Download to read offline
Injection moulding process
- 1. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V CENTRAL INSTITUTE OF PLASTICS ENGINEERING AND TECHNOLOGY
- 2. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V INJECTION MOULDING PROCESS - RESOURCES MATERIAL MACHINE MOULD MAN POWER
- 3. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V MATERIAL THERMOPLASTIC MATERIAL THERMOSET MATERIAL PLASTIC MATERIAL
- 4. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V •HEAT •COOL •SOLID •PRESS. IT CAN BE RECYCLED THERMPLASTIC MATERIAL •SOFT
- 5. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V •HEAT •HEAT •SOLID •PRESS. •IT CAN NOT BE RECYCLED •SOFT •CHARCOAL THERMOSET MATERIAL
- 6. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V Injection Moulding Definition Process whereby heat softening, plastics material is forced (injected) from a cyclinder into a cavity which is a replica of article. After allowing for cooling finished article can be ejected out from the cavity.
- 7. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V Injection Moulding Product Batch process of constant dimension with close dimensional control. Such as • video cassettee, • fuel pumps, • gear box, • small gears, • automobile parts, • pipe fittings disposable syringes & • other medical equipments. • bucket, • mug, • dustbin, • cups, • crates, • moulding luggauge, • cabinate for radios, • taperecorders, • housing for domestic appliances,
- 8. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V Injection Moulding Material All thermoplastics like LDPE, HDPE, PVC, ABS, Polycarbonate, etc. Thermoset on specific requirement & cost effective basis, Recommended MFI 8 to 10 and above.
- 9. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V Injection Moulding Rating • Clamping Capacity in Tonnes
- 10. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V Injection Moulding Major factor for consideration • Type of Clampings • L/D ratio and compression ratio, • Shot weight • Minimum and Maximum day light • Size of platen and distance tie rod/ • Type of Drive.
- 11. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V MACHINE HEATING PRESURISING AND CONVEYING MOULD CLAMPING Figure - The basic Injection Moulding Cycle
- 12. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V MOULD THE MOLD HAS 4 MAIN FUNCTIONS RECEIVE & DISTRIBUTE THE MATERIAL SHAPE FORMING COOLING(Water & oil) DISPOSAL
- 13. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V MANPOWER TO SET UP A PROCESS TO MONITOR AND TROUBLE SHOOT TO OPARATE MACHINE
- 14. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V Injection Moulding Types of Injection Unit •Plunger •Preplasticising •Reciprocating screw
- 15. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V PLUNGER TYPE MACHINE TYPES OF I.M MACHINES
- 16. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V PLUNGER-PLUNGER TYPE
- 17. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V SCREW – PLUNGER TYPE
- 18. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V IN LINE RESIPROCATING SCREW TYPE
- 19. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V Screw Rotation
- 20. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V The rotation of the screw produces frictional and shear together with the heat input from heater bands around the barrel cause the material to melt. These two sources of heat , combined with the mixing effect of the screw , provide a homogenous melt Screw Rotation
- 21. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V NOZZLE It provides thermal & mechanical connection from hot cylinder to cold injection mold TYPES OF NOZZLES An open channel with no mechanical valve An internal check - valve held closed by spring A shut off valve
- 22. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V SCREW-L/D RATIO It is the ratio of the flight length to the dia. of the screw Generally L/D ratio varies 20:1 to 30:1 Generally L/D ratio for PVC is 16:1 The larger the L/D ratio greater opportunity for mixing, resulting in better homogeneity of melt Greater the resident time of the plastic in the barrel permitting faster cycles of larger shots & more output
- 23. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V FEED ZONE: Promotes pumping/output rate adequately-It can be 50 to 60% of L COMPRESSION ZONE: Promotes shearing and hence melting of polymers at the output rate of feed zone-It can be 20 to 25% of L METERING ZONE: Promotes homogenization of entire melt stream emerging from compression zone- It can be 20 to 25% of L SCREW- VARIOUS ZONES IN SCREW
- 24. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V SCREW SIGNIFICANCE OF LENGTH OF EACH ZONE Longer feed zone creates greater potential throughput Longer compression zone results in less shear heat & more to compress & melt the plastic Longer meter zone allows screw to develop more pumping pressure and greater opportunity to homogenize Shorter meter zone allows less time to assure uniform melt temperature and viscosity
- 25. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V CLAMPPING-TYPES HYDAULIC CLAMPING TOGGLE CLAMPING PNEUMATIC CLAMPING
- 26. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V Hydraulic Clamping Toggle Clamping
- 27. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V
- 28. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V HYDRAULIC Vs TOGGLE-COMPARISION Much higher original cost Higher horse power needed.Therefore more expensive to run Unlimited stroke potential Direct readout of clamp force Lower original cost Lower horse power needed.More economical to run Limited stroke potential No Direct readout of clamp force
- 29. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V HYDRAULIC Vs TOGGLE-COMPARISION Easy adjustment of clamp force Easy mold setup Varies stroke to mold height Clamp speed easily controlled or stopped at any point Low maintenance as parts are self lubricated More difficult More involvement in mold setup Constant mold stroke Clamp speed more difficult to control and stop Higher maintenance cost
- 30. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V POLYMER MATERIAL TEMP.RANGE 0 C MOLD TEPMP. Nylon-6 230-260 80-90 Nylon-6 with GF 230-280 70-90 Nylon-66 270-290 80-90 Nylon11 210-240 30-60 Polysulphon 33-400 100-160 LDPE 160-240 30-50 LLDPE 200-280 30-50 HDPE 160-220 30-50 EVA copolymer 160-230 30-50 PP homopolymer 220-280 20-70 PP,20% Talc 200-280 20-70 PP,copolymer 170-230 20-60 PP,20% glass 220-280 20-80 GPPS 170-280 20-70 GPPS with GF 210-280 60-80 HIPS 190-260 50-80 SAN 200-280 30-80 ABS 240-280 40-80
- 31. ISO 9001 B U KA S QUALITY MANAGEMENT Qi 006 V POLYMER MATERIAL TEMP.RANGE 0 C MOLD TEPMP. PVC,Rigid 190-220 30-60 PVC,Soft 140-200 20-40 Acrylic 220-250 60-90 PET 280-295 5-15 PET,Not reinforced 235-280 20-70 PBT,30%GF 235-280 20-90 PET/PBT copolymer 235-280 20-90 PC 280-310 80-120 PC 40% GF 270-310 80-120 PPS 300-360 120-180 POM copolymer 180-230 60-120 PPO modified with GF 250-280 110-13 PPS/PS 270-300 70-110 PUR 170-220 10-30