INJECTION MOULDING

• Plastic Injection Moulding process demands

precise control of melt temperature, melt viscosity,
injection speed, injection follow-up pressure,
switch over point from speed to pressure, cycle
time. It is found that different polymers have
different characteristics and different limitations in
processing. Shear rate and shear stress influence
melt temperature, viscosity, density and flow
behavior of polymer.
• Some polymers are hygroscopic, some polymer
have limited thermally stable time which is
different at different temperature. Such polymers
have limited residence time. The changes in each
parameter has its own influences on other
parameters. Hence, process control becomes very
intricate. This calls for critical analysis of the
machine specifications and capabilities while
ordering the machine.
 INJECTION MOULDING MACHINE
The main functions of an injection moulding
machine is to take preheated granules from
hopper, heat it in a progressive way in the barrel,
mix the material homogenously by screw rod and
then inject the hot melt under high pressure
through a nozzle into a closed mould.
 PLASTICISING

There are two types of plasticising

methods adopted in injection molding
machines ,viz. Plunger plasticising and
Screw plasticising.Most efficient out of the two is the
Screw type which can produce high pressure and
homogenous melt by screw rotation as well as
reciprocation. Plunger types are used for easy flow
materials and for smaller capacity machine upto 5 Tons.
Plunger Injection Machine
 Reciprocating Screw
Injection Machine
NOZZLE

MOLD HEATERS SCREW SCREW DRIVE

MOTOR
PLUNGER TYPE INJ. MOULDING MACHINE

MOVING HOPPER
PLATEN
TIE RODS BAND HEATER
AUTO
FEEDER

TEMP.
CONTROLLERS

NOZZL
E SPREADER
 SCREW TYPE INJECTION MOULDING
MACHINE
(INJECTION UNIT)

FIXED
PLATEN

INJECTION BAND
CHAMBER HEATER
 Mechanical Nozzle between
Toggle barrel and mold
(not shown)
Hopper
Heater
bands

Clamping
Unit Hydraulic
Unit

Mold cooling fed Barrel Screw

Hyd. from external unit (Ram)
Cylinder

SCREW TYPE INJ. MOULDING

MACHINE PARTS & WORKING
30 ton, 1.5 oz (45 cm3) Engel

Injection Molding Machine

for wheel fabrication
 Process & machine schematics
*

Schematic of thermoplastic Injection molding machine

* Source: http://www.idsa-mp.org/proc/plastic/injection/injection_process.htm
 SCREW ROD DESIGN

1.General purpose screw rod length is divided into

three sections viz.
a)FEED b) TRANSITION and c) METERING

Feed section controls the quantity of granules

taken from Hopper every cycle.

Transition section converts efficiently the solid

granules into homogenously melted liquid.

Metering section controls the amount of material

that can be injected every shot.
 TYPES OF SCREW RODS

GENERAL PURPOSE SCREW

BEARING
PITCH FLIGHT WIDTH
METERING
DIA. DEPTH

KEY
FEED SECTION TRANSITION METERING
SECTION SECTION
OVERALL LENGTH
 INJ. MOULDING SCREW ROD
WITH BARREL ASSEMBLY
L METERIN
Feed MELTING G Section
Section (Transition) (25%L)
(25%L) Section(50%L)

Ds Ø S Hm
pitch
Hf
Hm = 0.22 minimum flight depth
DS = Nominal Screw Dia. ( Metering)
L = Overall length
Ø = 17.8 0 Helix angle (one turn
per screw dia.) δ = 0.005 flight clearance (Radial)
L / D = 16 : 1 to 24 : 1
Hf = Flight depth at Feed Hf / Hm = 2.0 to 2.2 Compression
ratio
TYPICAL METERING TYPE INJECTION MOLDING SCREW &
BARREL
 STANDARD NOZZLE

Thermo Cople
R

Dia.

Band Heater
 NEEDLE SHUT OFF NOZZLE

NEEDLE

PLATE
SPRING

USED FOR NYLON MATERIAL

TO AVOID DROOLING
NON RETURNVALVE
(RING TYPE)

NON RETURN VALVE

(RING TYPE)

BACK PRESSURE
NON RETURN
VALVE
(BALL TYPE)

ROTATIO
N STAGE

STOP PIN BALL

RECIPROCATION
STAGE
 MACHINE CLAMPING SYSTEMS

1. PURE HYDRAULIC CLAMPING SYSTEM

SHUT HT.

TIE BAR

DAY LIGHT
 DOUBLE TOGGLE CLAMPING

CLAMPED
POSITION

OPENED
POSITION
 SINGLE TOGGLE
CLAMPING

CLAMPED
POSITION

OPENED
POSITION
DOUBLE TOGGLE CLAMPING

CLAMPED
POSITION

OPENED
POSITION
 INJECTION MOULDING MACHINE
SPECIFICATION

1.SHOT CAPACITY : --
MAX.VOLUME OF PLASTIC, MACHINE
CAN
INJECT IN ONE
SPECIFIED SHOT, VOLUME V IN
AS SWEPT S,
C.C.
DEPENDS ON DENSITY AND MELT
TEMPERATURE OF THE PLASTIC.
 INJECTION MOULDING MACHINE
SPECIFICATION

• 2 PLASTICISING CAPACITY :
MAX. AMOUNT OF PLASTIC
(POLYSTYRENE), THE MACHINE
CAN BRING TO MOULDING
CONDITION IN A GIVEN TIME.

EXPRESSED AS Kg. / HOUR OF

POLYSTYRENE
 INJECTION MOULDING MACHINE
SPECIFICATION
3.CLAMPING TONNAGE : ---
Max. force machine can hydraulically
develop to clamp the two halves of mould against
the internal force due to injection of plastic,
expressed in tonnes.

4. INJECTION PRESSURE : ---

Max. pressure with which machine can inject
plastic through nozzle, specified in kg/cm2
DEPENDS ON THE L / D RATIO OF SCREW ROD
 SPECIFICATIONS OF SP80 WINDSOR M/C
INJECTION UNIT
Plasticising Capacity * 20 Kg/ Hr.

Maximum Shot Capacity

With Injection chamber Ф34 @ 1800 rpm 75 Cm3
With Injection chamber Ф42 @ 1200 rpm 110 Cm3
Screw Diameter 34 mm

Screw L/ d ratio 18 : 1

Injection stroke 80 mm Hopper capacity

30 Kg.

* Depends on material + Shot

SPECIFICATIONS OF SP80 WINDSOR M/C

LOCKING UNIT

Mould Clamping force 80 Tonnes

Size of Mould Plates ( h x v ) 500 x 500 mm
Distance between Tie bars 330 x 330 mm
(hxv)

Diameter of Tie bars 65 mm

Max. Mould opening 450 mm
Min. Mould Height 150 mm
Max. Daylight 600 mm
 WINDSOR MACHINE SPECIFICATIONS

MOD PLASTI MAX. MAX. MAX. DIST. MIN. MAX.

EL CISING SHOT CLAM. BETWEE SHUT DAY
CAPACITY CAPA FORCE INJ. N HT. LIGH
Kg/ hr cm3 Tonnes PRESS. TIE mm. Tmm.
Kg./cm2 BARS
(H X V)
mm
SP 15 44 30 1950 280X280 100 470
30
SP 20 75 80 1800 330X330 150 600
80
SP 50 190 130 1800 380X380 200 750
130
SP 90 320 180 1800 430X430 350 900
180
MACHINE SPECIFICATIONS
WINDSOR SP 80
Specifications – Fixed Platen SP80

0 .0
12 7
Ø H
Specifications – Moving Platen SP80