INJECTION MOLDING OF THERMOSET PLASTICS

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Presentation transcript:

INJECTION MOLDING OF THERMOSET PLASTICS BY ALOK KUMAR

THERMOSET INJECTION MOLDING MACHINE

PHOTO OF PLASTICIZING THE RESIN

PHOTO OF INJECTION OFTHE RESIN

PHOTO OF CROSSLINKING

PHOTO OF EJECTION

How injection molding works?

Difference between injection molding of thermoset and thermoplastics Barrel Screw Mold temperature

BARREL

Process characteristics Production Rate - high Can produce intricate parts Can produce a wide range of part sizes with different press sizes. Tooling cost - high

What is thermoset material? A material, such as an epoxy or polyester resin, which has the property of undergoing a chemical reaction by the action of heat, catalyst, ultraviolet light, etc., to become a relatively insoluble and infusible substance. They develop a well-bonded three-dimensional structure upon curing. Once hardened or cross-linked, they will decompose rather than melt.

Some of the thermoset materials Phenolics Urea Melamine Unsaturated polyester

Specialty of the thermoset polymers for injection molding Delayed curing even at higher temperature Good flow properties Fast reaction at tool temperature Improved wear characteristics

TEMPERATURE IN degree C MATERIAL NOZZLE CYLINDER MOLD PHENOLIC 80-100 55-75 170-190 110-130 UREA 85-115 65-80 130-150 120-140 MELAMINE 90-110 160-170 115-135 UN-SATURATED POLYESTERS 70-100 50-70 170-200

THERMAL PROFILE OF IM

Rheology HEAT EXPOSURE TIME TEMPERATURE SHEARING

Rheology of Thermoplastics and Thermosets

Advantages of Injection Molding Material handling is reduced

Advantages of Injection Molding Longer and smaller diameter core pins may be used

Advantages of Injection Molding Parting line flash can be held to minimal thickness if the mold is designed properly and well maintained

Advantages of Injection Molding Injection molding of thermoset materials lends itself to automating the process which can result in lower piece costs.

Disadvantages of Injection Molding The total amount of scrap produced during injection molding will usually be higher than that for compression molding

Disadvantages of Injection Molding Warpage can be a problem in injection

Disadvantages of Injection Molding The filling of the parts through one or two gates produces parts that have knit lines.

Applications Phenolics: Electrical plug and sockets circuit board cutlery handles

Applications Melamine-formaldehyde: Dinnerware Kitchen utensils Bathroom accessories

THANK YOU