1. The “Right” machine for the job?

2. Introduction
The Tool
The Material

3. But which Machines?????????

4. MSDS
Legal
Requirement

5. Moulding

6. What is Polycarbonate? C CH 3 O n

7. Molecular Weight Vs. Strength
Molecular weight (x10 )
Tensile strength (kg/cm2)
Izod impact strength (kg cm/cm)
800
700
600
100 50 2
2.5
3.0 4

8. Molecular Weight Vs. Flow
Flow Value (10 m/sec)
1.5 2 3 4 5 6 10
20,000
25,000
30,000

9. Injection Moulding
Hopper
Clamping unit
Screw & Barrel
Nozzle

10. Clamping Pressure
Calculated by multiplying the projected area of the cavity (cavities), including runner system by the maximum internal pressure (hold pressure).

11. Clamping Pressure ABS 0.45 to 0.65 T/cm2 LCP 0.75 to 0.8 T/cm2
PA to 0.75 T/cm2
PBTP to 0.75 T/cm2
PC to 0.8 T/cm2
PE to 0.55 T/cm2
PETP to 0.75 T/cm2
PMMA to 0.75 T/cm2
POM to 1 T/cm2
PP to 0.55 T/cm2
PPS to 0.6 T/cm2
PS to 0.5 T/cm2

12. Injection Unit
Hopper
Screw & Barrel
Nozzle

13. Screw Design

14. Screw Types

15. Screw Tangential Speed-M/S
ABS (GR,FR) - 0.3
ETPV 0.2
PA (GR,FR) – 0.4
PBTP (GR,FR) – 0.3
PC (GR,FR) - 0.3
PE – 0.6
PETP (FR) – 0.20
PMMA (ST) – 0.3

16. Screw Tangential Speed-M/S
POM (GR,ST) – 0.3
PP (GR) – 0.6
PPA
PPS
PS (HI) - 0.6
PVC <0.1
SAN 0.3
TPC-ET <0.2
TPUR <0.15

17. Screw Speed Calculation
Beware: High speed = high
heat (through shear).
High speed = high abrasion
with filled Materials.
Beware: High back pressure increases shear (temperature) and cycle time but not necessary melt quality.

18. Melt Viscosity characteristics
Shear Rate (Sec )
Melt viscosity (poise) 10 3 4 -1

19. Pressure Vs. Flow Spiral flow length (cm) Polycarbonate
PPH
PA 6
GPPS
PPC
HDPE
LDPE
POM
ABS
Polycarbonate
Injection Pressure
Spiral flow length (cm) 40
140
(Kg/cm G) 2 80
120

20. Temp. Vs. Molecular Weight
100
1000
10000
350
340
320
300
280
Moulding temp (deg.C)
Lowering of mol. wt. (Mv)
35 min
20 min
5 min
Residence time

21. Hold-on-time
Toughened Nylon 6.6

22. Temperature Profiles

23. Conclusion
The right Melt temperature
The right Melt quality

24. A Polymer for Every Application