113-1 ME3300302 Manufacturing processes

Yu-Chien Ho
Department of Mechanical Engineering
Classification of solidification processes

Glass working

Shaping processes for plastics

Solidification
processes
Sand casting
Expendable-mold
casting Investment casting
(Lost-wax process)
Casting of metals
Permanent-mold Die casting
casting
Centrifugal casting

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Plastic optical materials - Injection

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Shaping processes for plastics - Injection molding

ASTM D1238
Injection molding

Material Melting point, shrinkage,

melt index (g/10 min)

Hopper, injection system, clamping mechanisms,

Machine
and control panel for process parameters

Mold Runner, gate, heating and cooling, ejection

*Victor Taichung Machinery Works Co., LTD. 4

Thermoplastic

Semi-crystalline: PA, PP, PEEK, PET, etc.

Amorphous: ABS, PS, PC, PMMA, etc. Processing window

Glass transition temp. Melting temp.

Heat deflection temp. Decomposition temp.

Rubber-like state ASTM D648

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Injection molding machine - 1

*Mikell P. Groover, Chapter 13/Shaping Processes for Plastics

(Fundamentals of Modern Manufacturing: Materials,
Processes, and Systems), 5th Edition/Wiley, 2012.

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 Injection molding machine - 2

*Mikell P. Groover, Chapter 13/Shaping Processes for Plastics (Fundamentals of Modern Manufacturing: Materials, Processes, and Systems), 5th Edition/Wiley, 2012. 7
 Injection molding machine - 3

Rapid Heat Cycle Molding (RHCM)

*Mikell P. Groover, Chapter 13/Shaping Processes for Plastics (Fundamentals of Modern Manufacturing: Materials, Processes, and Systems), 5th Edition/Wiley, 2012. 8
 Injection molding machine - 4

Hot runner

*Mikell P. Groover, Chapter 13/Shaping Processes for Plastics (Fundamentals of Modern Manufacturing: Materials, Processes, and Systems), 5th Edition/Wiley, 2012. 9
 Injection molding machine - 5

Clamping force, F = A x P

p (kgf/cm2): Cavity pressure inside the mold

A (cm2): Total projection area

*Mikell P. Groover, Chapter 13/Shaping Processes for Plastics (Fundamentals of Modern Manufacturing: Materials, Processes, and Systems), 5th Edition/Wiley, 2012. 10
Injection mold - 1

Function:
- Molding
- Runner/gate (material transportation)
- Heating and cooling
- Ejection
…etc.

undercut
*Bo Li, One Picture to Understand the Structure of an Injection Mold, 2018. 11
Injection mold - 2

slide locking spring to hold the slide in the

Slide open position

ejector pin
angular pin product with undercut
slide

core/cavity 模仁 insert (鑲件/入子)

*3D Cad Model in Solidworks Tutorial, Langgeng Wahyu Hidayat. 12
Runner and gate design

Gate size, location, and type 13

Parting line

The criteria for selecting the most suitable draw direction:

1. Minimize undercuts (number and then volume of cores)
2. Minimize the total draw distance (for both halves)
3. Minimize draft allowance (volume increment).
or mismatch, solidification, side thrust, flash, and so forth.

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Aspects of injection molding theory

 Rheology is the science of fluids. The study of fluid flow in non-Newtonian fluids.
 Non-Newtonian fluid: A fluid whose viscosity varies with shear rate. As the shear
changes, the viscosity does not remain the same. (such as all plastics)

The shear rate is directly proportional to the injection speed. This will make mold
filling inconsistent and affect mass production products.

The effect of shear rate on viscosity is much greater than temperature.

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 Process operations

Temperature: barrel zones, tool,

mold zone
Pressure: injection max, hold
Time: injection, hold, tool
opening
Shot size: screw travel

Filling Packing Holding/Cooling Warping?

* Source: http://www.idsa-mp.org/proc/plastic/injection/injection_process.htm 16
Processing parameters: Temperature and pressure

*Shia-Chung Chen, Pham Son Minh, and Jen-An Chang, International

Communications in Heat and Mass Transfer 2011, 38(3): 304-312.

Injection pressure Clamping force  Holding pressure Back pressure

*OCEAN MOTION INDUSTRY COMPANY LIMITED *Eric, Injection molding Vs Vacuum casting, how to choose, 2021.
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Processing parameters: Speed

*PTC creo mold analysis extension (cma) tutorial 18

Processing parameters: Time

Cycle time 35s cycle time as an EXAMPLE

*D.E. Dimla, M. Camilotto, and F. Miani, Design and optimization of conformal cooling channels
in injection molding tools, Journal of Materials Processing Technology 2005, 164-165: 1294-1300. 19
Processing parameters of injection molding: Temperature, pressure, and speed

Injection pressure Clamping force  Holding pressure Back pressure

*OCEAN MOTION INDUSTRY COMPANY LIMITED *Eric, Injection molding Vs Vacuum casting, how to choose, 2021.

viscosity changes dramatically with temperature

*Retrieved: https://www.moldchina.com/optimum-injection-speed-in-plastic-injection-molding/
(Optimum Injection Speed in Plastic Injection Molding) 20
How to choose the injection machine?

 Mold size (product size, injection volume)

 Mold opening stroke
 Clamping force
 Screw compression ratio (feeding, compression, metering/discharge)

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22
 EXERCISE 1: Injection machine size

A batch of 10 cm diameter disk with a thickness of 8 mm are to be molded from high-density

PolyEthylene in a 6-cavity mold. Determine the appropriate machine size. (Given that,
approximately 50% of the pressure generated in the machine injection unit is lost.)

Sol.:

Projected area of each part: πD2/4 = π(10)2/4 = 78.5 cm2

Part volume = 78.5 x 0.8 = 62.8 cm3

Refer to TABLE 8.2, at 62.8 cm3 volume, the runner % is approximately 19%.
Therefore, total projected area: 6 x 1.19 x 78.5 = 560.5 cm2

Refer to TABLE 8.5, Recommend injection pressure for the high-density polyethylene: 965 bars
With lost of 50% of pressure generated, max. cavity pressure = 965 x 0.5 = 482.5 bars
(1 bar = 105 Pa = 0.1 MPa)
Estimated max. clamping force = Ncavity x A x P = {6x1.19x78.5x10-4} x 482.5 x 105 = 2700.4 KN
Refer to TABLE 8.4, the suitable machine is one with clamping force 5000 KN

Shot size for the product = 6 x 1.19 x 78.5 x 0.8 = 448.4 cm3
Therefore, 5000 KN injection machine is suitable because having shot size 2290 cm3
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Molding cycle time

 Injection/Filling
-A total time requires for polymer to flow through the runners, gates, and fulfil the
cavities.

 Cooling
-It is assumed that cooling in the mold takes place almost entirely by heat
conduction. (for flat-type part)

 Ejection/Resetting
-The summation of mold opening, part ejection, and mold closing times is referred
to as the resetting time and have been suggested by Ostwald as:
Treset = 1 + 1.75．Tdry [(2D + 5) / Ls]½ (sec)

Overall cycle time = Tfill + Tcool + Treset (sec)

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EXERCISE 2: Filling

Calculate the estimated injection time for the 10 cm disks molded in a

6-cavity mold as in EXERCISE 1.

Sol.:

 Shot size 448.4 cm3  Vs

 Recommended injection pressure, 965 x 105 N/m2  pj
 Injection power 63 KW  Pj

Therefore,

Tfill = 1.37 (sec)

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EXERCISE 3: Cooling

Min. cooling time, Tcool =

α = thermal diffusivity (0.11 x 10-6 m2/s)

h = plate thickness (3 x 10-3 m)
TW = mold temperature (27 °C)
TM = melt temperature (232 °C)
TE = ejection temperature (52 °C)

Min. cooling time for centerline to reach TE is Tcool: 19.45 (sec)

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EXERCISE 4: Resetting

Assume that 10 cm diameter plain cylindrical cups with a depth of 8 cm (same as

EXERCISE 1) are to be molded in a 6-cavity mold. Calculate the mold resetting time.

Treset = 1 + 1.75．Tdry [(2D + 5) / Ls]½ (sec)

Sol.:

We know that, machine size = 5000 KN

Then, refer to TABLE 8.4, given:
-Dry cycle time, Tdry = 6.1 (sec)
-Machine clamp stroke, Ls = 70 cm

Therefore, estimated resetting time Treset = 1 + 1.75．6.1 [(2 x 0.8 + 5) / 70]½ = 4.3 (sec)

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Injection quality

Short shots

Flash

Sink marks and

voids

Weld lines

Discoloration

Sticking

Warpage

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Product design considerations

Part complexity
(undercut)

Corners

Section thicknesses

Draft

Holes

Tolerances

Parting line

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Overmolding processes - Insert molding

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Overmolding processes - Two shot molding

A plastic molding process in which two different plastic resins

are molded together in a single manufacturing cycle.

Copyright © 2024 Gemini Group, Inc.

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Shaping processes for plastics - Blow molding

*Mikell P. Groover, Chapter 13/Shaping Processes for Plastics (Fundamentals of Modern Manufacturing: Materials,
Processes, and Systems), 5th Edition/Wiley, 2012. 32
Shaping processes for plastics - Thermoforming

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 Shaping processes for plastics - Sheet molding compound (SMC)

Thermoplastic mat

Lexus LFA

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Shaping processes for plastics - Resin transfer molding (RTM) / vRTM

Preform

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Shaping processes for plastics - Autoclave

Autoclave curing has traditionally been used to achieve the desired fiber content
(resin-to-fiber ratio) and the absence of resin voids to produce light weight and
strong components.

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Manufacture of tires and other rubber products - 1

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