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Introduction
Injection molding is one of the leading plastic processes,
both in money and quantity of parts produced. The
process involves heating plastic pellets through friction
and an outside heat source. The hot material is delivered
to the mold through the use of a large screw. When the
mold is closed, the screw extends forward laterally and
drives the hot plastic into the mold, where it is cooled
until fully solidified. More material is driven into the
mold as the part cools to maintain correct dimensions due
to parts shrinking during the cooling process. Material is
driven into the mold up until the time the gate freezes. See
figure A.
Figure 1. Thickness & Weight vs. Switch Over
Conclusion
For actual manufacturing profit and product quality are
main factors. If the temperature is too hot or cold, we will
either see a short shot or thermal degradation. If the
pressure is too high, flashing will occur, and if it is too
low, we will have too much shrinkage and the parts will
not be within specified tolerances. The product must be
within certain process parameters to ensure product
quality. The most profitable process is performed at the
lowest acceptable temperature and from our data, the
highest quality part is made using a higher pressure.
References:
Osswald, Tim A. Polymer Processing Fundamentals, Hanser Publisher, Munich, 1998.