Injection MoldingMolding Process Description

ver. 1

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

Overview
Equipment Process

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

Equipment
Cl Clamp M ld Mold B Barrel l Hopper

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

Equipment

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

KrausMaffei at Ford - 4000 tonnes

ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2009

Machine schematic

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

Mold

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

Mold

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

Modular molds

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

Mold schematic

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Mold
runner gate cavity sprue

sprue p

nozzle

front

ejection pin

side
11

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

Process

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Process
Pellets placed in hopper Pellets fall into barrel through throat Pellets P ll t packed k dt to f form solid lid b bed d
air forced out through hopper

Pellets melted by mechanical shear between barrel and screw

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Process
Melted plastic forms shot in front of screw
screw moves back b k as plastic l ti moves forward (reciprocating screw)

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Process
Screw moves forward to inject j p plastic into mold cavity

Part P t cools l and d solidifies lidifi

next shot is made

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Process
Mold opens Ejection pins move forward to eject part

Mold closes Process starts again

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Solid bed
Pellets crushed together Air ejected

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Melting zone
Solid bed melted by mechanical shear
barrel

secondary mixing flow

screw flight solid bed

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Homogenization zone
Melted polymer is homogenized thermally y and color-wise.

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Injection pressure
Typically 15,000 psi Ranges from 3 3,000 000 to 40 40,000 000 psi Hydraulic pressure is about 10x less

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Process time
Open and eject part p Close mold Injection j

33 35

1 5

Pack and hold Part cooling

15

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Pressure history y
Cycle time Mold closed time Cooling 50 Fas st closing Injection Pack Gate freez ze off Part ej jection 33 35

2 25

0 0 5 15 Time (s)
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009 22

Temperature history
Cooling Part ej jection 33 35 200 part p Fas st closing Injection gate Pack ze off Gate freez 15 Time (s)
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009 23

100

0 0 5

Gates and freeze freeze-off off

Filling & Packing

Cooling

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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