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INJECTION MOULDING
Pocketbook
INJECTION MOULDING – Pocketbook
Altdorfer Str. 15
D-90571 Schwaig
Tel. +49 911/50 61-0
Fax +49 911/50 61-265
E-Mail: info-dpde@dpg.com
www.dpg.com
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Operating instructions
for NC4 control system
No other publication enjoys such a long tradition as a key When the Emergency Stop button is pressed the machine shuts
source of information as the “Injection Moulding Pocketbook”. down immediately. This includes
The many requests we have for copies of the booklet from the
pump motor – Off
injection moulding industry shows that our booklet is providing
a source of valuable information for moulders in overcoming cylinder heating – Off
problems arising in day-to-day operation.
mould heating – Off
The emphasis in this publication is not so much on technological
developments. It is rather the total concept of optimisation of Each of the following functions is switched on by pressing
the injection moulding machine, which includes the evaluation the green keys:
and selection of process parameters and the elimination of sur- pump
face defects that forms the central focus of this handbook.
cylinder heating
We should like to thank Martin Bichler, Guenter Seibold, Ansgar
Jaeger, Reinhard Gottschild, and Dr. Sabine Pahlke for their active mould heating
support.
When the corresponding red buttons are pressed these functions
are switched off.
Start button:
When the Start button is pressed in “semi-automatic“ and
“automatic“ modes, this initiates the automatic machine cycle.
In “semi automatic” mode the machine runs for only one
cycle. The Start button must be pressed to initiate each cycle.
In “automatic” mode the machine runs continuously.
Attention!
Start-up can only occur when the following conditions have
been met:
mould fully open
9
hydr. ejector back
cores moved out
Injection Moulding Pocketbook
Special publication from the Demag Plastics Group metering stop reached
Demag Ergotech GmbH
5th edition 08/2004, circulation 2,000
Copyright © 1996
Id. No.: WA gb 08/04 01 2T PP
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Over the past few decades the injection moulding process, and Basics
1 all its associated processes, has advanced further than almost It is important to maintain constant environmental conditions. 1
any other manufacturing process and grown to incorporate the Avoid doors being left open, running ventilators or heating units
production of many more products. The advantages are clear: in the immediate vicinity of the machine, if possible.
favourable material All equipment in the production plant must be regularly maintai-
ned. This includes the machine, mould and all peripheral units.
lower energy consumption for moulding due to lower
processing temperatures For safety reasons, the following must be observed during
production:
direct route from raw material to end product
(single-stage operation, no secondary finishing) Work to be carried out on the open mould only when
the pump is switched off
There are a whole host of influencing factors which combine to
create cost-effective, high quality injection moulding production Gloves and safety goggles to be worn and a copper rod
which, when correctly selected and managed, all play a part in to be used when working on the hot runner
producing a first-class injection-moulded product.The factors All safety mechanisms on the machine to be checked
which influence injection moulding production are classified as at regular intervals
follows:
Setting up a machine should not just be a matter of following
1. Man tables and formulae, but each value should be considered logi-
Motivation, qualification, flexibility, experience cally and analysed.
2. The injection moulding machine Attention should be drawn to the basic difference between toggle-
Ergonomics, efficiency, accuracy, reliability, correct design, type and hydraulic direct lock injection moulding machines. In
monitoring options comparing the mould-opening strokes specified for equal-size
3. The mould toggle and hydraulic machines, it is invariably found that larger
Plastics-oriented component and gate design, thermal design, opening strokes are claimed for the hydraulic clamp. The point
rigidity, maintenance to be noted, however, is that this does not involve an increase in
the daylight between the platens, in other words, the maximum
4. The material opening stroke can be utilised only with the minimum mould
Correct choice, purity, pre-drying, only minor batch variations height. The useful opening stroke is smaller the greater the mould
5. Peripherals height – this also goes for a two-platen machine. But, actually, it
Temperature control units, hot runner control is the larger moulds that do need long opening strokes. Being a
“quasi-closed system”, the toggle clamp – with its larger daylight
6. Environment – provides the same opening stroke for every possible mould
Safety, environmental influences height. There are adequately long opening strokes available here
which, except for rare cases, accommodate all applications.
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Mould
Where is the mould stored?
Does the mould need any repairs or have these been dealt
with?
How can it be transported and lifted into the machine?
Which clamping devices are required to fix the mould
in the machine?
Comparison of mould opening strokes in toggle Have the following parameters been checked to establish
and hydraulic systems the suitability of the mould on the proposed machine?
1. mould fixing dimensions
2. centring device
3. shot weight
We hope you enjoy reading this booklet and wish
you every success in the operation of your injection 4. ejector rods to fit ejector coupling (connecting dimensions)
moulding machine.
5. nozzle radius and bore and corresponding sprue bush size
6. additional equipment (core pullers etc.)
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Are peripheral units required such as temperature control 2.2 Preparing the machine
units, cooling units, hot runner controllers, belt conveyors?
2.2.1 Setting up the clamping unit for Demag
Are the fittings on the cooling water connections on the toggle machines 125 to 2000
machine and the mould compatible?
2 Attention! All mould adjustments to be made in 2
Has the cooling water region of the mould been leak-tested? set-up mode only
(For pressure and speeds see screen page 10 on NC4 operator
Machine
panel)
Is the proposed machine available for the production target
1. Extend the toggle. The ACTUAL value for mould stroke
date?
must be “0”.
Is the maximum clamping force sufficient?
2. Using the “Mould height” function keys, set platen distance
Has the necessary maintenance work been carried out? slightly greater than the mould height.
Has the machine been running problem-free lately? 3. Move the moving platen to maximum opening distance.
Is the appropriate screw cylinder available (cylinder head 4. Attach the mould securely to the lifting gear. The mould
volume, injection pressure)? must hang straight. Make sure that the mould halves cannot
slide apart.
Material
5. Protect the machine tie bars from damage during mould
Is there sufficient material for the job? installation.
Where is the material stored? 6. Position the mould on the fixed platen, centre and attach.
Does the material need to be pre-dried? If the mould is to be fixed using mould clamps, ensure a
proper fit.
Is there a supply of masterbatch, if required?
7. Extend the toggle. Mould stroke on the OPERATOR PANEL
must indicate “0”. Take care that the ejector rod moves into
the ejector coupling without being forced. Now by using
mould height adjustment move the moving mould half until
platen contact is made. Clamping force is now “0” kN.
8. Tighten the mould half on the moving platen. Remove safety
strap from mould, if used. Connect the ejector rod with the
ejector coupling using the slide mechanism.
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9. Open the mould far enough to allow the moulding to fall 2.2.2 Setting up hydraulic clamps on Demag machines
out safely. An accurate setting of the opening stroke is 25 to 120
made later when optimising the injection moulding process.
Attention! All mould adjustments to be made
10. Enter clamping force. When the Start key is pressed the in set-up mode only
2 clamp unit moves automatically to approx. 75% of the set 2
value of the clamp force. In automatic mode, when clamp 1. Move clamp unit to maximum opening distance.
force control is fitted, clamp force is regulated in stages to 2. Attach the mould securely to the lifting gear. The mould
100% of the pro-selected value. If necessary, clamp force must hang straight, Make sure that the mould halves cannot
can be in creased or decreased using the “Mould height” slide apart.
function key.
3. Protect the machine tie bars from damage during mould
11. Now move the clamp unit in set-up mode until platen con- installation.
tact is made and read off the ACTUAL value for mould
stroke. The stroke point for “Mould protection end” must 4. Position the mould on the fixed platen, centre and attach.
be set approx. 0.5 mm higher than the ACTUAL value dis- If the mould is to be fixed using mould clamps, ensure a
played, in order to be able to lock the mould. proper fit.
12. The speeds and change-over points for the mould and the 5. Move the clamp unit until platen contact is made, taking care
ejector must be compatible with the specification of the that the ejector rod moves into the ejector coupling without
mould (see comments in chapter on Cycle Sequence). being forced.
13. When clamp force is set, tighten the clamps up on the 6. Set mould height using the program switch. Actual mould
mould. If necessary, heat the mould beforehand. stroke is indicated as 2 mm.
7. Tighten the mould half on the moving platen. Remove safety
strap from mould, if used. Connect the ejector rod with the
ejector coupling using the slide mechanism.
8. Enter required clamp force.
9. To achieve clamping pressure, stroke point “Mould protection
end” must be approx. 0.5 mm higher than the set mould
height.
10. The speeds and change-over points for the mould and the
ejector must be compatible with the specification of the
mould (see comments in chapter on Cycle Sequence).
11. When clamp force is set, tighten the clamps up on the
mould. If necessary, heat the mould beforehand.
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Follow instructions in the operating manual to change When all settings have been checked the machine can be switch-
the screw cylinder. ed to the “semi-automatic” program. To enable the machine
cycle to commence once the Start key has been pressed, the fol-
2 1. Enter the material-related temperatures required for the
lowing start conditions must be fulfilled:
2
cylinder heating zones and for flange temperature control.
Mould open stop reached Ejector back
2. Turn on water supply to the machine.
Metering Stop reached (dose manually beforehand and,
3. Switch on cylinder heating.
if necessary, depending on the type of material, purge the
4. Set reference point for injection unit. All heating zones must material a few times). If one or more of the start conditions
be up to SET temperature and the mould must be locked. are not met, alarms will be raised on the Operator panel.
5. In set-up mode, move the nozzle until it makes contact with As a rule, no monitoring functions or tolerances should be set
the mould. Then set to zero using program switch “Reference during the start-up phase.
point IU”.
The machine can be switched to “fully automatic” after a few
6. Check nozzle radius centring and dipping depth. cycles, once the mouldings are being ejected and falling clear.
At this point process optimisation can begin (more detailed
7. Enter nozzle contact pressure, strokes and speeds for the
information can be found in Chapter 5 “Process Optimisation
injection unit.
on the injection moulding machine”). The following sequence
8. Enter metering stroke according to the necessary shot weight. is recommended:
Calculate, if need be, taking into account the necessary melt
optimise metering
cushion.
optimise injection speed
9. Enter injection pressure, injection speed, follow-up pressure,
follow-up pressure time, cooling time, back pressure and determine follow-up pressure and follow-up pressure time
screw speed. See Chapter 4.1 “Processing Guidelines”.
limit injection pressure
10. Switch on program switch “Change over to follow-up
determine cooling time
pressure dependent on volume” (pN volume).
ensure smooth operation of the clamping unit
11. Enter stroke point for “Follow-up pressure start”. Follow-up
pressure start should occur at around 80 to 90 % of the shot optimise clamping force
volume. As a rule, we recommend that a mould filling study
carry out checks on mouldings
be made on new moulds to determine the exact change-over
point. In this case, follow-up pressure should be set to “0”.
12. If necessary, set decompression to release the pressure of melt
in the cylinder if an open nozzle is used.
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Fig. 2 When start conditions have been met (see Fig. 2) the injection
unit moves forward to Pos. [8] on speed “lU forward V1”.
At Pos. [8] there is a change over to speed “lU forward V2”.
The injection unit now moves forward on speed V2 until the
cylinder nozzle makes contact with the sprue bush on the
mould Pos. [9].
3 Nozzle contact pressure now starts to build. When the given
3
nozzle contact pressure is reached, this initiates injection.
The set values for “Injection pressure” and “Injection speed”
are also required.
Injection stages – 10 max. “Follow-up pressure start” at Pos. [10] initiates stroke depen-
Follow-up pressure stages – 10 max. dent change-over from injection pressure to follow-up pres-
sure. Alternatively, the change-over to follow-up pressure can
occur depending on time or pressure.
If it is necessary to inject at varying speeds, the machine can
operate on up to 10 different injection speeds. The speeds
and stroke-dependent change-over points required can be set
on the “Injection profile” page.
The follow-up pressure phase is operative from Pos. [10] to
Pos. [11]. If follow-up pressure needs to be stepped, this can
be set on the “Follow-up pressure profile” page.
A reading for the actual melt cushion can be taken from the
Process Optimisation page.
Start conditions: The tolerances are set on the “Process control” page.
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3.3 Metering, screw and injection unit back after Operating sequence
metering
When the "Follow-up pressure times" have finished,
Fig. 3 “Cooling time” begins. Metering (melt processing) begins at
Pos. [12] when “Delayed metering” (Time) is over. Fig. 3.
Metering begins at “Screw speed” Stage 1 and “Back
pressure” Stage 1 and ends at “Metering Stop” Pos. [13].
It is possible, however, to operate on up to 6 different screw
3 speeds and 6 different screw back pressures per cycle. The
3
relevant change-over points can be set on the “Metering
profiles” page.
Next, if set, comes screw decompression with “Screw back
after metering” up to Pos. [14].
Metering – 6 stages max., If the program “lU back after metering” is switched on,
Back pressure – 6 stages max. the injection unit can be moved back on 2 speeds.
When time “lU back delayed” has elapsed, the injection unit
moves back on speed “lU back V1”. At Pos. [15] there is a
change over to the second speed “lU back V2”. The injection
unit now moves back on speed V2 as far as Pos. [16] “lU
back stop”.
Start conditions:
All activated follow-up pressure times have elapsed
Delayed metering has finished
“Screw back before metering” has been completed, if set
“IU back after metering” program
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Start conditions:
Metering stop
“Screw back after metering” is completed
Injection unit back stop
Cooling time is finished
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This chapter sets out basic, relevant data for the treatment and Density:
processing of the most important plastics. 0.91-0.93 g/cm3
Thermal, optical, mechanical properties:
Material Page Material is harder and more heat resistant than PE, but is less
resistant to low temperature (special low-temperature resistant
PP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 grade available). Particularly suitable for hinges. Hard, non-fragile,
excellent dielectric properties, non-toxic, not odour-proof.
PE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 Chemical properties:
4
PS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
resistant to
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 acids, alkaline solutions, salt solutions, alcohol, petrol, fruit juices,
oil, milk
SAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
not resistant to
PA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 chlorinated hydrocarbons, avoid contact with copper, slight
POM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 tendency towards stress cracking
Material identification:
PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
PP is highly flammable, drips and continues to burn; burns
PMMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 brightly with blue core, strong smell of paraffin (tar-like).
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Re-processing: Polystyrene, PS
Up to 100 % regrind can be processed,
Structure:
Shrinkage: Amorphous
1.5-2.5 %, substantial shrinkage, substantial warpage. Final
shrinkage can only be assessed after 24 hours. (After-shrinkage). Density:
1.05 g/cm3
Gating:
Pin gate, hot runner, insulated runner, ante-chamber pin gate. Thermal, optical, mechanical properties:
Relatively small cross sections suffice. Hard, stiff, fragile, very good dielectric properties, low water ab-
sorption, good dimensional stability, crystal clear, brilliant, good
Machine shut-down: pigmentability, no smell or taste.
No other material is required to follow up. PE is very resistant to
4 high temperatures. Chemical properties: 4
resistant to
Cylinder equipment: acids, alkaline solutions, alcohol, grease, oil, salt solutions
Standard geometry for packaging parts; special geometry L:D
25:1 with shear and mixing section; open nozzle, non-return not resistant to
valve. petrol, benzene, large number of solvents, risk of stress cracking
Material identification:
PS is highly flammable, burns bright yellow, produces a lot of
black smoke, and typically smells slightly sweet (styrene).
Cylinder temperature:
Flange 30- 50 °C / 50 °C*
MH 1 160-220 °C / 200 °C*
MH 2 180-240 °C / 210 °C*
MH 3 210-280 °C / 230 °C*
MH 4 220-280 °C / 230 °C*
DH 220-280 °C / 230 °C*
* These temperature profiles are valid for stroke utilisation of between 35 and
65 % and for parts with a flow length/wall thickness ratio of between 50:1
and 100:1.
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Re-processing: Density:
Providing the material has not already been charred, up to 30 % 1.08 g/cm3
regrind can be added to virgin material. Thermal, optical, mechanical properties:
Shrinkage: Excellent transparency and high gloss, good stiffness and hard-
0.4-0.7 % ness. Good resistance to changes in temperature, good chemical
resistance, good heat resistance.
Gating:
4 Pin gate possible, likewise hot runner. Wall thickness should not Chemical properties: 4
be less than 0.7 mm. resistant to
acids, alkaline solutions, saturated hydrocarbons, mineral oils,
Machine shut-down: vegetable and animal fats
No more material is required to follow up.
not resistant to
Cylinder equipment: concentrated mineral acids, aromatic hydrocarbons and chlori-
Standard screw nated hydrocarbons, ester, ether and ketone
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Polyamide, PA PA 66
Flange 60- 90 °C / 80 °C*
Structure: MH 1 260-290 °C / 280 °C*
Partially crystalline MH 2 260-290 °C / 280 °C*
Density: MH 3 280-290 °C / 290 °C*
1.14 g/cm3 MH 4 280-290 °C / 290 °C*
DH 280-290 °C / 290 °C*
Thermal, optical, mechanical properties:
* Feed performance is most strongly affected by the flange temperatures and
In balanced humidity (2-3 %), very tough. In dry conditions,
the temperatures in zone MH 1. By raising these temperatures, feed perfor-
brittle. Hard, stiff, abrasion resistant, good frictional characte- mance becomes more uniform.
ristics. Good pigmentability, non-toxic, adhesive properties.
Melt temperature:
4 Chemical properties: PA 6 240-250 °C 4
resistant to PA 66 270-290 °C
oils, petrol, benzene, alkaline solutions, solvents, chlorinated
hydrocarbons, esters, ketone Reduced cylinder temperature:
PA 220°C
not resistant to PA 66 250°C
ozone, hydrochloric acid, sulphuric acid, hydrogen peroxide
Injection pressure:
Material identification: 1000-1600 bar; on thin-walled articles with long flow paths
PA is flammable. It continues to burn when removed from source (cable clip) up to 1800 bar.
of heat, drips and blisters, becomes stringy. Blue flame with
yellow rim. Smells like burnt bone. Follow-up pressure and follow-up pressure time:
Normally, approx. 50 % of the resulting injection pressure. Short
Cylinder temperature: follow-up pressure times are sufficient, as the material solidifies
PA 6 relatively quickly. As follow-up pressure decays, so the stress in
Flange 60- 90 °C / 70 °C* the moulding reduces.
MH 1 230-240 °C / 240 °C*
MH 2 230-240 °C / 240 °C* Back pressure:
MH 3 240-250 °C / 250 °C* Set very accurately. 20-80 bar, as excessive back pressure leads
MH 4 240-250 °C / 250 °C* to uneven plasticising.
DH 230-240 °C / 250 °C* Injection speed:
Inject relatively quickly. Ensure that the mould is properly vented,
otherwise charring occurs on the moulding.
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* These temperature profiles are valid for stroke utilisation of between 35 and
65 % and for parts with a flow length/wall thickness ratio of between 50:1
and 100:1. Most favourable processing temperature around 210 °C.
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Shrinkage:
1-2.5%
Gating;
The gate must be radiused towards the moulding. Pin gate
possible for small parts.
Machine shut-down:
Switch off heating. Plasticise several times without back pressure,
and squirt melt out.
Cylinder equipment:
Standard screw
4 4
Open nozzle
Non-return valve
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4
80
Material Cylinder temperature Melt Reduced
4.3
Flange MH1 MH2 MH3 MH4 DH temp. °C temp.
Polyethylene PE-LD 30-50 140-200 160-230 200-260 200-260 200-260 200-250 220
Polyethylene PE-HD 30-50 160-250 200-300 220-300 220-300 220-300 220-280 220
Polypropylene PP 30-50 160-250 200-300 220-300 220-300 220-300 220-280 220
Polystyrene PS 30-50 160-220 180-240 210-260 220-280 220-280 220-280 220
Acrylonit. -butad. styrene ABS 40-60 160-180 180-230 210-260 220-260 220-260 220-250 200
Styrene-acrylonit. copol. SAN 30-50 160-180 180-230 210-260 220-260 220-260 220-250 200
Polyvinyl chloride PVC rigid 30-50 140-160 165-180 180-210 180-210 180-210 210-220 120
Polyvinyl chloride PVC flexible 30-50 140-160 150-180 160-220 160-220 160-220 200-220 120
Cellulose acetate butyrate CAB 30-40 140-160 160-170 170-190 170-190 160-190 190-200 160
Polybutylene terephthalate PBT 50-70 230-250 240-260 250-260 250-260 250-260 250-260 210
Polyethylene terephthalate PET 50-70 240-260 240-260 250-290 250-290 250-290 270-280 220
Seite 80
unsatisfactory.
Polypropylene PP *90 1 20-60 70
Polystyrene PS *80 1 15-50 70
Acrylonit. -butad. styrene ABS 80 3 40-60 70
Styrene-acrylonit. copol. SAN 80 3 40-60 70
Polyvinyl chloride PVC rigid *70 1 30-60 70
Polyvinyl chloride PVC flexible *70 1 30-50 70
Poymethylmethacrylate PMMA 80 3 40-70 80
Polyoxymethylene POM *100 3 60-110 105
Polycarbonate PC 120 3 80-110 110
Polyamide 6 PA 6 80 4 60-90 100
Polyamide 66 PA 66 80 4 60-90 100
Cellulose acetate butyrate CAB 70 3 40-80 80
Concise material science
81
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increased shrinkage/dimensional variations Setting recommendations for mould temperatures can be found
in Chapter 4.4 of this booklet.
prolonged cooling time
5 In principle: 5
inferior mechanical properties
A higher cavity wall temperature ensures:
Melt temperature too low:
less after-shrinkage
inhomogeneous melt
less orientation, fewer internal stresses, less warpage
increased stresses in the moulded part
lower pressure requirement
higher pressure requirement during injection
improved crystallinity
flow lines and weld lines clearly visible
Mould temperature too high:
Normally, cylinder temperatures are set with a rising profile
(exception: PA). The first two heating zones (MH1 and MH2) longer cooling time (2 %/1 °C)
should be set at the lower limit when there is minimal stroke
dimensions undersized
utilisation, and at the upper limit for substantial stroke
utilisation. Mould temperature too low:
matt surface
ripple effect
flow lines/weld lines clearly visible
increased stresses in moulded part
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A high performance temperature control unit can be used to main- Injection speed too high:
tain a constant cavity wall temperature. Cavity wall temperature
flash formation
is one of the most important setting parameters which needs to
be kept within very tight tolerances. For parts with stringent re- surface defects near the gate
quirements (e.g. technical parts), if is advisable to use integrated
charring at end of flow path (Diesel effect)
temperature control units, whose setting values can be stored
and also monitored by the Operator panel. high clamp force requirement
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In general, change-over should occur when approx. 90-95 % of Re 5. Follow-up pressure time
cavity volume is filled. With thin-walled articles it may be neces- The injection phase, during which the volumes of the cavities are
sary to fill up to 98 % of cavity volume before switching over to completely filled, is followed by the follow-up pressure phase. It
follow-up pressure. compensates volume contraction of the material as it cools down
by continued delivery of melt into the cavity. The follow-up pres-
Change-over too soon: sure should act until the gate seal point is reached,after which no
change-over mark more melt can enter or flow out of the mould.
moulding not completely filed As long as there is no freezing of the plastic in the area of the
gating system, the cavity pressure may still be influenced by var-
sink marks ying the hydraulic pressure. Upon reaching the gate seal point,
dimensions undersized the pressure variation in the mould is determined only by the
cooling characteristics of the material.
weld line marks
As explained earlier in Chapt. 5.1, the follow-up pressure phase
Change-over too late: has the greatest influence on such quality criteria as weight, di-
5 flash formation
mensions, shrinkage, warpage, voids, sink marks and orientation. 5
increased clamp force requirement Follow-up pressure time too long:
increased stresses in the moulded part Follow-up pressure time too short:
Initially, an early change over point should be selected. Gradually, sink marks, voids
this should be set later (mould fill study) until volumetric filling
variations in component weight
is almost achieved. This also provides a valuable insight into the
flow front profile in the mould and into the development of flow dimensions undersized
lines and weld line marks.
fluctuations in melt cushion
In the case of multiple-cavity moulds, the form fill study will show
To establish optimum follow-up pressure time, continue to raise
the degree of filling in the individual cavities. The variation in fill
the setting until no further weight increase can be detected in
should not exceed 5-10 %, depending on moulded part require-
the moulded parts without sprues.
ments.
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For an initial estimate of cooling time with the aid of a diagram, Change in cooling time
the cooling time equations can be grouped according to the dif- by [secs] +5 +2 -1,2 -2 +20 +7,5 -5 -9
ferent plastics. These groups are determined by taking as a basis
the average temperatures for melt, cavity wall and demoulding. Influence of cavity wall temperature on cooling time with
(Compare with Chapter 4.1 “Processing guidelines for plastics”). wall thicknesses of 2 and 4 mm
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5.2 Cooling time as a function of wall thickness 5.2 Cooling time as a function of wall thickness
(1 to 2.5 mm) (2.5 to 4 mm)
5 5
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The correct evaluation and selection The correct evaluation and selection
of process parameters for quality of process parameters for quality
assurance in injection moulding assurance in injection moulding
Ever shorter machine cycles, the growing complexity of products At this point, of course, there is still no indication of which para-
and increasingly stiff competition all call for economic injection meters are required for controlling the quality of the mouldings.
moulding production. Quality assurance and the ability to reduce
scrap to a minimum are becoming increasingly important.
Only those processors who can accurately predict the output of
perfect mouldings will have costs under control, be able to meet
delivery deadlines and be acknowledged as reliable partners.
When it comes to quality control, the control and analysis featu-
res on modern injection moulding machines are highly efficient.
The operator can have complete control over the production pro-
cess, carry out long-term statistical evaluations or anticipate trends.
Of course, to make best use of these resources the setter needs
to know which machine and process parameters influence the
quality of a moulding – and, most importantly, to what extent.
Practice shows, however, that the significance of these parame-
ters varies from application to application and is determined by
the demands of the particular moulding.
6 6
The following report and data tables are the result of extensive
long-term testing and the evaluation of a large number of indi-
vidual cases. They assist in the selection and evaluation of the
correct parameters and in defining the required tolerances for
quality control on the machine.
The table opposite (Fig. 6.1) shows the 5 most significant quality
characteristics and their relative importance for the production of
different product groups. For technical precision parts, dimensio-
nal stability is clearly of greatest importance, while for optical
parts, for example, surface quality and melt homogeneity are cru-
cial factors.
Of course, there are still a good many other quality characteristics
– the “inherent properties”, for example, like molecular weight,
orientation on the skin and the core, dispersion of fillers and rein-
forcing materials etc. These selected criteria, however, represent
essential performance properties which can also be subjected to Fig. 6.1
direct and mainly non-destructive testing.
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The correct evaluation and selection The correct evaluation and selection
of process parameters for quality of process parameters for quality
assurance in injection moulding assurance in injection moulding
Fig. 6.2 shows important process parameters and their relation Fig. 6.3 illustrates the connection between quality characteristics
to the various quality characteristics. The correlation between and process parameters with the aid of the (integral) cavity pres-
machine or setting parameters and the characteristics of the sure profile. It shows clearly how the majority of quality characte-
mouldings is sometimes very complex. In almost all instances, ristics are influenced during the follow-up pressure phase. Con-
there are several setting parameters relating to a single quality sequently, the cavity pressure profile must fall within specified
characteristic, which is why more than one parameter needs tolerance limits during this phase. The diagram also shows those
to be controlled. setting and monitoring parameters relevant to quality. The cavity
pressure profile, mould temperature and melt temperature are
the most significant and informative factors here.
In 50 % of all cases cavity pressure monitoring proves very useful
from a processing point of view, but it is only realistic in 3 % of
these, since the cost in terms of machine, mould and personnel
is relatively high. Cavity pressure monitoring is applied to around
20 % of mouldings, predominantly technical precision and func-
tional components, optical products and automotive parts.
The use of cavity pressure enables the setting parameters for the
machine and peripheral equipment to be largely indirectly moni-
tored, because the smallest changes or disruptions – to mould or
6 melt temperature, to the function of the non-return valve, to the 6
change-over point to follow-up pressure or to the batch of mate-
rial – all have an effect on cavity pressure. Very often it is possible
to monitor several settings via one single parameter and also to
document them in accordance with DIN ISO 9000.
The time profile for cavity pressure can be divided into three phases.
These are the injection, compression and follow-up pressure
phases.
In the injection phase, cavity pressure is determined mainly by
flow resistance, viscosity of the moulding compound and injec-
tion speed, During the compression phase the melt is compres-
sed up to the so-called change-over point, which then initiates
the follow-up pressure phase. In this latter phase, the pressure
rises in the mould initially, because the mould is now completely
tilled.
Fig. 6.2
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The correct evaluation and selection The correct evaluation and selection
of process parameters for quality of process parameters for quality
assurance in injection moulding assurance in injection moulding
As the melt cools down, so the pressure falls slowly. In conjunc- Fig. 6.4 shows a characteristic profile of hydraulic and cavity pres-
tion with the cooling process, this phase is decisive in terms of sure. If, for example, the hydraulic pressure (upper curve) rises
shrinkage and internal orientation, and also for crystallisation in during the injection phase as a result of a lower mould tempera-
partially crystalline materials. ture (caused by increased flow resistance during injection), then
cavity pressure falls – (with hydraulic pressure remaining constant
Injection phase Compression Follow-up pressure phase during the follow-up pressure phase) – due to the reduced pres-
phase
sure transfer performance of the low-viscosity melt. The result is
Pressure
a lower integral cavity pressure. If it were only the hydraulic pres-
sure being monitored, no indication would be given as to the qua-
lity of the mouldings. The rise in hydraulic pressure during the in-
jection phase would indeed be noticeable, but the effects of this
increase once change-over has occurred could not be monitored,
since hydraulic pressure during this phase is regulated at a con-
stant level. By selecting integral cavity pressure with suitable inte-
gral limits, however, the quality-related phases can be accurately
monitored.
Time
The most important factors for technical precision parts are dimen-
contour definition
Surface
(roughness, gloss, colour)
weight, dimensional deviations
sional stability, melt homogeneity and low warpage, which means
flash formation, shrinkage, warpage
Quality
6 warpage, orientation in skin,
crystallinity
weight,
dimensional
voids, sink marks
internal orientation
characteristics that the parameters for monitoring must be selected from relevant 6
deviations phases in the process. Dimensional stability and warpage are main-
Injection speed change-over point follow-up pressure ly influenced during the follow-up pressure phase, which is why
temperature cylinder follow-up pressure time
temperature
Machine integral cavity pressure is particularly suitable.
mould temperature cylinder temperature parameters
mould mould temperature
temperature Changes in melt homogeneity occur during the metering phase
Injection time max. hydraulic integral cavity pressure due to fluctuations in screw speed and/or back pressure, and these
integral injection pressure or cavity pressure melt temperature
melt temperature mould temperature
Monitoring
parameters
can be diagnosed by monitoring the above-mentioned parame-
mould temperature ters. Where particularly sensitive materials are concerned, the me-
tering operation can also be monitored via the screw load.
Fig. 6.3
Pressure transducers have been used in the mould for more than
20 years and at the moment are probably the simplest form of
total control, without directly including the characteristics of the
moulded part. Care should be taken to ensure that the cavity
pressure sensor is located at a quality-determining point – as close
to the sprue as possible – approx. 30-40 % of the way along the
flow path. A pressure sensor can also be integrated in the hydrau-
lic circuit (in or on the hydraulic injection cylinder).
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The correct evaluation and selection The correct evaluation and selection
of process parameters for quality of process parameters for quality
assurance in injection moulding assurance in injection moulding
Selection criteria
On the assumption that the machine has been optimally set prior
to the start of the production cycle, the following selection crite-
ria have emerged in the course of daily practice for the 8 most
significant process parameters which need to be kept constant.
In general, cycle time says little about component quality, apart
from when processing thermally sensitive materials in semi-auto-
matic operation.
Consistent injection time is important for short injection times
and for parts with stringent surface requirements.
Ideally, a constant metering time should be observed, particu-
larly when processing (plasticising) material blends (LDPE-HDPE),
blends for automotive parts and regrind. It is also important
where irregularities occur during plasticising as a result of the
material (PA-PMMA), and when colouring using pigment paste
or masterbatch.
A decreasing melt cushion when processing with filled materials
6 indicates wear on the non-return valve. Fluctuations are often a 6
sign of inhomogeneous melt. Where there is only very slight fluc-
tuation in the melt cushion and the non-return valve is function-
ing correctly, the dimensions of the moulded part will then remain
constant. For products with relatively dense wall thicknesses re-
quiring a correspondingly long, high and uniform follow-up pres-
sure profile, integral cavity pressure is the first choice.
Maximum cavity pressure is informative for products with small
wall thicknesses and a short follow-up pressure time or high in-
jection pressure.
Melt temperature is important for thermally sensitive materials.
This is equally so for materials with a narrow processing range or
for materials whose properties change at the slightest variation in
temperature.
Finally, accurate mould temperatures are required, particularly
when processing any of the engineering materials (PC, PA, POM,
PMMA ...), for example, for the production of optical lenses in
Fig. 6.4 PMMA or gear wheels in POM.
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The correct evaluation and selection The correct evaluation and selection
of process parameters for quality of process parameters for quality
assurance in injection moulding assurance in injection moulding
achievable on
the products
fluctuations
0.05-0.15
0.05-0.10
0.10-0.20
0.10-0.20
0.20-0.30
0.50-1.00
0.20-0.30
0.20-0.40
0.20-0.40
0.20-0.40
0.20-0.40
0.30-0.50
0.20-0.40
0.30-0.60
essary first of all to evaluate the relative importance of the indivi-
Weight
dual process parameters for the different product groups and to
[%]
establish the tolerances.
PE, PP, PS
PE, PP, PS
PE, PP, PS
extent of the influence of the individual process parameters on the
PP, ABS
Typical
PMMA
PMMA
PS, PA
PE, PP
quality of the various product groups. The quality characteristic
PVC
here is the percentage weight fluctuation which can be achieved
Gear wheels, program control cylinders (thick-walled)
on the mouldings. The data shown is a recommendation as to
the level of quality to which the mouldings in the different pro-
Plugs, multi-point connectors (thin-walled)
Container systems
Optical parts
Fig. 6.6 goes one step further by showing the permissible percent-
Products
Toys
variation in values is as a result of varying processing conditions
for the respective products. For example, the mould temperature Cycle time
8
8
for technical functional parts is around 80 °C, while for high speed
Injection
precision parts it is only 25 °C. Thus, when converted to absolute
2
4
time
values, the permissible deviations are almost identical. Dosing
5
time 2
The percentage values also utilise the evaluation capacity of mod- Melt
6
pressure
Fig. 6.10). The recommended values can be directly compared
Max. cavity
with the current Actual values. If the deviations fall within the
1
pressure
tolerance limits, the component quality is acceptable. Melt
3
temperature
Mould
4
temperature
Fig. 6.5
106 107
6
Weight
Products very important Typical
time
time
108
Melt
Melt
fluctuations
Mould
materials
Dosing
achievable on
cushion
pressure
pressure
Injection
important
Fig. 6.6
the products
Cycle time
Max. cavity
temperature
temperature
Integr. cavity
less important [%]
Fig. 6.7
parameters to adhere to specific tolerances (Fig. 6.7).
assurance in injection moulding
of process parameters for quality
109
The correct evaluation and selection
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The correct evaluation and selection The correct evaluation and selection
of process parameters for quality of process parameters for quality
assurance in injection moulding assurance in injection moulding
Quality control on the machine Fig. 6.9 shows the maximum injection pressure in an unstable pro-
When activating quality control it is important to establish wheth- cess and how metering time fluctuations depend on and influen-
er the process is normally distributed i.e. without influences in- ce the residual melt cushion. In a stable process, the statistical
herent in the system. Quality control is only possible with normal evaluation reveals only minor fluctuations for all relevant process
distribution. A mean value and independent upper and lower to- parameters.
lerance limits are then specified for the quality-determining pro-
With the aid of just two statistics pages, the machine setter can
cess parameters.
easily monitor process constancy. “Process Statistics 1” indicates
Fig. 6.8 shows a screen page from the new NC4 control system the Actual values for the last 16 cycles. The penultimate line also
of the Demag machine range. Using this page the machine setter shows the mean value, and the last line the range of measured
can select from a total of 25 available parameters those which values. The control system provides not only tabular displays, but
are most important for a particular moulding. The Process Statis- also a wide range of control features in graph form.
tics page can display up to 20 parameters, and the selected para-
meters can then be controlled either continuously (CPC) or statis-
tically (SPC).
6 6
Fig. 6.9
Fig. 6.8
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The correct evaluation and selection The correct evaluation and selection
of process parameters for quality of process parameters for quality
assurance in injection moulding assurance in injection moulding
At the touch of a key the system not only provides graphic eva- Fig. 6.11 looks at tolerance settings for the selected process pa-
luation, but also percentage deviation from the mean value, and rameters, (parameters selected are indicated by a black square in
the statistical distribution – (black bars to the right of the screen) the column headed “permissible deviation”). In addition to the
– over the last 100 cycles for each selected process parameter upper and lower tolerances, the permissible number of deviations
(injection time, metering time, hydraulic pressure, melt cushion, per 1000 parts is also indicated. If a variable exceeds its set tole-
cycle time ...). A thermal printer integrated in the operator termi- rances, by using selected parameters reject indication can be given
nal is also available as optional equipment for printing out all and this is then shown in the deviation counter.
screen pages. It enables the relevant quality data and proof of
In such cases, providing tolerance deviation is switched on, moul-
quality to be documented directly at the machine.
dings can be automatically sorted by means of mechanical qua-
lity flaps or a robot fitted with a reject signal. Only the most ad-
vanced machine control systems can offer such a comprehensive
range of possibilities for keeping processing parameters constant
over long periods of production. Such systems can indicate the
effects of any emerging influences by deviations in the process
parameters and enable statistical evaluation. This represents the
first step towards our aim of “Total Quality Control”.
6 6
Fig. 6.10
Fig. 6.11
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Cause of defect
Follow-up pressure
Temperature
Open mould
Demoulding
Plasticising
Injection
Stability
Venting
Cooling
Gating
Surface, mechanical and dimensional defects
in injection-moulded parts
Flaws in appearance
Charred streaks X X X
Coloured streaks X X
Glass fibre streaks X X
Sink marks X X
Gloss, variations in gloss X X X X X
Unmelted material pellets in the moulding X X X
Weld line, flow lines X X X X
Jetting X X X
Diesel effect, charring X X
Visible ejector imprints X X X
Ripple effect X X
7 Dark spots X 7
Matt spots near the gate X X X
Delamination of surface layer X
Cold slug, cold flow marks X X X
Gray/black clouds X
Dimensional deviations
Mouldings not completely filled X X X X X
Moulding overpacked (flash formation) X X X X
Deformation on demoulding X X X X X
Component warpage X X X X X X X
Dimensional variations on the moulding X X X X X
Inadequate mechanical properties
Stress cracking on the moulding, stress whitening X X X
Entrapped air, blistering X X X
Voids X X
Thermal degradation of melt X X
Unmelted material pellets in the moulding X
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Change-over injection
to follow-up pressure
Follow-up pressure
Melt temperature
Injection speed
Back pressure
Locking force
Screw speed
Venting
Gating
Surface, mechanical and dimensional defects
in injection-moulded parts
Flaws in appearance
Charred streaks 1 2 4 3
Coloured streaks 2 1
Glass fibre streaks 3 4 2 1
Glasfaserschlieren 3 2 1
Sink marks 4 3 1 2 5
Gloss, variations in gloss 3 4 6 1 2 5
Unmelted material pellets in the moulding 3 2 1
Weld line, flow lines 3 2 1 4 5 6
Jetting 2 4 1 3 5
Diesel effect, charring 3 1 4 2
Visible ejector imprints 3 1 2
Ripple effect 2 3 1 5 4 6
7 Dark spots 1 7
Matt spots near the gate 2 4 1 3 5
Delamination of surface layer 4 3 1 2
Cold slug, cold flow marks 1 2 4 3
Gray/black clouds 2 3 1
Dimensional deviations
Mouldings not completely filled 4 5 1 3 2 7 6
Moulding overpacked (flash formation) 4 5 2 3 4 1
Deformation on demoulding 3 1 2
Component warpage 4 3 2 1 5
Dimensional variations on the moulding 1 2 3 4
Inadequate mechanical properties
Stress cracking on the moulding, stress whitening 4 3 1 2
Entrapped air, blistering 1 2
Voids 4 3 6 1 2 5
Thermal degradation of melt 1 2 3
Unmelted material pellets in the moulding 3 2 1
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pwi x Aproj
Fz =
100
where
Fz = clamping (locking) force [kN]
pwi = mean cavity pressure [bar] Fig. 8.1: Examples for calculating the projected area
of moulded parts
Aproj = projected area of moulded part [cm2]
120 121
8
Product category Article Material Injection Follow-up Injection Follow-up Cavity
122
time pressure pressure pressure pressure
time
s s bar bar bar
General injection mouldings Tote box PS 3.0 6.0 1000 450 280-350
Container PP 2.5 5.5 1250 550 350-400
Quality requirements Vacuum cleaner body ABS 2.5 7.0 980 550 350-400
Dim. and shape deviations modest Machine housing PA 2.5 7.0 1000 550 350-400
calculation
Quality requirements CD cover PS 0.4 1.0 1550 650 400-450
Dim. and shape deviations high Video-cassette PS 0.9 3.5 1300 500 280-350
Microstructure medium Slide frame PS 0.25 0.7 1600 600 400-450
Large automotive parts Connector PBTP 0.5 1.5 1200 600 750-800
Large automotive parts Center console PP 3.0 6.0 1300 550 350-400
Quality requirements Bumper PP 4.0 6.0 1200 500 350-400
Dim. and shape deviations modest Instrument panel PP 3.0 6.0 1200 550 350-400
Microstructure medium Door lining PP 2.5 5.0 1150 500 350-400
Surface finish medium Wheel casing PP 2.5 4.5 1450 550 350-400
Disposable functional parts Screw over PP 0.8 2.5 1200 500 330-380
Quality requirements Screw closure PE 1.3 3.5 950 500 350-400
Dim. and shape deviations medium Screw cap PE 1.2 2.5 1500 800 550-600
is then calculated.
Microstructure medium Hinged lid PE 0.7 1.5 1200 500 350-400
Surface finish medium Sput PE 0.8 1.6 1300 500 350-400
Reusable functional parts Mixing bowl PP 1.5 3.0 900 500 300-350
Quality requirements Strainer PP 1.3 3.0 1050 550 300-350
Dim. and shape deviations modest DIN A4 pad PS 1.8 2.2 1100 550 300-350
calculation
Microstructure modest Desk set SAN 1.9 2.2 1000 600 350-400
Surface finish medium Coffee filter SAN 1.4 3.5 950 600 350-400
Disposable functional parts Cylinder PP 0.5 1.8 1300 600 350-400
Quality requirements Piston PP 1.1 4.0 850 500 400-450
Dim. and shape deviations high Pipette PP 0.6 0.8 1400 600 400-450
Microstructure medium Test tube PS 0.6 1.0 1200 550 400-450
Surface finish medium Petri dish PS 0.3 1.3 1200 550 400-450
Throwaway/returnable containers Drinking cup PS 0.2 0.7 1300 650 550-600
Quality requirements Yoghurt container PP 0.15 0.4 1500 700 550-600
Dim. and shape deviations medium Planting pot PP 0.11 0.4 1600 700 600-700
Examples of clamp force
Microstructure medium Ice cream container PP 0.2 0.5 1600 800 550-600
Surface finish medium Pail PP 0.46 0.6 1800 800 450-500
Optical parts Taillight PMMA 1.4 9.0 1300 850 600-650
123
8
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The pressure drop along long and thin flow paths reduces the av-
erage cavity pressure, consequently, the opening force and, as a
result, clamping force requirements. For such thin-walled parts
with long flow lengths, it is possible on the strength of empirical
values to define a so-called “effective pressure location” the pres-
Fig. 8.3: Pressure drop along flow path in the injection phase sure of which can be used as an average value for the cavity pres-
(example: beaker made of PS, wall thickness: 0.55 mm) sure and, consequently, for the clamping force calculation. In a
plane moulded part, this effective pressure location is at half the
In order to ensure neat duplication of the cavity contours at the
flow length (Fig. 8.5). In cup-shaped moulded parts with long
end of the flow path, a packing pressure of at least 300 bar should
8 be effective there during filling. This makes it necessary to use a
flow paths, the effective pressure location in the light of experi- 8
ence is at approximately 1/7 of the flow path, which means it is
correspondingly higher pressure for injection. A general rule is:
still in the bottom of the container.
The thinner the wall thicknesses, the greater the pressure drop.
From the pressure drop between the gate and the end of the
The thicker the wall sections, the lesser the pressure drop.
flow path, it is possible to estimate the cavity pressure at the
The tougher the material, the greater the flow resistance and effective pressure location (Fig. 8.6).
the pressure loss. The more viscous the material, the lower the
flow resistance and the pressure drop.
The longer the flow distance, the greater the pressure drop.
The influence of flow path length, wall thickness, and material on
the pressure required is illustrated in Fig. 8.4.
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red taking into consideration the MFI value (Fig. 8.7a: MFI = 15,
Fig. 8.7b: MFI = 35, Fig. 8.7c: MFI = 45).
8 8
Fig. 8.6: Pressure drop along the flow path and pressure at the
effective pressure location on a beaker and a plate
As already mentioned, the material properties, such as viscosity,
influence mould filling and the pressure required for it. Fig. 8.7 Fig. 8.7 b: Cavity pressure required as a function of flow-length/
provides some guidance in establishing the cavity pressure requi- wall-thickness ratio and viscosity of the material (MFI = 35).
126 127
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INJECTION MOULDING
Pocketbook
INJECTION MOULDING – Pocketbook
Altdorfer Str. 15
D-90571 Schwaig
Tel. +49 911/50 61-0
Fax +49 911/50 61-265
E-Mail: info-dpde@dpg.com
www.dpg.com