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Machine Components: Injection System

The document describes the key components of an injection molding machine. It discusses the injection system which includes a hopper, screw and barrel assembly, and nozzle. The reciprocating screw is used to compress, melt and convey plastic material through different zones. It also describes the mold system, which includes platens and molding plates that contain cavities and cooling channels. The hydraulic, control and clamping systems are also summarized.

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Syed Mujtaba Ali Bukhari
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© Attribution Non-Commercial (BY-NC)
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84 views5 pages

Machine Components: Injection System

The document describes the key components of an injection molding machine. It discusses the injection system which includes a hopper, screw and barrel assembly, and nozzle. The reciprocating screw is used to compress, melt and convey plastic material through different zones. It also describes the mold system, which includes platens and molding plates that contain cavities and cooling channels. The hydraulic, control and clamping systems are also summarized.

Uploaded by

Syed Mujtaba Ali Bukhari
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Machine components

Injection system
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.

The hopper
Thermoplastic material is supplied to molders in the form of small pellets. The hopper on the
injection molding machine holds these pellets. The pellets are gravity-fed from the hopper
through the hopper throat into the barrel and screw assembly.

The barrel
As shown in Figure 1, the barrel of the injection molding machine supports the reciprocating
plasticizing screw. It is heated by the electric heater bands.

The reciprocating screw


The reciprocating screw is used to compress, melt, and convey the material. The
reciprocating screw consists of three zones (illustrated below):

 the feeding zone


 the compressing (or transition) zone
 the metering zone

While the outside diameter of the screw remains constant, the depth of the flights on the
reciprocating screw decreases from the feed zone to the beginning of the metering zone.
These flights compress the material against the inside diameter of the barrel, which creates
viscous (shear) heat. This shear heat is mainly responsible for melting the material. The
heater bands outside the barrel help maintain the material in the molten state. Typically, a
molding machine can have three or more heater bands or zones with different temperature
settings.

FIGURE 2. A reciprocating screw, showing the feeding zone, compressing (or transition) zone, and
metering zone.

The nozzle
The nozzle connects the barrel to the sprue bushing of the mold and forms a seal between the
barrel and the mold. The temperature of the nozzle should be set to the material's melt
temperature or just below it, depending on the recommendation of the material supplier.
When the barrel is in its full forward processing position, the radius of the nozzle should nest
and seal in the concave radius in the sprue bushing with a locating ring. During purging of
the barrel, the barrel backs out from the sprue, so the purging compound can free fall from
the nozzle. These two barrel positions are illustrated below.

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

Mold system
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.
FIGURE 4. A typical (three-plate) molding system.

An mold system is an assembly of platens and molding plates typically made of tool steel.
The mold system shapes the plastics inside the mold cavity (or matrix of cavities) and ejects
the molded part(s). The stationary platen is attached to the barrel side of the machine and is
connected to the moving platen by the tie bars. The cavity plate is generally mounted on the
stationary platen and houses the injection nozzle. The core plate moves with the moving
platen guided by the tie bars. Occasionally, the cavity plate is mounted to the moving platen
and the core plate and a hydraulic knock-out (ejector) system is mounted to the stationary
platen.

Two-plate mold
The vast majority of molds consist essentially of two halves, as shown below. This kind of
mold is used for parts that are typically gated on or around their edge, with the runner in the
same mold plate as the cavity.

Three-plate mold
The three-plate mold is typically used for parts that are gated away from their edge. The
runner is in two plates, separate from the cavity and core, as shown in Figure 5 below.
FIGURE 5. (Left) A two-plate mold. (Right) A three-plate mold.

Cooling channels (circuits)


Cooling channels are passageways located within the body of a mold, through which a
cooling medium (typically water, steam, or oil) circulates. Their function is the regulation of
temperature on the mold surface. Cooling channels can also be combined with other
temperature control devices, like bafflers, bubblers, and thermal pins or heat pipes.

Hydraulic system
The hydraulic system on the injection molding machine provides the power to open and
close the mold, build and hold the clamping tonnage, turn the reciprocating screw, drive the
reciprocating screw, and energize ejector pins and moving mold cores. A number of
hydraulic components are required to provide this power, which include pumps, valves,
hydraulic motors, hydraulic fittings, hydraulic tubing, and hydraulic reservoirs.

Control system
The control system provides consistency and repeatability in machine operation. It monitors
and controls the processing parameters, including the temperature, pressure, injection speed,
screw speed and position, and hydraulic position. The process control has a direct impact on
the final part quality and the economics of the process. Process control systems can range
from a simple relay on/off control to an extremely sophisticated microprocessor-based,
closed-loop control.

Clamping system
The clamping system opens and closes the mold, supports and carries the constituent parts of
the mold, and generates sufficient force to prevent the mold from opening. Clamping force
can be generated by a mechanical (toggle) lock, hydraulic lock, or a combination of the two
basic types.

Molded system
A typical molded system consists of the delivery system and the molded part(s), as shown
in Figure 6.
FIGURE 6. The molded system includes a delivery system and molded parts.

The delivery system


The delivery system, which provides passage for the molten plastic from the machine nozzle
to the part cavity, generally includes:

 a sprue
 cold slug wells
 a main runner
 branch runners
 gates

The delivery system design has a great influence on the filling pattern and thus the quality of
the molded part.

Cold runners
After molding, the cold-runner delivery system is trimmed off and recycled. Therefore, the
delivery system is normally designed to consume minimum material, while maintaining the
function of delivering molten plastic to the cavity in a desirable pattern.

Hot runners
The hot-runner (or runnerless) molding process keeps the runners hot in order to maintain
the plastic in a molten state at all times. Since the hot-runner system is not removed from the
mold with the molded part, it saves material and eliminates the secondary trimming process.

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