or 100 degrees Celsius.
 Cooling time accounts for more than half of the overall cycle time in nearly every molding
process. For the sake of efficiency, the part should be cooled as quickly as possible.
 The part must also be cooled evenly to prevent distortion of its dimensions and physical
properties.

Cooling Industry Tip 1

 Even part cooling is dependent on a steady flow of cooling throughout the mold. This could
be checked using a flow meter.
 An inadequate flow can be
o The result of a blockage
o A faulty valve
o A leak in a hose or bacteria build-up in the cooling lines

Part Ejection

 The final task of the mold is to remove the part.

 Removal should take place immediately after the park receives the appropriate amount of
cooling.
 A proper ejection system must evenly distribute the ejection force across the entire part.
 An uneven ejection force can result in a weekend or a damaged part.
 The most common forms of ejection used are
o Ejector pins
o Ejector sleeves
o Ejector blades
o Lifters
o Stripper plates
o And air poppet valves
  A mold ejection system may be comprised of multiple forms, yet should be kept as simple as
possible to avoid maintenance problems and added expenses.

Mold Construction Overview

 Injection molds are subjected to severe pressures and forces during each cycle.
 For this reason, mold should be constructed from high strength steels, especially high
production molds that are expected to make millions of parts.
 Low production molds are those used to produce less than 100,000 parts are typically made
out of softer materials such as aluminum or Kirk site.
 Most molds today are designed using computer aided drafting or CAD programs. These
computer applications can handle complex designs and help minimize human error.
 The data from CAD programs can be used with computer aided machining or cam programs.
Cam software can be integrated with most modern machining equipment, allowing mold
makers to construct accurate molds faster.
 Extreme care should be taken when working on injection molds as they are very expensive
and could take hundreds to thousands of hours to construct and assemble. Any damage to
the mold can directly affect the quality of the molded parts.
 Machining is the removal and shaping of steel to produce the molds, base inserts, cavity
core and any additional components. Today's mold maker has the luxury of choosing
between several different machining methods to construct a tool.
 The most common machining methods are milling, turning, grinding, electrical discharge
machining and polishing.

Milling Operations

 The first machining method will look at is milling. Milling is referred to as a chip making
process because pieces can fly off the table as the cutting tool shapes the work piece.
 This direct contact produces friction, which results in heat and stresses in the work piece. To
prevent the steel and cutting tool from overheating, milling machines use coolant to flow at
the point of contact.
 The cutting tools used in milling machines range in shape and size. Some cutting tools are
designed to remove large amounts of steel, while other tools air used to achieve highly
accurate dimensions.
 Milling leaves grooves on the surface and typically requires additional machining, such as
polishing before the work pieces ready for production.
 Milling machines are available in both vertical and horizontal styles. Modern milling
machines are equipped with computer numeric control or CNC, to increase accuracy.

Turning Operations

 Turning is a machining method that uses a lathe to shape the steel.

 A lathe is ideal for making round or symmetrical cores, cavities and inserts.
 The work pieces mounted to a chuck and the head of the chuck rotates, while the cutting
tool shapes the steel.
  But the cunning tool is typically a sharpened bit of hardened metal, such as carbon, steel or
carbide, and could be adjusted in either the X or Y direction to determine the length and
depth of the cut.
 As with milling machines, modern lathes are equipped with computer numeric control for
greater accuracy.
 Turning leaves a radial surface finish on the steel that often requires polishing before being
used.

Grinding Operations

 Grinding is the most accurate machining method and has performed on surface grinders,
cylindrical grinders or jig grinders.
 Conventional service grinders use Ah, high speed rotating wheel to grind a flat surface. The
table moves under the grinding wheel in both the X and Y axes, and a small amount of steel
is removed each pass.
 Cylindrical grinding is similar to turning, but uses a grinding wheel instead of a cunning tool.
Internal or external grinding wheels can be used to machine detail into the work piece.
 Jig grinders use the high speed rotating grinding stone to finish concentric holes. CNC
grinders can utilize computer aided machining programs so that complex details such as
contoured surfaces and profiles can be ground into the work piece.
 Grinding leaves a smooth finish on the work piece and typically does not require any
finishing operations before being used.

Electrical Discharge Machining Operations

Electrical discharge machining or EDM uses an electric spark to burn detail into the work piece. This
is accomplished by applying electrical charge to the work piece and the opposite charge to the
machining element.

 Since there is no direct contact between the machining element and the work piece, EDM is
a stress free form of machining.
 The two types of media machining Our Wire and Die sinker wire EDM uses a wire as its
machining element. The wire is threaded through the work piece and moves along a
computer controlled cutting path.
 Die sinker EDM uses a charged graphite or copper electrode to machine a mirror image of its
detail into the mold.
 The surface finish left behind from a conventional die sinker idiom machine is generally
rough. Yet both wire and CNC Die sinker EDM processes are capable of machining, accurate
and smooth services which require little or no finishing work.

Polishing Operations

Polishing is the smoothing of a surface using stones or compounds and is used solely as a finishing
operation.

Most polishing jobs air extremely time consuming and require a great deal of skill, experience and
patience.
High speed rotary vibrating and reciprocating machines, air used to minimize the time and strain of
the polishing process, as well as to improve the desired finish.

Both polishing stones and compounds come in a variety of textures ranging from course to extra
fine.

Polishing can be used to smooth any surface and can create a mirror finish.

Polishing Operation Industry Tip 1

Polishing is often considered a form of grinding, since the stone does remove small amounts of
metal with each motion.

Molds can require hundreds of hours of polishing before they're ready for production.

2- Plate Mold Part 1

 The three common mold configurations used today in the industry are the 2 plate, the 3
plate and the hot runner.
 The two plate mold is the most widely used design because of its simplicity and low cost. The
mold uses a cold runner system to transfer the material from the injection barrel into the
mold cavity.
 As the part cools, so does the runner system, and both rejected from the mold. The mold
half attached to the movable Platen of the two plate mold configuration is known as the B
half.
 The clamp plate is attached to the movable Platon and the ejector rails, air bolted to the
clamp plate. These are either recessed in the sides or have grooves to allow room for the
mold clamps.
 Buttons are pressed into the clam plate and service a landing or a stop for the ejection
system. The ejection system of the two plate mold consists of an ejector plate, a retainer
plate, a screw puller and return pins.
 The core retainer plate and the support plate are mounted to the ejector rails. The core
retainer plate houses the core detail as well as the leader pin bushings.
 The support pillars provide added support to the mold during injection and packing.

2- Plate Mold Part 2

 The stationary or A half of the two plate mold is mounted to the stationary Platen with the
clamp plate.
 Leader pins passed through the cavity retainer plate and are used to align the A and B half’s.
 One of the four leader pins is offset to ensure proper alignment during assembly.
 A screw bushing is inserted into the clamp plate and his ground flush with the parting line.
 The screw bushing and the mating nozzle must have equal radii to create a proper seal.
 The locating ring is bolted to the clamp plate and aligns the screw bushing with the nozzle as
the barrel comes forward.
 The two plate mold design is used for any molding application where runner scrap can be
tolerated.
3 – Plate Molds

 The three plate mold is similar to the two plate mold design, with an additional floating plate
between the mold half’s.
 Note that the behalf of the three plate mold does not contain a screw polar.
 Leader pin bushings guide the floating Center plate as it travels along the leader pins. The
runner system is located between the floating Center plate and the A half, while the part is
molded between the Center plate and the behalf of the mold.
 Material passes through the center plate of the three plate mold and fills parts from the top
using pin point gates.
 As the three plate mold begins to open, the Center plate and the behalf of the mold
remained together. This opens the cold runner parting line and separates the part from the
runner.
 As the mold continues to open, the Center plate is pulled away from the behalf and the parts
are rejected.
 The three played mold design is typically used for round and concentric parts, which are
gated from the top, and for applications that call for runner and part sorting.

Hot Runner Molds

 Hot runners remain heated throughout the entire cycle and stay in the mold during park
removal.
 The most common hot runner systems are insulated, externally heated and internally
heated.
 The movable or B side of the hot runner mold base is similar in design to the B half of the
two plate mold configuration.
 Both contain the core retainer plate, the support plate and the ejection assembly. The main
difference is that the hot runner mold does not contain a screw polar. The stationary or a
half of this design contains the hot runner system.
 Hot runners are kept in constant contact with the nozzle and act as an extension of the
machine barrel. These systems simplify automation and part removal, since the runner does
not eject from the mold.
 Hot runner molds are used for high production applications that cannot justify the cost of
runner scrap produced using to plate or three plate molds.

Cold Runner Systems

 A cold runner system is responsible for transferring the polymer from the screw to the gate
of the part.
 There are five common cross sectional shapes used for cold runner systems
o The Rectangular
o Trapezoidal
o Semi Circular
o Parabolic
o And Circular
 All five types are effective, but since the polymer melt flows best in a circular path.
  The circular design is generally the most effective note that other cross sectional designs
consumes less material than the circular design.
 This may be important in applications where scrap reduction is critical.

Manual Degating Gates

 2 plate molds use either manually delegating or self digating gates.

 Manual delegating gates must be separated from the part by an operator or through the use
of auxiliary equipment. These gates include the screw edge, flesh, fan disc spoke ring and
the tangential.
 The screw gate is the simplest gate and fills directly from the nozzle. Since it is the biggest
gate available, the Spree gate is ideal for filling large single cavity parts.
 Edge gates are ideal for molds with thin or small cavities. They are the most commonly used
gate in the industry due to their simple design.
 Flash gates air similar in design to edge gates. But use a wider contact area to pass the
material from the side of the runner to the mold cavity. Flash gates are also used to fill large
parts, especially when multiple parts are filled from a single runner.
 Fan gates are wide gates that spread the material flow across a large area. The fan becomes
wider as it approaches the mold cavity, while the thickness of the gate decreases. Fan gates
air commonly used for large, high tolerance parts.
 Disc gates around gates used in single cavity molds that Phil from the center of the part. At
the mold cavity, disc gates taper down in thickness so they can be easily removed. These
gates are ideal for round and concentric parts.
 A spoke gate consists of a series of edge gates projecting outward from a central screw.
These gates air used to fill large single cavity molds.
 Ring gates are large gates designed to fill the mold cavity, using a ring around the perimeter
of the part. Since the ring gate is approximately the same thickness is the part. Ah, large
amount of scrap is generated.
 Tangential gates spiral inward and taper down and thickness to the edge of the mold cavity.
Tangential gates are used to promote a circular flow in round parts.

Self Degating Gates

 Self to gating gates separate from the part during mold opening or the party ejects. These
gates include the pin, submarine and cashew.
 Pin gates consist of a single narrow passageway to transfer the material from the runner to
the part. This thin gate breaks from the part during ejection. Pin gates are used solely to fill
very small parts.
 Submarine gates also referred to as tunnel Gates Channel underneath the party line to
transfer the polymer from the runner to the mold cavities. The submarine gate tapers down
at the mold cavity and breaks from the part during ejection. These gates air used to avoid
gating on cosmetic surfaces.
 Cashew or banana gates tunnel beneath the parting line to gate on the underside of the
part. As with the submarine gate, the gate tapers down at the mold cavity.

General Mold Maintenance

  Designing and constructing an injection mold can be an expensive and time consuming
process.
 Molds are extremely valuable tools and must be properly cared for before, during and after
production.
 Good general mold maintenance can help avoid costly repairs and retooling.
 Before a molding operation begins, the mold should be closely inspected for any damage,
such as cracks, leaks or rust. All moving components should be checked for excessive wear.
This is usually evident by streaks or grooves, and if found, should be repaired by a trained
professional.
 Most mold contained venting on the cavities, runners and gates and should be thoroughly
clean with a cloth rag or a cotton swab.
 Before production begins, the mold should also be cycled without using any material. Dry
cycling is done to ensure proper alignment of the mold, halves and functionality of moving
components.
 During production, old should be checked every shift for damage, water leaks and
insufficient lubrication. Inspection and cleaning of all vents should also take place each shift.
 After production is complete, the mold surfaces should be sprayed with mold saver to
prevent rust and to prolong the life of the mold.
 Lastly, the tools should be stored in a moisture free environment to help prevent rust.
 The use of dehumidifiers or encasing the molds in sealed plastic bags may be necessary for
proper storage.

Conclusion

 After completing this course, participants should know

o The specific functions that an injection mold performs
o The machining methods used to construct a mold
o The three common mold configurations used in the industry
o Common runner shapes common gate types
o And an overview of mold maintenance
 This concludes "The injection molding basic Series"