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Scientific Troubleshooting of Common Injection Molding Defects

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Part Design for Reducing Cycle Time


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Practical Scientific Molding Techniques


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10 Easy Ways to Analyze Your Plastic Parts


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Intelligent Molder

intelligent
According to Encarta:

1 : the ability to learn facts and skills and apply them, especially when this ability is highly developed

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Intelligent Molder

According to the New York Times Intelligence is defined as problem solving ability
This is the basis of this presentation

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FREE 10-Day Online Training Offer Intelligent Molder Series: Process Evaluation
In-Mold Rheology Test Gate Seal Worksheet Decoupled II Process Worksheet More Details at the End of the Presentation

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Scientific Troubleshooting of Common Defects


Real-Life Troubleshooting Scenarios Who is a Scientific Troubleshooter? Process Documentation Causes for Common Defects Troubleshooting Methods FREE Training Offer Q & A Session

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Real-Life Troubleshooting Scenarios Case #1 Material Issue - Problem


Scenario:
Connector Mold New Material Supplier with Identical Material Could Not Maintain Desired Cycle Times 13.9 seconds vs. 11.2 seconds

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Real-Life Troubleshooting Scenarios Case #1 Material Issue Solution


Process, machine, & mold identical What changed Material
Internal lubricant was not the same Internal lubricant not at the same percentages

Established:
Correct internal lubricant Correct percentages of lubricant

Resulting in a cycle time under 9 seconds!

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Real-Life Troubleshooting Scenarios Case #2 Part Design Issue - Problem


Scenario:
Kitchen shelving support Operating at 17.2 second cycle time Needed to maintain critical dimensions Wanted to optimize process

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Real-Life Troubleshooting Scenarios Case #2 Part Design Issue Solution


Design Change
Added 0.25 draft angle

Resulting in a cycle time under 12 seconds!

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Real-Life Troubleshooting Scenarios Case #3 Machine Issue - Problem


Scenario:
3 plate mold replaced with hot runner mold 6 second capable automation added New machine could not plasticize fast enough New machine could not move all machine functions at simultaneously

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Real-Life Troubleshooting Scenarios Case #3 Machine Issue Solution


Specified new machine with:
Better screw design Independent machine functions

Resulting in cycle time under 4 seconds! Machine could outrun the automation!

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Real-Life Troubleshooting Scenarios Case #4 Mold Issue - Problem


Scenario:
Theft protection tag 3 plate mold has slow process Cycle time above 23 seconds High scrap rate ~35%

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Real-Life Troubleshooting Scenarios Case #4 Mold Issue Solution


Specified mold with hot runner system Significantly reduced scrap Resulting in cycle time under 10 seconds!

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Real-Life Troubleshooting Scenarios Case #5 Technology Issue - Problem


Scenario:
Tubular coat hanger Intermittent short shots Due to viscosity variations in off-spec materials

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Real-Life Troubleshooting Scenarios Case #5 Technology Issue Solution


Specified process monitoring system with:
Cavity pressure transducer Integration to boost cutoff

Resulting in elimination of short shots Variations in material viscosity had little to no change in process

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Who is a Scientific Troubleshooter?

trou ble shoot er


According to Merriam-Webster:

1 : a skilled worker employed to locate

trouble and make repairs in machinery and technical equipment

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Who is a Scientific Troubleshooter? A Typical Troubleshooter:


acts upon learned behavior makes multiple changes at one time rarely documents anything often blames the tool or material avoids speaking in specifics

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Who is a Scientific Troubleshooter?

sci ence
According to Merriam-Webster:

1 : the state of knowing : knowledge as

distinguished from ignorance or misunderstanding

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Who is a Scientific Troubleshooter?

sci ence + trou ble shoot er =


'a skilled worker who acts from a state of knowing'

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Who is a Scientific Troubleshooter? A Scientific Troubleshooter:


knows the history of the process, mold, machine, material, technology determines what has changed acts on knowledge verifies the results of any change

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Process Documentation Machine Inputs vs. Process Outputs

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Process Documentation Setup Technicians Typically Document:


machine-dependent inputs speed settings time settings temperature settings pressure settings tonnage settings

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Process Documentation Scientific Troubleshooters Document:


machine-independent process outputs
temperatures times plastic pressures weights additional data

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Process Documentation Process Outputs - Temperatures:


plastic melt temperature coolant temperature in coolant temperature out

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Process Documentation Process Outputs - Times:


fill time pack time hold time gate seal time cycle time recovery time

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Process Documentation Process Outputs - Plastic Pressures:


back pressure pressure at transfer
and/or peak pressure

pack pressure hold pressure

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Process Documentation Process Outputs - Weights:


fill weight pack weight final weight

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Process Documentation Process Outputs - Additional Data:


cavity measurements quality measurements clamp tonnage photographs observations cavity balance

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Process Documentation The Scientific Troubleshooter Uses Documentation To:


know how the process ran determine what changed act on knowledge verify the results

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Causes/Symptoms for Common Defects The Typical Troubleshooter Asks:

'what buttons do I push to correct the defect?


they often rely on learned behavior & troubleshooting guides

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Causes/Symptoms for Common Defects The Scientific Troubleshooter Asks:

what change occurred to cause this defect?


process documentation is crucial for these people

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Flash

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Flash
What Changed:
high melt temperature or degradation

Causes:
reduced melt viscosity more material enters cavity during fill

Symptom:
flash anywhere on part decreased plastic pressure at transfer
or peak pressure during fill

increased fill weight change in screw recovery time

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Flash
What Changed:
low melt temperature

Causes:
high melt viscosity more pressure is required to fill mold

Symptom:
flash near gate or center of mold increased plastic pressure at transfer
or peak pressure during fill

decreased fill weight

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Flash
What Changed:
decreased fill time due to high flow rate

Causes:
lower viscosity due to shear thinning excessive material enters mold during fill

Symptom:
flash anywhere on part increased fill weight decreased fill time increased pressure at transfer
or peak pressure during fill

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Flash
What Changed:
increased fill time due to a low transfer setpoint

Causes:
excessive material enters mold during fill

Symptom:
flash anywhere on part increased fill weight increased fill time increased pressure at transfer
or peak pressure during fill

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Flash
What Changed:
increased pack and hold pressure

Causes:
excessive pressure within mold

Symptom:
flash anywhere on part increased pack weight increased final weight

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Flash
What Changed:
low clamp tonnage

Causes:
insufficient tonnage to hold mold closed

Symptom:
little change in outputs increased pack weight flash anywhere on part

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Flash
What Changed:
high cavity imbalance

Causes:
excessive material enters during fill

Symptom:
not all cavities may flash intermittent shorts intermittent flash incorrect fill time flash anywhere on part

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Flash
What Changed:
inconsistent check ring

Causes:
inconsistent material during fill

Symptom:
intermittent shorts intermittent flash inconsistent fill time flash anywhere on part

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Flash
What Changed:
excessive mold and platen deflection

Causes:
inconsistent tonnage across parting line

Symptom:
little change in outputs flash near center of the mold

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Flash
What Changed:
mold damage or wear

Causes:
wear or damage occurs

Symptom:
little change in outputs flash in a unique area flash near a moving component

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Sinks and Voids

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Sinks and Voids


What Changed:
high melt temperature

Causes:
excessive shrinkage occurs

Symptom:
shrinkage anywhere on the part decreased pressure at transfer
or peak pressure during fill

increased fill weight

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Sinks and Voids


What Changed:
low melt temperature

Causes:
excessive pressure loss occurs

Symptom:
shrinkage near the end of fill increased pressure at transfer
or peak pressure during fill

decreased fill weight

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Sinks and Voids


What Changed:
increased fill time due to low flow rate

Causes:
excessive pressure loss occurs

Symptom:
shrinkage near the end of fill decrease pressure at transfer
or peak pressure during fill

change in fill weight

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Sinks and Voids


What Changed:
decreased fill time due to a high transfer setpoint

Causes:
insufficient material enters mold during fill

Symptom:
shrinkage near the end of fill decrease pressure at transfer
or peak pressure during fill

decrease in fill weight

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Sinks and Voids


What Changed:
decreased pack and hold pressure

Causes:
inadequate pressure within mold

Symptom:
shrinkage anywhere on part decreased pack weight decreased final weight

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Sinks and Voids


What Changed:
poor gate seal due to a low hold time

Causes:
material exits the cavity through the gate

Symptom:
shrinkage near the gate decreased final weight

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Sinks and Voids


What Changed:
high mold temperature

Causes:
excessive shrinkage occurs

Symptom:
shrinkage anywhere on the part decreased pressure at transfer
or peak pressure during fill

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Voids
What Changed:
low mold temperature

Causes:
polymer freezes to mold surface as part shrinks

Symptom:
voids anywhere on the part increased pressure at transfer
or peak pressure during fill

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Short Shots

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Short Shots
What Changed:
low melt temperature

Causes:
excessive pressure loss occurs

Symptom:
increased pressure at transfer
or peak pressure during fill

decreased fill weight decreased pack weight decreased final weight

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Short Shots
What Changed:
increased fill time due to low flow rate

Causes:
excessive pressure loss occurs

Symptom:
decrease pressure at transfer
or peak pressure during fill

change in fill weight decreased pack weight decreased final weight

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Short Shots
What Changed:
decreased fill time due to a high transfer setpoint

Causes:
insufficient material enters mold during fill

Symptom:
decrease pressure at transfer
or peak pressure during fill

decrease in fill weight decreased pack weight decreased final weight

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Short Shots
What Changed:
decreased pack pressure

Causes:
inadequate pressure to complete mold filling after transfer

Symptom:
decreased pack weight decreased final weight

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Jetting

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Jetting
What Changed:
low melt temperature

Causes:
high viscosity prevents fountain flow

Symptom:
increase pressure at transfer
or peak pressure during fill

decreased fill weight

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Jetting
What Changed:
decreased fill time due to high flow rate

Causes:
high flow rate prevents fountain flow

Symptom:
increase pressure at transfer
or peak pressure during fill

increased fill weight decreased fill time

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Jetting
What Changed:
low mold temperature

Causes:
poor adhesion to mold surface prevents fountain flow

Symptom:
increased pressure at transfer
or peak pressure during fill

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Causes/Symptoms for Common Defects as you can see if the process is documented, the scientific troubleshooter can quickly identify what changed

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Troubleshooting Methods Again A Scientific Troubleshooter:


knows the history of the process, mold, machine, material, and technology determines what has changed acts on knowledge (intelligence) verifies the results of any change

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Troubleshooting Methods Step 1: Examine the Part to Ensure:


proper diagnosis no other defects are present

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Troubleshooting Methods Step 2: Rule Out Obvious Causes:


check the simple causes
where applicable

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Troubleshooting Methods Step 3: Compare with Documented Process Outputs


focus on related outputs process of elimination

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Troubleshooting Methods Step 4: Return Process to Documented Standard


change one parameter at a time allow each change time to affect the process

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Troubleshooting Methods Step 5: Verify Other Process Outputs


verify any relevant parameters a full verification may be necessary if cause not found, check the mold, machine, & material

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Troubleshooting Methods Step 6: Document Any Changes Made


record actions and causes ensures others can follow

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Scientific Troubleshooting

In conclusion: it is not only about troubleshooting a process All factors such as material, mold, machine, part design and technology must be documented.
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FREE 10-Day Online Training Offer Intelligent Molder Series: Process Evaluation
In-Mold Rheology Test Gate Seal Worksheet Decoupled II Process Worksheet

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FREE 10-Day Online Training Offer Follow-Up Email Will Contain:


Instructions to Download Worksheets Instructions to Receive Free Trial Webinar Notes & Special Offer

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Scientific Troubleshooting of Common Defects

Q&A Session

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