Injection Molding Technology

Learning Outcome:
Develop an understanding of the injection molding process and relevant factors governing the design of the design of injection mould tools.

References: 1. Modern Plastic Handbook, (2000), Edited By Charles A Harper, McGraw Hill. 2. Injection Molding Handbook, D.V. Rosato, Chapman & Hall. 3. Plastics Engineering (1998) R.J. Crawford, Butterworth-Heinemann 4. Plastics Material and Processing By A.B. Strong. 5. Tool Knowledge 01, Injection Mold (Fundamentals) Pak Swiss Training Centre (PCSIR)

Over View:
Injection Molding Technology Products and Industry The process Cycle Tools Details Developments in Injection molding processes

Injection Molding Process

Injection molding is a versatile process that can produce small parts that weight in fraction as well as large parts that weight in kg.
During this process, molten plastic is forced (injected) into a mold and cooled until the melt solidifies. When the part is cooled sufficiently, the mold is opened, the part is ejected from the mold, and the mold is closed again to repeat the cycle.

Injection Molding Process

Injection molding permits mass-production, high-precision, and three-dimensional virtual net shape manufacturing of plastic parts. While there are many variations on the basic process, 90 percent of injection molding occurs with thermoplastic resin.

Injection molding requires an injection-molding machine, a mold, and ancillary equipment such as material-feeding and conveying equipment, dryers, mold temperature controllers, chillers, and robotics and conveyers.
The material-feeding and conveying equipment and the dryers are common to most thermoplastic manufacturing processes, while the robotics and conveyers automate the molding process.

Products Market Sectors

Automotive.

Aerospace / Defence.
Computers, telecoms & optical disks. Construction. Medical. Packaging. Appliances. Home & Leisure.

Products - Automotive

Products Telecoms and Computers

Products Medical:

Injection Molding Machine

Injection-molding machines have three components:

1. The injection unit. 2. The clamping unit. 3. The Mold. The injection unit plasticates and injects the polymer melt.
The clamping unit supports the mold, opens and closes the mold, and contains the part ejection system. Typically different injection units can be assembled with the same clamping unit.

Injection Molding Machine

Injection Molding Machine

1. The Injection Unit:
The injection unit brings the nozzle into contact with the sprue bushing of the mold, generates contact pressure between the nozzle and sprue bushing, melts the plastic material, injects the molten material into the mold, and builds up packing and holding pressure.

1.1 Types of Injection Unit.

Several types of injection units have been used. i) Single Stage Reciprocating Screw ii) Single Stage Plunger Unit iii) Two Stage Screw/Plunger Machine or Pre Plasticizing Machine

i. Single Stage Reciprocation Screw:

In single stage reciprocating screw injection unit, the screw rotate to plasticate the polymer and moves linearly to inject the melt. The injection unit has two major component, the plasticizing unit and a sled. The plasticizing unit melts and inject the resin while the sled translate the plasticizing unit. The plasticizing unit consists of a hopper , feed throat, barrel, screw, screw drive motors and nozzle. Single stage reciprocating operates like a extruder. During injection , the screw is driven forward by a hydraulic piston or motor. Injection molding barrels are shorter than extruder barrel with low L/D ratio. The injection unit (Sled) retracts away from the mold along its rail. This permits purging of the material from barrel when changing the resin type in the machine or getting rid of degraded material.

Single Stage Reciprocation Screw

ii. Single Stage Plunger Unit:

Single stage plunge unit melts the polymer by conduction from the barrel walls and then inject the melt using a hydraulic plunger. These unit provides limited shot size, poor shot size control, poor melting and mixing, non uniform heating of the melt, long resistance time and high pressure losses.

iii. Pre Plasticizing Machine:

Both the reciprocating screw and the plunger injection system combine the melting of the resin and the injection of the resin into a single system. When extremely fast cycle are desired, the melting of the resin is separated from the injection function.

This is done by attaching the barrel in which melting is done either by screw or ram to a second barrel that contain a plunger and a injection chamber. This barrel is called pre plasticating cylinder and the entire arrangement is called pre plasticizing machine.

Pre Plasticizing Machine

2. Clamping Unit:
The clamping Unit supports the mold, hold the mold, closed during injection, open and closes the mold as rapidly as possible, provide space for part protection. Types of Clamping Unit:
i. Hydraulic Clamping. ii. Toggle Clamping.

i.

Hydraulic Clamping.

A clamping unit actuate by a hydraulic cylinder that is directly connected to the moving platen. Direct fluid pressure is used to open and close the mould and to provide clamping force to hold the mold during injection.

ii. Toggle Clamping:

A Clamping unit with toggle mechanism directly connected to the moving platen. A hydraulic or some mechanical force device is connected to the toggle system to exert the opening & closing force and hold the mold close during injection.

3. Mold:
Injection Mold provides a passage way for molten plastic to travel from the barrel to the mold cavity. It gives final shape to the part, cools the material and eject the final part. They also must withstand the forces of injection and ejection, transfer motion. Injection mold can be classified as

1. Two Plate Mold 2. Three Plate Mold

The standard two plate mold has two halves. The division between these two halves is called, the parting.

Injection Mold
Two Plate Mold

Cavity and Punch:

A cavity in a mould is a the hollow space to accommodate the molten plastic injected under pressure into it. It determines the outer shape of the component and is located mostly on the injection side. Punch is gives inner shape to the part. Punch is normally located on ejector side (moving side) Cavity-Punch will be treated as one unit in respect of application but they are separated by parting line. In normal case both cavity and punch are used to form component.

Runner:
The runner is expected to offer to the hot plastic a quick flow path. The main runner starting from sprue is called Primary runner and further branches are known as secondary runner .

Number of Cavities:
When a small size molded component is required in a large quantity and a shorter period of time it is necessary to have more than one cavity in a mould. Some times multi cavity mould is also designed to produce different component in each cavity, mostly required for a common assemble. This is applicable only when equal numbers of each component are required and also in the same color and material. This is called group mould.

Number of Cavities:

Arrange of Runners:

Gates:
The small passage which is leading directly into the cavity is called gate. The selection of best suitable gate is very important.

1. Sprue Gate:

Advantages: Minimum pressure loss occur due to direct injection. Regular wall thickness can be obtained. Disadvantage: Additional labor for removing the sprue is needed. Sprue mark will always be visible.

Edge Gate:

Advantage: Easy removal of runner since the section is comparatively small. Rather minor gate marks.

Disadvantage: High injection pressure required since the material flow is poor due to small section of gate.

Diaphragm Gate:

Advantages: Uniformity in diameter and strength is assured by using this gate. Due to uniform filling no weld line will appear. In view of accuracy very good result can be obtained. Disadvantages: Extra labor is required for degating, mostly on machine. Core can be located on one side only, therefore length of hollow component to be molded must be restricted if accuracy is expected.

Ring Gate:

Advantages: Injection take place all around the cavity at the same time and provide uniform wall thickness and strength. Disadvantage: Extra labor is required for degating, mostly on machine.

Flash Gate:

Advantages: As the material is injected from one side so the flow of material is in one direction and no weld line will appear and homogeneous structure and good mechanical strength will be obtained. Disadvantage: Extra labor is required for degating.

Submarine Gate:

Advantages: Automatic Production is possible due to automatic degating. No extra labor cost.
Disadvantages: Relatively high injection pressure is required since material flow is rather poor due to small gate section.

Pin Point Gate:

Advantages: Automatic degating and therefore no extra cost. Disadvantages: Most of the time a more complicated mould is required and also the moulding machines is expected to be well developed, so initial cost are certainly higher.

EJECTION SYSTEM
In injection molding the component normally shrinks and grips on the punch which is generally on the moveable half of the tool. After the tool opens it is necessary to remove the component from the punch which demands considerable care. This removal of the component is called Ejection .

1. Pin Ejector

1. Pin Ejector

2. Blade Ejector

3. Sleeve Ejector

4. Stripper Plate

4. Stripper Plate

5. Disc Ejector

6. Air Ejection

7. Chain Ejection

Slider Mold

1. Pin Ejector:
These are the simplest, cheapest and most common types of ejectors. Generally cylindrical pins are used for this purpose. Such pins are often available in the market in different sizes and with one end peeled into a head (Cylindrical or 60o tapered).
The pins can be stepped or ground flat on one side. The ejector leaves the impression on the moulding. It should be located as not to damage the component, moreover the impression are not to disturb its function.

2. Blade Ejector:
The component is trapped between two opposite steel faces of the tool (cavity/punch). In case we put ejectors on the spots X (certainly cheaper) the component is not ejected nicely, it is likely to stick at the areas R (for resistance). The result is bent or torn component. This ejector shape increases the contact area. In cases like this pin ejectors could easily damage the component.

3. Sleeve Ejector:
This type of ejector is used to eject circular components, with a thin wall sticking on a core. The core itself is attached to the back plate (ejection side). The ejector in form of a sleeve is around this core pins ejects the component all around the edge.

4. Stripper Plate:
The stripper plate is an accurately adjusted plate around the core, being the parting line. During ejection the plate moves along the core pushing and removing the component.

5. Disc Ejector:
This mechanism is used basically for moulding house hold utensils or big enough components (circular). Is consists of a round disc operated by a centrally located rod. The disc ejects a comparatively delicate moulding at the base without damaging it (as the contact surface is large). It is cheap to manufacture and more effective when ejecting deep components with thin walls.

6. Air Ejection:
Compressed air enters through the punch plate and pushes the ejector towards the injection side. The air is of course not flowing continuously, but is regulated by a switch allowing one short blast after each mould opening .

7. Chain Ejection:
When is not possible to do centre ejection due to the machine design or the construction of the tool, this method can be used. Chains are always fixed on the sides of the tool. Provision to adjust the chain slackness equally on either side is very important.