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    Injection Molding

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    lovilove01
    Injection Molding is a manufacturing process where melted plastic is injected into a mold cavity. It involves: 1) Melting plastic and injecting it into a mold cavity at high pressure. As the plastic cools, it adopts the shape of the cavity. 2) Heat transfer from the plastic to the mold is important to control cycle times, with cooling generally dominating the cycle. 3) Proper part and gate design is needed to avoid defects like sink marks, weld lines, and warping. Gate location, rib placement, and draft angles all impact quality. 4) Tooling includes molds made of cavity and core plates. Nozzles, runners, and gates are

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    Injection Molding

    Uploaded by

    lovilove01
    144 views42 pages
    Injection Molding is a manufacturing process where melted plastic is injected into a mold cavity. It involves: 1) Melting plastic and injecting it into a mold cavity at high pressure. As the plastic cools, it adopts the shape of the cavity. 2) Heat transfer from the plastic to the mold is important to control cycle times, with cooling generally dominating the cycle. 3) Proper part and gate design is needed to avoid defects like sink marks, weld lines, and warping. Gate location, rib placement, and draft angles all impact quality. 4) Tooling includes molds made of cavity and core plates. Nozzles, runners, and gates are

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    Injection Molding is a manufacturing process where melted plastic is injected into a mold cavity. It involves: 1) Melting plastic and injecting it into a mold cavity at high pressure. As the plastic cools, it adopts the shape of the cavity. 2) Heat transfer from the plastic to the mold is important to control cycle times, with cooling generally dominating the cycle. 3) Proper part and gate design is needed to avoid defects like sink marks, weld lines, and warping. Gate location, rib placement, and draft angles all impact quality. 4) Tooling includes molds made of cavity and core plates. Nozzles, runners, and gates are

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    144 views42 pages

    Injection Molding

    Uploaded by

    lovilove01
    Injection Molding is a manufacturing process where melted plastic is injected into a mold cavity. It involves: 1) Melting plastic and injecting it into a mold cavity at high pressure. As the plastic cools, it adopts the shape of the cavity. 2) Heat transfer from the plastic to the mold is important to control cycle times, with cooling generally dominating the cycle. 3) Proper part and gate design is needed to avoid defects like sink marks, weld lines, and warping. Gate location, rib placement, and draft angles all impact quality. 4) Tooling includes molds made of cavity and core plates. Nozzles, runners, and gates are

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    At a glance
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    The key takeaways are the basic operation, cycle time and heat transfer, flow and solidification, part design, tooling, and new developments in injection molding and its environmental impacts.

    The main steps in the injection molding process are filling the mold cavity, maintaining pressure in the mold (packing), allowing the plastic to cool and solidify (cooling), and then opening the mold to eject the finished part.

    The cooling time generally dominates the overall cycle time, as it takes time for the plastic in the mold to cool and solidify before the mold can be opened.

    Injection Molding

    2.810 Fall 2004 Professor Tim Gutowski

    Short history of plastics


    1862 first synthetic plastic 1866 Celluloid 1891 Rayon 1907 Bakelite 1913 Cellophane 1926 PVC 1933 Polyethylene 1938 Teflon 1939 Nylon stockings 1957 velcro 1967 The Graduate

    Outline
    Basic operation Cycle time and heat transfer Flow and solidification Part design Tooling New developments Environment

    Readings
    Tadmore and Gogos
    n

    Molding and Casting pp584 -610

    Boothroyd Dewhurst
    n

    Design for Injection Molding pp 319 - 359

    Kalpakjian see Ch 18 Injection molding case study;Washing machine augers; see on web page

    30 ton, 1.5 oz (45 cm3) Engel

    Injection Molding Machine for wheel fabrication

    Process & machine schematics


    *

    Schematic of thermoplastic Injection molding machine


    * Source: http://www.idsa-mp.org/proc/plastic/injection/injection_process.htm

    Process Operation
    Temperature: barrel zones, tool, die zone Pressures: injection max, hold Times: injection, hold, tool opening Shot size: screw travel
    Processing window
    Temp. Thermal degradation Flash Shortshot

    Melt

    Pressure

    Typical pressure/temperature cycle


    * *

    Time(sec)

    Time(sec)

    Cooling time generally dominates cycle time

    * Source: http://islnotes.cps.msu.edu/trp/inj/inj_time.html

    thickness ) tcool = 10 3 cm3 sec for polymers


    2

    (half =

    Calculate clamp force, & shot size


    F=P X A = 420 tons
    3.8 lbs = 2245 cm3 =75 oz

    Actual ; 2 cavity 800 ton

    Clamp force and machine cost

    Heat transfer
    qx qx + qx

    Note; Tool > polymer

    1-dimensional heat conduction equation :

    Fouriers law

    q ( c p T ) xy = x xy t x T q x = k x T 2T T 2T cp = k 2 or = 2 t x t x
    1st kind 2nd kind 3rd kind T ( x = x' ) = constant T ( x = x' ) = constant x T k ( x = x' ) = h (T T ) x k

    Boundary Conditions:

    The boundary condition of 1st kind applies to injection molding since the tool is often maintained at a constant temperature

    Heat transfer
    T ii t TW x

    Let Lch = H/2 (half thickness) = L ; tch = L2/ ; Tch = Ti TW (initial temp. wall temp.) Non-dimensionalize: =

    -L

    +L

    T TW x t ; = + 1; FO = 2 Ti TW L L

    Dimensionless equation: Initial condition Boundary condition

    2 = 2 FO
    FO = 0
    =0 =2

    =1
    =0 =0

    Separation of variables ; matching B.C.; matching I.C.

    ( , FO ) = f ( FO ) g ( )

    Temperature in a slab Centerline, = 0.1, Fo = t/L2 = 1

    Bi-1 =k/hL

    Reynolds Number
    Reynolds Number:

    V2 inertia VL L Re = = V 2 viscous L

    For typical injection molding

    = 1 g cm3 = 10 3 N m 4 s 2 ; LZ = 103 m V Part length 10 = ; Fill time 1s


    1

    thickness

    = 103 N s m 2

    Re = 10 4

    For Die casting

    3 10 3 10 1 10 3 Re = 300 3 10

    * Source: http://www.idsa-mp.org/proc/plastic/injection/injection_process.htm

    Viscous Shearing of Fluids


    F h 1 v

    F/A

    F v A h
    Generalization:
    = (& ) &

    v = h
    v/h

    Newtonian Viscosity

    = &

    & : shear rate


    Injection molding

    Typical shear rate for Polymer processes (sec)-1 Extrusion Calendering Injection molding Comp. Molding 102~103 10~102 103~104 1~10

    Shear Thinning ~ 1 sec-1 for PE

    &

    Viscous Heating
    Rate of Heating = Rate of Viscous Work Rate of Temperature rise

    P F v F v v = = = Vol Vol A h h

    cp

    dT v = dt h

    or

    dT v = dt c p h

    Rate of Conduction out

    dT k d 2T k T = ~ dt c p dx2 c p h2

    Viscous heating v 2 = Conduction kT

    Brinkman number

    For injection molding, order of magnitude ~ 0.1 to 10

    Non-Isothermal Flow
    v

    Flow rate: 1/t ~V/Lx Heat transfer rate: 1/t ~a/(Lz/2)2

    Flow rate V L2 1 VL z Lz z ~ = Heat xfer rate 4 Lx 4 Lx


    For injection molding

    Small value => Short shot

    Flow rate 1 10cm / s 0.1cm 0.1cm ~ = 2.5 3 2 Heat xfer rate 4 10 cm / s 10cm
    For Die casting of aluminum

    Flow rate 1 10cm / s 0.1cm 0.1cm 2 ~ 10 Heat xfer rate 4 0.3cm2 / s 10cm
    * Very small, therefore it requires thick runners

    Injection mold

    die cast mold

    Fountain Flow
    *

    **

    * Source: http://islnotes.cps.msu.edu/trp/inj/flw_froz.html ; ** Z. Tadmore and C. Gogos, Principles of Polymer Processing

    Shrinkage distributions
    sample

    Transverse direction

    V=3.5cm/s

    V=8cm/s

    * Source: G. Menges and W. Wubken, Influence of processing conditions on Molecular Orientation in Injection Molds

    Gate Location and Warping


    Sprue 2.0 60 1.96 60.32

    Shrinkage Direction of flow 0.020 in/in Perpendicular to flow 0.012

    2.0

    1.976

    Before shrinkage

    After shrinkage

    Air entrapment Gate

    Center gate: radial flow severe distortion

    Edge gate: warp free, air entrapment

    Diagonal gate: radial flow twisting

    End gates: linear flow minimum warping

    Effects of mold temperature and pressure on shrinkage


    0.030 0.025 0.030 0.025 0.020 0.015 0.010 0.005

    LDPE

    PP Acetal Shrinkage Nylon 6/6

    LDPE Acetal PP with flow PP across flow

    Shrinkage

    0.020

    0.015 0.010 0.005

    Nylon 6/6

    PMMA
    0.000 100 120 140 160 180 200 220 240 0.000 6000

    PMMA
    8000 10000 12000 14000 16000 18000

    Mold Temperature (F)

    Pressure on injection plunger (psi)

    Where would you gate this part?

    Weld line, Sink mark


    Gate

    Weld line

    Mold Filling

    Solidified part

    Sink mark
    * Source: http://www.idsa-mp.org/proc/plastic/injection/injection_design_7.htm

    Basic rules in designing ribs to minimize sink marks

    Injection Molding
    *

    * Source: http://www.idsa-mp.org/proc/plastic/injection/injection_design_2.htm

    Where is injection molding?

    Ltotal = Lmold + Lshrinkage

    Effects of mold temperature and pressure on shrinkage


    0.030

    LDPE Acetal PP with flow

    0.025

    0.020

    Shrinkage

    0.015

    PP across flow

    Nylon 6/6

    0.010

    0.005

    PMMA
    6000 8000 10000 12000 14000 16000 18000

    0.000

    Pressure on injection plunger (psi)

    Tooling Basics
    Sprue Nozzle Cavity Plate Core Plate

    Moulding Cavity

    Core

    Cavity

    Basic mould consisting of cavity and core plate

    Gate

    Runner

    Melt Delivery

    Tooling for a plastic cup


    Nozzle

    Knob Runner Cavity

    Part Stripper plate Core

    Tooling for a plastic cup


    Nozzle Nozzle Runner Cavity Runner Part Cavity Cavity Knob

    Part

    Part
    Stripper plate

    Tooling
    * * *

    * * **

    * Source: http://www.idsa-mp.org/proc/plastic/injection/; ** http://www.hzs.co.jp/english/products/e_trainer/mold/basic/basic.htm (E-trainer by HZS Co.,Ltd.)

    Part design rules


    Simple shapes to reduce tooling cost
    n

    No undercuts, etc. In some cases, small angles (1/4) will do Problem for gears

    Draft angle to remove part


    n n

    Even wall thickness Minimum wall thickness ~ 0.025 in Avoid sharp corners Hide weld lines
    n

    Holes may be molded 2/3 of the way through the wall only, with final drilling to eliminate weld lines

    New developments- Gas assisted injection molding

    New developments ; injection molding with cores


    Injection Molded Housing shown in class

    Cores used in Injection Molding

    Cores and Part Molded in Clear Plastic

    Environmental issues
    Petroleum and refining Primary processing Out gassing & energy during processing End of life

    Environmental loads by manufacturing sector


    Carbon Dioxide and Toxic Materials per Value of Shipments
    5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 Plastics and Rubber Petroleum and Coal Chemicals

    Weight/Dollars

    CO2 (metric ton/$10,000)

    Toxic Mat'ls (lb/$1000)

    Primary Metal

    Manufacturing industries

    Transportation

    Fabricated Metal

    Machinery

    Electronic

    EPA 2001, DOE 2001

    The estimated environmental performance of various mfg processes (not including auxiliary requirements)

    *Energy per wt. normalized by the melt energy

    ** total raw matl normalized by the part wt.

    The printer goes in the hopper

    And comes out.

    The problem with plastics is

    Or remanufacture.

    Summary
    Basic operation Cycle time and heat transfer Flow and solidification Part design Tooling New developments Environment

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