Documente Academic
Documente Profesional
Documente Cultură
1
3 March 2004 Injection Molding Processes, Tech 140
Injection Molding of Thermoplastics
2
3 March 2004 Injection Molding Processes, Tech 140
Schematic of a Basic Reciprocating Screw Injection Unit
Joseph Dym, Injection Molds and Molding 2nd ed., pg. 244. 1987
3
3 March 2004 Injection Molding Processes, Tech 140
Plasticating Screw
Joseph Dym, Injection Molds and Molding 2nd ed., pg. 248. 1987
4
3 March 2004 Injection Molding Processes, Tech 140
Injection Molding Clamping Unit
The clamping unit must be able to keep the mold halves
closed during the pressurized injection of plastic and not
allow flashing
Common clamping mechanisms are direct hydraulic
clamping and mechanical toggle clamps, actuated by
hydraulic cylinders
Toggle clamps make use of mechanical advantage but are
opened and locked by use of a hydraulic cylinder
Today, many injection molding machines use direct hydraulic
clamping since it uses fewer moving parts and is reliable and
highly controllable
The methods by which molds are attached to clamping unit include
screw and bolt fixtures, key rods and vacuum to hold the mold,
magnetic force and friction or a combination of these.
5
3 March 2004 Injection Molding Processes, Tech 140
Toggle and Direct Hydraulic Clamps
6
3 March 2004 Injection Molding Processes, Tech 140
Injection Molding Molds
7
3 March 2004 Injection Molding Processes, Tech 140
Injection Molding of Thermosets
8
3 March 2004 Injection Molding Processes, Tech 140
Special Venting Barrels and Screws
10
3 March 2004 Injection Molding Processes, Tech 140
Reaction Injection Molding
Almost any low viscosity thermosetting liquid resin can be
used with RIM, (not just polyurethane polymers referred to
in the text)
Reactive components are initially mixed using
impingement or mechanical mixing
In either case, material must flow into the mold in a laminar
fashion to prevent air bubbles or reinforcement preforms from
moving (in the case of rigid parts)
Some of the advantages of RIM are
Tooling cost is relatively low
Ease of part removal and quick cycle times for large parts
Reference on RIM process
C.W. Macosko, RIM, Fundamentals of Reaction Injection
Molding, Hanser Publishers, New York (1989)
11
3 March 2004 Injection Molding Processes, Tech 140
Resin Transfer Molding (RTM)
Resin transfer molding falls under liquid resin molding
(LMR) techniques and has come about as an alternative to
hand lay up, spay-up and compression molding techniques
for reinforced thermosets
The process is similar to RIM but employs vacuum in
addition to injection of resin under pressure; many
different kinds of resins are used in this process including
polyesters, epoxies, nylons and methacrylates
Process advantages include energy savings compared to
manual methods, lowered volatile emissions, fast part
production compared to manual techniques, insert
materials easily designed into finished parts
12
3 March 2004 Injection Molding Processes, Tech 140
RTM Process
Specialized metering pumps are required to accurately
proportion the different components of the resin system
(typically a resin and catalyst) since cure times and
properties will be dependent on the ratio
A piston injector or the same metering pumps may be
employed to apply injection pressure
At the entrance of the mold, motionless mixers are
employed to mix the components in a laminar fashion to
avoid bubble formation
Molds are designed to be filled from the bottom up so as to
displace air from top vents; vents are closed once the liquid
resin saturates the fiber preform.
..\IMAGES\RTM[1].AVI
13
3 March 2004 Injection Molding Processes, Tech 140
Motionless Mixer for RTM
14
3 March 2004 Injection Molding Processes, Tech 140
Compression Molding
One of the simplest molding processes; consists of heating material
under pressure and temperature while in a mold cavity ( see lab
exercise #8)
Elastomers and thermosets, like phenolics and melamine compounds,
are often formed via compression molding; They can be reinforced
with glass cloth
Advantages include
Simple tooling no sprues or runners in the mold
No material waste, except possible flash
Tooling is relatively inexpensive
High part quality and consistency
Negative aspect include
Long cycle times for small parts compared to other processes
Intricate parts with small holes or sharp corners and undercuts
are not possible
15
3 March 2004 Injection Molding Processes, Tech 140
Compression Molding Process
Powdered, granular or preform materials may be
used as a starting form; preforms are often
preferred since they already contain the
appropriate amount of material and can be easily
preheated for more efficient processing times
Under heat and pressure the material is shaped
into the mold contours; thermoset are crosslinked
and hardened in the mold
While thermoplastics can be compression molded they
are not often processed in this manner as the mold has
to be cooled before removal of the part can occur
After the curing period, the part is removed
16
3 March 2004 Injection Molding Processes, Tech 140
Sintering
Sintering is required for materials that have such a high
viscosity they can not be processed by conventional means (for
example PTFE, UHMWPE, PBI)
The materials to be formed are initially compression molded at
room temperature
In this “green” preform state, they are heated from temperatures
ranging below the melt to well above it (since they are so
viscous they don’t sag unless very large sizes are sintered)
Sintering may be carried out in a mold as well to retain the original
shape without deformation due to sagging
Individual polymer particles will coalesce over time and fuse
together
A secondary machining step is often required to finish the part
17
3 March 2004 Injection Molding Processes, Tech 140
Transfer Molding
Transfer molding combines elements of compression and
injection molding
It is similar to compression molding in that only one part may be
made before more material has to be loaded
It is similar to injection molding in that material is fluid during
processing and is injected into the mold from an outside chamber;
molds are very similar to injection molding molds
Advantages include: ability to mold complex parts, less flash than
compression molding, multiple parts can be molded
Disadvantages include: more material waste than compression
molding (which can’t be recycled since thermosets are typically
used), more expensive tooling than compression molding, size
limitations
18
3 March 2004 Injection Molding Processes, Tech 140
Transfer Molding Process
A slug or charge of material is placed in the pot
(injection chamber) and heated to the process
temperature
The slug will most often be preheated to improve
processing efficiency and also improves the quality of
the part
The plunger then forces the material through the
sprue, runners and gates into the heated mold
cavity
Once the material cures sufficiently under pressure
and temperature, the entire part is ejected,
including waste sprues, runners and gates
19
3 March 2004 Injection Molding Processes, Tech 140
Schematic of Transfer Molding Machine
Text pg 159
20
3 March 2004 Injection Molding Processes, Tech 140
Machining Unreinforced Thermoplastics
21
3 March 2004 Injection Molding Processes, Tech 140
Machining of Rigid Composites
Instead of regular edged cutting tools, it is best to use an abrasive type
of cutting tool and slow speed to machine rigid thermosetting
composites
Use of abrasive tools is preferred to minimize the possibility of
Delamination – separation of plies in layered composites
Reinforcement pull out – pull our of fibers in the matrix
Splintering - Use of a backing material is highly recommended
Crack damage
Damage to composites as a result of impact from tools or other objects
may not be apparent
Abrasive blades use hard materials like diamond and tungsten carbide to
machine composites with glass, graphite, and boron reinforcement due to
the hardness of these materials
22
3 March 2004 Injection Molding Processes, Tech 140
Machining Safeguards
When machining rigid composites, the use of a
liquid coolant is highly recommended even if
cooling is not required
Using abrasive cutting tools creates a lot of dust
Liquid coolants and vacuum systems minimizes dust in
the air; graphite, glass, and other micron sized particles
are hazardous to breath because of the small size
Always use dust masks and eye protection when
machining any sort of plastic material
23
3 March 2004 Injection Molding Processes, Tech 140