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    Introduction Injection Molding

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    maran.sugu
    The document provides an introduction to injection molding. It describes the injection molding cycle which involves injecting melted plastic into a mold, holding pressure to fill the mold and compensate for cooling, and then ejecting the molded part. It outlines the characteristics of injection molding such as its use for large production runs but limitations on part size and thickness. Important process parameters that affect the molded part are identified such as cavity pressure, melt temperature and cooling time. Mold design features like the sprue and runner are also discussed.

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    Introduction Injection Molding

    Uploaded by

    maran.sugu
    177 views39 pages
    The document provides an introduction to injection molding. It describes the injection molding cycle which involves injecting melted plastic into a mold, holding pressure to fill the mold and compensate for cooling, and then ejecting the molded part. It outlines the characteristics of injection molding such as its use for large production runs but limitations on part size and thickness. Important process parameters that affect the molded part are identified such as cavity pressure, melt temperature and cooling time. Mold design features like the sprue and runner are also discussed.

    Original Description:

    Introduction to Injection Molding by Polymer Processing

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    The document provides an introduction to injection molding. It describes the injection molding cycle which involves injecting melted plastic into a mold, holding pressure to fill the mold and compensate for cooling, and then ejecting the molded part. It outlines the characteristics of injection molding such as its use for large production runs but limitations on part size and thickness. Important process parameters that affect the molded part are identified such as cavity pressure, melt temperature and cooling time. Mold design features like the sprue and runner are also discussed.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    177 views39 pages

    Introduction Injection Molding

    Uploaded by

    maran.sugu
    The document provides an introduction to injection molding. It describes the injection molding cycle which involves injecting melted plastic into a mold, holding pressure to fill the mold and compensate for cooling, and then ejecting the molded part. It outlines the characteristics of injection molding such as its use for large production runs but limitations on part size and thickness. Important process parameters that affect the molded part are identified such as cavity pressure, melt temperature and cooling time. Mold design features like the sprue and runner are also discussed.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    Injection molding is a manufacturing process where melted plastic is injected into a mold cavity to produce parts of a specific shape. The key stages in the injection molding cycle are injection, holding, cooling and ejection.

    The injection molding cycle consists of injecting melted plastic into a mold cavity, holding pressure to pack the mold, cooling to solidify the plastic part, and then ejecting the finished part from the mold.

    Some characteristics of injection molding include expensive molds for large production runs, high pressure which limits part size, long products require multiple gates, part thickness affects cooling time, and cycle time impacts costs.

    Introduction to injection molding

    Injection molding machine

    Injection molding cycle


    Injection of the melt into the mold
    Holding pressure and plasticating
    Additional melt is injected to compensate for
    contraction due to cooling
    As the melt cools and solidifies, the pressure
    should be high enough to avoid sinkmark

    Ejection

    Injection molding cycle


    t=0
    Screw pushed
    forward
    Mold filling

    Hold time

    Screw recovery
    Part cooling

    Mold closed

    Soak time
    Part ejected
    Mold open

    Characteristics

    Expensive molds for large production runs


    Low assembly cost
    High pressure limits the size of the product
    Long products require multiple gates
    Part thickness less than 5mm limits the cooling time
    Part thickness larger than 0.5mm premature solidification
    Cycle time is money

    Clamping

    Clamping force pushes the mold halves together, while the pressure of
    the melt inside the mold pushes the mold halves apart.

    Mold

    Sprue: entry channel of the mold

    Mold

    Runner

    The objective is to have the plastic reach all gates at the same time.

    Flow into the mold

    high degree of orientation of the surface layers


    significant gradient in orientation and morphology

    Weldline

    orientation

    Important process parameters


    Product parameters
    Product dimension, weight, appearance

    Main process parameters


    Cavity pressure, injection pressure, fill time

    Additional process parameters


    Melt temperature, mold temperature, hold pressure,
    cooling time, total cycle time, barrel temperature, screw
    speed, power consumption (screw, barrel heater)

    CAE S/W
    MOLDFLOW
    - MF/VIEW
    - MF/FLOW
    - MF/PACK
    - MF/COOL
    - MF/GAS
    - MF/FIBER
    - MF/WARP
    - MF/STRESS

    : Pre/post processing
    : Mold filling analysis
    : Packing analysis
    : Cooling analysis
    : Gas-assisted injection molding,PFP
    : Fiber orientation analysis
    : Shrinkage/Warpage analysis
    : Structural/stress analysis

    C-MOLD C-SET: Reactive molding


    ANSYS

    : Structural analysis

    CAD S/W

    : AUTO-CAD, Pro-engineer

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