The Injection Molding of High-Quality Molded Parts

ATI 1144 e Production equipment/Machinery

Bayer service for innovative

solutions and successful
applications in virtually all
sectors.

The plastics developed by Bayer are backed

up by the know-how of our development,
design and process engineering service.
Comprehensive information on our
products, assistance with materialselection
and detailed answers to application-
technology questions may be found in our
Technology Center in the internet under
//plastics.bayer.com

Bayer AG
Bayer plastics on the Internet: Plastics Business Group
http://www.plastics.bayer.com 51368 Leverkusen

This information and our technical advice - whether verbal, in writing Unless specified to the contrary, the values given have been established
or by way of trials - are given in good faith but without warranty, and on standardised test specimens at room temperature. The figures should
this also applies where proprietary rights of third parties are involved. be regarded as guide values only and not as binding minimum values.
Our advice does not release you from the obligation to verify the in- Please note that, under certain conditions, the properties can be affect-
formation currently provided - especially that contained in our safety da- ed to a considerable extent by the design of the mold/die, the process-
ta and technical information sheets - and to test our products as to their ing conditions and the coloring.
suitability for the intended processes and uses. The application, use and
processing of our products and the products manufactured by you on
the basis of our technical advice are beyond our control and, therefore,
Plastics
entirely your own responsibility. Our products are sold in accordance
Edition: 2000-03 Business Group
Gr
with the current version of our General Conditions of Sale and Deliv-
ery. Order no.: KU11827-0003e/5667875 KL
 Production equipment

Contents Page Machinery

In order to select the right size of machine Metering stroke 1 to 3 D (up to 4 D in exceptional cases)
and the correct components, it is necessary
to know:
Machinery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
● the material and type
Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ● the shot weight or volume Metering Compression Feed zone
zone zone
Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ● the mold mounting dimensions
Residual length halved 50 to 60 %
● the requisite locking force
Locking force/clamping force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Screw length 18 to 22 D (according to EUROMAP)
● any special conditions for attaining
the specified quality.
Temperature control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Fig. 1: Standard screw geometry
Since this brochure is not intended as a text
book for up-and-coming injection molders,
only those points which we feel to be par- 16
ticularly necessary for achieving a satisfac-
tory result will be covered in what follows.
mm
One of the important topics in this respect Feed zones
is the selection of the right screw size and
geometry. 12 ** For amorphous
thermoplastics
10 *
For semi-crystalline

Flight depth H
thermoplastics
8 Compression zone
Screws
The most commonly used geometry for a 6
standard screw today is shown in Figs. 1 and
H~D0,7
2. This is characterized by a relatively long
4 Metering zone
feed zone (50 to 60 %) and a not-too-short
compression zone (25 to 20 %).
2
In the case of semi-crystalline materials,
it is a good idea for screws with diame- 0
0 20 40 60 80 100 120 mm 160
ters in excess of 80 mm to have a re- Screw diameter D
duced flight depth (Fig. 2). This is be-
cause of the greater amount of energy **
that is required for plastication (shear 2.0:1 2.1:1 2.2:1 2.3:1 2.4:1 2.4 :1 2.5 :1 2.5:1
heating). Flight depth ratios
Constant
*
flight depths 1.8: 1 2.0 : 1 2.0 : 1 2.1: 1
Fig. 2: Correlation between screw diameter and flight depth ratio

2 3
 Production equipment

Contents Page Machinery

In order to select the right size of machine Metering stroke 1 to 3 D (up to 4 D in exceptional cases)
and the correct components, it is necessary
to know:
Machinery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
● the material and type
Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ● the shot weight or volume Metering Compression Feed zone
zone zone
Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ● the mold mounting dimensions
Residual length halved 50 to 60 %
● the requisite locking force
Locking force/clamping force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Screw length 18 to 22 D (according to EUROMAP)
● any special conditions for attaining
the specified quality.
Temperature control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Fig. 1: Standard screw geometry
Since this brochure is not intended as a text
book for up-and-coming injection molders,
only those points which we feel to be par- 16
ticularly necessary for achieving a satisfac-
tory result will be covered in what follows.
mm
One of the important topics in this respect Feed zones
is the selection of the right screw size and
geometry. 12 ** For amorphous
thermoplastics
10 *
For semi-crystalline

Flight depth H
thermoplastics
8 Compression zone
Screws
The most commonly used geometry for a 6
standard screw today is shown in Figs. 1 and
H~D0,7
2. This is characterized by a relatively long
4 Metering zone
feed zone (50 to 60 %) and a not-too-short
compression zone (25 to 20 %).
2
In the case of semi-crystalline materials,
it is a good idea for screws with diame- 0
0 20 40 60 80 100 120 mm 160
ters in excess of 80 mm to have a re- Screw diameter D
duced flight depth (Fig. 2). This is be-
cause of the greater amount of energy **
that is required for plastication (shear 2.0:1 2.1:1 2.2:1 2.3:1 2.4:1 2.4 :1 2.5 :1 2.5:1
heating). Flight depth ratios
Constant
*
flight depths 1.8: 1 2.0 : 1 2.0 : 1 2.1: 1
Fig. 2: Correlation between screw diameter and flight depth ratio

2 3
 Production equipment Production equipment

In cases where the mixing effect of a stan- Extensive experience has shown that the best
dard screw is not sufficient (such as for col- Single-flighted three-section screw (DZS) metering stroke is between 1D and 3D (D
oring by the processor or for the processing = screw or cylinder diameter). In exceptional 1D 2D 3D 4D
of regrind), different special-purpose screw cases, it can be up to 4D. Deviations from
designs have proved successful. These are this range can lead to defects on the molded
equipped with additional shearing and mix- part. Screw
ing elements in the metering zone (Fig. 3). Non-return valve
They permit clearly improved mechanical
and thermal homogenization of the melt Compression
without any drawbacks in terms of plasti- Metering zone zone Feed zone
cating performance or other aspects. The
improved thermal homogenization simulta-
neously reduces the development of local Single-flighted three-section screw <1D >4D
shrinkage differentials on the molded part. with shearing and mixing section (DZM 1-G)
This is particularly important for precision
components made of semi-crystalline ma- 1D to 3D optimum range
terials, yet also reduces the tendency to warp 3D to 4D possible in exceptional cases
in general. Work on optimizing these screws <1D and >4D not recommended
Non-return valve

Shearing section
Mixing section

is not yet completed. Here too, the aim is

for a standard screw that can be employed as
a universal screw as far as possible.
In the case of standard and special-purpose
screws, the screw diameter is selected on
the basis of the shot weight or shot volume
that is required to fill the mold. To this end
it is necessary to make allowance for both
the metering stroke and the residence time.
Fig. 4: Optimum and potential metering stroke for injection molding
Compression
Metering zone zone Feed zone
In the 1980s, the machine industry tended
to increase the shot volume in an inexpen-
Double-flighted three-section screw sive manner by lengthening the metering
with shearing and mixing section (DZM 2-G) stroke (> 4D). This led to an increased oc-
currence of large-area air streaks. Air bub-
bles were also observed in isolated cases,
which were not always visible on the sur-
Non-return valve

Shearing section

face as bulges. The big bubble in Fig. 5,

Mixing section

however, developed under extremely unfa-

vorable conditions.
Compression
Metering zone zone Feed zone

Barrier screw (BS)

Melt channel Solids channel
Non-return valve

Shearing section
Mixing section

Fig. 5: Air streaks and an air bubble on a large injection molding due to an
excessively long metering stroke
Barrier zone Feed zone

Fig. 3: Examples of special screws with shearing and mixing elements in the
metering zone
4 5
 Production equipment Production equipment

In cases where the mixing effect of a stan- Extensive experience has shown that the best
dard screw is not sufficient (such as for col- Single-flighted three-section screw (DZS) metering stroke is between 1D and 3D (D
oring by the processor or for the processing = screw or cylinder diameter). In exceptional 1D 2D 3D 4D
of regrind), different special-purpose screw cases, it can be up to 4D. Deviations from
designs have proved successful. These are this range can lead to defects on the molded
equipped with additional shearing and mix- part. Screw
ing elements in the metering zone (Fig. 3). Non-return valve
They permit clearly improved mechanical
and thermal homogenization of the melt Compression
without any drawbacks in terms of plasti- Metering zone zone Feed zone
cating performance or other aspects. The
improved thermal homogenization simulta-
neously reduces the development of local Single-flighted three-section screw <1D >4D
shrinkage differentials on the molded part. with shearing and mixing section (DZM 1-G)
This is particularly important for precision
components made of semi-crystalline ma- 1D to 3D optimum range
terials, yet also reduces the tendency to warp 3D to 4D possible in exceptional cases
in general. Work on optimizing these screws <1D and >4D not recommended
Non-return valve

Shearing section
Mixing section

is not yet completed. Here too, the aim is

for a standard screw that can be employed as
a universal screw as far as possible.
In the case of standard and special-purpose
screws, the screw diameter is selected on
the basis of the shot weight or shot volume
that is required to fill the mold. To this end
it is necessary to make allowance for both
the metering stroke and the residence time.
Fig. 4: Optimum and potential metering stroke for injection molding
Compression
Metering zone zone Feed zone
In the 1980s, the machine industry tended
to increase the shot volume in an inexpen-
Double-flighted three-section screw sive manner by lengthening the metering
with shearing and mixing section (DZM 2-G) stroke (> 4D). This led to an increased oc-
currence of large-area air streaks. Air bub-
bles were also observed in isolated cases,
which were not always visible on the sur-
Non-return valve

Shearing section

face as bulges. The big bubble in Fig. 5,

Mixing section

however, developed under extremely unfa-

vorable conditions.
Compression
Metering zone zone Feed zone

Barrier screw (BS)

Melt channel Solids channel
Non-return valve

Shearing section
Mixing section

Fig. 5: Air streaks and an air bubble on a large injection molding due to an
excessively long metering stroke
Barrier zone Feed zone

Fig. 3: Examples of special screws with shearing and mixing elements in the
metering zone
4 5
 Production equipment Production equipment

The cause is shown in the schematic dia-

gram. By having the screw move back a 1D 3D
2D 4D 4D
long way, a zone containing entrapped air After metering 2
develops in the cylinder. This then causes 10 4
the surface defects that are pictured above 8
Granules cm 3
6
to form in the molded part at a certain dis- Melt Melt Air 4 3D
tance from the gate. 2
Melt Melt 10 3
Conversely, with an excessively small me- Air
tering stroke (generally < 1D), there is a dan- Air 8
6
Residual granules 4
ger of material damage or a color change ge
an
gr

Metering volume VD
2 rin
through an excessively long residence time. After injection mete
10 2 mu
m
The residence time can be determined em- 8 ti
6 Op
pirically with the aid of an indicator (e.g. Granules 4

color concentrate). This can be calculated Melt Air 2

for known plasticizing units or established 10 1 1D
with the aid of nomograms. In practice, it is Melt 8
6
Air
necessary to make allowance for the ther- Residual granules
4

mal sensitivity of the material being 2

processed. The following time ranges apply Metering volume VD 10 0

for the mean permitted residence time: After the start of the next metering stroke 10 1 2 3 4 5 6 7 8 9 10 2 mm 2

cm 3
10 4

10 3

10 2

10 1

10 0
Screw diameter D

8
6
4

8
6
4

8
6
4

8
6
4
2
10 0
● 4 to 6 min for (PC + ABS), Melt Granules
(ABS+PA) and Melt Residual granules Air 2

4 Example A
(PBT+PC) blends Melt Melt 6 Screw diameter 25 mm
and FR grades 8
Air Air 10 1 12 g
Shot weights

● 4 to 8 min for ABS, PC, PC-HT, Residual granules 2 to 20 g

35 g
SAN, PET and PBT 4 to
Fig. 6: Zones with entrapped air for a metering stroke of > 4 D

Shot weight
6 66 g
● 4 to 10 min for PA 8
10 2
*1
2
*2
These ranges commence at 4 minutes be- Taking into account the optimum melt In Example B, the best screw diameter 4
cause experience has shown that (especial- stroke range, the nomogram shown in Fig. 7 range for a shot weight of 2,500 g is to be 6
8
ly with semi-crystalline materials) operat- can be used to allocate the shot weight in determined. This is somewhere between 100 10 3 *1
ing conditions with residence times of less question to the appropriate plasticizing units and 150 mm for the optimum metering 2

than 4 minutes can produce an insufficient- and hence machine sizes. The converse al- stroke range. It shifts towards correspond- 4
g
ly compounded melt. The broader a materi- location is, of course, also possible. ingly smaller dimensions as the melt densi- 6
8
Example B ~100 to 150 mm
al’s residence time range, the larger its pro- ty increases. 10 4 Molded part weight
In Example A that is plotted on the nomo- 2.500 g
cessing window. 2 Screw diameter
gram, the potential shot weight range is be- *2 Highest-density
ing sought for an existing screw diameter of BAYER thermoplastic (at ϑ )
M

25 mm. With low-density melts, this is 12 Reference values for plotting individual density curves on the
to 35 g and, with high-density melts (e.g. *1 Lowest-density
BAYER thermoplastic (at ϑ ) nomogram:
M

highly filled grades), between 20 and 66 g ● with a low melt density = 0.85 x density at room temperature
The density range specified covers all Bayer thermoplastics and grades. with a high melt density = 0.95 x density at room temperature
(corresponding to the change in shot weight ●

as a function of density for an identical shot Fig. 7: Determination of screw diameter or shot weight with allowance for the metering stroke
volume).

6 7
 Production equipment Production equipment

The cause is shown in the schematic dia-

gram. By having the screw move back a 1D 3D
2D 4D 4D
long way, a zone containing entrapped air After metering 2
develops in the cylinder. This then causes 10 4
the surface defects that are pictured above 8
Granules cm 3
6
to form in the molded part at a certain dis- Melt Melt Air 4 3D
tance from the gate. 2
Melt Melt 10 3
Conversely, with an excessively small me- Air
tering stroke (generally < 1D), there is a dan- Air 8
6
Residual granules 4
ger of material damage or a color change ge
an
gr

Metering volume VD
2 rin
through an excessively long residence time. After injection mete
10 2 mu
m
The residence time can be determined em- 8 ti
6 Op
pirically with the aid of an indicator (e.g. Granules 4

color concentrate). This can be calculated Melt Air 2

for known plasticizing units or established 10 1 1D
with the aid of nomograms. In practice, it is Melt 8
6
Air
necessary to make allowance for the ther- Residual granules
4

mal sensitivity of the material being 2

processed. The following time ranges apply Metering volume VD 10 0

for the mean permitted residence time: After the start of the next metering stroke 10 1 2 3 4 5 6 7 8 9 10 2 mm 2

cm 3
10 4

10 3

10 2

10 1

10 0
Screw diameter D

8
6
4

8
6
4

8
6
4

8
6
4
2
10 0
● 4 to 6 min for (PC + ABS), Melt Granules
(ABS+PA) and Melt Residual granules Air 2

4 Example A
(PBT+PC) blends Melt Melt 6 Screw diameter 25 mm
and FR grades 8
Air Air 10 1 12 g
Shot weights

● 4 to 8 min for ABS, PC, PC-HT, Residual granules 2 to 20 g

35 g
SAN, PET and PBT 4 to
Fig. 6: Zones with entrapped air for a metering stroke of > 4 D

Shot weight
6 66 g
● 4 to 10 min for PA 8
10 2
*1
2
*2
These ranges commence at 4 minutes be- Taking into account the optimum melt In Example B, the best screw diameter 4
cause experience has shown that (especial- stroke range, the nomogram shown in Fig. 7 range for a shot weight of 2,500 g is to be 6
8
ly with semi-crystalline materials) operat- can be used to allocate the shot weight in determined. This is somewhere between 100 10 3 *1
ing conditions with residence times of less question to the appropriate plasticizing units and 150 mm for the optimum metering 2

than 4 minutes can produce an insufficient- and hence machine sizes. The converse al- stroke range. It shifts towards correspond- 4
g
ly compounded melt. The broader a materi- location is, of course, also possible. ingly smaller dimensions as the melt densi- 6
8
Example B ~100 to 150 mm
al’s residence time range, the larger its pro- ty increases. 10 4 Molded part weight
In Example A that is plotted on the nomo- 2.500 g
cessing window. 2 Screw diameter
gram, the potential shot weight range is be- *2 Highest-density
ing sought for an existing screw diameter of BAYER thermoplastic (at ϑ )
M

25 mm. With low-density melts, this is 12 Reference values for plotting individual density curves on the
to 35 g and, with high-density melts (e.g. *1 Lowest-density
BAYER thermoplastic (at ϑ ) nomogram:
M

highly filled grades), between 20 and 66 g ● with a low melt density = 0.85 x density at room temperature
The density range specified covers all Bayer thermoplastics and grades. with a high melt density = 0.95 x density at room temperature
(corresponding to the change in shot weight ●

as a function of density for an identical shot Fig. 7: Determination of screw diameter or shot weight with allowance for the metering stroke
volume).

6 7
 Production equipment
Nozzles
Open nozzles are generally employed. Shut-
off nozzles can be used for easy-flow ma-
terials, although these more readily lead to
problems such as material degradation
through shear, or extensive residence time
in stagnant spots. Long color-change times
will also be necessary with an unfavorable
design.
Use is made of needle valve nozzles, slid-
ing shut-off valves and bolt-type shut-off
nozzles.
With needle valve nozzles (Fig. 8), there is
a danger of the needle being jammed by the
inflowing melt. Spring-loaded systems also
consume pressure for opening and keeping
open the valve, which is then not available
as injection and filling pressure, and a high
shear stress acts on the melt for a short time.
Pneumatically or hydraulically opening sys-
tems do not have these drawbacks.
The sliding shut-off nozzles that are con-
trolled by the cylinder movement (Fig. 9)
and the externally-controlled bolt-type shut-
off nozzles (Fig. 10) do not generate any
major pressure losses, providing that the
channels are of sufficiently large dimensions
and are favorably designed in flow engi-
neering terms. With bolt-type shut-off noz-
zles, particular care must be taken to ensure
channel alignment (when the nozzle is
open).
8 9
Production equipment
All nozzles should be heated and con-
a b trolled separately. 0.5 to 2 mm
To ensure a good seal between the nozzle R
and the sprue bush, the nozzle radius should
dA dD r
be 0.5 to 1 mm smaller than the radius of
the contact surface on the sprue bush. 2 to 3°
The nozzle aperture must also be adapted to
the sprue bush and be 0.5 to 1 mm smaller dD = dA- 0.5 to 1 mm
d: nozzle diameter
than the gate diameter (see Fig. 11). r: nozzle radius
Fig. 8: Needle valve nozzles: a) made by Fuchslocher, b) sliding shut-off nozzle with R: radius for contact surface
Care must also be taken to ensure an ade-
a needle valve (made by OKW, Buchen) quate alignment of the sprue-bush and noz- on the sprue bush break point R = r + 0.5 to 1 mm
zle apertures.
Fig. 11: The nozzle in contact with the sprue bush
a b
Recommendations (for the sprue gate):
Locking force/Clamping force ● nozzle radius 0.5 to 1.0 mm smaller than the sprue-bush radius
A sufficient clamping force is a further key
● aperture at the nozzle tip 0.5 to 1.0 mm smaller than the smallest aperture of the
criterion when selecting a machine. It is im-
sprue bush with which it is in contact (avoidance of rivet-head formation)
portant for flash caused by mold opening to
be avoided right from the outset. On large
surface-hardened molds, in particular, the
flash will press itself into the parting plane.
Fig. 9: Sliding shut-off nozzles Any subsequent flash which develops due
a) Nozzle mouth touches the sprue bush on the mold, nozzle open to deformation of the parting edges can then
b) Plasticating cylinder is retracted, nozzle closed only be eliminated again by re-machining
the parting planes. This, in turn, is highly a
complex and time-consuming task in the
case of molded parts that have been de-
signed to achieve the lowest possible wall
thickness with a view to mold filling. In-
stead of this, the parts are frequently de-
flashed on an individual basis.
The minimum clamping force required can
be worked out by multiplying the area of the
molded part that is projected onto the part-
ing plane by the mean filling pressure pre-
vailing in the mold.
Fig. 10: Externally controlled bolt-type shut-off nozzle
(made by Krauss-Maffei, Munich)
 Production equipment
Nozzles
Open nozzles are generally employed. Shut-
off nozzles can be used for easy-flow ma-
terials, although these more readily lead to
problems such as material degradation
through shear, or extensive residence time
in stagnant spots. Long color-change times
will also be necessary with an unfavorable
design.
Use is made of needle valve nozzles, slid-
ing shut-off valves and bolt-type shut-off
nozzles.
With needle valve nozzles (Fig. 8), there is
a danger of the needle being jammed by the
inflowing melt. Spring-loaded systems also
consume pressure for opening and keeping
open the valve, which is then not available
as injection and filling pressure, and a high
shear stress acts on the melt for a short time.
Pneumatically or hydraulically opening sys-
tems do not have these drawbacks.
The sliding shut-off nozzles that are con-
trolled by the cylinder movement (Fig. 9)
and the externally-controlled bolt-type shut-
off nozzles (Fig. 10) do not generate any
major pressure losses, providing that the
channels are of sufficiently large dimensions
and are favorably designed in flow engi-
neering terms. With bolt-type shut-off noz-
zles, particular care must be taken to ensure
channel alignment (when the nozzle is
open).
8 9
Production equipment
All nozzles should be heated and con-
a b trolled separately. 0.5 to 2 mm
To ensure a good seal between the nozzle R
and the sprue bush, the nozzle radius should
dA dD r
be 0.5 to 1 mm smaller than the radius of
the contact surface on the sprue bush. 2 to 3°
The nozzle aperture must also be adapted to
the sprue bush and be 0.5 to 1 mm smaller dD = dA- 0.5 to 1 mm
d: nozzle diameter
than the gate diameter (see Fig. 11). r: nozzle radius
Fig. 8: Needle valve nozzles: a) made by Fuchslocher, b) sliding shut-off nozzle with R: radius for contact surface
Care must also be taken to ensure an ade-
a needle valve (made by OKW, Buchen) quate alignment of the sprue-bush and noz- on the sprue bush break point R = r + 0.5 to 1 mm
zle apertures.
Fig. 11: The nozzle in contact with the sprue bush
a b
Recommendations (for the sprue gate):
Locking force/Clamping force ● nozzle radius 0.5 to 1.0 mm smaller than the sprue-bush radius
A sufficient clamping force is a further key
● aperture at the nozzle tip 0.5 to 1.0 mm smaller than the smallest aperture of the
criterion when selecting a machine. It is im-
sprue bush with which it is in contact (avoidance of rivet-head formation)
portant for flash caused by mold opening to
be avoided right from the outset. On large
surface-hardened molds, in particular, the
flash will press itself into the parting plane.
Fig. 9: Sliding shut-off nozzles Any subsequent flash which develops due
a) Nozzle mouth touches the sprue bush on the mold, nozzle open to deformation of the parting edges can then
b) Plasticating cylinder is retracted, nozzle closed only be eliminated again by re-machining
the parting planes. This, in turn, is highly a
complex and time-consuming task in the
case of molded parts that have been de-
signed to achieve the lowest possible wall
thickness with a view to mold filling. In-
stead of this, the parts are frequently de-
flashed on an individual basis.
The minimum clamping force required can
be worked out by multiplying the area of the
molded part that is projected onto the part-
ing plane by the mean filling pressure pre-
vailing in the mold.
Fig. 10: Externally controlled bolt-type shut-off nozzle
(made by Krauss-Maffei, Munich)
 Production equipment Production equipment

a) Estimation method b) From rheological calculations

Clamping force ≥ mold opening force [kN]
The actual clamping force required can be When rheological calculations are used for 800 Switchover pressure1
greater than the minimum clamping force projected surface [cm2] x mean cavity pressure [bar] the mold filling process, the pressure pro-
= 700 Filling pressure from rheological calculation
established with the aid of the formulae on 100 file over the filling path is obtained as a
the right. function of the material, the processing pa-
rameters and the molded part geometry.
Projected surface = sum of all the surfaces subject to pressure projected onto the

Filling pressure at gate [f]

Allowance must also be made for addition- This, together with the projected dimensions
al parameters, such as
plane of the clamping platen (see example in Fig. 12)
of the molded part, will permit the requisite 500 bar
clamping force to be calculated more pre- 450 bar
● the rigidity of the machine and the
cisely.
mold
A number of programs, however, calculate
● the permitted breathing of the mold 100 bar
the filling pressure requirement in such a
● the processing parameters way that the filling pressure is at precisely 0
bar at the end of the flow path. In practice, Cavity pressure over flow path [P]
● the molding compound
it is necessary to select a higher pressure
● the design of the molded part. both for setting the switchover point during
injection molding (pressure measurement Pressure at gate = 800 bar
The empirical values for estimating the
point close to the gate) and for calculating Pressure at end of flow path = 100 bar
clamping force set out below (Table 1) can
the clamping force. The increase in pressure

D
d
thus only be regarded as a guide. = 900 bar : 2 = 450 bar
is based on the residual pressure that is need-
ed at the end of the flow path (see graph, ~ 500 bar
Fig. 13).
With long flow paths, it may be necessary to 1 Safety allowance for melt compression prior to switchover to holding pressure
Molded part have a high initial holding pressure surge
Projected surface A (graded holding pressure). This is propa- Fig. 13: Determination of the mean cavity pressure (opening pressure) for wall thick-
Projected surface: A = (D - d ) · π
2 2 gated over the entire molded part with loss- nesses of up to approx. 3 mm
4 es and with a time lag and must be taken in-
to account when specifying the clamping
Fig. 12: Truncated-cone-shaped disc as an example of the surface projected onto the force. The latest computer programs for simu-
parting plane, forcing open the mold lating mold filling (3D FEA) also make
allowance for the holding pressure pro-
Apec® PC-HT 300 to 500 bar file, establishing the overall opening
Bayblend® (PC+ABS) 250 to 400 bar force, among other things, as a basis for
selecting the minimum clamping force.
Desmopan® TPU 300 to 700 bar*
Durethan® PA 250 to 700 bar*
Novodur®/Lustran® ABS ABS 250 to 350 bar
Lustran® SAN SAN 250 to 350 bar
Makrolon® PC 300 to 500 bar
Pocan® PBT 250 to 700 bar*
Triax® (ABS+PA) 250 to 500 bar
* For material grades with very good flow behavior, it may be necessary to use the higher pressures in order to prevent flash
formation.

Table 1: Mean cavity pressures (opening pressures) for the mathematical determina-
tion of the clamping force
10 11
 Production equipment Production equipment

a) Estimation method b) From rheological calculations

Clamping force ≥ mold opening force [kN]
The actual clamping force required can be When rheological calculations are used for 800 Switchover pressure1
greater than the minimum clamping force projected surface [cm2] x mean cavity pressure [bar] the mold filling process, the pressure pro-
= 700 Filling pressure from rheological calculation
established with the aid of the formulae on 100 file over the filling path is obtained as a
the right. function of the material, the processing pa-
rameters and the molded part geometry.
Projected surface = sum of all the surfaces subject to pressure projected onto the

Filling pressure at gate [f]

Allowance must also be made for addition- This, together with the projected dimensions
al parameters, such as
plane of the clamping platen (see example in Fig. 12)
of the molded part, will permit the requisite 500 bar
clamping force to be calculated more pre- 450 bar
● the rigidity of the machine and the
cisely.
mold
A number of programs, however, calculate
● the permitted breathing of the mold 100 bar
the filling pressure requirement in such a
● the processing parameters way that the filling pressure is at precisely 0
bar at the end of the flow path. In practice, Cavity pressure over flow path [P]
● the molding compound
it is necessary to select a higher pressure
● the design of the molded part. both for setting the switchover point during
injection molding (pressure measurement Pressure at gate = 800 bar
The empirical values for estimating the
point close to the gate) and for calculating Pressure at end of flow path = 100 bar
clamping force set out below (Table 1) can
the clamping force. The increase in pressure

D
d
thus only be regarded as a guide. = 900 bar : 2 = 450 bar
is based on the residual pressure that is need-
ed at the end of the flow path (see graph, ~ 500 bar
Fig. 13).
With long flow paths, it may be necessary to 1 Safety allowance for melt compression prior to switchover to holding pressure
Molded part have a high initial holding pressure surge
Projected surface A (graded holding pressure). This is propa- Fig. 13: Determination of the mean cavity pressure (opening pressure) for wall thick-
Projected surface: A = (D - d ) · π
2 2 gated over the entire molded part with loss- nesses of up to approx. 3 mm
4 es and with a time lag and must be taken in-
to account when specifying the clamping
Fig. 12: Truncated-cone-shaped disc as an example of the surface projected onto the force. The latest computer programs for simu-
parting plane, forcing open the mold lating mold filling (3D FEA) also make
allowance for the holding pressure pro-
Apec® PC-HT 300 to 500 bar file, establishing the overall opening
Bayblend® (PC+ABS) 250 to 400 bar force, among other things, as a basis for
selecting the minimum clamping force.
Desmopan® TPU 300 to 700 bar*
Durethan® PA 250 to 700 bar*
Novodur®/Lustran® ABS ABS 250 to 350 bar
Lustran® SAN SAN 250 to 350 bar
Makrolon® PC 300 to 500 bar
Pocan® PBT 250 to 700 bar*
Triax® (ABS+PA) 250 to 500 bar
* For material grades with very good flow behavior, it may be necessary to use the higher pressures in order to prevent flash
formation.

Table 1: Mean cavity pressures (opening pressures) for the mathematical determina-
tion of the clamping force
10 11
 Production equipment Production equipment

Temperature control units

10 2
The cavity wall temperature has a key in- ϑ W (°C)
fluence on the filling process and the prop-
erties of the molded part. (More details will kW
160
be given of this under “Mold temperatures”.) 120
Correct mold cooling is thus one of the key
Heating capacity

quality-assuring measures. 80
Apart from an appropriate heating/cooling 10 1
platen area

channel system in the mold, selecting the

Insulated

correct temperature control unit is also im-

portant.
{ 40

One key requirement for the rapid attain-

ment and reliable control of the mold tem-
perature is a sufficient heating and cool-
ing capacity for the temperature control
units employed. The diagram (Fig. 14) con- 10 0
tains guide values for a heating capacity 10 1 10 2 10 3 kg 10 4
which is dependent on the mold size and the Mold weight
mold temperature.
Fig. 14: Guide values for the requisite heating capacity f (mold weight and ϑW)

A further requirement is that the pumps on

the temperature control unit should have a
sufficient conveying capacity (with a mass Channel diameter 6 mm Channel diameter 12 mm
flow rate of 10 to 15 l/min for the heat- 8 8 Fig. 16: Mold with heating/cooling circuits connected up via external hose sections
ing/cooling medium). It should be borne in ∆p/bar 10 ∆p/bar 28
18 15 8 25
mind here that a flow resistance can rapid- 6 6
Flow rate 20 Assistance can be provided by using more An excessively high temperature differ-
ly build up as a function of the length and than one heating/cooling unit and thus hav- ential between the inflow and outflow of
cross-section of the heating/cooling chan- l/min
Pressure loss

4 4 ing a separate temperature control for the the heating/cooling medium indicates that
nel and the number of flow deflections. The Flow rate two halves of the mold, for example. It may the flow rate is too low. For standard qual-
pump may not then be able to supply the 15
l/min also be necessary to further divide up the ity requirements, the differential should be
requisite pressure (Fig. 15). 2 2 heating/cooling channels into sections. ≤ 4 K and for precision parts ≤ 1 K.
5 10
These modifications can be performed on
0 0 molds that are already in use if the heat-
0 2 4 6 m 8 0 2 4 6 m 8 ing/cooling circuits are series-connected via
hose or pipe connections on the outside, as
Length of heating/cooling channel is frequently the case with large molds (Fig.
16).
Fig. 15: Pressure loss as a function of the heating/cooling channel geometry and the
flow rate At times, it will be necessary to employ spe-
cially constructed, separate circuits to
counter warpage effects through having a
temperature control suitably tailored to the
local heat levels prevailing within the cavi-
ty.

12 13
 Production equipment Production equipment

Temperature control units

10 2
The cavity wall temperature has a key in- ϑ W (°C)
fluence on the filling process and the prop-
erties of the molded part. (More details will kW
160
be given of this under “Mold temperatures”.) 120
Correct mold cooling is thus one of the key
Heating capacity

quality-assuring measures. 80
Apart from an appropriate heating/cooling 10 1
platen area

channel system in the mold, selecting the

Insulated

correct temperature control unit is also im-

portant.
{ 40

One key requirement for the rapid attain-

ment and reliable control of the mold tem-
perature is a sufficient heating and cool-
ing capacity for the temperature control
units employed. The diagram (Fig. 14) con- 10 0
tains guide values for a heating capacity 10 1 10 2 10 3 kg 10 4
which is dependent on the mold size and the Mold weight
mold temperature.
Fig. 14: Guide values for the requisite heating capacity f (mold weight and ϑW)

A further requirement is that the pumps on

the temperature control unit should have a
sufficient conveying capacity (with a mass Channel diameter 6 mm Channel diameter 12 mm
flow rate of 10 to 15 l/min for the heat- 8 8 Fig. 16: Mold with heating/cooling circuits connected up via external hose sections
ing/cooling medium). It should be borne in ∆p/bar 10 ∆p/bar 28
18 15 8 25
mind here that a flow resistance can rapid- 6 6
Flow rate 20 Assistance can be provided by using more An excessively high temperature differ-
ly build up as a function of the length and than one heating/cooling unit and thus hav- ential between the inflow and outflow of
cross-section of the heating/cooling chan- l/min
Pressure loss

4 4 ing a separate temperature control for the the heating/cooling medium indicates that
nel and the number of flow deflections. The Flow rate two halves of the mold, for example. It may the flow rate is too low. For standard qual-
pump may not then be able to supply the 15
l/min also be necessary to further divide up the ity requirements, the differential should be
requisite pressure (Fig. 15). 2 2 heating/cooling channels into sections. ≤ 4 K and for precision parts ≤ 1 K.
5 10
These modifications can be performed on
0 0 molds that are already in use if the heat-
0 2 4 6 m 8 0 2 4 6 m 8 ing/cooling circuits are series-connected via
hose or pipe connections on the outside, as
Length of heating/cooling channel is frequently the case with large molds (Fig.
16).
Fig. 15: Pressure loss as a function of the heating/cooling channel geometry and the
flow rate At times, it will be necessary to employ spe-
cially constructed, separate circuits to
counter warpage effects through having a
temperature control suitably tailored to the
local heat levels prevailing within the cavi-
ty.

12 13
 Production equipment Notes

A further selection criterion for a service-

able heating/cooling unit is a sufficiently ac- 120
curate form of temperature control. The
medium input temperature should be as con- Cavity wall
stant as possible, and the control fluctua- °C
temperature
tions kept to a minimum. Excessive control
fluctuations can generally be avoided by 100
changing the controller characteristics, cor-
Temperature

rectly positioning the temperature sensor 90

and ensuring that there are sufficient heat-
ing/cooling medium reserves in the system.
80
The introduction of heat via the hot melt Medium input
means that the mean equilibrium tempera- temperature
ture that develops can be up to 30 K above 70
the temperature of the heating/cooling medi-
um (Fig. 17). This actual temperature can 60
be recorded by means of a temperature sen- 6 8 10 12 14 16 18 20 min 24
sor in the mold and reduced to the setpoint Time t
temperature through a corresponding cor-
rection to the medium input temperature. Fig. 17: Mold and medium input temperature profiles over time
The saw-tooth-like fluctuations in the cavi-
ty wall temperature follow the same rhythm
as the cycle time. They develop through the
short-term heating that results from the hot
melt coming into contact with the cavity
wall. The level of the temperature increase
is determined by the temperature differen-
tial between the melt and the mold and
through the rate of heat dissipation from the
mold cavity.
Any change in the curve profile for the cav-
ity wall temperature with a steady cycle
time, melt temperature and medium input
temperature indicates a changed flow rate
for the heating/cooling medium (pump char-
acteristics of a different heating/cooling unit
or a furring up of the heating/cooling chan-
nels when water is used as the heating/cool-
ing medium).

14 15
 Production equipment Notes

A further selection criterion for a service-

able heating/cooling unit is a sufficiently ac- 120
curate form of temperature control. The
medium input temperature should be as con- Cavity wall
stant as possible, and the control fluctua- °C
temperature
tions kept to a minimum. Excessive control
fluctuations can generally be avoided by 100
changing the controller characteristics, cor-
Temperature

rectly positioning the temperature sensor 90

and ensuring that there are sufficient heat-
ing/cooling medium reserves in the system.
80
The introduction of heat via the hot melt Medium input
means that the mean equilibrium tempera- temperature
ture that develops can be up to 30 K above 70
the temperature of the heating/cooling medi-
um (Fig. 17). This actual temperature can 60
be recorded by means of a temperature sen- 6 8 10 12 14 16 18 20 min 24
sor in the mold and reduced to the setpoint Time t
temperature through a corresponding cor-
rection to the medium input temperature. Fig. 17: Mold and medium input temperature profiles over time
The saw-tooth-like fluctuations in the cavi-
ty wall temperature follow the same rhythm
as the cycle time. They develop through the
short-term heating that results from the hot
melt coming into contact with the cavity
wall. The level of the temperature increase
is determined by the temperature differen-
tial between the melt and the mold and
through the rate of heat dissipation from the
mold cavity.
Any change in the curve profile for the cav-
ity wall temperature with a steady cycle
time, melt temperature and medium input
temperature indicates a changed flow rate
for the heating/cooling medium (pump char-
acteristics of a different heating/cooling unit
or a furring up of the heating/cooling chan-
nels when water is used as the heating/cool-
ing medium).

14 15
 The Injection Molding of High-Quality Molded Parts

Production equipment/Machinery

Bayer service for innovative

solutions and successful
applications in virtually all
sectors.

The plastics developed by Bayer are backed

up by the know-how of our development,
design and process engineering service.
Comprehensive information on our
products, assistance with materialselection
and detailed answers to application-
technology questions may be found in our
Technology Center in the internet under
//plastics.bayer.com

Bayer AG
Bayer plastics on the Internet: Plastics Business Group
http://www.plastics.bayer.com 51368 Leverkusen

This information and our technical advice - whether verbal, in writing Unless specified to the contrary, the values given have been established
or by way of trials - are given in good faith but without warranty, and on standardised test specimens at room temperature. The figures should
this also applies where proprietary rights of third parties are involved. be regarded as guide values only and not as binding minimum values.
Our advice does not release you from the obligation to verify the in- Please note that, under certain conditions, the properties can be affect-
formation currently provided - especially that contained in our safety da- ed to a considerable extent by the design of the mold/die, the process-
ta and technical information sheets - and to test our products as to their ing conditions and the coloring.
suitability for the intended processes and uses. The application, use and
processing of our products and the products manufactured by you on
the basis of our technical advice are beyond our control and, therefore,
Plastics
entirely your own responsibility. Our products are sold in accordance
Edition: 2000-03 Business Group
Gr
with the current version of our General Conditions of Sale and Deliv-
ery. Order no.: KU11827-0003e/5667875 KL