Injection moulding ppt

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INJECTION MOULDING ABHISHEK DOBHAL Me 8 th Semester Roll No. :- FEJB13ME13 JBKP,FARIDABAD Email :- [email protected]
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Transcript of Injection moulding ppt

  1. 1. INJECTION MOULDING ABHISHEK DOBHAL Me 8th Semester Roll No. :- FEJB13ME13 JBKP,FARIDABAD Email :- [email protected]
  2. 2. What Is Injection Moulding? Injection moulding is a manufacturing process for producing parts by injecting material into a mould. Injection moulding can be performed with a host of materials mainly including metals, glasses, elastomers, confections, and most commonly thermoplastic and thermosetting polymers. Material for the part is fed into a heated barrel, mixed, and forced into a mould cavity, where it cools and hardens to the configuration of the cavity.
  3. 3. Injection Moulding Machine
  4. 4. Main Components Of Injection Moulding Machine Clamping unit Injection unit Drive unit Mould Hydraulic system Control system Hopper Heaters Cooling channels
  5. 5. Injection Moulding Process - Resources Material Machine Mould Manpower
  6. 6. Most Commonly Used Materials PVC ABS(Acrylonitrile Butadiene Styrene) Polypropylene Polystyrene HDPE( High density poly ethylene) LDPE(Low density poly ethylene) Rubber Thermoplastic Epoxy
  7. 7. Injection Moulding Process Material preparation Feeding into hopper Injection Mould holding and cooling Ejection
  8. 8. Injection Moulding Machine Process Material granules are fed into hopper then melted down in barrel which is surrounded by the heaters.
  9. 9. Injection Moulding Machine Process Melted material is injected into mould cavity and mold is held under pressure until the material cools and hardens.
  10. 10. Injection Moulding Machine Process Once the material hardens, the mold is opened and the component is ejected by runner plate.
  11. 11. Injection Moulding Machine Process And the process can be repeated.
  12. 12. Injection Moulding Machine Process
  13. 13. Mould Moulds are the common terms used to describe the tool used to produce components in moulding. Moulds are constructed from hardened steel, pre- hardened steel, aluminium, beryllium-copper alloy. In general, steel moulds cost more to construct, but their longer lifespan will offset the higher initial cost over a higher number of parts made before wearing out. The moulds can be manufactured either by CNC machining or by using electrical discharge machining processes.
  14. 14. Mould Design The mould consists of two primary components, the injection mould (A plate) and the ejector mould (B plate).
  15. 15. Mould Design Consideration Shrinkage allowance: Depends on shrinkage property of material core and cavity size. Cooling circuit: In order to reduce the cycle time, water circulates through holes drilled in both the core and cavity plates. Ejection gap: The gap between the ejector plate face and core back plate face should hold dimension within the core. It must allow component to be fully removed from the mold.
  16. 16. Mould Design Consideration Mold polishing : The core, cavity, runner and sprue should have good surface finish and should be polished along material flow direction. Mold filling : The gate should be placed such that the component is filled from the thicker section to thinner section. Draft: Required in both the core and cavity for easy ejection of the finished component.
  17. 17. Mould Storage Manufacturers go to great lengths to protect custom moulds due to their high average costs. The perfect temperature and humidity level is maintained to ensure the longest possible lifespan for each custom mould. Custom moulds such as those used for rubber injection moulding are stored in temperature and humidity controlled enviornments to prevent warping.
  18. 18. Mould Cooling Constant mold temperature for uniform quality Reduced cycle time for productivity Improved surface finish without defects Long mold life Avoiding warpage by uniform mold surface temperature (warpage caused by nonuniform cooling)
  19. 19. Mould Cooling
  20. 20. Moulding Defects Blister Flash Burn marks Warping Weld lines Colour streaks Voids
  21. 21. Manpower To set up process To monitor process and troubleshoot To operate machine
  22. 22. Injection Moulding Used For Plastic Injection Moulding Rubber injection Moulding Metal Injection Moulding
  23. 23. Plastic Injection Moulding It is a manufacturing process for producing components by injecting polymer material into a mould. Thermoplastic and Thermosetting plastic material are used. Thermoplastic materials are reusable.
  24. 24. Plastic Injection Moulding
  25. 25. Plastic Injection Moulding Applications Writing instruments components ( pen barrel, cap, bush etc) Computer Electronics Automative Components Aerospace Components Electronic Components Toys etc.
  26. 26. Rubber Injection Moulding Injection molds can make many rubber components. It makes valve steam seals, oil seals for engines, telecommunication items etc.
  27. 27. Metal injection moulding Injection molds can stamp out small to large items. It can stamp out automobile parts from spark plugs and floor pans to ball bearings. It also can stamp out items like TV hangers and knitting needles.
  28. 28. Advantages Of Injection Moulding Fast production. Low labour costs. Design flexibility. High-output production. Multiple materials can be used at the same time. Can be used to produce very small parts. Leaves little post-production scrap. Ability to include inserts. Good colour control. Good product consistency. Reduced requirements for finishing. Good dimensional control.
  29. 29. Disadvantages Of Injection Moulding High initial tooling and machinery cost. Part design restrictions. Small runs of parts can be costly
  30. 30. Applications Of Injection Moulding Injection moulding is used to create many things such as Cups, Containers, tools, Mechanical parts (Including gears). Injection moulding is the most common modern method of manufacturing parts. It is ideal for producing high volumes of the same object.
  31. 31. THANK YOU