INJECTION MOULDING

Historical Background
A single-action hydraulic injection machine was designed in the U.S.A. in
1870 by Hyatt
Heating-cylinder design was first recognised in a patent issued to Adam
Gastron in 1932.
Large-scale development of injection moulding machinery design towards the
machines we know today did not occur until the 1950's in Germany
InjectionMouldingProcess Over View

Solid Wide neck, Flat Product is made like bucket, cabinets, Automobile &
Industrial parts etc. by injecting molten thermoplastic material in to a closed
mould which is relatively cool.
Type of Injection Moulding Machine
Hand Injection Moulding M/C
Plunger type Injection Moulding M/C
Reciprocating Screw Type Injection Moulding M/C
Hand Injection Moulding Machine

vertical machine consists of Barrel, Plunger, Band Heaters along with energy
regulator, Rack & Pinion system for Injecting the material by the plunger, a
torpedo and nozzle. 2 | P a g e
Plunger Type Injection

Moulding Machine
Vertical & Horizontal Plunger Type Injection Moulding Machine
The Reciprocating Screw
The feeding zone
The compressing (or transition) zone
The metering zone

Machine components 3 | P a g e
The Injection Process
Plasticises the material by reciprocating Screw.
Injects the molten material to a closed mould
o via a channel system of gates and runners.
Cools the Mould.
Refills the material for the next cycle.
Ejects the Product.
Closes the Mould for further cycle.
Injection Moulded Items
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Advantages of Injection Moulding Process
Parts can be produced at high production rates.
Large volume production is possible.
Relatively low labour cost per unit is obtainable.
Process is highly susceptible to automation.
Parts require little or no finishing.
Many different surfaces, colours, and finishes are available.
Good decoration is possible.
For many shapes this process is the most economical way to fabricate.
Process permits the manufacture of very small parts which are almost
impossible to fabricate in quantities by other methods.
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Minimal scrap loss result as runners, gates, and rejects can be reground and
reused.
Same items can be moulded in different materials, without changing the
machine or mould in some cases.
Close dimensional tolerances can be maintained.
Parts can be moulded with metallic and non-metallic inserts.
Parts can be moulded in a combination of plastic and such fillers as glass,
asbestos, talc and carbon.
The inherent properties of the material give many advantages such as high
strength-weight rates, corrosion resistance, strength and clarity.

Limitations of Injection Moulding

Intense industry competition often results in low profit margins.
Mould costs are high.
Moulding machinery and auxiliary equipment costs are high.
Lack of knowledge about the fundamentals of the process causes problems.
Lack of knowledge about the long term properties of the materials may result
in long-term failures.

Machine operation sequence

The mould closes and the screw begins moving forward for injection.
The cavity fills as the reciprocating screw moves forward, as a plunger.
The cavity is packed as the screw continuously moves forward. 6 | P a g e
The cavity cools as the gate freezes off and the screw begins to retract to plasticize
material for the next shot.
The mould opens for part ejection
The mould closes and the next cycle begins 7 | P a g e
Mould system
A typical (three-plate) moulding system
A two-plate mould. A three-plate mould.
The moulded system includes a delivery system and moulded parts.
Screw Used in Injection Moulding Machines 8 | P a g e
The screw has three zones with a ring-plunger assembly. The Feed Zone, where
the plastic first enters the screw and is conveyed along a constant root diameter;
the Transition Zone, where the plastic is conveyed, compressed and melted along
a root diameter that increases with a constant taper; and the Metering Zone, where
the melting of the plastic is completed and the melt is conveyed forward along a
constant root diameter reaching a temperature and viscosity to form parts.
L/D RATIO
The L/D ratio is the ratio of the flighted length (Effective Length) of the screw
to its outside diameter.
Most injection screws use a 20:1 L/D ratio. But it may range from 18:1 to 24:1
In the case of Thermoset it may range from 12:1 to 16:1.

High L/D Ratio results the following .

More shear heat can be uniformly generated in the plastic without degradation;
Greater the opportunity for mixing, resulting in a better homogeneity of the
melt.
Greater the residence time of the plastic in the barrel possibly permitting faster
cycles of larger shots.

COMPRESSION RATIO (CR)

The ratio of the first flight depth of feed zone to the last flight depth of meter
zone ,
Or,
First Channel Volume of feed zone to last channel volume of metering zone,
Typically ranges from 1.5:1 to 4.5:1 for most thermoplastic materials.
Most injection screws classified as general purpose have a compression ratio
of 2.5:1 to 3.0:1.
Thermo set screws have a 1:1 ratio.
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Higher the CR results the following .
Greater shear heat imparted to the resin
Greater heat uniformity of the melt
High Potential for creating stresses in some resins
High energy consumption

Back Pressure (Kg/Cm2 or bar)

Back pressure is the amount of pressure exerted by the material ahead of the screw,
as the screw is pushed back in preparation for the next shot.