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    Plastic Injection Molding: Akash Deep.B.N 1SJ03ME121

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    Maheesaras
    This document provides an overview of plastic injection molding. It discusses the injection molding process, including the injection molding machine components like the barrel and screw. It describes the injection molding cycle of filling, packing, cooling, and ejection. Common materials like ABS and polypropylene that are used are also listed. Applications include automotive parts like radiator end caps and sail panels. Problems like air traps and flash are discussed along with solutions.

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    Attribution Non-Commercial (BY-NC)
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    Plastic Injection Molding: Akash Deep.B.N 1SJ03ME121

    Uploaded by

    Maheesaras
    687 views20 pages
    This document provides an overview of plastic injection molding. It discusses the injection molding process, including the injection molding machine components like the barrel and screw. It describes the injection molding cycle of filling, packing, cooling, and ejection. Common materials like ABS and polypropylene that are used are also listed. Applications include automotive parts like radiator end caps and sail panels. Problems like air traps and flash are discussed along with solutions.

    Original Title

    INJECTION MOULDING

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    This document provides an overview of plastic injection molding. It discusses the injection molding process, including the injection molding machine components like the barrel and screw. It describes the injection molding cycle of filling, packing, cooling, and ejection. Common materials like ABS and polypropylene that are used are also listed. Applications include automotive parts like radiator end caps and sail panels. Problems like air traps and flash are discussed along with solutions.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    687 views20 pages

    Plastic Injection Molding: Akash Deep.B.N 1SJ03ME121

    Uploaded by

    Maheesaras
    This document provides an overview of plastic injection molding. It discusses the injection molding process, including the injection molding machine components like the barrel and screw. It describes the injection molding cycle of filling, packing, cooling, and ejection. Common materials like ABS and polypropylene that are used are also listed. Applications include automotive parts like radiator end caps and sail panels. Problems like air traps and flash are discussed along with solutions.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 20

    PLASTIC INJECTION MOLDING

    AKASH DEEP.B.N
    1SJ03ME121
    Plastic Injection Molding
    O Overview
    O Injection Molding
    O Injection Molding machine
    O Injection molding processes
    O Injection molding materials
    O Injection molding problems and solutions
    O Typical applications and Products
    Overview
     Injection molding is the most widely used polymeric fabrication
    process.
     It is the primary process for manufacturing thermo plastic
    products.
     Injection molding can be used to form a wide variety of products.
    Complexity is virtually unlimited, sizes may range from very
    small to very large, and excellent control of tolerances is also
    possible.
     The major reasons that injection is so popular is that it produces
    light weight parts of specific color with built in surface texturing.
     Most polymers may be injection molded, including
    thermoplastics, fiber reinforces thermoplastics, thermosetting
    plastics, and elastomers.
    Injection molding
     Injection molding is a method to obtain molded products by injecting
    plastic materials molten by heat into a mold, and then cooling and
    solidifying them.
    The method is suitable for the mass production of products with
    complicated shapes, and takes a large part in the area of plastic
    processing.

    Advantages of Injection Molding


     High production rates
     Wide range of materials can be used
     Low labor costs
     Minimal scrap losses
    Types of Injection Molding Machines

     Hand injection molding machine


     Piston type injection molding machine
     Reciprocating type injection molding
    machine
    Injection Molding Machine
     Injection molding machine is divided into 3 units
    i.e. a clamping unit, an injection unit and mold.

     The functions of the clamping unit are opening


    and closing a die, and the ejection of products.
    There are 2 types of clamping methods, namely
    the toggle type shown in the figure below and the
    straight-hydraulic type in which a mold is directly
    opened and closed with a hydraulic cylinder.
    The functions of the injection unit are to melt
    plastic by heat and then to inject molten plastic
    into a mold.
    Y  

      
     
    
    The injection system consists of a hopper, a reciprocating screw and
    barrel assembly, and an injection nozzle, as shown in Figure 1. This
    system confines and transports the plastic as it progresses through the
    feeding, compressing, degassing, melting, injection, and packing stages.
     FIGURE 1. A single screw injection molding machine for
    thermoplastics, showing the plasticizing screw, a barrel, band heaters to
    heat the barrel, a stationary platen, and a movable platen.
     w 

     w 

     w 
     
    The reciprocating screw is used to compress,
    melt, and convey the material. The reciprocating
    screw consists of three zones (illustrated below)
    
    
    
      
      
    
    
    
    
    FIGURE 2. A reciprocating screw, showing the feeding
    zone, compressing (or transition) zone, and metering
    zone.
     w

    FIGURE 3. (a) Nozzle with barrel in processing position. (b) Nozzle with
    barrel backed out for purging.

    Y 
    
    The mold system consists of tie bars, stationary and moving platens, as
    well as molding plates (bases) that house the cavity, sprue and runner
    systems, ejector pins, and cooling channels, as shown in Figure 4. The
    mold is essentially a heat exchanger in which the molten thermoplastic
    solidifies to the desired shape and dimensional details defined by the
    cavity.
    Mold System

    3 plate mold 2 plate mold


    ! m  
    
    ! 
     
    
    !    
    
    ! w 
    
    The delivery system, which
    provides passage for the
    molten plastic from the
    machine nozzle to the part
    cavity, generally includes:
    ÿ a sprue
    ÿ cold slug wells FIGURE 6. The molded system
    ÿ a main runner includes a delivery system and molded parts.
    ÿ branch runners
    ÿ gates.
    Injection molding processes
    The Injection molding process
    basically is divided into 6 major
    steps
    à   
       
    
     
     
    Y! 
    " # 
    
    
     
    
     The injection molding cycle can be divided
    into several stages. They aremold closing,
    filling, packing, cooling, mold opening and
    ejection as shown here.
     Cooling Time is a major fraction of the total
    cycle time.

    Materials for injection molding


    ÿ Acrylonitrile butadiene styrene (ABS)
    ÿ Polyethylene
    ÿ Polypropelene
    ÿ Polystyrene
    w  $ 
    
     Injection molding is widely used in a wide variety of
    industries: automotive, appliance, computer,
    communication and industrial equipment. Examples of
    injection molded parts in the automotive industry include
    sail panels, radiator end caps, door panels, lamp housings,
    and fuel rails.

    Automobile parts Automotive Sail Panel Radiator End Cap Fuel Rails with Injectors
    Injection Molding Problems and
    Solutions
    Fault Solution
    Air trap Reduce injection speed,
    Proper venting.
    Black streaks Lower the barrel temp.
    Clean the injection unit.
    Flash Adjust the clamp force.
    Reduce the injection pressure.
    Short shot Increase the injection value.
    Sink mark Increase the cooling time.
    Conclusion
     As the injection molding technology is now
    living its most rapid development times. The
    most important factors behind this situation is
     There is no potential competitors
     Injection molding is especially suitable for mass
    production.
     The profitable molding in today¶s competitive
    market depends on precise clamping action
    coupled with both high plasticizing performance
    and reliability integrated with complete plant
    operating performance.
    References
     Injection Molding Hand Book
     Dominick V Rosato
     Donald V Rosato

     Theory of Molds
     R S Nagesh
     WWW.Google.com

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