Unit Two: Injection Molding Text: Richardson and Lokensgard Pages 143 - 151

Unit Two
 Injection Molding
 Text: Richardson and Lokensgard

 Pages 143 - 151
Section I
Machines
Golf Story
A gushy reporter told Tiger Woods, “You are

spectacular, your name is synonymous with
the game of golf. You really know your way
around the course. What’s your secret?
Woods replied, “The holes are numbered.”

Injection Molding Machines
Plunger Style
 Example: Dake Press in

Lab
Reciprocating Screw
Example: Toyo
Injection Molding Terminology
 Clamp force (tonnage, Toyo = 35 ton

maximum clamping force)
 Shot size (in ounces, LBS for large machines)
 Hydraulic, most common
 Electric, clean room applications

Terminology
 Mold requirements (physical)
 Ejection, (various mechanical and other

systems)
 Nozzle
Machine Styles
 Plunger
 Reciprocating Screw
 Multi-Shot
 Reaction Injection Molding (RIM)

Terminology
 Non-
return
valve (one
way valve)
Injection Molding Cycle
 Mold Cycle Time elapsed between a

particular point in one cycle of production
and the same point in the next cycle.
Parts of the Injection Molding
Cycle
 Melt
 Inject
 Pack (compress)
 Cool
Mold Cycle
Melt
 heater bands
 back pressure
 screw compression
 residence time
Mold Cycle
Inject
 flow or cavity fill rate
 affects amount of molecular alignment

Mold Cycle
Pack (compress)
 peak cavity pressure
 affects shrinkage
 sink
Mold Cycle
Cool
 affects molecular orientation
 duration determines amount of crystalline

structure
 affects shrinkage
Section II
Molds (Tools)
Mold (Tool) Terminology
 Sprue
 Runner
 Gate (numerous styles)

 Cavity  Venting
 Cavity half  Cooling

 Stationary
 “A” half
 Ejector pins
 Core half
 movable
 “B” half)
 Sprue Puller
 Guide pins and bushings
 Locating ring
 Sprue Bushing
Section III
Molded Part Design

Molded Part Design
 Parting line
 Gating (marks)
 Weld/meld lines
 Family molds (produces non-identical parts

simultaneously)
Molded Part Design
 Ejector pins (mark off)
 Surface finish
 Mold shrinkage: shrinkage in mold calculated

in inch/inch, mils/in, or %.
 Post-mold shrinkage (measurements after 24

hours)
Molded Part Design
 Life span
 Part strength
 Recycle (Vs reprocessed)
 Draft (degree of taper)
 Fillets and rounds

Section IV
Design /Software
Computer Software
 Mold Flow
 design tooling
 simulates resin flow
 Moisture analysis
 Melt rheology
 melt flow
 Viscosity
 resistance to flow
 A computer application usually exists for items requiring

measurement or control
Section V
Molding Defects
Molding Defects
Short Shot Flash

 Failure to fill the mold  Surplus material formed
completely.
 Material may be solidifying
between mating mold
before filling cavity surfaces and remains
 insufficient injection pressure attached to parte.
 shot size set too small
 May require  Causes:

 increasing shot size  insufficient clamping
 Increasing temperatures pressure
 Increasing injection pressure In
 excessive injection pressure.
 May require mold redesign

Injection Molding Defects
Sink Void
 A void on the surface of the  In solid plastic, unfilled
part resulting from an spaces.
outside wall yielding to the
still shrinking interior mass.  Cause: Moisture in material
 Cause: insufficient packing

pressure
Weld Line Warpage

 The intersection of two  Distortion caused by non-
confronting flow fronts uniform change of internal
stresses.
 creates areas of local
weakness
 may be caused by:
 part design
 weld lines should be  gate location
positioned in the least  improper molding conditions
sensitive are (temperatures, pressures,
etc.)
Golf Story
The bride came down the aisle and when she

reached the altar, the groom was standing
there with his golf bag and clubs at his side.
She said: “What are your golf clubs doing here?”
He looked her right in the eye and said, “This

isn’t going to take all day, is it?”
Shrinkage Brittleness
 A volume reduction of  May be caused by over
polymers heating or excessive
residence time
 occurs during cooling
 due to a reduction in space

between the molecules.

Unit Two: Injection Molding Text: Richardson and Lokensgard Pages 143 - 151

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Unit Two

 Text: Richardson and Lokensgard

A gushy reporter told Tiger Woods, “You are

Woods replied, “The holes are numbered.”

 Example: Dake Press in

 Clamp force (tonnage, Toyo = 35 ton

 Shot size (in ounces, LBS for large machines)

 Hydraulic, most common

 Electric, clean room applications

 Mold requirements (physical)

 Ejection, (various mechanical and other

 Reaction Injection Molding (RIM)

 Mold Cycle Time elapsed between a

 affects amount of molecular alignment

 duration determines amount of crystalline

 Gate (numerous styles)

 Cavity half  Cooling

 Guide pins and bushings

Molded Part Design

 Family molds (produces non-identical parts

 Ejector pins (mark off)

 Mold shrinkage: shrinkage in mold calculated

 Post-mold shrinkage (measurements after 24

 Recycle (Vs reprocessed)

 Draft (degree of taper)

 Fillets and rounds

 A computer application usually exists for items requiring

Short Shot Flash

 May require  Causes:

 May require mold redesign

 Cause: insufficient packing

Weld Line Warpage

The bride came down the aisle and when she

She said: “What are your golf clubs doing here?”

He looked her right in the eye and said, “This

 due to a reduction in space

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