INJECTION MOULDING PROCESS -
RESOURCES
MATERIAL
MACHINE
MOULD
MAN POWER
MATERIAL
P L A S A TIC M A TE R IA L
TH E R M O P L A S TIC TH E R M O S E T
M A TE R IA L M A TE R IA L
THERMPLASTIC MATERIAL
•SOFT
•HEAT •COOL •SOLID
•PRESS.
IT CAN BE RECYCLED
THERMOSET MATERIAL
•SOFT •SOLID
•HEAT •HEAT
•CHARCOAL
•PRESS.
•IT CAN NOT BE RECYCLED
MACHINE
• HEATING
• PRESURISING AND CONVEYING
• MOULD CLAMPING
MOULD
• THE MOLD HAS 4 MAIN FUNCTIONS
• RECEIVE & DISTRIBUTE THE MATERIAL
• SHAPE FORMING
• COOLING(Water & oil)
• DISPOSAL
MANPOWER
• TO SET UP A PROCESS
• TO MONITOR AND TROUBLE SHOOT
• TO OPARATE MACHINE
TYPES OF INJECTION MOULDING MACHINES
PLUNGER TYPE
PLUNGER-
PLUNGER TYPE
SCREW –
PLUNGER
TYPE
IN LINE
RESIPROCATING
SCREW TYPE
Screw Rotation
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 Speed
It is important that the speed the screw is kept constant from cycle to
cycle. If the speed of rotation of the screw is increased, or if takes
longer to refill the amount of sheer put in to melt will be increased.
Screw stroke:
The return stroke of the injection is determined by the amount of
material to be injected ( shot weight). The longer the stroke larger
the volume.
Injection Pressure and Hold on Pressure
MELT TEMPARATURE
• CAN BE CHANGED BY
BARREL TEMPARATURE
BACK PRESSURE
SCREW RPM
CYCLE TIME
PRESSURE PROFILE IN CAVITY
NOZZLE
• It provides thermal&mechanical connection
from hot cylinder to cold injection mold
• TYPES
An open channel with no mechanical valve
An internal check - valve held closed by
spring
A shut off valve
Standard / Open
Channel nozzle
Reverse tapered /
Nylon nozzle
Needle type shut –off nozzle
Non-return valve
Ring type
Ball Type
Standard
Type
P.V.C
Purpose
SCREW-TYPES
GENERAL PURPOSE SCREW
ENTED SCREW
BARRIER SCREW
SCREW FOR THERMOSET
Screw
nomenclature
SCREW-L/D RATIO
The flighted length of screw to the dia. Of 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 the 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
SCREW- VARIOUS ZONES IN SCREW
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
SIGNIFICANCE OF LENGTH OF EACH
ZONE
Longer feed zone creates greater potential
throughput
Longer compression zone results in less shear
heat and more to compress and 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
SCREW-CHANNEL DEPTH
• Higher channel depth in feed zone conveys more material
and hence more torque is required to rotate.Shallow
channel depth screw requires higher rpm and lower torque
for a given output rate.Shear rate is lower on the polymer
in screws with deeper channel depth at lower rpm.Hence it
is preferred for shear sensitive polymers
• A shallow screw channel
Increases the exposure of plastic to the heated barrel
wall
Increases the shear heat imparted to the polymer
Reduces potential throughput of the screw
COMPRESSION RATIO
IT IS THE RATIO OF THE VOLUME OF FIRST TURN OF
SCREW TO VOLUME OF LAST TURN OF THE SCREW
IT IS NORMALLY BETWEEN 1.5 to 4.5 FOR GENERAL
PURPOSE SCREW
LOWER CR SUITS LOW VISCOCITY MELTS AND
HIGHER CR SUITS HIGHER VISCOCITY MELTS
HIGHER THE CR,GREATER THE RESULLTING
Shear heat imparted to the polymer
Heat uniformity of melt
Potential for creating stresses in some polymers
Energy consumption
CLAMPPING-TYPES
• MAJORLY OF TWO TYPES
HYDAULIC CLAMPING
TOGGLE CLAMPING
Hydraulic Clamping
Toggle Clamping
HYDRAULIC Vs TOGGLE-COMPARISION
• Much higher original • Lower original cost
cost
• Higher horse power • Lower horse power
needed.Therefore more needed.More economical
expensive to run to run
• Unlimited stroke • Limited stroke potential
potential • No Direct readout of
• Direct readout of clamp clamp force
force
HYDRAULIC Vs TOGGLE-COMPARISION
• Easy adjustment of • More difficult
clamp force
• Easy mold setup • More involvement in
mold setup
• Varies stroke to mold • Constant mold stroke
height
• Clamp speed easily • Clamp speed more
controlled or stopped at difficult to control and
any point stop
• Low maintenance as • Higher maintenance cost
parts are self lubricated
MACHINE SELECTION
INJECTION TO UNDERSTAND
UNIT
Maximum swept volume,cc Shot weight for a material
How it ensures melt to spread
Max.Inj.Speed, gm/sec or
throughout when in fluid condition-
cc/sec
before it freezes
How it overcomes to flow during
Max.Inj.Pressure,Kg/cm2
filling on account of flow ratio and
viscosity
Max.Plasticizing rate,gm/sec
How it influences cycle time
or Kg/hr
Max.Injection power, How it takes care of difficulty in
Kg-cm/sec filling of thinner walled and
high flow ratio parts
MACHINE SELECTION
CLAMPING UNIT TO UNDERSTAD
Clearance between tie bar and
How it accommodates mold
platen size
Max.day light =
Max.day light and mold open mold open stroke + min.day light
stroke (it`s significance for ejection of
deep parts)
Clamping force in tons Depends on cavity pressure
HYDROMOTOR
MACHINE SELECTION
DRIVE POWER TO UNDERSTAND
Power supply frequency 60
Its influence on speeds
or 50 hz
Pump-motor raring,Kw To match the application-usage of
machine
Conventional/Proportional valve
Controlls hydraulic controls
Electrical/microprocessor controls
Open/closed loop controls
It indicates the time for non
No load cycle time processing part of the cycle time
MACHINE
SELECTION
Force on melt
(F1)= Force in
Hydraulic cylinder
( F2 )
Pm As = Ph Ah
Ph D2h
Pm = _-------------
D2s
INJECTION MOULDING PROCESS
• MATERIAL PREPARATIOIN
• PLASTICIZING
• INJECTION
• COOLING
• EJECTION
• PACKING
Elements of the Injection Moulding Cycle
POLYMER MATERIAL TEMP.RANGE 0 C MOLD TEPMP.
Nylon-6 230-260 80-90
Nylon-6 with GF 230-280 70-90
80-90
Nylon-66 270-290
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
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
THREMOSET INJECTION MOULDING PROCESS
ADVANCED INJECTION MOULDING PROCESS
VENTED
BARREL
TYPE
SCREW
COOLING
TYPE
REACTION INJECTION MOULDING PROCESS
TWO COLOR
MOULDING
MULTI
COLORED
MOULDING
GAS ASSISTED
INJECTION
MOULDING
PROCESS
CLOSED LOOP CONTROLS SYSTEM
In closed loop controls the effect of disturbances in the
process is eliminated by counter acting or by opposing the
effects of disturbance by automatically triggering certain
reaction
The above is done in response of feedback which is compared
with the set value to take the required corrective action
OPEN-LOOP CONTROLS SYSTEM
Set process parameters in open loop control influences the
process. But does not make correction by providing the
feedback, if there is any disturbance is effecting the process .
In open loop controls the effect of disturbances in the
process is eliminated or held constant to ensure the
uniformity in the process
SRUCTURAL FOAM MOULDING
( SANDWHICH )
•THANK YOU
