Rubber injection molding is not a new idea. The process has been successfully developed in the United States since the 1940s, albeit on a very limited scale. Today, however, injection molding has become an increasingly important manufacturing process for molded rubber parts, since it is an essentially high-speed operation, which conducts itself through a semi-automatic or fully automatic system.
Although injection molding‚ is used for a relatively small proportion of molded artifacts today, by the mid-1970s it will be the method of choice for approximately 25% of all technical molded parts.
Transformation and vulcanization of rubberLuis Tormento
In the manufacture of molded rubber artifacts, the raw compound is introduced into the cavity of a heated metallic mold, with the shape of the artifact to be manufactured, and, under molding pressure, the plastic compound flows and acquires the shape of the cavity; the heat transmitted from the press to the mold vulcanizes the compound, which permanently acquires the configuration adopted in the mold
While choosing the right rubber calender is important, learning to operate it smartly to avoid these 8 common calendering defects is equally key for your success with this machine.
Injection moulding is a manufacturing technique for making parts from both thermoplastic and thermosetting. Plastic material in production molten plastic is injected at high pressure into a mould.
Transformation and vulcanization of rubberLuis Tormento
In the manufacture of molded rubber artifacts, the raw compound is introduced into the cavity of a heated metallic mold, with the shape of the artifact to be manufactured, and, under molding pressure, the plastic compound flows and acquires the shape of the cavity; the heat transmitted from the press to the mold vulcanizes the compound, which permanently acquires the configuration adopted in the mold
While choosing the right rubber calender is important, learning to operate it smartly to avoid these 8 common calendering defects is equally key for your success with this machine.
Injection moulding is a manufacturing technique for making parts from both thermoplastic and thermosetting. Plastic material in production molten plastic is injected at high pressure into a mould.
Rubber extruders have a varied field of application. So, when you come across a rubber profile, strip, hose, cable, wire, cord coating, tire tread, v-belt, tube, or blank remember that they are only a few handful of products manufactured using extrusion process. In this Knowledge On-The-Go Special Supplement, we bring to you a ‘collector’s edition’ on Extruders and Extrusion incorporating the fundamentals.
Project report on injection molding machineAmol Torane
This ppt contains, the working of injection molding machine, type of plastic granules used, reshaping the old plastic products into a new shape and design, the clamping mechanism used and lots more..
Resin transfer molding (RTM) is a method of fabricating high-tech composite structures. The RTM process is capable of consistently producing composite parts with high strength, complex geometries, tight dimensional tolerances, and part quality typically required of aerospace applications. RTM uses a closed mold commonly made of aluminum. A fiber "layup" such as graphite is placed into the mold. The mold is closed, sealed, heated, and placed under vacuum. Heated resin is injected into the mold to impregnate the fiber layup. Having the mold heated and under vacuum assists the resin flow. The mold is then held at a temperature sufficient to cure the resin. Current RTM technology produces lightweight parts with excellent mechanical properties. With these qualities, composite materials are gaining wide use in a variety of structural and non-structural applications common in aerospace and aviation. RTM is one method of fabricating these composite structures.
How to select a plastic injection molding machine.Naik Devang
Buying a PIMM is not a small investment. Too much machine for the job at hand is wasteful. Too little machine does not get job done. Careful matching of the jobs needs and the attributes of a PIMM is well worth the effort.
RTM is a low-pressure molding process, where a mixed resin and catalyst are injected into a closed mold containing a fiber pack or preform . when the resin has cured the mold can be opened and finished component removed.
http://www.spiratex.com/ : Understand the complete process of custom plastic extrusion with step by step details of the process through this presentation. It also explains the various specialized forms of plastic extrusions.
Choosing the right Rubber Calender is important; learning to operate it smartly is equally key for your success with this machine. This edition covers all these aspects in a descriptive manner.
it is PDF are typed of myself. study triks & short & sweet (Technical manual) Of Diploma in Plastics technology(DPT-DPMT). All machine knowlage in plastics processing.
Er. Naresh Dhaker
(8890881858)
(CIPET JAIPUR)
Rubber extruders have a varied field of application. So, when you come across a rubber profile, strip, hose, cable, wire, cord coating, tire tread, v-belt, tube, or blank remember that they are only a few handful of products manufactured using extrusion process. In this Knowledge On-The-Go Special Supplement, we bring to you a ‘collector’s edition’ on Extruders and Extrusion incorporating the fundamentals.
Project report on injection molding machineAmol Torane
This ppt contains, the working of injection molding machine, type of plastic granules used, reshaping the old plastic products into a new shape and design, the clamping mechanism used and lots more..
Resin transfer molding (RTM) is a method of fabricating high-tech composite structures. The RTM process is capable of consistently producing composite parts with high strength, complex geometries, tight dimensional tolerances, and part quality typically required of aerospace applications. RTM uses a closed mold commonly made of aluminum. A fiber "layup" such as graphite is placed into the mold. The mold is closed, sealed, heated, and placed under vacuum. Heated resin is injected into the mold to impregnate the fiber layup. Having the mold heated and under vacuum assists the resin flow. The mold is then held at a temperature sufficient to cure the resin. Current RTM technology produces lightweight parts with excellent mechanical properties. With these qualities, composite materials are gaining wide use in a variety of structural and non-structural applications common in aerospace and aviation. RTM is one method of fabricating these composite structures.
How to select a plastic injection molding machine.Naik Devang
Buying a PIMM is not a small investment. Too much machine for the job at hand is wasteful. Too little machine does not get job done. Careful matching of the jobs needs and the attributes of a PIMM is well worth the effort.
RTM is a low-pressure molding process, where a mixed resin and catalyst are injected into a closed mold containing a fiber pack or preform . when the resin has cured the mold can be opened and finished component removed.
http://www.spiratex.com/ : Understand the complete process of custom plastic extrusion with step by step details of the process through this presentation. It also explains the various specialized forms of plastic extrusions.
Choosing the right Rubber Calender is important; learning to operate it smartly is equally key for your success with this machine. This edition covers all these aspects in a descriptive manner.
it is PDF are typed of myself. study triks & short & sweet (Technical manual) Of Diploma in Plastics technology(DPT-DPMT). All machine knowlage in plastics processing.
Er. Naresh Dhaker
(8890881858)
(CIPET JAIPUR)
Recycling and Reuse of Rubber Goods.pptxLuis Tormento
Why Recycle or reuse rubber goods?
Rubber Recovery can be a difficult process. There are many reasons, however why rubber should be reclaimed or recovered?
Recovered rubber can cost half that of natural or synthetic rubber.
Recovered rubber has some properties that are better than those of virgin rubber.
Producing rubber from reclaim requires less energy in the total production process than does virgin material.
It is an excellent way to dispose of unwanted rubber products, which is often difficult.
It conserves non-renewable petroleum products, which are used to produce synthetic rubbers.
Recycling activities can generate work in developing countries.
Many useful products are derived from reused tires and other rubber products.
If tires are incinerated to reclaim embodied energy then they can yield substantial quantities of useful power. For example, some cement factories use waste tires as a fuel source.
The objective of this presentation is to give a briefly description of:
The legislation about the use of rubber in contact with food.
Both in US / Europe.
Implications.
Challenges for the future.
While each component is designed to meet a set of operational requirements, there are a number of common principles that will reduce the time and cost to obtain an economical component. Many of these are evident, but some need a perfect understanding of the differences between molding thermoset rubbers and molding plastics.
The parts will be obtained at a minimal cost when there are no surprises in the design, delivery or use. Good communication and prior contact with suppliers will particularly assist in the development of the new part
What is and what is the function of a rubber seal
The Increasing of the speed of mechanical systems, driven by the desire for greater productivity, leads to higher operating temperatures and reduced fluid viscosities. This, coupled with higher pressures, causes an increasing tendency for fluid to leak. This leak in fuel systems that handle highly flammable solvents cannot be overlooked as there is a high probability of a fire hazard.
For this reason it has become common practice to include a safe leak path in the system design, to an escape or collection point, in order to minimize risk.
Seals prevent fluid from escaping from a hollow cylinder when a shaft penetrates the cylinder wall. Most commonly, the axis will have a rotary or linear motion. If a seal is not made for functional requirements, or installed and maintained properly, it can fail, causing fluid loss. The two main functions of a seal are to keep the fluid in while keeping dirt and debris out.
A hose is a flexible tube designed to transport fluids from one location to another. The shape of a hose is generally cylindrical. Having a circular cross section. Hose design is based on a combination of application and performance. Common factors are size, working pressure, weight, length, shape (straight or molded) and chemical compatibility.
Reinforced rubber products combine a rubber matrix and a reinforcement material so that high rates of strength and flexibility can be achieved. The reinforcing material, usually a type of fiber, provides strength and rigidity. The rubber matrix, with low strength and rigidity, provides air-fluid tightness and supports the reinforcement materials to maintain their relative positions. These positions are of great importance as they influence the resulting mechanical properties.
Rubber and textiles have been used together, each working in combination to deliver performance in a wide range of applications, since the early days of the rubber industry in the most developed areas of the world.
For many years, sizable rubber companies, using textile reinforcement, employed their own textile technologist working alongside rubber technologists. But in the last third of the 20th century, faced with global competition and the need to control and reduce total costs, this luxury has practically disappeared, as well as large companies (especially tire companies). Most organizations now rely on their textile suppliers to provide technical knowledge and experience. As a result, the textile component for many applications is now considered in the same way as other raw materials, that is, as an existing product, which only requires introduction into the manufacturing process, without any special knowledge or understanding, and is supplied with an agreed specification, which was probably drawn up by the textile manufacturer.
Zinc oxide (ZnO) is added to rubber compounds to activate sulfur vulcanization and thereby reduce the vulcanization time. ... The release of zinc into the environment from rubber occurs during the production, disposal, and recycling of rubber products (e.g., through leaching in landfill sites).
Its most common application is as a vulcanization activator in conjunction with stearic acid. Its addition is recommended at the beginning of the mixture, after the addition of stearic acid - its addition before stearic acid causes difficulty in incorporation and problems with dispersion.
The objective of this presentation is to give an overview of rubber compounding. We will briefly focus on:
Elastomer System
Filler System
Protection system
Process Aids
Cure System
Nanotechnology applied in rubber compounds current market and new developmentsLuis Tormento
Nanotechnology is fast becoming a key technology of the 21st century.
Nanotechnology can be defined as the engineering of matter at scales smaller than 100 nanometers (nm), to achieve properties and functions depending on size.
Nanotechnology is seen as one of the key technologies of the future. Nanotechnology refers to a wide range of scientific and technological phenomena which focuses on nanoscale (0.1 to 100 nm). It is the science of developing materials through individual control of atoms and molecules to create products that are thousands of times smaller than current technology allows for. The basis of this technology is to modify the inherent material properties such as color, abrasion resistance, conductivity, etc. the reduction of its size without modifying its chemical composition. nano-particles artificially produced have new properties which are important for the development of new products and applications.
The composition of an organic coating (paint) may be may be a formulation simple or complex, with a variety of materials, each having a specific function. The formulations generally have three components designed to be permanent and serve specific functions in the dry film. These components are the pigment, carrier and additives. Pigments provide color and other functions. The vehicles commonly called ligands act as an adhesive to adhere the pigment particles to the substrate or to each other. Finally, the additives are chemicals which modify the coating properties in fluid or solid state.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
CW RADAR, FMCW RADAR, FMCW ALTIMETER, AND THEIR PARAMETERSveerababupersonal22
It consists of cw radar and fmcw radar ,range measurement,if amplifier and fmcw altimeterThe CW radar operates using continuous wave transmission, while the FMCW radar employs frequency-modulated continuous wave technology. Range measurement is a crucial aspect of radar systems, providing information about the distance to a target. The IF amplifier plays a key role in signal processing, amplifying intermediate frequency signals for further analysis. The FMCW altimeter utilizes frequency-modulated continuous wave technology to accurately measure altitude above a reference point.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
NUMERICAL SIMULATIONS OF HEAT AND MASS TRANSFER IN CONDENSING HEAT EXCHANGERS...ssuser7dcef0
Power plants release a large amount of water vapor into the
atmosphere through the stack. The flue gas can be a potential
source for obtaining much needed cooling water for a power
plant. If a power plant could recover and reuse a portion of this
moisture, it could reduce its total cooling water intake
requirement. One of the most practical way to recover water
from flue gas is to use a condensing heat exchanger. The power
plant could also recover latent heat due to condensation as well
as sensible heat due to lowering the flue gas exit temperature.
Additionally, harmful acids released from the stack can be
reduced in a condensing heat exchanger by acid condensation. reduced in a condensing heat exchanger by acid condensation.
Condensation of vapors in flue gas is a complicated
phenomenon since heat and mass transfer of water vapor and
various acids simultaneously occur in the presence of noncondensable
gases such as nitrogen and oxygen. Design of a
condenser depends on the knowledge and understanding of the
heat and mass transfer processes. A computer program for
numerical simulations of water (H2O) and sulfuric acid (H2SO4)
condensation in a flue gas condensing heat exchanger was
developed using MATLAB. Governing equations based on
mass and energy balances for the system were derived to
predict variables such as flue gas exit temperature, cooling
water outlet temperature, mole fraction and condensation rates
of water and sulfuric acid vapors. The equations were solved
using an iterative solution technique with calculations of heat
and mass transfer coefficients and physical properties.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
2. Rubber Injection Moulding
• Synthetic rubber is the most widely applied elastomeric macro-
molecular material in vehicle, aerospace, shoe and tire industries. After
creating molecular stereo structure by vulcanization, synthetic rubber
based products will be strengthened for high elastomeric, better
insulating, perfect sealing, high chemical resistance, high temperature
resistance and all other excellent mechanical performance.
3. Rubber Injection Moulding
• Rubber injection molding is not a new idea. The process has been
successfully developed in the United States since the 1940s, albeit on a
very limited scale. Today, however, injection molding has become an
increasingly important manufacturing process for molded rubber parts,
since it is an essentially high-speed operation, which conducts itself
through a semi-automatic or fully automatic system.
• Although injection molding‚ is used for a relatively small proportion
of molded artifacts today, by the mid-1970s it will be the method of
choice for approximately 25% of all technical molded parts.
4. Rubber Injection Moulding
• The advantages obtained over conventional compression moulding
methods stand out through:
• Reduced molding cycle, therefore increased productivity per cavity.
• Minimum material preparation.
• Minimal or almost no burr, therefore reduced scrap level and lower final
costs.
• More uniform cure on thick pieces.
• Increased dimension accuracy, resulting in greater product uniformity.
• Generally lower scrap rate.
• Reduction of labor in the finished product.
5. Rubber Injection Moulding
• All these factors combined contribute to achieving reduced production
costs and increased productivity, the main reasons for producing parts
on large scales.
• The biggest disadvantage of injection molding machinery compared to
compression or transfer molding equipment is the complexity and high
capital expenditure. Reasonably large amounts of a given rubber
product are needed to justify the expense of tooling.
6. Rubber Injection Moulding
• The increased automation associated with injection molding was
responsible for the proportional reduction of the total costs
attributable to the labor cost from more than 80% to less than 25%.
Higher working temperatures as the putty penetrates into the cavity
and higher cure temperatures facilitate the use of cure cycles that are
5 to 20 times faster than those associated with conventional
compression molding and therefore contribute to. the desired
production increase. On a general average, we can consider that the
cure cycle is 10 times faster with injection molding compared to
compression molding
7. Rubber Injection Moulding
• It is the ultimate goal of the injection process to achieve the shortest
possible cure times for a given molding cycle, where cure
temperatures ranging from 177ºC to 232ºC are common. By reducing
to a minimum the temperature differential between the mold and the
mass being injected into the mold, both require heat transfer during
the cure cycle and the cure cycle time is reduced.
8. Rubber Injection Moulding
• The rubber injection molding process starts with an uncured rubber
ribbon stock that is fed into a rotating screw of the injection unit. A
controlled amount of material is pulled into the injection unit. Here the
material is plasticized to a target elevated temperature. The rubber
material is then injected into the mold cavity through a runner and gate
system where it is held in the mold under high pressure and elevated
temperature to activate the cure system in the rubber compound
(rubber is vulcanized). The cycle time is established to reach an
optimal level of cure. At the end of the cycle, the parts are removed or
ejected from the cavities and the next cycle begins.
10. Rubber Injection Moulding
Rubber Injection Molding Steps:
1.) Material in injection unit ready for injection into cavity.
2.) Material is injected from injection unit through runner system
& gates into cavities.
3.) Parts (material) are cured in mold until the cure process is
completed.
4.) Molded rubber parts are removed from mold and the
process is ready to begin again.
11. Rubber Injection Moulding
• Advantages of Rubber Injection Moulding:
Suits automation with automatic material feeding
Complementary to high precision molding applications
High level of repeatability
Closed mold injection supports molding of complex geometries and
overmoulding
• Disadvantages of Injection Moulding vs. other rubber moulding
methods
Higher start-up / shutdown costs, better suited for high volume applications
Runner systems can lead gross material weights when cold runner systems
or other low waste options are not utilized.
Not all cure systems and elastomers are suitable for injection molding.
12. Rubber Injection Machines
There are three main types of injection machine: the ram type, the in-
line reciprocating screw type, and the out-of-line non-reciprocating
screw type.
Simple ram machines cost less than screw machines and because the
ram can be made to fit very tightly in the cylinder, they can develop
very high injection pressures. However, as the mix receives heat only
by thermal conduction from the barrel, high injection temperatures and
thermal homogeneity are difficult to achieve, and they are not widely
used.
13. Rubber Injection Machines
Simple ram machines cost less than screw machines and because the ram can
be made to fit very tightly in the cylinder, they can develop very high injection
pressures. However, as the mix receives heat only by thermal conduction from
the barrel, high injection temperatures and thermal homogeneity are difficult to
achieve, and they are not widely used.
The screw in the in-line reciprocating screw type acts both as an extruder and a
ram. In this type of machine, the mix is heated and plasticized as it progresses
along a retractable screw. When the necessary shot volume has accumulated in
front of the screw it is injected by a forward ramming action of the screw. With this
system, a more uniformly controlled feeding of the material can be achieved,
together with more rapid heating of the stock from mechanical shearing,
additional distributive mixing from the rotational screw action, a greater degree of
thermal homogeneity, and a temperature 20 to 30 °C higher than the jacket
temperature. However, during the injection stage, when the screw is acting as a
ram, there is inevitably some leakage back past the flights and this limits the
achievable injection pressure.
14. Rubber Injection Machines
The out-of-line non-reciprocating screw machines have
separate screw and injection chambers and combine the
advantages of the above two types. The screw plasticizes the
compound and delivers it through a non-return valve into a
separate injection chamber. Machines of this type can generate
injection pressures of up to 200 MPa and can efficiently mold
high viscosity mixes and effectively fill large volume molds.
15. Rubber Injection Machines
In the standard injection process described above, the compound is
injected into a closed mold; there are two variations on this:
• Injection-compression molding: The mold is partially opened and a
vacuum applied to the cavity area which is sealed by a compressible
silicone gasket. A measured amount of rubber is injected into the partially
opened mold. The mold is then closed and the excess rubber is forced
outward to flow off channels. This process is used for articles such as
precision O-rings, where runner marks are unacceptable.
• Injection-transfer molding: The rubber is injected into a transfer chamber
and then forced from the transfer chamber into the mold. This combination
process uses the plasticization and heat generation advantages of the
injection unit with the controlled flash pad and cavity layout advantages of
the transfer press.
16. Rubber Injection Machines
All of the above systems have been in use for many years. The
equipment manufacturers are constantly improving the design,
operation, and control of their machines, but in general, available
equipment is based on the systems described above. The equipment
manufacturers' concentration has been on data acquisition and
process control systems to enable the processors to implement on-
line statistical process control. This has been in response to the end-
users demands, especially from the automobile industry, for defect-
free products. Another major pressure on suppliers to the automotive
industry is cost. This, in turn, is reflected onto equipment
manufacturers to provide cheaper, more efficient machines to allow
the processors to make parts more cheaply, but with no loss in
quality.
17. Rubber Injection Compounds
Rubber compounds for injection molding differ mainly in the shapes of the vulcanization
curves. Appropriate induction period with constant plasticity and high speed of
vulcanization are required. This is achieved by a suitable combination of vulcanization
accelerators and retarders in the selected vulcanization system. In case of rubber
injection molding, screw plastication units are used. The material is filled either in form of
a belt or granules. Due to the properties of rubber compounds the plastication is carried
out in a cylinder with a significant assistance of dissipated energy. The plasticated
material is often transferred into an injection cylinder, goes through it and is injected into
the cavity of the mold. When filling the mold, the material also flows in the surface layer
because the temperature of the mold is higher than the temperature of the injection
molded material. It is necessary to choose sufficient diameters of the runners and the
cavity of the mold, too. The mold must have impeccable breathing. The ejecting system
must be selected with respect to the high elasticity and low strength of the injection
molded pieces. The injection molding of rubber compounds allows production of thick-
walled products in a reduced time and higher quality of the vulcanized rubber. However, it
requires more complex processing equipment and, unlike the previous technologies, it is
less convenient for piece production.
18. Rubber Injection Compounds
Organic rubber injection starts with more efficient material preparation. The material is mixed,
and then stripped into continuous strips and fed into a screw which charges a barrel as needed
with a pre-defined amount of material. When the mold is closed, the material in the barrel is
injected into the mold cavities and cured. Benefits of injection molding include:
Complete elimination of operator placement of pre-forms
The injection screw pre-heats the material before forcing it into the cavities. This decreases the viscosity of
the material, allowing it to flow more easily into the cavities.
Moderately quicker cycle times than compression and transfer molding
Liquid Injection Molding (LIM) or (LSR) Injection is the process where a two part liquid silicone compound (A &
B parts) are delivered at a fixed ratio into a static mixer. The LSR mixture blends with a platinum cure system
and is delivered into the injection unit where it is injected through a runner and gate system into the closed
mold until cured. At the end of the cycle the parts are removed or ejected from the cavities and the next cycle
begins. Benefits of LIM molding include: •
Automated closed-loop systems limit contamination
Nearly “flash-less” parts
Optimized cycle times
LIM is well suited to the unique needs of the medical product industry
19. Rubber Injection Compounds
LIM materials are biocompatible, inert and stable, flexible, have a low compression set
with a wide range of Durometers, and offer superior heat resistance.
High quality components with complex shapes can be repeated in high quantities in a
cost effective manner.
20. Rubber Used in Injection Molding
Not every type of rubber can be used in the injection process, parameters such as
temperature, injection speed, and pressure can affect the vulcanization system, making
its use unfeasible. The most common rubbers are:
EPDM,
NBR,
NR,
SBR,
FKM,
Silicone,
Fluorsilicone
21. Raw Material used in Injection Molding
Other key points to consider are:
Acceleration system (process temperature can affect its effectiveness)
Type of filler (Moisture can lead to the formation of bubbles that show defects in the molded
artifact)
Process oil (volatility)
Process Aids
22. Raw Material used in Injection Molding
Other key points to consider are:
Acceleration system (process temperature can affect its effectiveness)
Type of filler (Moisture can lead to the formation of bubbles that show defects in the molded
artifact)
Process oil (volatility)
Process Aids
23. Typical Problems with Injected Moulded
Rubber
• There are countless quality control issue that can arise from manufacturing injection
molded rubber. Here are five common problems and possible solutions.
• Short shot
• A short shot is the incomplete filling of a mould cavity, resulting in a incomplete injection
moulded rubber part. There are several possible solutions to remedy short shote issues.
• Possible solutions:
• Increase shot size
• Use higher melt flow rate material
• Increase melt or mould temperature
• Increase fill speed, pack pressure or injection time
24. Typical Problems with Injected Moulded
Rubber
• Shinkage
• A common problem when manufacturing rubber products is the fact that moulded rubber parts
always come out of the mould smaller than the cavity that produced then. In other words, they
shrink.
• Possible solutions:
• Maintain adequate cushion
• Delay gate sealing to allow pack out
• Increase the size of the mould cavity
• Increase cavity pressure and hold time
25. Typical Problems with Injected Moulded
Rubber
• Excess flashing
• With injection moulding, the rubber material can leak between the mould´s surfaces along
the parting line. Flashing can affect an injection moulded rubber part´s surface finishing
and sealing capabilities
• Possible solutions:
• Use a larger press
• Increase clamp force
• Decrease peak cavity pressure
26. Typical Problems with Injected Moulded
Rubber
• Warpage
• Warpage is when the intended shape of the moulded rubber part becomes distorted during
the cooling process, which can cause it to fold, twist, bend or bow.
• Possible solutions:
• Increase cycle time
• Decrease injection fill rate
• Minimise hot spots in the mould
• Mould at high temperatures and low pressures
27. Typical Problems with Injected Moulded
Rubber
• Brittleness
• Brittleness can result from shorter molecular chain lengths. This Impairs the physical
integrity of an injection moulded rubber part, resulting in cracks or breakages.
• Possible solutions:
• Increase injection fill rate
• Increase mould temperature and cool time
• Eliminate contamination from other polymers