PROSES MANUFAKTUR

Injection Molding

PROSES-PROSES
MANUFAKTUR
Forming
j
Casting
Sand Casting
Die Casting
Shell Molding

Machining
ReForming
Forging
Extrusion

Rolling

Injection Molding

Coining
Drawing

Turning
Drilling
Milling
Flame Cutting
Reaming
Grinding

Joining

Welding
Screw
Rivets
Pins
Clips
Keys

INJECTION MOLDING PROCESS

Introduction
Polymer/Plastik

Thermoset

A plastic that, when cured by application of heat or by chemical means, changes into a
substantially infusible and product
General properties: more durable, harder, tough, light.
Typical uses: automobile parts, construction materials.
Examples:
Unsaturated Polyesters: varnishes, furniture
Epoxies & Resins: glues, coating of electrical circuits,
composites: fiberglass

INJECTION MOLDING PROCESS

Introduction
Polymer/Plastik

Elastomers

General properties: these are thermosets, and have rubber like properties.
Typical uses: medical masks, gloves
Examples:
Polyurethanes
Silicones

Thermoplastics

A plastic that can be repeatedly softened by heating and hardened by cooling through a
temperature range characteristic of the plastic, and that in the softened state, can be
shaped by flow into an article by molding or extrusion
General properties: low melting point, softer, flexible.
Typical uses: bottles, food wrappers, toys,

INJECTION MOLDING PROCESS

EXAMPLE
Polyethylene: packaging, electrical insulation, milk & water bottles
Polypropylene: carpet fibers, bumpers, microwave containers
Polyvinyl chloride (PVC): cables cover, credit cards, car instrument panels
Polystyrene: spoons, Styrofoam
Acrylics (PMMA: polymethyl methacrylate): paints, fake fur, plexiglass
Polyamide (nylon): textiles, gears, bushing, bearings
PET (polyethylene terephthalate): bottles for acidic foods like juices, food trays
PTFE (polytetrafluoroethylene): non-stick coating, dental floss

INJECTION MOLDING PROCESS

Plastic Shaping Processes are
Important

Almost unlimited variety of part geometries

Plastic molding is a net shape process
Further shaping is not needed
Less energy is required than for metals due to much lower processing temperatures
Handling of product is simplified during production because of lower temperatures
Painting or plating is usually not required

INJECTION MOLDING PROCESS

Injection Molding
Polymer is heated to a highly plastic state and forced to flow under high pressure
into a mold cavity where it solidifies and the molding is then removed from cavity
Produces components almost always to net shape
Typical cycle time 10 to 30 sec, but cycles of one minute or more are not
uncommon
Mold may contain multiple cavities, so multiple moldings are produced each
cycle

INJECTION MOLDING PROCESS

Injection Molded Parts

Complex and intricate shapes are possible

Shape limitations:
Capability to fabricate a mold whose cavity is the same geometry as part
Shape must allow for part removal from mold
Part size from 50 g up to 25 kg (more than 25 KG), e.g., automobile bumpers
Injection molding is economical only for large production quantities due to high
cost of mold

INJECTION MOLDING PROCESS

Injection Molding Machine

Two (or four) principal components:

1. Injection unit
Melts and delivers polymer melt
Operates much like an extruder
2. Clamping unit
Opens and closes mold each injection cycle
3. Injection mold
4. Control system

INJECTION MOLDING PROCESS

INJECTION UNIT TYPE

A)
RAM

C) PREPLASTICIZER

B) RECIPROCATING
SCREW

Reciprocating Screw Injection

Molding Machine
Resin is melt by mechanical shear and
thermal energy from heaters
The molten resin is conveyed to a space at
the end of the screw- collects in a pool
Here, the mold is closed

Reciprocating Screw Injection

Molding Machine
The entire screw move forward and pushes the
molten resin out through the end of barrel
To ensure the resin does not flow backward, a
check valve or nonreturn valve is attached to
the end of screw
Normally the screw will stay in the forward
position, until resin began to harden in the mold

Reciprocating Screw Injection

Molding Machine
Retraction of the screw, create space at the end of the
screw
Cooling of the part in the mold, until it can be removed
While the part is cooling, the screw turns and melts
additional resin

Reciprocating Screw Injection

Molding Machine

Feed Zone: The portion of the screw that picks up the material from the feed opening (base
of the hopper) and begins to soften the material as it is being conveyed. The flight depths are
constant.
Transition Zone: The portion of the screw where the root diameter increases gradually
resulting in the decrease of the flight depth. This causes the softened plastic pellets to
further melt and compress eliminating any of the air pockets.
Metering Zone: The depth of the flights in this section are minimum but constant. This
helps the accurate control of the melt discharge for the molding shot. In other words, it
meters the amount of melt. The flight depths are constant.

CHECK RING
The check ring is used to prevent the plastic from being blown back during the
injection phase of the molding cycle. It is similar to a non return valve

Reciprocating Screw Injection Molding

Machine
Advantages
More uniform melting
Improved mixing or additives and dispersion throughout the
resin
Lower injection pressure
Fewer stresses in the part
Faster total cycle

INJECTION MOLD
Designing and making mold for injection
molding is more complicated than making
extrusion die
Mold Parts mold is placed in between
stationary plate and the moveable plate

CLAMPING
UNIT UNIT

HYDROLIC

TOGLE

Limited clamp force

Lower costs
Lower horsepower
No feedback on load
Not controllable
speed

High clamp forces

Higher costs
Higher horse power
Easily adjustable
Clamp speed controllable
Slow speed

PART DEFECT
SHRINKAGE AND WARPAGE

What are shrinkage and warpage?

Shrinkage geometric reduction in size of the part. If
the shrinkage is uniform, the part does not deform or
change in shape, it simply becomes smaller
Warpage when shrinkage is not uniform or if regions
of the part shrink unequally

Shringkage

Shrinkage and consequently warpage is affected by

processing condition.
It is a complex function of machine settings, however a
major factor is the pressure and time history during fills,
packs and cools.

Warpage

PART DEFECT
OTHER DEFECT
Burnt streaks
If the melt was damaged thermally by to high
themperatures

Weld line
High viscosity
If themperature and preesure is not high enough, the corner of the flow front will not clompletely
develope

PART DEFECT
OTHER DEFECT
Jetting
Jetting is caused by an undeveloped frontal flow of melt in the
cavity

Incomplete filled part

Long flow distance or thin wall
Injected volume compound to small- Injection pressure not sufficient premature frezzing