Injection Molding MFG 355. 15 Ton Injection Molding Machine Click on frame to start video.
Transcript of Injection Molding MFG 355. 15 Ton Injection Molding Machine Click on frame to start video.
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Injection Molding
MFG 355
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15 Ton Injection Molding Machine
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77 Ton Injection Molding Machine
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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