INJECTION MOULDING

ABDULREHMAN AHMED SOOMRO

F16ME11
Injection molding is a process in which a 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 a molding, is then removed from the cavity. The process produces discrete
components that are almost always net shape. The production cycle
time is typically in the range of 10 to 30 sec, although cycles of 1 min or longer are
not uncommon for large parts. Also, the mold may contain more than one cavity,
so that multiple moldings are produced each cycle.
MOULDED PLASTIC MATERIALS
Complex and intricate shapes are possible with injection molding. The challenge
in these cases is to fabricate a mold whose cavity is the same geometry as the part
and that also allows for part removal. Part size can range from about 50 g (2 oz) up
to about 25 kg (more than 50 lb), the upper limit represented by components such
as refrigerator doors and automobile bumpers. The mold determines the part shape
and size and is the special tooling in injection molding. For large, complex parts, the
mold can cost hundreds of thousands of dollars. For small parts, the mold can be
built to contain multiple cavities, also making the mold expensive. Thus, injection
molding is economical only for large production quantities.
A large
(3000-ton capacity)
injection molding
machine. (Courtesy of
Cincinnati Milacron.)
 in g m a c hine,
a n i n j e c tion mold e c hanical
g ra m o f so m e m
Dia s c re w type (
ti ng
reciproca
details are
).
simplified
 PROCESS AND EQUIPMENT
• EQUIPMENT FOR INJECTION MOLDING EVOLVED FROM METAL DIE CASTING.
• AN INJECTION MOLDING MACHINE CONSISTS OF TWO PRINCIPAL
• COMPONENTS: (1) THE PLASTIC INJECTION UNIT AND (2) THE MOLD CLAMPING UNIT. THE INJECTION
• UNIT IS MUCH LIKE AN EXTRUDER. IT CONSISTS OF A BARREL THAT IS FED FROM ONE END
• BY A HOPPER CONTAINING A SUPPLY OF PLASTIC PELLETS. INSIDE THE BARREL IS A SCREW WHOSE
• OPERATION SURPASSES THAT OF AN EXTRUDER SCREW IN THE FOLLOWING RESPECT: IN ADDITION TO
• TURNING FOR MIXING AND HEATING THE POLYMER, IT ALSO ACTS AS A RAM THAT RAPIDLY MOVES
• FORWARD TO INJECT MOLTEN PLASTIC INTO THE MOLD. A NONRETURN VALVE MOUNTED NEAR THE
• TIP OF THE SCREW PREVENTS THE MELT FROM FLOWING BACKWARD ALONG THE SCREW THREADS.
• LATER IN THE MOLDING CYCLE THE RAM RETRACTS TO ITS FORMER POSITION. BECAUSE OF ITS DUAL ACTION,
IT IS CALLED A RECIPROCATING SCREW.
 PARTS OF ANY INJECTION MOULDING UNIT

• 1 THE CLAMPING UNIT

• 2 A SHOT OF POLYMER MELT
INJECTION MOULDING CYCLES
TWO-PLATE MOLD
 THE MOULD

• THE MOLD IS THE SPECIAL TOOL IN INJECTION MOLDING; IT IS CUSTOM-DESIGNED

AND FABRICATED
• FOR THE GIVEN PART TO BE PRODUCED. WHEN THE PRODUCTION RUN FOR THAT
PART IS FI NISHED,
• THE MOLD IS REPLACED WITH A NEW MOLD FOR THE NEXT PART. THIS SECTION
EXAMINES SEVERAL
• TYPES OF MOLD FOR INJECTION MOLDING.
• TYPE OF MOULD : TWO PLATE MOULD, THREE PLATE MOULD.
 OTHER PROCESSES
INVOLVING INJECTION
MOULDING
1 EJECTING SYSTEM
2 COOLING SYSTEM
THREE PLATE MOULD
 INJECTION MOLDING MACHINES

• INJECTION MOLDING MACHINES DIFFER IN BOTH INJECTION UNIT AND

CLAMPING UNIT. THIS SECTION.
• DISCUSSES THE IMPORTANT TYPES OF MACHINES AVAILABLE TODAY. THE NAME
OF THE
• INJECTION MOLDING MACHINE IS GENERALLY BASED ON THE TYPE OF
INJECTION UNIT USED.
 INJECTION MOLDING MACHINES

• INJECTION UNITS: RECIPROCATING SCREW MACHINE, PLUNGER TYPE

INJECTION MOLDING MACHINE.

• CLAMPING UNITS: CLAMPING DESIGNS ARE OF THREE TYPES

• TOGGLE CLAMPS (TOGGLE MECHANISM USED)
• HYDRAULIC CLAMPS (FLOODED MECHANISM USED)
• HYDRO MECHANICAL CLAMPS (COMBINATION OF ABOVE BOTH)
 DEFECTS IN INJECTION MOLDING

• SHORT SHOTS.
• FLASHING.
• SINK MARKS AND VOIDS.
• WELD LINES.
THANK YOU !
ANY QUESTIONS