Islamabad Injection Molding It is a processes in which polymer is heated to a highly plastic state and forced to flow under high pressure into a mold cavity, where it solidifies. The molded part, called the molding, is then removed from the cavity. It produce discrete components that are almost always net shape The production cycle is typically in the range of 10 to 30 sec. Simultaneous multiple moldings are also common. Injection Molding Complex and intricate shapes are possible Part removal may be a main limiting parameter Part up to 25 kg (e.g. Refrigerator doors) are common This process is economical only for mass production Most widely used process for thermoplastics Process & Equipment An injection molding machine consists of two principal components The plastic injection unit The mold clamping unit The injection unit is much like and extruder. It contains a barrel that is fed from one end by a hopper The screw can provide additional features like It acts as a ram which rapidly moves forward to inject molten plastic into the mold A non return valve at the tip prevents flow backwards The screw is called reciprocating screw. An Injection Molding Unit Process & Equipment The clamping unit is concerned with the operation of the mold. It can Hold the two halves of the mold in proper alignment Keep the mold closed during injection by applying a clamping force sufficient to resist the injection force Open and close the mold at the appropriate times in the mold cycle Of the two platens in the clamping unit one is fixed while the other is movable ,usually operated by hydraulic piston Injection Molding Process The sequence of operation in an injection molding unit is as follow: The mold is closed and clamped A shot of plastic of the desired properties is injected under high pressure into the mold cavity The plastic cools and begins to solidify , maintained ram pressure insures packing of melt into cavity to compensate for contraction during cooling The screw is retracted to permit fresh polymer to flow into the forward portion of the barrel, as the polymer in mold solidifies The mold is opened and the part is ejected and removed Injection Molding Process The Mold The mold is the special tool in injection molding It is custom designed and fabricated for the given part to be produced. Two Plate Mold: it consists of two halves fastened to the two platens . When the clamp unit is opened the tw0 mold halves open. This mold can contain more than one cavity A mold consists of One or more cavities that determine part geometry Distribution channels An ejection system Cooling system Vents to permit evacuation of air from cavities The Mold Injection Molding Machines Types Injection Unit Reciprocating Screw Machines Screw pre-plasticizer machines or Two Stage Machines Plunger-type Machines The third one is the oldest type and is not currently in use now a days Injection Molding Machines a. Screw Preplasticizer b. Plunger Type Injection Molding Machines The Clamping Unit: there are three common types Toggle Clamping units Hydraulic Clamping units Hydro-mechanical Clamping units Toggle Clamping Units Hydraulic Clamping Units Shrinkage Polymers have high thermal expansion coefficients and significant shrinkage occurs during cooling of plastic in the mold Volumetric contractions of around 10% are not very uncommon Contraction of crystalline plastics is more that for amorphous polymers. It is expressed as the reduction in linear size that occurs during cooling to room temperature from mold temperature. It has units of mm/mm or in/in Defects in Injection Molding Short Shots: like casting short shot in a molding is a molding that has solidified before completely filling the cavity Flashing: It occurs when the polymer melt is squeezed into the parting surface between mold plates , it can also occur around ejector pins Sink Marks and voids: A sink mark occurs when the outer surface on the molding solidifies, but contraction of the internal material causes the skin to be depressed below its intended profile. A void is caused by the same phenomena , except it is internal. Defects in Injection Molding Weld lines: they occur when the polymer melt flows around a core or other convex details in the mold cavity and meets from opposite direction. Other Injection Molding Processes Thermoplastic Foam Injection Molding It involves the molding of thermoplastic parts that posses a dense outer skin surrounding a light weight foam center It can be produced either by introducing a gas into the molten plastic in the injection unit or by mixing a gas production ingredient with the starting pellets. Items made of structural foam include electronic cases, business machine housings, furniture components and washing machine tanks. Low injection pressure and clamping force means production of larger components Surface tends to be rough so extra operation may be required Other Injection Molding Processes Multi-Injection Molding Processes Sandwich molding: involves injection of two separate polymers. A specially designed nozzle controls the flow sequence of the two polymers, such that the core polymer is completely surrounded by the skin material inside the mold cavity. Bi-injection molding: it involves sequential injection of two polymers into a two position mold. Used to combine plastics of two different colors or to achieve different properties in different sections of the same part Other Injection Molding Processes Injection of Thermosets: certain modifications are required to account for the cross-linking. The machines for Thermosets are similar but the barrel length is shorter to avoid premature curing and solidification. Most of the Thermosets materials contain large proportions of fillers like glass fibers, clay, wood fibers etc. Other Injection Molding Processes Reaction Injection Molding(RIM): it involves the mixing of two highly reactive liquids and immediately injecting the mixture into a mold cavity. RIM was developed with polyurethanes to produce large automotive components like bumpers and spoilers. They typically posses a foam internal structure. Reaction Injection Molding Compression Molding A process widely used for thermosetting plastics. Also used for thermoplastic, rubber tires and various polymer matrix composites. It is a four step process Loading a precise amount of molding compound called the charge into the bottom half of a heated mold Bringing the mold halves together to compress the charge. Heating the charge to polymerize and cure the material Opening the mold halves and removing the part from the cavity Compression Molding Transfer Molding Two types Pot transfer molding Plunger transfer molding The scrap produced in each cycle is called cull It is generally used for thermoplastics Also used for inserts, metal or ceramic insert is placed into the cavity and the heated plastic bonds to the insert during molding. Transfer Molding Blow Molding Air pressure is used to inflate soft plastic int0 a mold cavity. Blow molding is accomplished in two steps Fabrication of a starting tube of molten plastic , called a parison Inflation of the tube to the desired final shape Formation of the parison is accomplished by either extrusion or injection molding Stretch Blow Molding Instead of Extrusion, injection molding is used to form the starting parison. In Stretch blow molding the blowing rod extends downward into the injection molded parison, thus stretching the soft plastic and creating a more favorable stressing of the polymer than conventional injection processes. The resulting structure is more rigid, with higher transparency and better impact resistance. Stretch Blow Molding Rotational Molding Rotational molding uses gravity inside a rotating mold to achieve a hollow form. It is also called rotomolding It can be achieved in four steps A predetermined amount of polymer is loaded into the cavity The mold is then heated and simultaneously rotated on two perpendicular axis While still rotating the mold is cooled The mold is opened and the part is unloaded. Rotational M0lding Thermoforming The process in which flat thermoplastic sheet is heated and deformed into desired shape. It consists of two main steps Heating Forming Forming methods can be further classified as Vacuum thermoforming Pressure thermoforming Mechanical thermoforming Vacuum thermoforming Pressure Thermoforming Mechanical Thermoforming Positive & Negative Molds Negative molds have concave shape Positive mold have convex shape Polymer Foam processing A polymer foam is a polymer and gas mixture It is also called cellular polymer, blown polymer or expanded polymer They have Low density High strength per unit weight Good thermal insulation Good energy absorbing properties they can be elastomeric, flexible or rigid Foaming processes Common gases used are air, nitrogen and carbon dioxide The common processes are Mixing a liquid resin with air by mechanical agitation and then hardening Mixing a physical blowing agent with the polymer Mixing the polymer with chemical compounds (chemical blowing agents) Product Design Considerations General Considerations Strength and stiffness Impact resistance Service temperatures Thermal expansion Degradation Extruded Plastics Wall thickness Hollow sections corners Product Design Considerations Molded Parts Economic productions quantities Part complexity Wall thickness Reinforcing Corner radii and fillets Holes draft tolerances End of Lecture
Modified Polymers, Their Preparation and Properties: Main Lectures Presented at the Fourth Bratislava Conference on Polymers, Bratislava, Czechoslovakia, 1-4 July 1975