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  • Process Parameters in Injection Moulding: by Devang Naik

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    Amit Prasad
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    1. Ideal process parameters for injection molding include proper injection pressure, screw speed, barrel temperature, melt temperature, cavity pressure, cooling time, and screw surface speed. 2. Key factors that affect the melt temperature include the barrel temperature setting, screw speed, back pressure, residence time in the barrel, and cycle time. 3. Cavity pressure is the most important pressure parameter and the injection pressure must be set based on the required cavity pressure for the part.

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    1. Ideal process parameters for injection molding include proper injection pressure, screw speed, barrel temperature, melt temperature, cavity pressure, cooling time, and screw surface speed. 2. Key factors that affect the melt temperature include the barrel temperature setting, screw speed, back pressure, residence time in the barrel, and cycle time. 3. Cavity pressure is the most important pressure parameter and the injection pressure must be set based on the required cavity pressure for the part.

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    65 views24 pages

    Process Parameters in Injection Moulding: by Devang Naik

    Uploaded by

    Amit Prasad
    1. Ideal process parameters for injection molding include proper injection pressure, screw speed, barrel temperature, melt temperature, cavity pressure, cooling time, and screw surface speed. 2. Key factors that affect the melt temperature include the barrel temperature setting, screw speed, back pressure, residence time in the barrel, and cycle time. 3. Cavity pressure is the most important pressure parameter and the injection pressure must be set based on the required cavity pressure for the part.

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    of 24

    IDEAL

    PROCESS PARAMETERS
    In injection Moulding

    BY DEVANG NAIK
    Injection Molding: -
    It is a cyclic
    process, where a heat soften
    material injected in to close mold,
    which gives the desired shape.
    Plastics :-
    It is an organic
    substance which can be
    converted in to any shape by
    application of heat and pressure.
    Terms used in injection molding
    machine.
    Injection Pressure.
    It is a
    maximum pressure excreting on
    plastic melt at screw tip.
    measuring unit kg/cm2 or bar.
    Speed:-
    Rate of displacement of
    screw per second. Measuring unit
    gm/sec, cc/sec, mm/sec.
    Back Pressure :-
    It is a pressure /force
    which force the screw backward direction
    even as it is conveying polymer forward.
    This back pressure
    controlled by throttling the oil behind
    injection cylinder.
    It is not more than 14
    bar.
    Screw:-
    It is a mechanical device
    (helical flighted shaft) which convey
    the heat soften material.
    Nozzle:-
    It is a tube like
    mechanical device which provide
    mechanical & thermal connection
    from not cylinder (barrel) to
    much colder mold.
    Types of nozzle:-
    1. open channel.
    2. Check valve type.
    3. Shut off valve nozzle.
    Size of orifice with respect to
    sprue bush

    M/C
    Up to 180T 4 mm
    3 mm
    350 T 5 mm
    4 mm
    650T 6 mm
    5 mm
    850T 10mm
    8 mm
    How to start machine ?
    Check points
    Sprue bush dia.
    Nozzle orifice.
    Cavity pressure.
    Cooling line looping.
    Water pressure & Water temp. Delta
    T : 2 to 5 degree
    Temp. profile
    Screw surface speed (SSS) .
    Speed profile.
    Hold on position.
    Melt temp.
    Process Setting.

    Mould
    Machine
    Mold temp. 1. Injection
    pressure
    Cavity pressure. 2. System Pressure
    Sprue bush dia 3. Barrel temp.
    System Flow 4. Hot runner
    Air pin/Ejector pin
    Water cooling
    Gate mechanism
    Raw material
    Materials Drying
    Hygroscopic Non Hygroscopic
    Polymers with high Very little or no
    affinity
    Affinity for moisture. For moisture.
    Nylon, ABS Polystyrene.
    Polycarbonate Polyethylene.
    Polyester PVC,PP.
    Polyurethane Acetal.
    L/D and
    Compression
    ratio.
    Non return valve

    1 Set up m/c to run


    standard parts.
    2 Turn of pack and hold
    time pressure.
    3 Weigh the parts and
    record weight.
    Mold Venting
    Why Vent?
    Evacuation of latent air
    that is in the closed mold.
    Allow the evacuation of
    gases produced by low
    molecular weight polymers
    and additives.
    Problem associated with
    poor venting.
    Burn marks.
    Poor mold filling.
    Weak wield lines.
    Internal bubble and non-fill area.
    Sink mark.
    Longer cycle time.
    Stress cracking.
    Temperature
    What is important barrel temp or
    melt temp?
    Optimum MELT TEMP is the key to
    successful molding.
    Factors affecting melt temp.
    Barrel temp setting.
    Screw speed.
    Screw back pressure.
    Residence time.
    Key point
    In order to reproduce
    the same process on
    multiple machines .
    Melt temperature is one
    variable that must be
    controlled and
    duplicated.
    Flow Rate
    Plastic materials viscosity decreases
    as shesr rate increases.
    WHY IS THIS IMPORTANT?
    Screw speed----Lower viscosity at
    higher RPM.
    Inj speed---Flow rate easier with
    higher inj speed.
    Flow Rate=Time in sec,measured
    from start of injection to transfer to
    pack/hold.
    How does velocity
    profiling help?
    Allows the mold to be filled as
    fast as possible.
    Reduces burning, splay and
    other aesthetic issues.
    Helps with weld line.
    Surface finish.
    Best speed for each area of the
    segment can be selected.
    Pressure
    What is pressure?
    Pressure is Resistance to FLOW.
    Injection pressyre-----1st Stage
    pressure.
    Packing pressure-------2nd Stage
    pressure.
    Back pressure.
    Cavity pressure--------Most Important
    Cavity pressure
    Injection pressure must always
    be set per requirement of cavity
    pressure. This can be done by
    gradually increasing the set inj.
    Prs. On monitor and observe the
    increment in pr.gauge.The set
    point after which the gauge pr.
    Does not change is your require
    injection pressure.
    Hydraulic Pr.Vs Plastic
    Pr.
    Hydraulic pressure: Measure of
    how much force a machine can
    generate against the ram.
    Plastic (Melt) pressure: Pressure
    generated in the nozzle of a
    molding machine usually derived
    from the intensification ratio of the
    machine.
    Cavity Pressure: Actual pressure in
    the cavity MOLD).
    Time
    Injection
    Pack and Hold-----Gate freeze study.
    Cooling.
    Mold open.
    Mold close.
    Cooling Time= 150 * Thickest wall of
    the part.
    = 150*.100=15sec.
    Screw surface speed
    Screw surface
    speed=0.052 * Screw
    Dia*Screw RPM.For HDPE
    and PP 750.SSS is low
    than definable require
    higher barrel temp.
    Melt Temperature
    There are few processing parameters
    in the injection process that have
    significant influence on the melt
    temp., the temp of the melt as it
    leaves the injection unit.
    The temp setting of barrel heaters.
    RPM of screw.
    Back pressure applied.
    Residence time.
    Cycle time.
    EDUCATION
    Is the key to
    successful
    implementation
    of injection
    molding.
    Thank you.

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