Setting Conditions, Producing, and Sampling

THEORETICAL BACKGROUND
The machine setting at the beginning of each injection molding process
procedure should be as close as possible to the most desirable processing
conditions. To start with a calculated guess of the possible process
condition
for a given material, we should also consider some important factors like:
injection molding machine size, material grades, mold design, etc. Process
conditions settings is influenced by these following parameters:
Injection molding machine
Injection mold
Material
Geometrical parameters of the part
Desired properties of the product
Data inputs are based on each stage of the machine work cycle as shown
below:
(

Produce Good Sample Product

Prepare all materials & equipment for running the machine, e.g.,
spanner,
screw driver, etc.
Use previous Mold Setup Chart & QA product approval, if any, to run
the machine.
Try to get best machine setting for the product & take 3-5 good samples
for QA visual & functional check/ test

Visual Appearance Checking

One product performance criterion is to check product condition visually.

Be sure that the product is

inspected at its front, side

&
back.
_ If defects are noticed,
please
do the necessary
adjustments
until you get a good
product

Functionality Checking (Product Specifications)

One product performance criterion is to measure good functioning of
product using some tools & methods

Ensure the scale is reset to

zero
_ Place one full shot on the
scale
_ Compare the weight to the
standard shot weight
_ Product Dimension
_ Warpage or flatness
_ Flash, shorts or sink
_

Machine Setting Conditions and Trial Run

1. Go to the molding machine area.

2. Familiarize yourself with the display of the control panel. Copy the
parameter setting currently in the display panel to your worksheet for the
following:
Mold Closing
Mold Opening
Barrel Temperature
Dosage
Holding
3. Observe and try to familiarize yourself with the entire injection molding
process cycle.
4. Run the machine based on the current settings and collect samples.
PART II Sampling
1. Take 5 samples of the product.
2. Check each of the products using Visual Checking and Functionality
Checking method.
3. Record the results using the forms found in your worksheet.

Machine Setting Conditions and Trial Run

SETTINGS FOR MOLD CLOSING
SETTINGS FOR MOLD OPENING
SETTINGS FOR BARREL TEMPERATURE
SETTINGS FOR DOSAGE
SETTINGS FOR INJECTION
SETTINGS FOR HOLDING

THEORETICAL BACKGROUND
INJECTION SPEED
Injection speed is the filling speed of the molten material in to the mold
with
the forward movement of a screw. Unit: cubic centimeter (cc)/sec.

INJECTION PRESSURE (Pmax)

Injection pressure is the term for the pressure applied to the molten
material
when a screw moves forward to inject it from the nozzle at high speed.
(unit:
Bar )

HOLDING PRESSURE
The pressure applied to the molten material after completion of Injection
Phase. It pushes further plastic melt into the cavity before gate freezing.
Unit: Bar.
SHOT CAPACITY
The maximum amount of plastic melt that can be injected from the barrel
of
an injection molding machine in a single shot. Unit: grams of polystyrene.
INJECTION RATE
The injection rate is expressed in terms of the volume of the molten
material
which can be injected in the unit time. Unit: cm3/s.
SCREW SPEED
The rotational speed of the screw during dosing. It is expressed in rpm
(rotations per minute).
BACK PRESSURE
The molten material is plasticated and kneaded by the rotation of a screw
and
transferred to the tip of the screw, where the molten material accumulates
and recoils, causing the backward motion of a screw. In order to suppress
this movement, slight pressure is applied to the injection cylinder side.
This

is called back pressure. Unit: bar.

CLAMPING FORCE
Clamping force (CF) is the force which keeps the mould closed during
injection.

Required Mould Clamping Force

Clamping force ( F ) in the diagram should be

bigger than the force ( f ) which makes the
mould open during injection