Injection Moulding Process

Basic Process: Injection molding is the most widely used molding process for thermoplastics. It
is based on the ability of thermoplastic materials to be softened by heat and to harden when
cooled. The process thus consists essentially of softening the material in a heated cylinder and
injecting it under pressure into the mould cavity, where it hardens by cooling. Each step is
carried out in a separate zone of the same apparatus in the cyclic operation.

Applications: Solid Wide neck, Flat Product is made like bucket, Automobile & Industrial parts,
Moulded chairs, Computer/ TV/ Radio Cabinets, Washing machine Cabinets, Mobile, Power-
tool housings etc. Moulded House hold items etc. by injecting molten thermoplastic material in
to a closed mould which is relatively cool.

Type of Injection Moulding Machine:

 Hand operated, Plunger and Screw type Injection Moulding Machine

1. Hand Injection Moulding M/C

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 2. Plunger type Injection Moulding M/C

 Single stage plunger unit

A diagram of a typical injection-moulding machine is shown in fig. Granular material (the

polymer) fed from the hopper into the barrel when the plunger is withdrawn. The plunger then
pushes the material into the heating zone, where it is heated and softened (plasticized or
plasticated). Rapid heating takes place due to spreading of the polymer into a thin film around a
torpedo. The already molten polymer displaced by this new material is pushed forward through
the nozzle, which is in intimate contact with the mould. The molten polymer flows through the
sprue , runner and gate, into the mould cavity. The mould is held tightly closed by the clamping
action of the press platen. The material in the mold must be cooled under pressure below Tm or
Tg before the mould is opened and the molded part is ejected.

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 3. Reciprocating Screw Type Injection Moulding M/C

 In line reciprocating single stage screw unit

Injection molding involves two distinct processes. The first comprises the elementary steps
of solids transport, melt generation, mixing, and pressurization and flow, which are carried
out in the injection unit of the moulding machine; the second is the product shaping and
‘‘structuring,’’ which takes place in the mould cavity. Most injection moulding machines are the
in-line, reciprocating-screw type, as illustrated in the following Fig.

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 4. Two stage plunger type and reciprocating screw type Injection moulding
machine

Process of Injection Moulding:

Cyclic Process: Mould Closed to Mould open. (Gate to Gate operation)

Cycle: The complete sequence of operations in a process to complete one set of mouldings. The
cycle is taken at a point in the operation and ends when this point is again reached and moving
platens of the clamp unit in the fully open position.

Cycle Time: The time required by an injection moulding system to mould a part.

Main process steps:

Clamping, Injection, Cooling, Ejection and Refilling for next cycle.

1. The mould closes and the screw begins moving forward for injection.
2. The cavity fills as the reciprocating screw moves forward, as a plunger.
3. The cavity cools as the gate freezes off and the screw begins to retract to plasticized material for the
next shot.
4. The mould opens for part ejection
5. The mould closes and the next cycle begins.

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 1. 2.

3. 4.

Setting Machine Process Conditions

 Set the melt temperature
 Set the mold temperature
 Set the switch-over position
 Set the screw rotation speed
 Set the back pressure
 Set the injection pressure to the machine
 Set the holding time
 Set the cooling time
 Set the mold open time
 Set the mold opening stroke
 Set the ejector stroke

5.

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Main Machine Elements:

 Injection Unit, Mould Unit and Clamping Unit

Injection Unit:
1. Screw driven motor:

2. Hydraulic injection cylinder

3. Screw:

The screw has three zones with a ring-plunger assembly. The Feed Zone, where the plastic first
enters the screw and is conveyed along a constant root diameter; the Transition Zone, where the
plastic is conveyed, compressed and melted along a root diameter that increases with a constant
taper; and the Metering Zone, where the melting of the plastic is completed and the melt is
conveyed forward along a constant root diameter reaching a temperature and viscosity to form
parts.

L/D Ratio: A term used to help define an injection screw. This is the screw nominal length-to-
diameter ratio. Usually 20 to 22:1.

Compression Ratio: It is the ratio between the channel depth is the first flight of feed zone to
that of the last flight of metering zone. Usually from 1.5 to 4:1

4. Barrel: Hardened steel Cylindrical housing in which the screw rotates reciprocates.

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5. Hopper: Raw material feed system. Funnel like device, mounted on Hopper throat. Holds a
constant reserve of material.

 Hopper Throat: Circular opening at the feed end through which the material enters the
screw.
6. Heater: Electric Heating system

7. Thermocouples: Heating Measuring device

8. Nozzle: The hollow-cored, metal nose screwed into the injection end of a plasticator. The
nozzle matches the depression in the mold. This nozzle allows transfer of the melt from the
plasticator to the runner system and cavities.

Mould Unit:

1. Mould: A series of machined steel plates containing cavities into which plastic resin is
injected to form a part. The mould is made of two halves or two half, the male and female known
as core and cavity.

2. Core: The projection which fits into the cavity when the mould is closed.

3. Cavity: The space inside a mold into which material is injected.

4. Moulding: The gap between core and cavity has a projection ones gives the shape of the
moulded article known as moulding.

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5. Mould Feed System: Distribution channel through which polymer melt flows from nozzle
into mould cavity.

 Sprue: The feed opening provided in injection molding between the nozzle and cavity or
runner system.
 Runner: The channel that connects the sprue with the gate for transferring the melt to the
cavities.
 Gate: An orifice through which the melt enters the mould cavity.

6. Cooling system: consists of external pump connected to passageways in mould, through

which water is circulated to remove heat from the hot plastic

7. Ejection system: To eject moulded part from cavity at end of molding cycle.

 Ejector pin: Ejector pins built into moving half of mould usually accomplish this
function

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7. Two Plate Injection Mould:

Clamping System:

1. Clamp: The part of an injection moulding machine incorporating the platens that provides the
force necessary to hold the mould closed during injection of the molten resin and open the mould
to eject the moulded part.

2. Types of clamping (Toggle/Hydraulic)

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Toggle: A type of clamping mechanism that exerts pressure by applying force on a knee joint. A
toggle is used to close and exert pressure on a mould in a press.

 A toggle is mechanically device to amplify force.

 In a moulding machine, which consists of two bars joined, together end to end with a pivot .
 The end of one bar is attached to a stationary platen, and the other end of a second bar is attached
to the movable platen.
 When the mould is open, the toggle is in the shape of a V.
 When pressure is applied to the pivot, the two bars form a straight line.

Toggle Type Clamping: Single and Double Toggle Type clamping

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Hydraulic Clamping: (Hydraulic clamping cylinder is used)
 A clamping unit actuated by hydraulic cylinder, which is directly connected to the moving, closed
the mould. In this case ram of hydraulic system is attached to moving platen. There are two
halves in hydraulic cylinder, which is actually inlet and outlet of oil.
 When oil goes to the cylinder with pressure oil pushes the ram to forward direction by which
moving platen moves and mould closed and when oil comes from the cylinder the ram come back
and mould is open.

Machine Specification:
Projected Area: Projected area is calculated by multiplying length times width.

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Injection Pressure: The pressure on the face of the injection screw or ram when injecting
material into the mould, usually expressed in PSI or Tons/cm2.

Injection Speed (cm/Sec): The injection speed is the forward speed of the screw during its
injection operation per unit time.

Screw Rotation Speed: The screw rotation speed (RPM) is the rate at which the plasticizing
occurs when screw rotates.

Clamping Pressure/Force: The pressure applied to the mould to keep it closed during a cycle,
usually expressed in tons.

Clamping Force= Projected Area x 1/2 or 1/3 Injection Pressure.

= Cm2 x Tons/Cm2

= Tons

Tonnage: The measure by which injection moulding machines are typically categorized,
representing the clamping force (Tons) of the injection molding machine.

Shot: The complete amount of melt injected during a moulding cycle, including that which fills
the runner system.

Shot Capacity: Generally based on polystyrene, this is the maximum weight of plastic that can
be displaced or injected by a single injection stroke. Generally expressed as ounces of
polystyrene.

Short Shot: Failure to completely fill the mould or cavities of the mould. Edges may appear
melted.

Back Pressure (Kg/Cm2 or bar): Back pressure is the amount of pressure exerted by the material
ahead of the screw, as the screw is pushed back in preparation for the next shot.

Cushion:

The cushion is the difference in the final forward position of the screw and its maximum
allowable forward position. Typically a cushion of 3 to 6 mm is used.

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Process Controls

Injection Moulding cycle can be broken down into four phases:

Fill, Pack, Hold, and Cooling/plastication

These phases can be controlled by following variables:

 Injection Speed,
 Plastic Temperature,
 Plastic Pressure,
 Cooling Temperature and Time.

Advantages of Injection Moulding Process

• Parts can be produced at high production rates.

• Large volume production is possible.
• Relatively low labour cost per unit is obtainable.
• Process is highly susceptible to automation.
• Parts require little or no finishing.
• Many different surfaces, colours, and finishes are available.
• Good decoration is possible.
• For many shapes this process is the most economical way to fabricate.
• Process permits the manufacture of very small parts which are almost impossible to
fabricate in quantities by other methods.
• Minimal scrap loss result as runners, gates, and rejects can be reground and reused.
• Same items can be moulded in different materials, without changing the machine or
mould in some cases.
• Close dimensional tolerances can be maintained.
• Parts can be moulded with metallic and non-metallic inserts.
• Parts can be moulded in a combination of plastic and such fillers as glass, asbestos, talc
and carbon.
• The inherent properties of the material give many advantages such as high strength-
weight rates, corrosion resistance, strength and clarity.

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