The document discusses cycle time optimization in injection molding, specifically using the Milacron 80to machine to produce card holders. It identifies key factors affecting cycle time, such as cooling time, and presents experimental data that shows an optimized cycle time of 17.5 seconds. The analysis indicates that cooling time significantly impacts overall cycle time, comprising about 50% of the total.

1. Dr. K.N Modi University
Cycle Time Optimization In Injection Moulding
Injection Moulding Machine
Milacron 80to
26.04.2019 Industrial and Production engineering 1

2. Dr. K.N Modi University
Cycle Time Optimization In Injection Moulding
Injection Moulding Machine
Milacron 80to
26.04.2019 Industrial and Production engineering 2
Applying heat and
pressure
Desired shape
or final product
Raw material

3. Dr. K.N Modi University
Cycle Time Optimization In Injection Moulding
26.04.2019 Industrial and Production engineering 3
NEED FOR THE STUDY
• To Study about the factors that are responsible
for cycle time
• To optimize the cycle time over cooling time
• To understand the procedure of optimization for
cycle time
• To enhance the quality of the product by
considering cycle time

4. Dr. K.N Modi University
Cycle Time Optimization In Injection Moulding
26.04.2019 Industrial and Production engineering 4
CYCLE TIME
Cycle time is the time which is taken to complete all
the stage of the injection moulding
2
1.3
2.4
5
1
Cycle time
Mould closing Injection filling Back pressure Cooling time part ejection

5. Dr. K.N Modi University
Cycle Time Optimization In Injection Moulding
26.04.2019 Industrial and Production engineering 5
THERE ARE 5 STAGE IN INJECTION
MOULDING TO COMPLETE ITS PROCESS
THE MOLD
CLOSES
INJECTION COOLING
PLASTICIZING
THE RESIN
EJECTION

6. Dr. K.N Modi University
Cycle Time Optimization In Injection Moulding
26.04.2019 Industrial and Production engineering 6
FACTORS WHICH INFLUENCE THE CYCLE TIME IN INJECTION
MOUDLING
Wall Thickness
Plastic Type
Part Design
Mold Material
Mold Cooling Design

7. Dr. K.N Modi University
Cycle Time Optimization In Injection Moulding
26.04.2019 Industrial and Production engineering 7
• Temperature check
• Inject
• Switch over to holding pressure
• Cooling time
• Closing time
• Dosing
• Cycle time
• Data back up
• Long time monitoring
• Reproducibility
PROCEDURE FOR OPTIMIZATION

8. Dr. K.N Modi University
Cycle Time Optimization In Injection Moulding
26.04.2019 Industrial and Production engineering 8
EXPERIMENT
Machine Specification
• Power pack- 20 HP
• 80to injection screw stroke
• Inj. Cap. Max. (GPPS)- 64 gm.
• Total heat capacity-6.4 kW rpm
• Screw diameter -28mm
• Injection rate- 107 cc/sec
• Screw speed – 400
IIM Milacron 80to

9. Dr. K.N Modi University
Cycle Time Optimization In Injection Moulding
26.04.2019 Industrial and Production engineering 9
Product-
Card Holder (Base and Cover),
produced on IIM MILACRON 80to
• Specifications:
• Raw material- Poly propylene
• Density of PP-0.91 gm./cm3
• Wall thickness- 0.3 mm

10. Dr. K.N Modi University
Cycle Time Optimization In Injection Moulding
26.04.2019 Industrial and Production engineering 10
OPTIMIZED CYCLE TIME OVER COOLING TIME
Shot no. Cooling time
(second)
Cycle time
(second)
DE moulding
Temperature (oC)
remark
1 3 12 115 GP not
proper
2 3.5 12.3 110 GP not prop.
3 4 13.8 110 GP not prop.
4 4.5 14.0 105 GP not prop.
5 5 14.9 104 GP not prop.
6 5.5 15.3 103 GP not prop.
7 6 15.6 102 GP not prop.
8 6.5 16.05 95 GP not prop.
9 7 16.8 93 GP not prop.
10 7.5 17.5 85 GP ok
After the measurement control, the following cooling time
is used: 7.5 sec
This result in a cycle time of 17.5 sec

11. Dr. K.N Modi University
Cycle Time Optimization In Injection Moulding
26.04.2019 Industrial and Production engineering 11
SUMMARY
• This presentation contents the analytical and experiment data which are collected
by performing on IIM Milacron 80ton.
• In this presentation the cycle time is optimized for the card holder by changing the
cooling time. Best cycle time for the product is found 17.5 sec.
• This presentation also represent the procedure for the optimization of cycle time.
• Cooling time, hold time and robot take out time are most effective parameters to
reduce the cycle time. But in this presentation the main focus is on the cooling time
that is about 50% responsible for the cycle time

12. Dr. K.N Modi University
Cycle Time Optimization In Injection Moulding
26.04.2019 Industrial and Production engineering 12

13. Dr. K.N Modi University
Cycle Time Optimization In Injection Moulding
26.04.2019 Industrial and Production engineering 13