12 injection molding i
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Injection Molding
MFG 355
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1
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15 Ton Injection Molding Machine
Click on frame to start video
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77 Ton Injection Molding Machine
Click on frame to start video
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Click on frame to start video
150 Ton Injection Molding Machine
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Equipment
• Injection Unit
Screw drive arrangement
Feed hopper
Barrel heaters Nozzle
Tool
Screw Check valve Screw tip
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Equipment
• Injection Unit
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Injection
• Parts of the injection screw– Screw– Head and check ring
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Equipment
• Molds
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Molds
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Mold Materials
• Aluminum filled epoxy
• Aluminum
• Tool steel
• Stainless steel
• Hotwork die steel
• Beryllium-copper
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Mold Materials
• Choice based on critical properties– Machinability– Coefficient of thermal expansion– Specific heat capacity– Thermal conductivity– Density– Hardness (abrasion resistance)– Yield strength– Weldability
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Mold Parts
• Bases– Standard sizes– Hold mold inserts– Can decrease overall mold costs
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Mold Parts
• Guide pins– Align mold cavities
Guide pins
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Mold Parts
• Sprue Bushing– Hot sprue– Cold sprue
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Mold Parts
• Sprue Bushing– Hot sprue
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Mold Parts
• Sprue Bushing– Cold sprue– Sprue puller
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Mold Parts
• Sprue Bushing– Cold sprue– Sprue puller
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Mold Parts
• Runner
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Mold Parts
• Runner– Layout
Conventional Improved Balanced “H” Circular
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Mold Parts
• Runner– Layout
Conventional Improved Balanced “H” Circular
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Mold Parts
• Runner– Cold well
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Mold Parts
• Runner
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Mold Parts
• Gates
Submarine Gate
Pinpoint Gate
Fan or Edge Gate
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Mold Parts
• Gates
Sprue Gate
Tab Gate
Flash Gate
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Mold Parts
• Gates
Internal Ring GateExternal Ring Gate
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Mold Parts
• Gate
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Mold Parts
• Gate
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Mold Parts
• Gate
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Mold Parts
• Cavity– Where the part is made– Layout is critical to material flow
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Mold Parts
• Cavity– Knit/weld lines
This shows where the weld lines (shown in red) will most likely occur withthe part gated in the center (yellow cone).
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Mold Parts
• Cooling– Reduce cycle time– Control formation of crystalline areas – Freeze part
Mold cavity
Cooling lines
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Mold Parts
• Ejector system
Ejector Plate
Ejector pins
Return Springs
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Equipment
• Clamping Unit
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Equipment
• Clamping Unit– Toggle clamping– Hydraulic clamping– Hybrid hydraulic-toggle clamping
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Equipment
• Clamping Unit
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Equipment
• Clamping Unit– Toggle system
Click on frame to start video
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Plant Concepts
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Safety
• High clamping forces
• High pressure lines
• High voltage
• High temperatures
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Safety
• Position switches– Mechanical, hydraulic and electrical
• Shields
• Lock out/tag out
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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
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Sliding Mechanism
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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
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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)
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Special Injection Molding Processes
• Coinjection molding– Two separate screws– Two different material selections
• Color, strength, flexibility
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Special Injection Molding Processes
• Coinjection molding
1 2 3
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Special Injection Molding Processes
• Coinjection molding
Part 1
Part 2
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Special Injection Molding Processes
• Flow-controlled injection processes– Sometimes called Scorim
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Special Injection Molding Processes
• Flow-controlled injection processes– Sometimes called Scorim
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Special Injection Molding Processes
• Gas injection molding– Employs gas to create hollow parts
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Special Injection Molding Processes
• Injection-compression molding
Injection-CompressionMolding
Injection Molding
Parts were made with the same mold. The only difference between the two parts is the use of the compression cycle
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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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Thank You