Injection Molding MFG 355

15 Ton Injection Molding Machine Click on frame to start video

77 Ton Injection Molding Machine Click on frame to start video

150 Ton Injection Molding Machine Click on frame to start video

Equipment Injection Unit Screw drive arrangement Feed hopper Barrel heaters Nozzle Tool Screw Check valve Screw tip

Equipment Injection Unit

Injection Parts of the injection screw Screw Head and check ring

Equipment Molds

Molds

Mold Materials Aluminum filled epoxy Aluminum Tool steel Stainless steel Hotwork die steel Beryllium-copper

Mold Materials Choice based on critical properties Machinability Coefficient of thermal expansion Specific heat capacity Thermal conductivity Density Hardness (abrasion resistance) Yield strength Weldability

Mold Parts Bases Standard sizes Hold mold inserts Can decrease overall mold costs

Mold Parts Guide pins Align mold cavities Guide pins

Mold Parts Sprue Bushing Hot sprue Cold sprue

Mold Parts Sprue Bushing Hot sprue

Mold Parts Sprue Bushing Cold sprue Sprue puller

Mold Parts Sprue Bushing Cold sprue Sprue puller

Mold Parts Runner

Mold Parts Runner Layout Conventional Improved Balanced “H” Circular

Mold Parts Runner Layout Conventional Improved Balanced “H” Circular

Mold Parts Runner Cold well

Mold Parts Runner

Mold Parts Gates Submarine Gate Fan or Edge Gate Pinpoint Gate

Mold Parts Gates Tab Gate Sprue Gate Flash Gate

Mold Parts Gates Internal Ring Gate External Ring Gate

Mold Parts Gate

Mold Parts Gate

Mold Parts Gate

Mold Parts Cavity Where the part is made Layout is critical to material flow

Mold Parts Cavity Knit/weld lines This shows where the weld lines (shown in red) will most likely occur with the part gated in the center (yellow cone).

Mold Parts Cooling Reduce cycle time Control formation of crystalline areas Freeze part Mold cavity Cooling lines

Mold Parts Ejector system Ejector pins Return Springs Ejector Plate

Equipment Clamping Unit

Equipment Clamping Unit Toggle clamping Hydraulic clamping Hybrid hydraulic-toggle clamping

Equipment Clamping Unit

Equipment Clamping Unit Toggle system Click on frame to start video

Plant Concepts

Safety High clamping forces High pressure lines High voltage High temperatures

Safety Position switches Shields Lock out/tag out Mechanical, hydraulic and electrical Shields Lock out/tag out

Material and Product Considerations Shapes Possible to do very complex shapes Structural features Pins, ribs, bosses, threads, holes Deep parts are possible Internal or external threads Undercuts require sliding mold sections

Sliding Mechanism

Material and Product Considerations Part design Uniform wall thickness Helps reduce dimples, shrink marks and distortion Ribs Save weight at given strength No sharp bends Helps to fill the mold cavity easier Oversize the mold Shrinkage amount is dependant on material and additives/fillers

Operations and Control Temperature of melt Temperature of mold Pressure of injection and hold Injection or fill rate and time Dwell time Freeze time Ejection (dead time)

Special Injection Molding Processes Coinjection molding Two separate screws Two different material selections Color, strength, flexibility

Special Injection Molding Processes Coinjection molding 1 2 3

Special Injection Molding Processes Coinjection molding Part 1 Part 2

Special Injection Molding Processes Flow-controlled injection processes Sometimes called Scorim

Special Injection Molding Processes Flow-controlled injection processes Sometimes called Scorim

Special Injection Molding Processes Gas injection molding Employs gas to create hollow parts

Special Injection Molding Processes Injection-compression molding Parts were made with the same mold. The only difference between the two parts is the use of the compression cycle Injection-Compression Molding Injection Molding

Modeling and Computer-Aided Mold-Flow Analysis Used to help identify potential problems with the mold/part design Models based on the CAD part Adjusted by resin

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