Injection Molding

MFG 355


15 Ton Injection Molding Machine
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77 Ton Injection Molding Machine
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150 Ton Injection Molding Machine
Equipment
Injection Unit
Screw drive
arrangement
Feed
hopper
Barrel heaters
Nozzle
Tool
Screw
Check valve Screw tip
Equipment
Injection Unit


Injection
Parts of the injection screw
Screw
Head and check ring
Equipment
Molds
Molds

Mold Materials
Aluminum filled epoxy
Aluminum
Tool steel
Stainless steel
Hotwork die steel
Beryllium-copper
Mold Materials
Choice based on critical properties
Machinability
Coefficient of thermal expansion
Specific heat capacity
Thermal conductivity
Density
Hardness (abrasion resistance)
Yield strength
Weldability
Mold Parts
Bases
Standard sizes
Hold mold inserts
Can decrease overall mold costs

Mold Parts
Guide pins
Align mold cavities

Guide pins
Mold Parts
Sprue Bushing
Hot sprue
Cold sprue
Mold Parts
Sprue Bushing
Hot sprue

Mold Parts
Sprue Bushing
Cold sprue
Sprue puller
Mold Parts
Sprue Bushing
Cold sprue
Sprue puller
Mold Parts
Runner
Mold Parts
Runner
Layout
Conventional
Improved Balanced H Circular
Mold Parts
Runner
Layout
Conventional
Improved Balanced H Circular
Mold Parts
Runner
Cold well
Mold Parts
Runner
Mold Parts
Gates
Submarine Gate
Pinpoint Gate
Fan or Edge Gate
Mold Parts
Gates
Sprue Gate
Tab Gate
Flash Gate
Mold Parts
Gates
Internal Ring Gate
External Ring Gate
Mold Parts
Gate
Mold Parts
Gate
Mold Parts
Gate
Mold Parts
Cavity
Where the part is made
Layout is critical to material flow
Mold Parts
Cavity
Knit/weld lines
This shows where the
weld lines (shown in red)
will most likely occur with
the part gated in the
center (yellow cone).
Mold Parts
Cooling
Reduce cycle time
Control formation of crystalline areas
Freeze part
Mold cavity
Cooling lines
Mold Parts
Ejector system
Ejector Plate
Ejector pins
Return Springs
Equipment
Clamping Unit
Equipment
Clamping Unit
Toggle clamping
Hydraulic clamping
Hybrid hydraulic-toggle clamping
Equipment
Clamping Unit
Equipment
Clamping Unit
Toggle system
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Plant Concepts

Safety
High clamping forces
High pressure lines
High voltage
High temperatures
Safety
Position switches
Mechanical, hydraulic and electrical
Shields
Lock out/tag out

Material and Product
Considerations
Shapes
Possible to do very complex shapes
Structural features
Pins, ribs, bosses, threads, holes
Deep parts are possible
Internal or external threads
Undercuts require sliding mold sections
Sliding Mechanism
Material and Product
Considerations
Part design
Uniform wall thickness
Helps reduce dimples, shrink marks and distortion
Ribs
Save weight at given strength
No sharp bends
Helps to fill the mold cavity easier
Oversize the mold
Shrinkage amount is dependant on material and
additives/fillers
Operations and Control
Temperature of melt
Temperature of mold
Pressure of injection and hold
Injection or fill rate and time
Dwell time
Freeze time
Ejection (dead time)

Special Injection Molding
Processes
Coinjection molding
Two separate screws
Two different material selections
Color, strength, flexibility
Special Injection Molding
Processes
Coinjection molding
1 2 3
Special Injection Molding
Processes
Coinjection molding
Part 1
Part 2
Special Injection Molding
Processes
Flow-controlled injection processes
Sometimes called Scorim
Special Injection Molding
Processes
Flow-controlled injection processes
Sometimes called Scorim
Special Injection Molding
Processes
Gas injection molding
Employs gas to create hollow parts
Special Injection Molding
Processes
Injection-compression molding
Injection-Compression
Molding
Injection Molding
Parts were
made with the
same mold.
The only
difference
between the
two parts is the
use of the
compression
cycle
Modeling and Computer-Aided
Mold-Flow Analysis
Used to help identify
potential problems
with the mold/part
design
Models based on the
CAD part
Adjusted by resin

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