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Page 1: Injection moulding ppt

INJECTION MOULDING

ABHISHEK DOBHAL

Me 8th Semester

Roll No. :- FEJB13ME13

JBKP,FARIDABAD

Email :- [email protected]

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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.

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Injection Moulding Machine

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Main Components Of Injection

Moulding Machine

Clamping unit

Injection unit

Drive unit

Mould

Hydraulic system

Control system

Hopper

Heaters

Cooling channels

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Injection Moulding Process -

Resources

Material

Machine

Mould

Manpower

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Most Commonly Used Materials

PVC

ABS(Acrylonitrile Butadiene Styrene)

Polypropylene

Polystyrene

HDPE( High density poly ethylene)

LDPE(Low density poly ethylene)

Rubber Thermoplastic

Epoxy

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Injection Moulding Process

Material preparation

Feeding into hopper

Injection

Mould holding and cooling

Ejection

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Injection Moulding Machine

Process

Material granules are fed into hopper then

melted down in barrel which is surrounded by

the heaters.

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Injection Moulding Machine

Process

Melted material is injected into mould cavity

and mold is held under pressure until the

material cools and hardens.

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Injection Moulding Machine

Process

Once the material hardens, the mold is opened

and the component is ejected by runner plate.

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Injection Moulding Machine

Process

And the process can be repeated.

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Injection Moulding Machine

Process

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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.

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Mould Design

The mould consists of two primary

components, the injection mould (A plate) and

the ejector mould (B plate).

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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.

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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.

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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.

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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)

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Mould Cooling

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Moulding Defects

Blister

Flash

Burn marks

Warping

Weld lines

Colour streaks

Voids

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Manpower

To set up process

To monitor process and troubleshoot

To operate machine

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Injection Moulding Used For

Plastic Injection Moulding

Rubber injection Moulding

Metal Injection Moulding

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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.

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Plastic Injection Moulding

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Plastic Injection Moulding

Applications

Writing instruments components ( pen barrel,

cap, bush etc)

Computer Electronics

Automative Components

Aerospace Components

Electronic Components

Toys etc.

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Rubber Injection Moulding

Injection molds can make many rubber

components. It makes valve steam seals, oil

seals for engines, telecommunication items

etc.

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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.

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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.

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Disadvantages Of Injection

Moulding

High initial tooling and machinery cost.

Part design restrictions.

Small runs of parts can be costly

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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.

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