Q2 (a) Describe and explain the defects of short mouldings and flashing.

Short mouldings happens when the length of the product is shorter than the expected length. This
is because the amount of material injected is too low. Flashing happens when there is excessive
material produced on the top part of the product and have and abnormal shape. This is because
the material injected for the moulding procrss is in excess.

Q3. For a given component geometry, injection pressure and moulding temperature, comment
on the ease of mould filling and the length of the cycle time when moulding materials with the
following properties
a) Moulding materials with high thermal conductivity and high viscosity require a higher
temperature and higher pressure for mould filling process. Hence, the injection temperature and
the injection pressure will be higher making the process harder and length of cycle time longer
because it takes longer time for the cooling process.
b) Moulding materials with low thermal conductivity and low viscosity require a low
temperature and lower pressure for mould filling process. The injection temperature and
pressure will be lower making it easier and have a shorter cycle time due to the shorter time of
cooling process.

Q4. High pressure die casting of aluminium and injection moulding of polymers are very
similar process (in that molten material is forced under pressure to fill and solidify in a metal
mould). By considering the property data for molten aluminium in Table 2 below and the
property data for polystyrene in Table 1, state, with reasoning, how you expect the following to
vary for the two different processes.
a) The injection temperature will be higher for aluminum because it has higher thermal
conductivity which require more heat energy than polymer.
b) The injection pressure will be higher for aluminum because it has higher viscosity which
require a higher pressure force than polymer to be exerted.
c) The cycle time will be longer because the injection temperature is higher which require a
longer time for cooling process.