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BMM 4843
Introduction
When injection mold is fixed in a molding
machine, and molten polymer is injected into
the cavity from a nozzle, a high filling pressure
acts on the inside surface of the cavity.
Since the parting surfaces of the mold try to
expand outward due to this pressure, it is
necessary to clamp the mold so that it does
not open instantaneously.
2
Clamping tonnage/force
Clamp tonnage or clamping force defines from
the clamping mechanism which keep the mold
closed during injection.
Direction of clamping tonnage
Clamping tonnage/force
Clamp tonnage requirements are determined by
the melt flow index (MFI) or viscosity of the
material being molded.
The melt flow index (MFI) is a measure of the
ease of flow of the melt of a thermoplastic
polymer.
It is defined as the mass of polymer, in grams,
flowing in 10 min through a capillary of a specific
diameter and length by a pressure applied via
prescribed alternative gravimetric weights
alternative prescribed temp.
Thermometer inside
an oil filled well
Barrel
Insulation
Polymer Melt
Die
14
Clamping tonnage/force
The projected area is multiplied by a factor
(injection pressure) from 1 5 tons/inch2
(13.8 68.9 MPa) to determine the total
amount of clamp tonnage required. The exact
number depends on material viscosity, with
the easy flowing materials needing only 1 3
tons/inch2 (13.8 41.4 MPa).
Stiffer materials needing between 2.5 5
tons/inch2 (34.5 68.9 MPa).
Clamping tonnage/force
The following is an example of how to
determine proper clamp tonnage in U.S.
customary units.
Example 1:
The part to be molded is a square plague that is 6
x 6 inch and 0.060 inch thick. Determine the
clamp tonnage for both molding material which is
Nylon and Polycarbonate. Nylon factor: 2
tons/inch2 & Polycarbonate factor: 5 tons/inch2.
Clamping tonnage/force
After, the total amount of tonnage is
determined, 10 % should be added as a safety
factor, and a machine that provides clamp
tonnage closest to that number should be
used.
Clamping tonnage/force
For instance, in the polycarbonate case noted
earlier, there was a need for 180 tons clamp
tonnage.
Adding 10 % safety factor brings that number
to 198 tons. Ideally, a 200 ton machine would
be used or 225 or 250 tons could be used.
Clamping tonnage/force
The following is an example of how to
determine proper clamp tonnage in U.S.
customary units.
Example 1:
The part to be molded is a square plague that is 6
x 6 inch and 0.060 inch thick. Determine the
clamp tonnage for both molding material which is
Nylon and Polycarbonate. Nylon factor: 2
tons/inch2 & Polycarbonate factor: 5 tons/inch2.
Clamping tonnage/force
Example 2:
Consider calculating the required mold clamping
force when four molded items are obtained using
Polybutylene terephthalate (PBT) plastic with 30
% glass fiber added.
Let us assume that the assumptions for calculation
are that the pressure inside the cavity is p = 2.13
tons/inch2, the projected area of one cavity is A1 =
2.37 inch2, and the projection area of the runner
is A2 = 0.85 inch2.
Answer:
21
Thank You
&
Any Questions?
Objectives
To determine specifically the clamp tonnage
required from the material being molded in
plastic injection moulding.
Clamping tonnage/force
Answer: The part to be molded is a square
plague that is 6 x 6 inch and 0.060 inch thick.
The projected area of that plaque would be
found by multiplying length times width, or 6
x 6 inch, which equals to 36 inch2.
Clamping tonnage/force
If the molding material is nylon, which is very easy
flowing, the lower range number of 2 tons/inch2
could be used; 36 inch2 x 2 tons = 72 tons clamping
force is required to keep the mold closed against
necessary injection pressures.
If the molding material is stiffer flowing resins, such
as polycarbonate, the projected area would need to
be multiplied times a factor of 5 instead of 2. That
would yield a total clamp tonnage requirement of 36
x 5, or 180 tons.