1 6 Plastik Enjeksiyon Parca Hataları Ve Cozumleri

1.6.
Plastik Enjeksiyon Para Hatalar ve

zmleri
(Plastic Part Troubleshooting)
Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 1

Tam Doldurulamam Paralar

Basn kalb tam doldurmak iin yetersiz. Malzeme kalp

Hata Nedeni dolmadan nce katlayor.
Olas Neden ve zmler Enjeksiyon Parametreleri

Injection pressure too low Increase injection pressure
Injection speed too low Increase injection speed
Back pressure too low Increase back pressure
Switching to Holding pressure too soon Switch later to hold pressure
Increase cylinder temperature
Melt temperature too low
Increase screw back pressure
Holding time to short Lengthen holding time
Mould temperature too low Increase mould temperature

Hata Basn kalb tam doldurmak iin yetersiz. Malzeme kalp

Nedeni dolmadan nce katlayor.
Olas Neden ve zmler Tasarm Parametreleri
Runner or Gate cross section too small Increase runner or gate cross section
Mould ventilation too small Increase mould ventilation
Nozzle runner too small Increase Nozzle runner diameter
Walls too thin in thin wall areas Increase wall thickness
Very long flow length Decrease flow length with additional gate

Boluklar / Kabarcklar
Kaln duvarl PMMA parada boluklar : Kabarck

blgesinde duvar kalnl 28mm, yolluk giri blgesinde
15 mm.
Yolluk giri blgesindeki malzeme daha abuk
Vakum kabarcklar soumakta ve paradaki ekmeyi karlayamadndan
Gaz, skm hava veya nem vakum boluklar olumaktadr.

Boluklar
Farkl et
kalnlklarndaki
Polysulfon (PSU) Kaln duvarl
para: blgesinde
kabarcklar
Et kalnlnn byk Salata Ka (PMMA) : (PC)
olduu blgede Yolluk giriinden uzak kaln
kabarcklar blgede kabarck

Boluklar
Hata Kaln kesitli blgedeki ekme tutma basnc ile

Nedeni karlanamamaktadr.

Holding Pressure too low Increase holding pressure
Holding time too short Increase holding time
Mould Temperature too low Increase mould temperature
Melt temperature too low Increase melt temperature

Boluklar
Hata Shrinkage of the thick section is not compensated by holding

Nedeni pressure.
Gate cross section too small Increase gate cross section
Nozzle runner too small Increase runner diameter
Part is molded at a thin wall section Gate the part where wall thickness is greater
Melt accumulation too high Avoid melt accumulation
Wrong gate position Change gate position

Gaz Kabarcklar
nce et kalnlkl Poliamid Para :

Gaz Kabarcklar nce et kalnl nedeni ile gaz
(PC) Gaz kabarkl kabarklar yzeyi deforme
PET taslak etmekte.
(preform)

Gaz Kabarcklar
Hata
Gas bubbles created during plastic processing
Nedeni

Reduce cylinder temperature
Melt temperature too high Reduce back pressure
Reduce screw RPM 's
Melt resides in cylinder too long Use smaller diameter screw

Gaz Kabarcklar
Hata
Gas bubbles created during plastic processing
Nedeni
Unsuitable screw geometry use a screw with lower compression

Parada Siyah-Gri Duman zleri
ift Renkli Lamba : Sar parada

(PMMA) , eritme srasnda
yapsnda gri duman izleri
skan hava parada siyah
bulunan Kaln duvarl PMMA
duman izlerine neden olmaktadr.
para

Para yzeyinde
koyu gri ak
hatlar
Silindirde skan hava sonucu

siyah duman izleri olan Tp
(PC) para

Vidadaki ergitme
srasnda hava
besleme blgesi
ynne
kaabilmektedir(st).
Malzemenin ok hzl
ergitilmesi
durumunda hava
kaamamakta, skan
hava siyah veya gri
duman izlerine neden
olmaktadr.

Hata
Plastikletirme srasnda skarak yanan hava
Nedeni

Screw back pressure too low Increase screw back pressure
Cylinder temperature in the feed section too Reduce cylinder temperature in the
high feed section
Screw RPM s too high Reduce screw RPM s
Plasticating unit contaminated
Clean plasticating unit
Wear on the plasticating unit Replace complete plasticating unit or

individual components. Use a corrosion
and abrasion resistant plasticating unit

Hata Burned air at the plastification progress in the cylinder.

Nedeni
Unsuitable screw geometry Install a screw with a longer feed section and
greater gear depth feed section

Hzl Ak zleri (Jetting)
nce etli
parada ak
hattnn
oluumu.
Kaln etli parada

yolluk giriinde ak
izleri.
nce effaf
parada tm
boyda aka
grlen ak hatt.

Hzl Ak zleri (Jetting )
The speed of the material across the gate is so fast it did

Hata
not exhibit fountain flow behaviour but acted in slug flow
Nedeni behaviour

Injection speed too high Reduce injection speed;
Injection speed too constant Variable injection speed. Slow - Fast
Increase cylinder temperature (with thermallly
Melt temperature too low sensitive materials, just to the Meeting Zone).
Mould temperature too low Increase mould temperature in the gate area

Hzl Ak zleri (Jetting )
Hata The speed of the material across the gate is so fast it did not
Nedeni exhibit fountain flow behaviour but acted in slug flow
behaviour
Sharp edges in the transition between the Round off the transition between the gate
gate and the part. and the part
Gate too small Increase gate size
Gate in the middle of the part cross section Move the gate; Inject (mould) against some
resistance.

Souk Birleme zleri (Weld Lines)
effaf parada bayraklar arasnda souk birleme izleri.

eliin etrafndan dnen ki ak cephesinin

birlemesi ile souk iz meydana gelmektedir.
Cepheler birbirine nekadar dik ise grnen iz o
kadar daha bariz olacaktr.
Souk birleme izi grlen PMMA
para .

Boluk arkasnda
souk birleme izi

Hata
The two faces did not weld together
Nedeni

Injection speed too slow Increase injection speed
Mould surface temperature too low Increase mould temperature
Increase back pressure.
Back pressure too low
Change to back pressure sooner

Hata
Nedeni The two faces did not weld together

Gate in improper position Move gate. Move weld line to a non visible position
No venting at the parting line Adjust venting according to material (ABS - 0,02mm
deep, PA - 0,01mm deep)

apak (Overmoulding)
Blgesel apakl Para .

Kalp szdrmazl yeterli
deil
Blgesel (stte) ve evresel (Altta)
apakl paralar

apak (Overmoulding)
Hata The pressure of the material exceed the ability of the mold
Nedeni to stay closed

Clamping force too low Increase clamping force
Reduce injection speed possibly variable
Injection speed too high
injection speed Fast - slow
Switch to holding pressure too late Switch to holding pressure sooner
Melt temperature too high Reduce cylinder temperature
Mould temperature too high Reduce mould temperature
Back pressure too high Reduce back pressure

apak (Overmoulding)
Hata The pressure of the material exceed the ability of the mold to
Nedeni stay closed

Mould dimensionally unstable More rigid mould design
Mould doesn't adequately seal at the at Modify mould
the parting line
Mould sealing faces worn Refinish mould sealing faces

knt zleri ( Sink Marks )
ABS parada et
kalnlndan kaynaklanan
PS para da knt izleri. knt izleri.

Yetersiz tutma sreleride knt

ye neden olmaktadr. Arttrlan
tutma basnc ve sresi kntleri
yok edecektir.
knt izlerinin ana nedeni
blgesel ktle artdr.

Hata
Material contracts haven been unsufficiently packed
Nedeni

Back pressure too low Increase back pressure
Back pressure time too short Increase back pressure time
Mould wall temperature too high Reduce mould wall temperature
Reduce melt temperature
Melt temperature too high
Reduce cylinder temperature

Hata Nedeni Material contracts haven been unsufficiently packed

Gate cross section too small Increase gate cross section
Pressure drop too great increase melt channels
Nozzle runner diameter too small Increase runner diameter
Part is gated on the small wall thickness Gate part on the larger wall thickness
Unsuitable wall thickness / rib ratio Redesign wall thickness / rib ratio

tici zleri ( Ejection Marks )
This part (PS)has visible (white)ejection

marks,. Too much pressure was required
to eject the part.

Hata
The pressure from the pin is sufficient to dig into the part
Nedeni

Back pressure too high Reduce back pressure
Back pressure time too long Shorten back pressure time
Switch to back pressure too late Switch to back pressure sooner
Cooling time to short Lengthen cooling time

Hata The pressure from the pin is sufficient to dig into the part
Nedeni

Taper too flat Increase the taper
Cavity wall in the taper direction too rough Polish cavity surface
Vacuum on the ejection side Install air vents in the core

arplma ( Warpage )
Moulded parts do
not match
specification
drawing, suffer
warpage at corners
or do not fit
accurately

arplma ( Warpage )
Hata
Internal stresses of the part bent it to relax.
Nedeni

Pressure in the part too high Reduce back pressure
Switch to back pressure sooner
Mould temperature too low Increase mould temperature
Flow front speed too slow Increase injection speed

arplma ( Warpage )
Hata Nedeni Internal stresses of the part bent it to relax.

Inconsistent mould temperature Cool the mould evenly
Inconsistent wall thickness Strive for proper part geometry
Part poorly designed. Unsuitable distribution of Optimize part design.Improve glass fibre
glass fibre oriantation by optimising gate.

Part deformation -Ejection
Part deformed during

demoulding

Part deformation -Ejection
Hata Nedeni
Olas Neden ve zmler
Cavity pressure too high Optimise injection speed. Reduce holding pressure.
Switch to holding pressure at an earlier stage
Inadequate mould rigidity Strengthen mould
Cooling time too short or mould

Optimise cooling / mould temperature control
temperature too high in places
Mould not sufficiently polished. Ejector Polish cavity surface in direction of demoulding,
choose a suitable surface coating or depth of
pins poorly positioned or surface area
texture. Optimise position and size of ejector pins
too small
(it is particularly important to locate them near
corners,under ribs and bosses)
Poor mould design. Undercuts too Optimise mould design. Reduce size of undercuts
pronounced, draft angles too small and optimise draft angles

Part Sticking in Cavity
Part remain in mould

cavity

Part Sticking in Cavity
Hata
Nedeni
Olas Neden ve zmler
Mould overloaded pressure at an Reduce injection speed and holding pressure,
earlier stage and switch to holding
Undercuts too pronounced, draft Reduce size of undercuts and improve draft
angles too small angles
Mould not sufficiently polished at ribs Polish cavity surface in direction of demoulding
and bosses
Vacuum between mould surface and
Optimise mould venting
part
Premature demould: part sticks or is Increase cooling time, reduce mould
still too soft temperature

Thickness Variation
Part thickness does

not match up to
requirements, or
varies a great deal
and lies outside
tolerance range

Thickness Variation
Hata Nedeni
Olas Neden ve zmler
Check rigidity of mould and strengthen it if

Inadequate mould rigidity
necessary
Failure to allow for shrinkage, mould Check mould dimensions and compare with raw
dimensions incorrect material manufacturer's data on shrinkage
Cavity pressure too high or locking force Reduce cavity pressure by switching from
injection to holding pressure at an earlier stage,
too low
reducing holding pressure and increasing locking
force
Mould centring mechanism defective or Check and if necessary renew mould centring
worn mechanism

Weight Variations
Weight and
dimensions of parts
vary greatly

Weight Variations
Hata Nedeni
Olas Neden ve zmler
Examine plasticating unit and particularly non-

Plasticating unit worn
return valve for wear
Fluctuations in temperature of melt and Check temperature control and heating circuits of
mould the plasticating unit
Material not thoroughly dried Check drying process
Set locking force higher or use a machine with a
Locking force too low
higher locking force
Variations in metering stroke or melt Check injection stroke and metering stroke of the
cushion machine

Sinking over entire surface
Part shrinks
away from the
mould wall
over a large
area, with the
exception of
the edges

Sinking over entire surface
Hata Nedeni
Olas Neden ve zmler

Glass fibres perpendicular to flow Alter flow front profile or shift weld line to a non-
direction at end of flow path or at weld critical area
lines
Switch from injection to holding pressure at a
Holding pressure ineffective later stage, increase holding pressure and
holding pressure time

Desenli yzeylerde parlaklk fark
Parlaklk fark yolluk giriine olan uzaklktan

kaynaklanan basn farklar nedeni ile
olumaktadr.
Yolluk giriinden en uzak noktada(sol), Arkasnda destek bayraklar bulunan katkl
basn en dk deerdedir ve para tam poliamid den otomotiv paras(st).
sktrlamadndan yzey tam olarak Para yzeyinde bayraklarn karsnda
olumamaktadr. parlak izler grlmekte. Yksek deerde ve
Yolluk giriine en yakn noktada (sa), kap uzun sreli tutma basnc parlakl
basnc en yksek deerindedir ve para kaldrmakta ( sa) .
yzeyi ok iyi ekillenmitir.

Hata
Cavity pressure efficiency
Nedeni

Holding Pressure too low Increase holding pressure
Holding time too short Increase holding time
Mould Temperature too low Increase mould temperature
Melt temperature too low Increase melt temperature

Hata
Cavity pressure efficiency
Nedeni
Wall thickness difference too great Make wall thickness consistent
Excess material accumulation Avoid excess mel accumulation and thick ribs
Inadequate ventilation at the flowlines Increase mould ventilation at the flowlines

Yolluk girii uzanda Diesel Etkisi
effaf PC para : Bu parada (PA-GF30) souk

Bayrak zerinde gaz birleme blgesinde skan
yan (Diesel etkisi) havann yaratt gaz yan

Parann en son dolan

Kenar yolluk girii ve Gaz k
olan bu parada, bulunmayan blgesin
yolluk konumu de yanan plastik
deitirilerek gaz malzeme
yan
giderilmektedir.

Hata
Hot air/gas overheats the material and burn it
Nedeni

Reduce injection speed;
Injection speed too high
Variable injection speed: fast - slow
Melt temperature too high Reduce cylinder temperature
Clamping force too high Reduce clamping force

Hata
Hot air/gas overheats the material and burn it.
Nedeni
No venting Add ventilation; adjust ventilation according to material (ABS
- 0,02mm deep, PA - 0,01mm deep); install venting pins.
Move ejection pins to critical areas.
Unsuitable part geometry Adjust part geometry to achieve proper filling. Move gate.

1 6 Plastik Enjeksiyon Parca Hataları Ve Cozumleri

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1 6 Plastik Enjeksiyon Parca Hataları Ve Cozumleri

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1.6.

Plastik Enjeksiyon Para Hatalar ve

(Plastic Part Troubleshooting)

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 1

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 2

Basn kalb tam doldurmak iin yetersiz. Malzeme kalp

Olas Neden ve zmler Enjeksiyon Parametreleri

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 3

Hata Basn kalb tam doldurmak iin yetersiz. Malzeme kalp

Olas Neden ve zmler Tasarm Parametreleri

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 4

Kaln duvarl PMMA parada boluklar : Kabarck

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 5

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 6

Hata Kaln kesitli blgedeki ekme tutma basnc ile

Olas Neden ve zmler Enjeksiyon Parametreleri

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 7

Hata Shrinkage of the thick section is not compensated by holding

Wrong gate position Change gate position

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 8

nce et kalnlkl Poliamid Para :

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 9

Olas Neden ve zmler Enjeksiyon Parametreleri

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 10

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 11

ift Renkli Lamba : Sar parada

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 12

Silindirde skan hava sonucu

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 13

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 14

Olas Neden ve zmler Enjeksiyon Parametreleri

Wear on the plasticating unit Replace complete plasticating unit or

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 15

Hata Burned air at the plastification progress in the cylinder.

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 16

Kaln etli parada

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 17

The speed of the material across the gate is so fast it did

Olas Neden ve zmler Enjeksiyon Parametreleri

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 18

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 19

effaf parada bayraklar arasnda souk birleme izleri.

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 20

eliin etrafndan dnen ki ak cephesinin

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 21

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 22

Olas Neden ve zmler Enjeksiyon Parametreleri

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 23

Olas Neden ve zmler Tasarm Parametreleri

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 24

Blgesel apakl Para .

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 25

Olas Neden ve zmler Enjeksiyon Parametreleri

Back pressure too high Reduce back pressure

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 26

Olas Neden ve zmler Tasarm Parametreleri

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 27

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 28

Yetersiz tutma sreleride knt

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 29

Olas Neden ve zmler Enjeksiyon Parametreleri

Tasarm Seminerleri 1.6. Plastik Enjeksiyon Para Hatalar ve zmleri 30

Hata Nedeni Material contracts haven been unsufficiently packed