A BRIEF STUDY ON PLASTIC INJECTION MOLDING PROCESS

ABSTRACT:

Injection molded components are consistently designed to minimize the design and manufacturing information content of the enterprise system. The resulting designs, however, are extremely complex and frequently exhibit coupling between multiple qualities attributes. Axiomatic design principles were applied to the injection molding process to add control parameters that enable the spatial and dynamic decoupling of multiple quality attributes in the molded part. There are three major benefits of the process redesign effort. irst, closed loop pressure control has enabled tight coupling between the mass and momentum equations. This tight coupling allows the direct input and controllability of the melt pressure. !econd, the use of multiple melt actuators provides for the decoupling of melt pressures between different locations in the mold cavity. !uch decoupling can then be used to maintain functional independence of multiple qualities attributes. Third, the heat equation has been decoupled from the mass and momentum equations. This allows the mold to be filled under isothermal conditions. "nce the cavities are completely full and attain the desired pac#ing pressure, then the cooling is allowed to progress.

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CHAPTER-01 1.0 INTRODUCTION:

Injection molding is the most commonly used manufacturing process for the fabrication of plastic parts. A wide variety of products are manufactured using injection molding, which vary greatly in their size, complexity, and application. The injection molding process requires the use of an injection molding machine, raw plastic material, and a mold. The plastic is melted in the injection molding machine and then injected into the mold, where it cools and solidifies into the final part. The steps in this process are described in greater detail in the next section.

ig. $.$ Injection molding overview Injection molding is used to produce thin%walled plastic parts for a wide variety of applications, one of the most common being plastic housings. &lastic housing is a thin%walled enclosure, often requiring many ribs and bosses on the interior. These housings are used in a variety of products including household appliances, consumer electronics, power tools, and as automotive dashboards. "ther common thin%walled products include different types of open containers, such as buc#ets. Injection molding is also used to produce several everyday items such as toothbrushes or small plastic toys. 'any medical devices, including valves and syringes, are manufactured using injection molding as well.

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1.1 INJECTION MOLDING-OVERVIEW:

Injection molding is a manufacturing process for producing parts from both thermoplastic and thermosetting plastic materials. 'aterial is fed into a heated barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration of the mold cavity. After a product is designed, usually by an industrial designer or an engineer, molds are made by a mold ma#er (or toolma#er) from metal, usually either steel or aluminum, and precision%machined to form the features of the desired part. Injection molding is widely used for manufacturing a variety of parts, from the smallest component to entire body panels of cars.

ig. $.* !chematic +iagram of &lastic Injection molding

1.2.

PROCESS CHARACTERISTICS: ,tilizes a ram or screw%type plunger to force molten plastic material into a mold cavity &roduces a solid or open%ended shape which has conformed to the contour of the mold ,ses thermoplastic or thermo set materials &roduces a parting line, sprue, and gate mar#s -jector pin mar#s are usually present

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1.3 HISTORY& DEVELOPMENT:

The first man%made plastic was invented in .ritain in $/0$ by Alexander &ar#es. 1e publicly demonstrated it at the $/2* International -xhibition in 3ondon4 calling the material he produced 5&ar#esine.5 +erived from cellulose, &ar#esine could be heated, molded, and retain its shape when cooled. It was, however, expensive to produce, prone to crac#ing, and highly flammable. In $/2/, American inventor 6ohn 7esley 1yatt developed a plastic material he named 8elluloid, improving on &ar#es9 invention so that it could be processed into finished form. Together with his brother Isaiah, 1yatt patented the first injection molding machine in $/:*. This machine was relatively simple compared to machines in use today. It wor#ed li#e a large hypodermic needle, using a plunger to inject plastic through a heated cylinder into a mold. The industry progressed slowly over the years, producing products such as collar stays, buttons, and hair combs. The industry expanded rapidly in the $;<=s because 7orld 7ar II created a huge demand for inexpensive, mass%produced products. In $;<2, American inventor 6ames 7atson 1endry built the first screw injection machine, which allowed much more precise control over the speed of injection and the quality of articles produced. This machine also allowed material to be mixed before injection, so that colored or recycled plastic could be added to virgin material and mixed thoroughly before being injected. Today screw injection machines account for the vast majority of all injection machines. In the $;:=s, 1endry went on to develop the first gas%assisted injection molding process, which permitted the production of complex, hollow articles that cooled quic#ly. This greatly improved design flexibility as well as the strength and finish of manufactured parts while reducing production time, cost, weight and waste. The plastic injection molding industry has evolved over the years from producing combs and buttons to producing a vast array of products for many industries including automotive, medical, aerospace, consumer products, toys, plumbing, pac#aging, and construction.

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CHAPTER-02 2.0 PROCESS CYCLE:

The process cycle for injection molding is very short, typically between * seconds and * minutes, and consists of the following four stages>

1. Clamping % &rior to the injection of the material into the mold, the two halves of the mold

must first be securely closed by the clamping unit. -ach half of the mold is attached to the injection molding machine and one half is allowed to slide. The hydraulically powered clamping unit pushes the mold halves together and exerts sufficient force to #eep the mold securely closed while the material is injected. The time required to close and clamp the mold is dependent upon the machine % larger machines (those with greater clamping forces) will require more time. This time can be estimated from the dry cycle time of the machine.

2. Injection % The raw plastic material, usually in the form of pellets, is fed into the injection

molding machine, and advanced towards the mold by the injection unit. +uring this process, the material is melted by heat and pressure. The molten plastic is then injected into the mold very quic#ly and the buildup of pressure pac#s and holds the material. The amount of material that is injected is referred to as the shot. The injection time is difficult to calculate accurately due to the complex and changing flow of the molten plastic into the mold. 1owever, the injection time can be estimated by the shot volume, injection pressure, and injection power.

3. Cooling % The molten plastic that is inside the mold begins to cool as soon as it ma#es

contact with the interior mold surfaces. As the plastic cools, it will solidify into the shape of the desired part. 1owever, during cooling some shrin#age of the part may occur. The pac#ing of material in the injection stage allows additional material to flow into the mold

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and reduce the amount of visible shrin#age. The mold can not be opened until the required cooling time has elapsed. The cooling time can be estimated from several thermodynamic properties of the plastic and the maximum wall thic#ness of the part.
4. Ejection % After sufficient time has passed, the cooled part may be ejected from the mold

by the ejection system, which is attached to the rear half of the mold. 7hen the mold is opened, a mechanism is used to push the part out of the mold. orce must be applied to eject the part because during cooling the part shrin#s and adheres to the mold. In order to facilitate the ejection of the part, a mold release agent can be sprayed onto the surfaces of the mold cavity prior to injection of the material. The time that is required to open the mold and eject the part can be estimated from the dry cycle time of the machine and should include time for the part to fall free of the mold. "nce the part is ejected, the mold can be clamped shut for the next shot to be injected.

ig.*.$ Injection molded part. After the injection molding cycle, some post processing is typically required. +uring cooling, the material in the channels of the mold will solidify attached to the part. This excess material, along with any flash that has occurred, must be trimmed from the part, typically by using cutters. or some types of material, such as thermoplastics, the scrap material that results from this trimming can be recycled by being placed into a plastic grinder, also called regrind machines or granulators, which regrinds the scrap material into pellets. +ue to some degradation of the

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material properties, the regrind must be mixed with raw material in the proper regrind ratio to be reused in the injection molding process.

2.1 MACHINERY & E UIPMENT:

Injection molding machines consist of a material hopper, an injection ram or screw%type plunger, and a heating unit. They are also #nown as presses, they hold the molds in which the components are shaped. &resses are rated by tonnage, which expresses the amount of clamping force that the machine can exert. This force #eeps the mold closed during the injection process. Tonnage can vary from less than 0 tons to 2=== tons, with the higher figures used in comparatively few manufacturing operations. The total clamp force needed is determined by the projected area of the part being molded. This projected area is multiplied by a clamp force of from * to / tons for each square inch of the projected areas. As a rule of thumb, < or 0 tons/in2 can be used for most products. If the plastic material is very stiff, it will require more injection pressure to fill the mold, thus more clamp tonnage to hold the mold closed. The required force can also be determined by the material used and the size of the part, larger parts require higher clamping force.

ig.*.* Injection 'olding 'achine. Injection molding machines have many components and are available in different configurations, including a horizontal configuration and a vertical configuration. 1owever, regardless of their design, all injection molding machines utilize a power source, injection unit, mold assembly, and clamping unit to perform the four stages of the process cycle.

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2.2 POWER RE UIREMENTS:

The power required for this process of injection molding depends on many things and varies between materials used. Manufacturing Processes Reference Guide states that the power requirements depend on 5a material9s specific gravity, melting point, thermal conductivity, part size, and molding rate.5 .elow is a table from page *<? of the same reference as previously mentioned which best illustrates the characteristics relevant to the power required for the most commonly used materials. 'aterial -poxy &henolic Bylon &olyethylene &olystyrene !pecific @ravity $.$* to $.*< $.?< to $.;0 $.=$ to $.$0 =.;$ to =.;20 $.=< to $.=: 'elting &oint (A ) *</ *</ ?/$ to 0=; *?= to *<? ??/

Table $ &ower Cequirements.

2.3 INJECTION UNIT:

The injection unit is responsible for both heating and injecting the material into the mold. The first part of this unit is the hopper, a large container into which the raw plastic is poured. The hopper has an open bottom, which allows the material to feed into the barrel. The barrel contains the mechanism for heating and injecting the material into the mold. This mechanism is usually a ram injector or a reciprocating screw. A ram injector forces the material forward through a heated section with a ram or plunger that is usually hydraulically powered. Today, the more common technique is the use of a reciprocating screw. A reciprocating screw moves the material forward by both rotating and sliding axially, being powered by either a hydraulic or electric motor. The material enters the grooves of the screw from the hopper and is advanced towards the mold as the screw rotates. 7hile it is advanced, the material is melted by pressure, friction, and additional heaters that surround the reciprocating screw. The molten plastic is then injected very

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quic#ly into the mold through the nozzle at the end of the barrel by the buildup of pressure and the forward action of the screw. This increasing pressure allows the material to be pac#ed and forcibly held in the mold. "nce the material has solidified inside the mold, the screw can retract and fill with more material for the next shot.

ig.*.? Injection molding machine % Injection unit.

2.! CLAMPING UNIT:

&rior to the injection of the molten plastic into the mold, the two halves of the mold must first be securely closed by the clamping unit. 7hen the mold is attached to the injection molding machine, each half is fixed to a large plate, called a platen. The front half of the mold, called the mold cavity, is mounted to a stationary platen and aligns with the nozzle of the injection unit. The rear half of the mold, called the mold core, is mounted to a movable platen, which slides along the tie bars. The hydraulically powered clamping motor actuates clamping bars that push the moveable platen towards the stationary platen and exert sufficient force to #eep the mold securely closed while the material is injected and subsequently cools. After the required cooling time, the mold is then opened by the clamping motor. An ejection system, which is attached to the rear half of the mold, is actuated by the ejector bar and pushes the solidified part out of the open cavity.

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ig.*.< Injection molding machine % 8lamping unit.

2." LUBRICATION AND COOLING:

"bviously, the mold must be cooled in order for the production to ta#e place. .ecause of the heat capacity, inexpensiveness, and availability of water, water is used as the primary cooling agent. To cool the mold, water can be channeled through the mold to account for quic# cooling times. ,sually a colder mold is more efficient because this allows for faster cycle times. 1owever, this is not always true because crystalline materials require the opposite> a warmer mold and lengthier cycle time.

2.# MACHINE SPECIFICATIONS:

Injection molding machines are typically characterized by the tonnage of the clamp force they provide. The required clamp force is determined by the projected area of the parts in the mold and the pressure with which the material is injected. Therefore, a larger part will require a larger clamping force. Also, certain materials that require high injection pressures may require higher tonnage machines. The size of the part must also comply with other machine specifications, such as shot capacity, clamp stro#e, minimum mold thic#ness, and platen size.

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Injection molded parts can vary greatly in size and therefore require these measures to cover a very large range. As a result, injection molding machines are designed to each accommodate a small range of this larger spectrum of values. !ample specifications are shown below for three different models (.abyplast, &owerline, and 'axima) of injection molding machine that are manufactured by 8incinnati 'ilacron. B$%&'($)* C($2' 3+.4- 5*+06 S7+* 4$'$4/*& 5+8.6 C($2' )*.+9- 5/0.6 M/0. 2+(: *7/490-)) 5/0.6 P($*-0 )/8- 5/0.6 2.2 P+,-.(/0??= M$1/2$ <<== <$? % $=0< $??./ ?$.0
122.0 106.3 x

=.$? % =.0= / % ?< <.?? $.$/ *?.2 :.;

*.;0 x *.;0 <=.00 x <=.00

Table * 'achine !pecifications.

ig.*.0 Injection molding machine.

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2.; TOOLING:
The injection molding process uses molds, typically made of steel or aluminum, as the custom tooling. The mold has many components, but can be split into two halves. -ach half is attached inside the injection molding machine and the rear half is allowed to slide so that the mold can be opened and closed along the mold9s parting line. The two main components of the mold are the mold core and the mold cavity. 7hen the mold is closed, the space between the mold core and the mold cavity forms the part cavity, that will be filled with molten plastic to create the desired part. 'ultiple%cavity molds are sometimes used, in which the two mold halves form several identical part cavities.

ig.*.2 'old overview.

2.< MOLD BASE:

The mold core and mold cavity are each mounted to the mold base, which is then fixed to the platens inside the injection molding machine. The front half of the mold base includes a support plate, to which the mold cavity is attached, the sprue bushing, into which the material will flow from the nozzle, and a locating ring, in order to align the mold base with the nozzle. The rear half of the mold base includes the ejection system, to which the mold core is attached,

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and a support plate. 7hen the clamping unit separates the mold halves, the ejector bar actuates the ejection system. The ejector bar pushes the ejector plate forward inside the ejector box, which in turn pushes the ejector pins into the molded part. The ejector pins push the solidified part out of the open mold cavity.

ig.*.: 'old base.

2.= MOLD CHANNELS:

In order for the molten plastic to flow into the mold cavities, several channels are integrated into the mold design. irst, the molten plastic enters the mold through the sprue. Additional channels, called runners, carry the molten plastic from the sprue to all of the cavities that must be filled. At the end of each runner, the molten plastic enters the cavity through a gate which directs the flow. The molten plastic that solidifies inside these runners is attached to the part and must be separated after the part has been ejected from the mold. 1owever, sometimes hot runner systems are used which independently heat the channels, allowing the contained material to be melted and detached from the part. Another type of channel that is built into the

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mold is cooling channels. These channels allow water to flow through the mold walls, adjacent to the cavity, and cool the molten plastic.

ig.*./ 'old channels.

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CHAPTER-03 3.0 MOLD DESIGN:

In addition to runners and gates, there are many other design issues that must be considered in the design of the molds. irstly, the mold must allow the molten plastic to flow easily into all of the cavities. -qually important is the removal of the solidified part from the mold, so a draft angle must be applied to the mold walls. The design of the mold must also accommodate any complex features on the part, such as undercuts or threads, which will require additional mold pieces. 'ost of these devices slide into the part cavity through the side of the mold, and are therefore #nown as slides, or side%actions. The most common type of side%action is a side%core which enables an external undercut to be molded. "ther devices enter through the end of the mold along the parting direction, such as internal core lifters, which can form an internal undercut. To mold threads into the part, an unscrewing device is needed, which can rotate out of the mold after the threads have been formed.

ig.?.$ 'old D 8losed.

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ig.?.* 'old % -xploded view.

ig.?.? !tandard two plates tooling D core and cavity are inserts in a mold base D 5 amily mold5 of 0 different parts.

The mold consists of two primary components, the injection mold (A plate) and the ejector mold (. plate). &lastic resin enters the mold through a sprue in the injection mold, the sprue bushing is to seal tightly against the nozzle of the injection barrel of the molding machine and to allow molten plastic to flow from the barrel into the mold, also #nown as cavity. The sprue bushing directs the molten plastic to the cavity images through channels that are machined into the faces of the A and . plates. These channels allow plastic to run along them, so they are

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referred to as runners. The molten plastic flows through the runner and enters one or more specialized gates and into the cavity geometry to form the desired part. The amount of resin required to fill the sprue, runner and cavities of a mold is a shot. Trapped air in the mold can escape through air vents that are ground into the parting line of the mold. If the trapped air is not allowed to escape, it is compressed by the pressure of the incoming material and is squeezed into the corners of the cavity, where it prevents filling and causes other defects as well. The air can become so compressed that it ignites and burns the surrounding plastic material. To allow for removal of the molded part from the mold, the mold features must not overhang one another in the direction that the mold opens, unless parts of the mold are designed to move from between such overhangs when the mold opens (utilizing components called 3ifters). !ides of the part that appear parallel with the direction of draw (The axis of the cored position (hole) or insert is parallel to the up and down movement of the mold as it opens and closes) are typically angled slightly with (draft) to ease release of the part from the mold. Insufficient draft can cause deformation or damage. The draft required for mold release is primarily dependent on the depth of the cavity> the deeper the cavity, the more draft necessary. !hrin#age must also be ta#en into account when determining the draft required. If the s#in is too thin, then the molded part will tend to shrin# onto the cores that form them while cooling, and cling to those cores or part may warp, twist, blister or crac# when the cavity is pulled away. The mold is usually designed so that the molded part reliably remains on the ejector (.) side of the mold when it opens, and draws the runner and the sprue out of the (A) side along with the parts. The part then falls freely when ejected from the (.) side. Tunnel gates, also #nown as submarine or mold gate, is located below the parting line or mold surface. The opening is machined into the surface of the mold on the parting line. The molded part is cut (by the mold) from the runner system on ejection from the mold. -jector pins, also #nown as #noc#out pin, is a circular pin placed in either half of the mold (usually the ejector half) which pushes the finished molded product, or runner system out of a mold. The standard method of cooling is passing a coolant (usually water) through a series of holes drilled through the mold plates and connected by hoses to form a continuous pathway. The

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coolant absorbs heat from the mold (which has absorbed heat from the hot plastic) and #eeps the mold at a proper temperature to solidify the plastic at the most efficient rate. To ease maintenance and venting, cavities and cores are divided into pieces, called inserts, and sub%assemblies, also called inserts, blocks, or chase blocks. .y substituting interchangeable inserts, one mold may ma#e several variations of the same part. 'ore complex parts are formed using more complex molds. These may have sections called slides that move into a cavity perpendicular to the draw direction, to form overhanging part features. 7hen the mold is opened, the slides are pulled away from the plastic part by using stationary Eangle pinsF on the stationary mold half. These pins enter a slot in the slides and cause the slides to move bac#ward when the moving half of the mold opens. The part is then ejected and the mold closes. The closing action of the mold causes the slides to move forward along the angle pins. !ome molds allow previously molded parts to be reinserted to allow a new plastic layer to form around the first part. This is often referred to as over molding. This system can allow for production of one%piece tires and wheels. *%shot or multi%shot molds are designed to 5over mold5 within a single molding cycle and must be processed on specialized injection molding machines with two or more injection units. This process is actually an injection molding process performed twice. In the first step, the base color material is molded into a basic shape. Then the second material is injection%molded into the remaining open spaces. That space is then filled during the second injection step with a material of a different color. A mold can produce several copies of the same parts in a single 5shot5. The number of 5impressions5 in the mold of that part is often incorrectly referred to as cavitations. A tool with one impression will often be called a single impression (cavity) mold. A mold with * or more cavities of the same parts will li#ely be referred to as multiple impression (cavity) mold. !ome extremely high production volume molds (li#e those for bottle caps) can have over $*/ cavities. In some cases multiple cavity tooling will mold a series of different parts in the same tool. !ome toolma#ers call these molds family molds as all the parts are related.

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3.1 DESIGN RULES

3.1.1 MA>IMUM WALL THIC?NESS:

+ecrease the maximum wall thic#ness of a part to shorten the cycle time (injection time

and cooling time specifically) and reduce the part volume INCORRECT CORRECT

&art with thic# walls

&art redesigned with thin walls

,niform wall thic#ness will ensure uniform cooling and reduce defects

INCORRECT

CORRECT

Bon%uniform wall thic#ness (t$ G t*)

,niform wall thic#ness (t$ H t*)

3.1.2 CORNERS:

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Cound corners to reduce stress concentrations and fracture Inner radius should be at least the thic#ness of the walls

INCORRECT

CORRECT

!harp corner 3.1.3 DRAFT:

Counded corner

Apply a draft angle of $A % *A to all walls parallel to the parting direction to facilitate

removing the part from the mold.

INCORRECT

CORRECT

Bo draft angle

+raft angle ()

3.1.! RIBS:

Add ribs for structural support, rather than increasing the wall thic#ness

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INCORRECT

CORRECT

Thic# wall of thic#ness t

Thin wall of thic#ness t with ribs

"rient ribs perpendicular to the axis about which bending may occur INCORRECT CORRECT

Incorrect rib direction under load

8orrect rib direction under load

Thic#ness of ribs should be 0=%2=I of the walls to which they are attached 1eight of ribs should be less than three times the wall thic#ness Cound the corners at the point of attachment Apply a draft angle of at least =.*0A

INCORRECT

CORRECT

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Thic# rib of thic#ness t

Thin rib of thic#ness t

8lose up of ribs 3.1." BOSSES:

7all thic#ness of bosses should be no more than 2=I of the main wall thic#ness Cadius at the base should be at least *0I of the main wall thic#ness !hould be supported by ribs that connect to adjacent walls or by gussets at the base.

INCORRECT

CORRECT

Isolated boss

Isolated boss with ribs (left) or gussets (right)

If a boss must be placed near a corner, it should be isolated using ribs.

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INCORRECT

CORRECT

.oss in corner 3.1.# UNDERCUTS:

Cibbed boss in corner

'inimize the number of external undercuts

o-xternal o!ome

undercuts require side%cores which add to the tooling cost

simple external undercuts can be molded by relocating the parting line

!imple external undercut

oCedesigning

'old cannot separate

Bew parting line allows undercut

a feature can remove an external undercut

&art with hinge

1inge requires side%core

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Cedesigned hinge

Bew hinge can be molded

'inimize the number of internal undercuts

oInternal

undercuts often require internal core lifters which add to the tooling cost an opening in the side of a part can allow a side%core to form an internal

o+esigning

undercut

Internal undercut accessible from the side

oCedesigning

a part can remove an internal undercut

&art with internal undercut

'old cannot separate

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&art redesigned with slot

'inimize

Bew part can be molded

number of side%action directions side%action directions will limit the number of possible cavities in the mold

oAdditional

3.1.; THREADS
If

possible, features with external threads should be oriented perpendicular to the parting features that are parallel to the parting direction will require an unscrewing device,

direction.
Threaded

which greatly adds to the tooling cost.

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CHAPTER-0! !.0 MATERIALS:

There are many types of materials that may be used in the injection molding process. 'ost polymers may be used, including all thermoplastics, some thermosets, and some elastomers. 7hen these materials are used in the injection molding process, their raw form is usually small pellets or a fine powder. Also, colorants may be added in the process to control the color of the final part. The selection of a material for creating injection molded parts is not solely based upon the desired characteristics of the final part. 7hile each material has different properties that will affect the strength and function of the final part, these properties also dictate the parameters used in processing these materials. -ach material requires a different set of processing parameters in the injection molding process, including the injection temperature, injection pressure, mold temperature, ejection temperature, and cycle time. A comparison of some commonly used materials is shown below ( ollow the lin#s to search the material library).

M$*-./$( 0$2Acetal

A%%.-@/$*/+0 &"'

T.$:- 0$2-)

D-)4./'*/+0

A''(/4$*/+0) .earings, cams, gears, handles, plumbing components,

8elcon, +elrin, !trong, rigid, 1ostaform, excellent fatigue 3ucel resistance, excellent creep

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resistance, rollers, chemical slide resistance, valves moisture resistance, naturally opaque white, lowJmedium cost Acrylic &''A

rotors, guides,

+ia#on, Cigid, brittle, +isplay stands, "roglas, 3ucite, scratch resistant, #nobs, lenses, &lexiglas transparent, light housings, optical clarity, panels, lowJmedium reflectors, signs, cost shelves, trays 8ycolac, 'agnum, Bovodur, Terluran !trong, flexible, low mold shrin#age (tight tolerances), chemical resistance, electroplating capability, naturally opaque, lowJmedium cost Automotive (consoles, panels, trim, vents), boxes, gauges, housings, inhalors, toys

Acrylonitrile .utadiene !tyrene

A.!

8ellulose Acetate

8A

+exel, 8ellidor, Tough, 1andles, !etilithe transparent, high eyeglass frames cost A#ulon, 1igh strength, .earings, ,ltramid, @rilon fatigue bushings, gears, resistance, rollers, wheels chemical resistance, low creep, low friction, almost opaqueJwhite, mediumJhigh

&olyamide 2 (Bylon) &A2

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cost &olyamide (Bylon) 2J2 &A2J2 Kopa, Cadilon Lytel, 1igh strength, 1andles, levers, fatigue small housings, resistance, zip ties chemical resistance, low creep, low friction, almost opaqueJwhite, mediumJhigh cost

&olyamide (Bylon)

$$M$* &A$$M$*

Cilsan, @rilamid 1igh strength, Air filters, fatigue eyeglass frames, resistance, safety mas#s chemical resistance, low creep, low friction, almost opaque to clear, very high cost

&olycarbonate

&8

8alibre, 3exan, Nery tough, 'a#rolon temperature resistance, dimensional stability, transparent, high cost

Automotive (panels, lenses, consoles), bottles, containers, housings, light covers, reflectors, safety helmets and shields Automotive (filters, handles, pumps), bearings, cams, electrical components (connectors,

&olyester Thermoplastic

% &.T, &-T

8elanex, Cigid, heat 8rastin, 3upox, resistance, Cynite, Nalox chemical resistance, mediumJhigh cost

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sensors), gears, housings, rollers, switches, valves &olyether !ulphone &-! Nictrex, ,del Tough, very Nalves high chemical resistance, clear, very high cost !trong, thermal stability, chemical resistance, abrasion resistance, low moisture absorption ,ltem 1eat resistance, flame resistance, transparent (amber color) Aircraft components, electrical connectors, pump impellers, seals

&olyetherether#etone &--K--K

&olyetherimide

&-I

-lectrical components (connectors, boards, switches), covers, sheilds, surgical tools Kitchenware, housings, covers, and containers

&olyethylene % 3ow 3+&+ensity

Al#athene, -scorene, Bovex

3ightweight, tough and flexible, excellent chemical resistance, natural waxy appearance, low cost Tough and stiff, excellent chemical resistance, natural waxy appearance, low cost

&olyethylene % 1igh 1+&+ensity

-raclene, 1ostalen, !tamylan

8hair seats, housings, covers, and containers

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&olyphenylene "xide

&&"

Boryl, Thermocomp, Namporan

Tough, heat resistance, flame resistance, dimensional stability, low water absorption, electroplating capability, high cost

Automotive (housings, panels), electrical components, housings, plumbing components

&olyphenylene !ulphide

&&!

Cyton, ortron

Nery high .earings, strength, heat covers, fuel resistance, system brown, very components, high cost guides, switches, and shields 3ightweight, heat resistance, high chemical resistance, scratch resistance, natural waxy appearance, tough and stiff, low cost. Automotive (bumpers, covers, trim), bottles, caps, crates, handles, housings

&olypropylene

&&

Bovolen, Appryl, -scorene

&olystyrene @eneral purpose

% @&&!

3acqrene, .rittle, 8osmetics !tyron, !olarene transparent, low pac#aging, pens cost &olystyrol, Kostil, &olystar Impact strength, -lectronic rigidity, housings, food toughness, containers, toys dimensional stability, naturally translucent, low cost Tough, flexible, -lectrical

&olystyrene % 1igh 1I&! impact

&olyvinyl 8hloride % &N8

7elvic, Narlan

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&lasticised

flame resistance, transparent or opaque, low cost &olycol, Trosiplast Tough, flexible, flame resistance, transparent or opaque, low cost

insulation, housewares, medical tubing, shoe soles, toys "utdoor applications (drains, fittings, gutters)

&olyvinyl 8hloride % ,&N8 Cigid

!tyrene Acrylonitrile !AB

3uran, Arpylene, !tarex

!tiff, brittle, 1ousewares, chemical #nobs, syringes resistance, heat resistance, hydrolytically stable, transparent, low cost Tough, flexible, .ushings, high cost electrical components, seals, washers

Thermoplastic -lastomerJCubber

T&-JC

1ytrel, !antoprene, !arlin#

Table ?> 'aterials.

!.1 MOLDING DEFECTS: Injection molding is a complex technology with possible production problems. They can either be caused by defects in the molds or more often by part processing (molding) M+(:/0A D-3-4*) .lister A(*-.0$*/@N$2.listering D-)4./'*/+0) C$B)-)

Caised or layered Tool or material is too hot, often caused zone on surface of by a lac# of cooling around the tool or a faulty heater brown Tool lac#s venting, injection speed is too

.urn mar#s

Air @as

the part .urnJ .lac# or

.urnJ burnt areas on the high

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+ieseling

part

located

at

furthest points from gate or where air is 8olor strea#s 8olour (,!) strea#s (,K) trapped 3ocalized change of 'asterbatch isn9t mixing properly, or the colorJcolour material has run out and it9s starting to come through as natural only. &revious colored material 5dragging5 in nozzle or +elamination Thin layers mica formed chec# valve. li#e 8ontamination of the material e.g. && in mixed with A.!, very dangerous if the part is being used for a safety critical application as the material has very little strength lash .urrs when delaminated as the materials cannot bond -xcess material in 'old is over pac#ed or parting line on thin layer exceeding the tool is damaged, too much injection normal geometry -mbedded contaminates -mbedded particulates oreign part speedJmaterial injected, clamping force too low. 8an also be caused by dirt and contaminants around tooling surfaces. particle &articles on the tool surface,

part wall

(burnt material or contaminated material or foreign debris other) embedded in in the barrel, or too much shear heat the part +irectionally patterns burning the material prior to injection 5off Injection speeds too slow (the plastic has injection speeds must be set as fast as

low mar#s

low lines

tone5 wavy lines or cooled down too much during injection, you can get away with at all times) +eformed part by &oor tool design, gate position or runner. turbulent flow of Injection speed set too high. Knit 3ines 7eld lines material !mall lines on the 8aused by the melt%front flowing around bac#side of core an object standing proud in a plastic part pins or windows in as well as at the end of fill where the parts that loo# li#e melt%front comes together again. 8an be

6etting

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just lines.

minimized or eliminated with a mold% flow study when the mold is in design phase. "nce the mold is made and the gate is placed one can only minimize this flaw by changing the melt and the mold

&olymer degradation !in# mar#s Osin#sP

temperature. polymer brea#down -xcess water in the granules, excessive from hydrolysis, temperatures in barrel 1olding timeJpressure too low, cooling (In time too short, with sprueless hot runners this can also be caused by the gate temperature being set too high. -xcessive material or thic# wall thic#ness. 3ac# of material, injection speed or pressure too low, mold too cold pattern 'oisture in the material, usually when Trapping of gas in 5rib5 areas due to excessive injection velocity in these oxidation etc. 3ocalized depression thic#er zones)

!hort shot !play mar#s

Bon%fill

J &artial part

!hort mold !plash mar# J 8ircular !ilver strea#s by hot gas

around gate caused hygroscopic resins are dried improperly.

!tringiness

!tringing

areas. 'aterial too hot. !tring li#e remain Bozzle temperature too high. @ate hasn9t from previous shot frozen off transfer in new shot -mpty space within 3ac# part (Air poc#et)

Noids

of

holding

pressure

(holding

pressure is used to pac# out the part during the holding time). illing to fast, not allowing the edges of the part to set up. Also mold may be out of registration (when the two halves don9t center properly and part walls are not the same thic#ness). line 'oldJmaterial temperatures set too low

7eld line

Knit

line

J +iscolored two fronts meet

'eld line J where Transfer line

flow (the material is cold when they meet, so they don9t bond). &oint between injection

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and transfer (to pac#ing and holding) too 7arping Twisting +istorted part early. 8ooling is too short, material is too hot, lac# of cooling around the tool, incorrect water temperatures (the parts bow inwards towards the hot side of the tool) ,neven shrin#ing between areas of the part Table <> 'olding +efects.

!.2 TOLERANCES AND SURFACES:

'olding tolerance is a specified allowance on the deviation in parameters such as dimensions, weights, shapes, or angles, etc. To maximize control in setting tolerances there is usually a minimum and maximum limit on thic#ness, based on the process used.O?2P Injection molding typically is capable of tolerances equivalent to an IT @rade of about ;D$<. The possible tolerance of a thermoplastic or a thermoset is Q=.==/ to Q=.==* inches. !urface finishes of two to four micro inches or better are can be obtained. Cough or pebbled surfaces are also possible.

M+(:/0A T&'Thermoplastic Thermoset

T&'/4$( P+))/%(Q=.==/ Q=.==/ Q=.==* Q=.==*

Table 0> Tolerances.

CHAPTER-0"

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".0 COSTING & ESTIMATION:

".1 MATERIAL COST> The material cost is determined by the weight of material that is required and the unit price of that material. The weight of material is clearly a result of the part volume and material density4 however, the part9s maximum wall thic#ness can also play a role. The weight of material that is required includes the material that fills the channels of the mold. The size of those channels, and hence the amount of material, is largely determined by the thic#ness of the part.

".2 PRODUCTION COST: The production cost is primarily calculated from the hourly rate and the cycle time. The hourly rate is proportional to the size of the injection molding machine being used, so it is important to understand how the part design affects machine selection. Injection molding machines are typically referred to by the tonnage of the clamping force they provide. The required clamping force is determined by the projected area of the part and the pressure with which the material is injected. Therefore, a larger part will require a larger clamping force, and hence a more expensive machine. Also, certain materials that require high injection pressures may require higher tonnage machines. The size of the part must also comply with other machine specifications, such as clamp stro#e, platen size, and shot capacity.

The cycle time can be bro#en down into the injection time, cooling time, and resetting time. .y reducing any of these times, the production cost will be lowered. The injection time can be decreased by reducing the maximum wall thic#ness of the part and the part volume. The cooling time is also decreased for lower wall thic#nesses, as they require less time to cool all the way through. !everal thermodynamic properties of the material also affect the cooling time. 3astly, the resetting time depends on the machine size and the part size. A larger part will require larger motions from the machine to open, close, and eject the part, and a larger machine requires more time to perform these operations.

".3 TOOLING COST:

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The tooling cost has two main components % the mold base and the machining of the cavities. The cost of the mold base is primarily controlled by the size of the part9s envelope. A larger part requires a larger, more expensive, mold base. The cost of machining the cavities is affected by nearly every aspect of the part9s geometry. The primary cost driver is the size of the cavity that must be machined, measured by the projected area of the cavity (equal to the projected area of the part and projected holes) and its depth. Any other elements that will require additional machining time will add to the cost, including the feature count, parting surface, side%cores, lifters, unscrewing devices, tolerance, and surface roughness.

The quantity of parts also impacts the tooling cost. A larger production quantity will require a higher class mold that will not wear as quic#ly. The stronger mold material results in a higher mold base cost and more machining time.

"ne final consideration is the number of side%action directions, which can indirectly affect the cost. The additional cost for side%cores is determined by how many are used. 1owever, the number of directions can restrict the number of cavities that can be included in the mold. or example, the mold for a part which requires ? side%action directions can only contain * cavities. There is no direct cost added, but it is possible that the use of more cavities could provide further savings.

81A&T-C%=2

#.0. APPLICATIONS:

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Injection molding is used to create many things such as wire spools, pac#aging, bottle caps, automotive dashboards, poc#et combs, and most other plastic products available today. Injection molding is the most common method of part manufacturing. It is ideal for producing high volumes of the same object. !ome advantages of injection molding are high production rates, repeatable high tolerances, and the ability to use a wide range of materials, low labor cost, minimal scrap losses, and little need to finish parts after molding. !ome disadvantages of this process are expensive equipment investment, potentially high running costs, and the need to design moldable parts. 'ost polymers may be used, including all thermoplastics, some thermo sets, and some elastomers. In $;;0 there were approximately $/,=== different materials available for injection molding and that number was increasing at an average rate of :0= per year. The available materials are alloys or blends of previously developed materials meaning that product designers can choose from a vast selection of materials, one that has exactly the right properties. 'aterials are chosen based on the strength and function required for the final part but also each material has different parameters for molding that must be ta#en into account.O/P 8ommon polymers li#e -poxy and phenolic are examples of thermosetting plastics while nylon, polyethylene, and polystyrene are thermoplastic.

#.1 GENERAL PLASTIC INJECTION MOLDING APPLICATIONS:

Aerospace components Automotive components Avionics components 8able assemblies 8omputer electronics -lectronics components -ncapsulations -ngineering prototypes

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 @eophysics Instrumentation 'ar#eting samples 'aterial quality testing 'edical R dental products 'edical laboratories 'odel shops, toys, hobby Bew product design R development CR+ labs Test specimens

#.2 THE FUTURE OF INJECTION MOLDING:

!ome of the new tendencies and technology in injection molding are the electric injection machines and the gas assisted injection molding. The electric machines have several advantages over the old design of the conventional injection machine. It runs silent, its operating cost is less, and they are more accurate and stable.

ig.2.$ An all%electrical Injection 'achine.

CONCLUSION:

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Injection molding is one of the most important processes for plastics and it has a very wide list of #inds of products it can produce, which ma#es it very versatile.

REFERENCES:

31

$. '-B@-! J 'I81A-3I J '"1C-B4 1ow to 'a#e Injection 'olds4 Third -dition4 1anser4 8incinnati, ,!A4 *==$
2. CI81AC+!"B R 3"K-B!@AC+4 Industrial &lastics, Theory and Applications4

Third -dition4 +elmar &ublishers Inc.4 Albany, BS, ,!A4 $;;: ?. .-CBI- A. "3'!T-+ R 'ACTIB -. +ANI!4 &ractical Injection 'olding4 !&-4 'arcel+e##er4 Bew Sor#, ,!A4 *==$ <. 'AB, A8T,CIB@ T-81B"3"@S4 &rof. &.B. Cao, ,nivarsiti 'ara, !hah Alam, 'alasia. URL: http>JJwww.energyusernews.comJ8+AJArticleInformationJfeaturesJ.B&TT eaturesTTIte mJ=,*0/<,222==,==.html www.plasticsone.com www.badgercolor.com http>JJwww.mhi.co.jp www.gasassist.com www.plasticnews.com www.engelmachinery.com www.modernplastics.com www.plasticstechnology.com

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