This document provides an overview of injection molding machines and their components and operation. It begins with defining injection molding as a process that uses heat and pressure to mold raw plastic materials into products within a reusable metal mold. It then describes the main parts of the machine including the clamping unit, injection unit, mold, and electric panel board. The document provides details on the injection and clamping processes, parameter settings, common product defects, and safety procedures. It also includes a section for maintenance technicians that covers the machine's energy flow, control system, key equipment, and safety checks.
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Introduction to Injection Molding Machine.pptx
1. Introduction to Injection
Molding Machine
Presented by :
Samir Ahmed
Deputy Director,
Electronics & Automation- ESM,
Walton Hi-Tech Industries PLC.
2. At a Glance
What is injection molding Machine ?
What is the process of Producing plastic product?
How Machine function ?
Main parts of machine.
Some parameter setting.
Basic troubleshooting (product).
Safety .
2
3. What is injection molding
machine?
There are two principal methods for processing plastics.
1. Extrusion
2. Injection molding.
A machine which is used to make different types of plastic product by
plasticizing row martial and Inject at high pressure into a reusable
interlocking metal frame (called mould) can define as injection
molding machine.
3
9. Mould: Mould or die are the common terms used to
describe the tool used to produce plastic parts in
molding.
Type:
cold runner, two plate mold
cold runner, three plate mold
hot runner mold
insulated runner mold
According to construction- Double Platte, Triple Plate etc
According to runner type- Cold runner ,Hot runner .
According to Cavity- 1, 2,3,4 ….N
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Useful website: http://www.custompartnet.com/wu/InjectionMolding
12. Some row materials:
Low Density Polyethylene (LDPE)
High Density Polyethylene (HDPE)
Polyethylene Terephtalate (PET)
Polypropylene (PP)
Polyvinyl Chloride (PVC)
Polycarbonate (PC)
Polystyrene (PS)
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13. Operation:
Machine work according to the bellow Steps.
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Mold Close Injection
Holding
(optional)
Charging
Suck
Back(optional)
Cooling
Mold Opening
Core Open
(optional)
Ejector
Forward/&
Air Blast
4b
2 3 4a
1
6
7
8
Product drop
and Ejector
back
9
Core close
( optional)
10 4
28. Common Plastic Product defects :
Problems:
Short shot or short molded
Flash
Flow marks
Silver streaking
Sink marks
Burn marks/Black spot
Filler marks/White spot etc.
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Helpful apps for android phone: i-moulder
https://www.sabic.com/europe/en/products-
services/plastics/troubleshootingguide
29. Continue
Short shot or short molded
Ⅰ. Description:
A molded product that is incomplete because the mold cavity was not filled completely.
Ⅱ. Causes :
Insufficient injection-molding machine performance (shot capacity, plasticizing capacity,
etc.)
Poor material flow ability
Gate cross-section surface area is too small. Molded product thickness is too thin.
Poor gas venting.
Ⅲ. Countermeasures:
<Molding equipment>
Increase the amount of material feed. If material feed is still insufficient at maximum
material feed capacity, change to a larger capacity machine.
Install a screw with a back-flow check valve.
Increase injection pressure
Raise the cylinder temperature setting. Raise the nozzle temperature, too.
Make sure there are no severed lines to the heater.
Make sure the nozzle is not clogged. If the nozzle clogs frequently, raise the mold
temperature or shorten the cycle time.
Increase injection speed
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30. Continue
<Mold>
Raise the mold temperature.
Increase the mold gas release.
Increase gate cross section surface area.
Increase the molded product thickness.
Add ribs to the molded product design to improve flowability.
<Materials>
Choose a low-viscosity high flow material type.
Apply surface lubricant. (Add 0.05-0.1% by weight.)
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31. Safety Check
Mechanical Safety
Hydraulic safety
Front door safety limit
Rear door safety limit
Nozzle safety gate
Nozzle safety gate limit
Body Earth
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34. Energy Conversation
Electric Energy
3 ,380V AC
Main oil Pump motor
Mechanical energy
Main oil Pump
Hydraulic oil Pressure
Directional /Proportional valve
Hydraulic oil Pressure
Cylinder/& Hydraulic motor
Mechanical energy
Mechanical Movement
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Energy flow chart
41. Continue
10. Sensor (All area):
a) Proximity sensor:
Size: Cylinder type ,Rectangular
Type: 3 Wire PNP NO 0-30 VDC
3 Wire PNP NC 0-30 VDC
3 Wire NPN NO 0-30 VDC
3 Wire NPN NC 0-30 VDC
b) Photo sensor (all area):
3 Wire PNP NO 0-30 VDC
3 Wire PNP NC 0-30 VDC
3 Wire NPN NO 0-30 VDC
3 Wire NPN NC 0-30 VDC
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42. Continue
11. Emergency Switch:
Press to stop all operation at
Emergency situation.
12.Hydrolic Pump:
Max. Pressure(Mpa)
Capacity (cc/rev)
RPM
13. Servo Motor:
42
43. Continue
13 B. Teflon Coupling
Use for coupling motor and pump
14 . Hydraulic Hose Pipe:
Use to transmit hydraulic oil pressere
43
44. Continue
15. Motor Frequency Drive (inverter):
Use to control and drive servo motor according
to the required pressure and flow setting
Controller:
Techmation, KEBA…..Etc
Pressure Flow control card
Temperature control card
Digital input output card
CPU card
44
45. Continue
16.Solid state relay:
Contract Channel : 1 (220 VAC)
Control : 3-32 VDC
Use at IMM: Heater circuit
17. Magnetic contractor:
Channel: 3 Line(Phase),380 V AC
Control: 220VAC (Coil)
Use at IMM : Motor circuit
45
46. Continue
18.Air Solenoid valve:
2 Way, 24 V DC.
Also use 2 Way 220 VAC
It has some other types.
19. Cooling Fan :
Single Phase, 220 V AC
Size: 4”, 6” & 8” etc.
Use at IMM: Electric Panel
box cooling.
46
49. Continue
24. Heater:
220V AC.
Different size and watt
25. Y-Ring:
Example size: 44 x 55 x 7
Use at cylinder
26. Dust seal:
Example size: 44 x 55 x 7
Use at cylinder
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