Injection Moulding

Dharmendra Kumar Yadav

Mtech, Rubber Technology
IIT Kharagpur
 Type of Injection Moulding
Machine
Hand Injection Moulding M/C

Plunger type Injection Moulding M/C

Reciprocating Screw Type Injection

Moulding M/C
Machine components
 The Reciprocating Screw
The feeding zone
The compressing (or transition) zone
The metering zone
 Screw Used in Injection Moulding Machines

The screw has three zones with a ring-plunger assembly. The Feed
Zone, where the plastic first enters the screw and is conveyed along a
constant root diameter; the Transition Zone, where the plastic is
conveyed, compressed and melted along a root diameter that increases
with a constant taper; and the Metering Zone, where the melting of the
plastic is completed and the melt is conveyed forward along a constant
root diameter reaching a temperature and viscosity to form parts.
 The Injection Process
Plasticises the material by reciprocating Screw.
Injects the molten material to a closed mould
via a channel system of gates and runners.
Cools the Mould.
Refills the material for the next cycle.
Ejects the Product.
Closes the Mould for further cycle.
 Machine operation sequence
The mould closes and the screw begins moving forward for
injection.

The cavity fills as the reciprocating screw moves forward, as a

plunger.
 Machine operation sequence
The cavity is packed as the screw continuously moves forward.

The cavity cools as the gate freezes off and the screw begins
to retract to plasticize material for the next shot.
 Machine operation sequence
The mould opens for part ejection

The mould closes and the next cycle begins

During Refilling
During Injection
Cycle time in injection moulding
A two-plate mould. A three-plate mould.

The moulded system includes a delivery system and moulded parts.

TOGGLE TYPE CLAMPING
 TOGGLE TYPE CLAMPING

ADVANTAGE

Low cost and lower horsepower needed to run.

Positive clamp of the mould

DISADVANTAGE

Do not read the clamp force.

Clamping is more difficult.
Higher maintenance as lubricant is provided.
 HYDRAULIC CLAMPING
A clamping unit actuated by hydraulic cylinder, which is
directly connected to the moving, closed the mould. In
this case ram of hydraulic system is attached to moving
platen. There are two halves in hydraulic cylinder, which
is actually inlet and outlet of oil.

When oil goes to the cylinder with pressure oil pushes

the ram to forward direction by which moving platen
moves and mould closed and when oil comes from the
cylinder the ram come back and mould is open.
HYDRAULIC CLAMPING
 HYDRAULIC CLAMPING
ADVANTAGE

Clamp speed easily controlled and stopped at any point.

Direct a read out of clamp force.
Easy adjustment of clamped force and easy mould set
up.
Low maintenance as part is self lubricated.

DISADVANTAGE

It is higher cost and more expensive than toggle

system.
None positive clamp.
 Materials for Injection Moulding
Acrylonitrile butadiene styrene (ABS)
Acetal
Acrylic
Polycarbonate (PC)
Polyester
Polyethylene
Fluoroplastic
Polyimide
Nylon
Polyphenylene oxide
Polypropylene (PP) **
Polystyrene (PS)
Polysulphone
Polyvinyl chloride (PVC)
 Advantages of Injection
Moulding Process
Parts can be produced at high production rates.
Large volume production is possible.
Relatively low labour cost per unit is obtainable.
Process is highly susceptible to automation.
Parts require little or no finishing.
Many different surfaces, colours, and finishes are
available.
Good decoration is possible.
For many shapes this process is the most economical way
to fabricate.
Process permits the manufacture of very small parts which
are almost impossible to fabricate in quantities by other
methods.
 Advantages of Injection
Moulding Process
Minimal scrap loss result as runners, gates, and rejects
can be reground and reused.
Same items can be moulded in different materials,
without changing the machine or mould in some cases.
Close dimensional tolerances can be maintained.
Parts can be moulded with metallic and non-metallic
inserts.
Parts can be moulded in a combination of plastic and
such fillers as glass, asbestos, talc and carbon.
The inherent properties of the material give many
advantages such as high strength-weight rates,
corrosion resistance, strength and clarity.
Limitations of Injection Moulding
Intense industry competition often results in low profit
margins.

Mould costs are high.

Moulding machinery and auxiliary equipment costs are

high.

Lack of knowledge about the fundamentals of the

process causes problems.

Lack of knowledge about the long term properties of the

materials may result in long-term failures.
Injection Moulded Items
Injection Moulded Items
Injection Moulded Items
THANK YOU