Topworks Weekly Digest

Injection Moulding Process

by Steven Cheng on September 04

In the injection moulding process a relatively cold mould, shaped as the negative of the component to be
producedis filled under pressure by the injection of a pre-determined quantity of heated and plasticized
material. The injected material solidifies, and after a period of further cooling the mould is opened and the
product removed.
The following illustrate the main phases of the process as carried out on a horizontal plunger type
injection moulding machine The course of the material from granulate to the finished product as
illustrated in these diagrams is as follows:

The granulate is loaded into the hopper of the measuring or dosing device above the injection unit. From
the hopper, a predetermined quantity of material falls in front of the plunger. This charge of material is
pushed forward by the plunger so that it is depositedfirst on to the injection plunger and then, after
withdrawal of the latter, in front of it.
As the injection plunger moves forward, it forces the material through the plunger guide into the heating
cylinder In this cylinder which is heated on its outer surface by electric resistance- type heater bands, the
material is brought to a state of thermoplastic melt. Even heating of the material as it passes through the
cylinder is aided by a spreader inside the cylinder. This spreader, or torpedo as it is also known, forces the
material against the hot inner wall of the cylinder.
As successive strokes of the injection plunger force the material through the heating cylinder it's
consistency changes until, at the front part of the cylinder, it is in the state of a homogeneous melt ready
for injection. The melt is forced into the mould through the injection nozzle. This operation is also
referred to as shooting \ while the speed of injection, which is regulated to suit the material being used
and the component, is known as the c shot rate
The mould, which is clamped or bolted in position in the injection machine consists basically of halves;
one member mounted on the stationary platen and one on the moving platen.
From the injection nozzle the material passes through the sprue bush in the nozzle or fixed side of the
mould. It is then distributed to the cavities through interconnecting channels or 'runners.When the cooling
period has elapsed the mould is opened and the components (T) are ejected from the moving mould-half
by means of ejector pins which, as the mould approaches the fully open positionare operated by the
ejector tail striking the stroke limiting screw.
Thus, the injection moulding cycle may be divided into five stages, as follows :

The measuring out, in front of the injection plunger, of a quantity of granulate equivalent to the
capacity of the mould cavity or cavities.

The melting of this material in the heating cylinder to a consistency suitable for injection.

Injection of the melted material into the closed and relatively cold mould.

Cooling the injected material to the point of solidification.

Opening the mould and removing the product.

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Mold Center/ West District

Huangyan, Zhejiang,China 318020