Draw the freehand sketching of the Injection molding machine and name its

parts.
Explain each part in detail?
Function of Each Part of An Injection Molding Machine.
The injection molding process is a high speed, automated process that can be used to
produce plastic parts with very complex geometries. The process can produce either very
small or very large parts using virtually any plastic material. It is important, however, for
part designers to recognize that the design of the product will ultimately determine the
“ease of molding” or the“manufacturability” of the part, as well as the tooling requirements
and cost.
It is also important for the part designer to recognize that the overall shape of a product and
specific feature details may need to be altered in order to improve the moldability of the
plastic part.
In addition, the part designer must recognize that the properties of the molded plastic part
will be greatly influenced by factors such as the tool design and processing conditions.
In order to develop a quality part, the plastic part designer, the mold designer, the material
supplier, and the process engineer must all work together in an effort to develop a part that
is both moldable and fully functional. Plastic part designs are more likely to be successful if
such concurrent engineering practices are followed.
Hopper:
Here we insert the ingredients of plastic material for the molding process.
Screw Motion or Archimedean Screw:
It pushes the ingredients of plastic material in a forward direction.
Heaters:
It is used to increase the temperature of the system to prepare the product in a good
finished and We can say that the heater works is to melt the ingredients of plastic polymers.
Nozzle:
The material temperature increases to such an extent it quickly enters into the mold cavity.
Extraction Pin:
It works like split molds and the shape formed to remove from it and further process to be
carried out.
Split Mold or Cooling channels:
Cooling of the product done into the system.
Clamping unit:
It is used to clamp the tool.
Injection unit:
In the Injection unit, it can be used to inject the mold (Plastics).
Drive unit:
The driving unit is used to ram the mold in the cavity.
Hydraulic system:
Raming the mold by the press.

2.What is the core? What is a Cavity? Explain in detail with free hand
sketches.
Cavity:
The machined shape within a mold which created the form of the plastic part. The plate
used to fit the cavity insert, the cavity insert will have gap of the details to fill the plastic
material and form plastic component Cavity plate usually of mild steel material cavity.
Core:
A protrusion or set of matching protrusions, which form the inner surface of a plastic part.
They are often considered they “male” side of the part. The plate used to fit the core insert,
the core insert will have projection and will create hallow portion in plastic component.
The mold is one of the most important parts of injection molding. A mold is made up of two
halves that have a hollow space between them into which a melted material is injected. This
hollow space is shaped by both the core and the cavity when the mold is closed.
Many people confuse the cavity with the core. In injection molding, the cavity is the female
portion of the mold that forms a product’s external shape. The core is the male part that is
responsible for forming the product’s internal shape.

3.What is the ideal wall thickness of an injection molded component?

The ideal wall thickness of an injection molded component is the uniform thickness
thorough out the molded component. Following are some of the thickness suggested for a
particular material of the mold.

4.What is the minimum precision that can be expected of an injection

molded component?
The precision of the mold mainly depends on the high precision of the mold cavity size,
accurate positioning of the cavity or whether the precision of the parting surface meets the
requirements. The dimensional tolerances of the general precision injection moulds should
be controlled below 1/3 of the dimensional tolerance of the products.

5.What are the Stages of injection molding?

Explain the stages of injection molding in detail with clear sketches of the
same.
The injection molding process is a complex process that involves a series of sequential
process steps. The different phases of the injection molding process include the mold filling
phase, the packing phase, the holding phase, the cooling phase, and part ejection.
Mold Filling After the mold closes, the melt flows from the injection unit of the molding
machine into the relatively cool mold through the sprue, the runners, the gates, and then
into the cavity.
Packing The melt is pressurized and compressed to ensure complete filling and detailed
surface replication.
Holding The melt is held in the mold under pressure to compensate for shrinkage as the
part cools. Holding pressure is usually applied until the gate solidifies. Once gate
solidification occurs, melt can no longer flow into (or out of) the cavity.
Cooling The melt continues to cool and shrink without shrinkage compensation. Part
Ejection The mold opens and the cooled part is then stripped from the core or cavity, in
most cases using a mechanical ejector system.

Injection molding process step by step:

Material particles are nourished into a hopper then from hopper it comes into the system.
There is an Archimedean screw which works is to rotate and sends forward the present
material.
Now it comes to the heated area here it gets heated between ingredients plastic polymer.
At the nozzle, the temp having high at such extent it send fast to the Mould cavity and
Here the cooling process is done.
Now Extraction pin removes the mold cavity parts and then formed the product.
6.Draw the free hand sketch of an injection molded component of your own
(Along with Sprue, runner, etc.)
Explain the parts in detail.
Injection Molding Definition:
The injection molding is an old technique in which various product is made by using the
injection machine.
By using a required amount of forces for their developed finished product.
By introducing the new product design and its existence in the required field.
Injection molding will make the product very fast and the rate of production is quick.
So the come into the mass production of the product.
In today’s world product is of high good quality and finished with a good edge.

Injection molding started with a host of the material mainly include the metals.

The particle is the unit of fed into a heated barrel, mixed (using helically shaped).

Parts of Injection Molding machine:

Hopper:

Here we insert the ingredients of plastic material for the molding process.

Screw Motion or Archimedean Screw:

It pushes the ingredients of plastic material in a forward direction.

Heaters:

It is used to increase the temperature of the system to prepare the product in a good
finished and We can say that the heater works is to melt the ingredients of plastic polymers.

Nozzle:

The material temperature increases to such an extent it quickly enters into the mold cavity.

Extraction Pin:

It works like split molds and the shape formed to remove from it and further process to be
carried out.

Split Mold or Cooling channels:

Cooling of the product done into the system.

Clamping unit:

It is used to clamp the tool.

Injection unit:

In the Injection unit, it can be used to inject the mold (Plastics).

Drive unit:

The driving unit is used to ram the mold in the cavity.

Hydraulic system:

Raming the mold by the press.

n injection molding machine consists of the following parts:

Injection molding process step by step:

 Material particles are nourished into a hopper then from hopper it comes into the
system.
 There is an Archimedean screw which works is to rotate and sends forward the
present material.
 Now it comes to the heated area here it gets heated between ingredients plastic
polymer.
 At the nozzle, the temp having high at such extent it send fast to the Mould cavity
and Here the cooling process is done.
 Now Extraction pin removes the mold cavity parts and then formed the product.
 Here you can make any of product like a bucket, Mobile parts, Helmet and many
more.

 Injection Moulding is a modern technique in which the grain is made up of the

desired material like PVC, Plastics, etc.
Types of injection moldings:
These are some types of injection moldings:
 Metal injection molding
 Die casting
  Injection molding of liquid silicone rubber
 Thin-wall injection molding
 Reaction injection molding

Sprues，runners and gates fulfil the function of conveying the plastics melt from the
nozzle of the injection unit to the individual cavities.

sprue
sprue is the vertical passage through which liquid material is introduced into a mold and it
is a large diameter channel through which the material enters the mould. It connects
pouring basin to the runner. In many cases it controls the flow of material into the mold.

The sprue may be considered the continuation of the mold to the nozzle of injection
machine.
Single-cavity molds where the sprue links directly to the molded part are said to have direct
sprue gating.
Very often, the performance of a single-cavity injection mold is determined by the cooling
time of this sprue.
In addition to providing adequate cooling of the sprue bushing, the diameter of the smallest
opening in the sprue bushing should be kept as small as possible and permitted by proper
filling of the cavity.
No universally applicable rules can be given here，since filling of the cavity depends on very
many factors.
The sprue should have 1.5° draft.
Greater draft may simplify removal from the sprue bushing, but function of the length of the
runner，since it may be assumed that the pressure lost in a runner increases at least
proportionally with the length.
In all likelihood it will probably increase more than proportionally,since the cross section is
reduced by solidification of the melt along the walls，and the more so the greater the
distance from the sprue.
Because the sprue and runner system represent lost material and lost plasticating capacity,
the runners should be designed to be as short as possible and with the smallest possible
cross section.
The length of the runners is determined by the number of cavities in the mold and the
geometrical arrangement of the individual cavities.
Runner
Runners follow channels cut into the parting line, as opposed to sprues, which deliver
material into the center of the mold plate. Their design affects part quality and molding
efficiency.
Thicker runners can make filling pressures too high and cause unwanted long cycle times.
Conversely, thick runners can cause unnecessary lengthening of cycle time and increases in
costs associated with regrinding. The optimal runner design must strike a balance between
mould feasibility and filling pressures.
During mold filling, freezing occurs as the heat of the melt is transferred to the mold. The
result is less melting material flowing through the runner and a large pressure drop. The
smallest cross-sectional area of the frozen wall is created by the round runners.
A trapezoid runner can be an alternative more effective to round runners, because it only
requires machining in one mold half. Round runners require the matching and low flow
restriction of two mold halves.

Runner Cross Sections

More than 35% of the pressure required to fill the mold is often attributed to the runner
system. In order to eliminate this additional pressure drop, optimize the route to each gate.
For example, substitute diagonal paths or reorient the cavity to shorten the runner.
Factors such as runner thickness, packing density, and runner volume have a direct impact
on filling pressure and cycle time.In order to determine the optimum runner diameter, a
number of factors have to be considered. These involve parts volume, filling velocity, filling
pressure, runner length, and material viscosity.
Make runners that are at least the same thickness as the nominal wall thickness of the part
to ensure adequate packing.
For runners that are long and subject to high volumetric flow rates, increase the runner
thickness.
For semicrystalline resins, runners must be smaller than for amorphous resins.
Runners for Multicavity Molds
Runners for multicavity molds are particularly important. A runner must be designed well so
that each part is filled at the same time during a single shot in a family mold.
By adjusting gate locations and/or runner section lengths and diameters, you can achieve
balanced flow to each cavity while reducing over-packing and flash in the cavities that fill
first.
 Gate
The gate is a narrow intersection between the main runner and the mould cavity, and the
intersection is also the shortest part on the whole mold.
Its function is to make the molten plastic enter into the mould cavity quickly, which is
beneficial to the rapid filling of the cavity.
After filling, the gate is condensed first to block the cavity, prevent the melted plastic from
falling and avoid the pressure drop of the cavity too fast