Injection Molding

Overview
1
Introduction
Aim
The aim of this chapter is to review
The injection molding process
Why do it
Understanding injection molding
2
Hopper
Screw
(Ram)
Barrel
Hydraulic
Unit
Tool
Injection Molding Machine
3
Injection Molding Terminology
Part Cavity
Polymer Entrance Point
Secondary Runner
Gate
Cold Slug Well
Primary Runner
Sprue
Mold Components
4
Hopper
Barrel
Screw
Mold
Screw is applying a specified
pressure to the polymer melt in
order to pack more plastic into
the cavity.
Injection Molding Process
Filling
Mold closes
Screw forward
Frozen polymer skin
forms at mold walls
Packing Time
Cavity filled
Pressure applied to
polymer
Cooling occurs
Gate freezes



Injection Molding Process
Cooling
Part continues to cool until
rigid enough to withstand
ejection
Screw moves back
plasticating resin for next
shot
Mold Open
Part is ejected
6
Cycle Time:

Fill Time:

Pack Time:

Cooling Time:

Mold Open Time:
22
Sec.
1
9
10
2
Injection Molding Cycle
7
The Injection Mold
a.k.a.
Stationary Half
a.k.a.
Moving Half
8
Injection Pressure
Pressure is required to push the plastic
into the mold cavity
Limited by machine capability
Hydraulic pump limitations
Usually around 140 180 MPa (20,000
26,000 psi)
Modern machines can go up to 300 MPa
(43,500 psi)
Major influence on final part dimensions

9
Variables Affecting Injection
Pressure
Part Design
Mold Design
Processing
Conditions
Material Selection
Each area is affected by
other areas
Some are easily changed,
while others are not
10
Pressure - Drives Flow
Flow is driven by pressure
Overcomes the melt's resistance to flow
Plastics flow from high to low pressure areas
Pressure decreases along the flow length
Sprue
P
r
e
s
s
u
r
e

Runner
Gate
Part
Advancing
Flow Front
Flow Length
Part Design Affecting Injection
Pressure
Part Thickness Surface Area
Higher
Pressure
Thin Part
Thick Part
Lower
Pressure
More surface
area to be
cooled
Higher
Pressure
Lower
Pressure
Less surface
area to be
cooled
12
Mold Design Affecting Injection
Pressure
Gate size Flow length (gate
location)
Restrictive Gate Higher
Pressure
Generous Gate Lower
Pressure
Long Flow Length Higher Pressure
Short Flow Length Lower Pressure
13
Processing Conditions Affecting
Injection Pressure
Injection time [Sec.]
I
n
j
e
c
t
i
o
n

P
r
e
s
s
u
r
e

[
M
P
a
]
Injection Pressure vs Time
Optimum time Range
Fill time
14
Processing Conditions Affecting
Injection Pressure
Melt temperature Mold temperature
Colder Melt Higher Pressure
Hotter Melt Lower Pressure
Colder Coolant Temperature Higher
Pressure
Hotter Coolant Temperature Lower
Pressure
15
Material Selection Affecting
Injection Pressure
Different grades of the same material can
have widely different pressure requirements
Pressure Vs Material Viscosity PP
50
100
150
200
250
300
350
0 2 4 6
Injection Time [Sec.]
P
r
e
s
s
u
r
e

[
M
P
a
]
High Viscosity
Low Viscosity
16
Material Selection Affecting
Injection Pressure
Material selection affects injection pressure
Different materials have different required pressures
Resin Flow Properties
Low melt index g/10 min = higher pressure
High melt index
g/10 min = lower
pressure

Pressure Vs Material Type
0
50
100
150
200
250
300
0 2 4 6 8
Injection Time [Sec.]
P
r
e
s
s
u
r
e

[
M
P
a
]
PC
ABS
PP
17
Factors Affecting Injection Pressure
Requires Higher
Injection Pressure
Requires Lower
Injection Pressure
Variable Change Inj. Press.
Thin
Thick
High
Low
Small
Large
Long
Short
Too Short
Too Long
Optimal
Low
High
Low
High
Improper
Optimal
Low
High
Low
High
Melt Index
Viscosity
Fill Time
Melt Temperature
Mold Temperature
Velocity Profile
Part Thickness
Surface Area
Gate Size
Flow Length
18