Troubleshooting For Injection Molding by IDES

Scientific Troubleshooting of Common Injection Molding Defects
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FREE Information Please visit: www.traininteractive.com

Free Weekly Focused Training Modules Free Training Report & Payback Calculator Ongoing Informational Webinars
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FREE Information
2009 Upcoming Webinars
Part Design for Reducing Cycle Time

February 18, 2009 traininteractive.com | 978.957.0700
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FREE Information
Practical Scientific Molding Techniques

March 11, 2009 traininteractive.com | 978.957.0700
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FREE Information
10 Easy Ways to Analyze Your Plastic Parts

April 1, 2009 traininteractive.com | 978.957.0700
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FREE Information
2009 Upcoming Webinars 10 Procedures to Fine-Tune Any Molding Process

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FREE Information
Best Molding Practices

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Intelligent Molder
intelligent
According to Encarta:
1 : the ability to learn facts and skills and apply them, especially when this ability is highly developed
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Intelligent Molder
According to the New York Times Intelligence is defined as problem solving ability
This is the basis of this presentation
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FREE 10-Day Online Training Offer Intelligent Molder Series: Process Evaluation
In-Mold Rheology Test Gate Seal Worksheet Decoupled II Process Worksheet More Details at the End of the Presentation
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Scientific Troubleshooting of Common Defects

Real-Life Troubleshooting Scenarios Who is a Scientific Troubleshooter? Process Documentation Causes for Common Defects Troubleshooting Methods FREE Training Offer Q & A Session
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Real-Life Troubleshooting Scenarios Case #1 Material Issue - Problem

Scenario:
Connector Mold New Material Supplier with Identical Material Could Not Maintain Desired Cycle Times 13.9 seconds vs. 11.2 seconds
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Real-Life Troubleshooting Scenarios Case #1 Material Issue Solution

Process, machine, & mold identical What changed Material
Internal lubricant was not the same Internal lubricant not at the same percentages
Established:
Correct internal lubricant Correct percentages of lubricant
Resulting in a cycle time under 9 seconds!
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Real-Life Troubleshooting Scenarios Case #2 Part Design Issue - Problem

Scenario:
Kitchen shelving support Operating at 17.2 second cycle time Needed to maintain critical dimensions Wanted to optimize process
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Real-Life Troubleshooting Scenarios Case #2 Part Design Issue Solution

Design Change
Added 0.25 draft angle
Resulting in a cycle time under 12 seconds!
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Real-Life Troubleshooting Scenarios Case #3 Machine Issue - Problem

Scenario:
3 plate mold replaced with hot runner mold 6 second capable automation added New machine could not plasticize fast enough New machine could not move all machine functions at simultaneously
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Real-Life Troubleshooting Scenarios Case #3 Machine Issue Solution

Specified new machine with:
Better screw design Independent machine functions
Resulting in cycle time under 4 seconds! Machine could outrun the automation!
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Real-Life Troubleshooting Scenarios Case #4 Mold Issue - Problem

Scenario:
Theft protection tag 3 plate mold has slow process Cycle time above 23 seconds High scrap rate ~35%
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Real-Life Troubleshooting Scenarios Case #4 Mold Issue Solution

Specified mold with hot runner system Significantly reduced scrap Resulting in cycle time under 10 seconds!
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Real-Life Troubleshooting Scenarios Case #5 Technology Issue - Problem

Scenario:
Tubular coat hanger Intermittent short shots Due to viscosity variations in off-spec materials
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Real-Life Troubleshooting Scenarios Case #5 Technology Issue Solution

Specified process monitoring system with:
Cavity pressure transducer Integration to boost cutoff
Resulting in elimination of short shots Variations in material viscosity had little to no change in process
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Who is a Scientific Troubleshooter?
trou ble shoot er

According to Merriam-Webster:
1 : a skilled worker employed to locate
trouble and make repairs in machinery and technical equipment
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Who is a Scientific Troubleshooter? A Typical Troubleshooter:

acts upon learned behavior makes multiple changes at one time rarely documents anything often blames the tool or material avoids speaking in specifics
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sci ence
According to Merriam-Webster:
1 : the state of knowing : knowledge as
distinguished from ignorance or misunderstanding
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sci ence + trou ble shoot er =

'a skilled worker who acts from a state of knowing'
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Who is a Scientific Troubleshooter? A Scientific Troubleshooter:

knows the history of the process, mold, machine, material, technology determines what has changed acts on knowledge verifies the results of any change
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Process Documentation Machine Inputs vs. Process Outputs
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Process Documentation Setup Technicians Typically Document:

machine-dependent inputs speed settings time settings temperature settings pressure settings tonnage settings
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Process Documentation Scientific Troubleshooters Document:

machine-independent process outputs
temperatures times plastic pressures weights additional data
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Process Documentation Process Outputs - Temperatures:

plastic melt temperature coolant temperature in coolant temperature out
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Process Documentation Process Outputs - Times:

fill time pack time hold time gate seal time cycle time recovery time
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Process Documentation Process Outputs - Plastic Pressures:

back pressure pressure at transfer
and/or peak pressure
pack pressure hold pressure
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Process Documentation Process Outputs - Weights:

fill weight pack weight final weight
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Process Documentation Process Outputs - Additional Data:

cavity measurements quality measurements clamp tonnage photographs observations cavity balance
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Process Documentation The Scientific Troubleshooter Uses Documentation To:

know how the process ran determine what changed act on knowledge verify the results
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Causes/Symptoms for Common Defects The Typical Troubleshooter Asks:
'what buttons do I push to correct the defect?

they often rely on learned behavior & troubleshooting guides
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Causes/Symptoms for Common Defects The Scientific Troubleshooter Asks:
what change occurred to cause this defect?

process documentation is crucial for these people
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Flash
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Flash
What Changed:
high melt temperature or degradation
Causes:
reduced melt viscosity more material enters cavity during fill
Symptom:
flash anywhere on part decreased plastic pressure at transfer
or peak pressure during fill
increased fill weight change in screw recovery time
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Flash
What Changed:
low melt temperature
Causes:
high melt viscosity more pressure is required to fill mold
Symptom:
flash near gate or center of mold increased plastic pressure at transfer
decreased fill weight
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Flash
What Changed:
decreased fill time due to high flow rate
Causes:
lower viscosity due to shear thinning excessive material enters mold during fill
Symptom:
flash anywhere on part increased fill weight decreased fill time increased pressure at transfer
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Flash
What Changed:
increased fill time due to a low transfer setpoint
Causes:
excessive material enters mold during fill
Symptom:
flash anywhere on part increased fill weight increased fill time increased pressure at transfer
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Flash
What Changed:
increased pack and hold pressure
Causes:
excessive pressure within mold
Symptom:
flash anywhere on part increased pack weight increased final weight
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Flash
What Changed:
low clamp tonnage
Causes:
insufficient tonnage to hold mold closed
Symptom:
little change in outputs increased pack weight flash anywhere on part
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Flash
What Changed:
high cavity imbalance
Causes:
excessive material enters during fill
Symptom:
not all cavities may flash intermittent shorts intermittent flash incorrect fill time flash anywhere on part
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Flash
What Changed:
inconsistent check ring
Causes:
inconsistent material during fill
Symptom:
intermittent shorts intermittent flash inconsistent fill time flash anywhere on part
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Flash
What Changed:
excessive mold and platen deflection
Causes:
inconsistent tonnage across parting line
Symptom:
little change in outputs flash near center of the mold
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Flash
What Changed:
mold damage or wear
Causes:
wear or damage occurs
Symptom:
little change in outputs flash in a unique area flash near a moving component
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Sinks and Voids
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Sinks and Voids

What Changed:
high melt temperature
Causes:
excessive shrinkage occurs
Symptom:
shrinkage anywhere on the part decreased pressure at transfer
increased fill weight
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Sinks and Voids

What Changed:
Causes:
excessive pressure loss occurs
Symptom:
shrinkage near the end of fill increased pressure at transfer
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Sinks and Voids

What Changed:
increased fill time due to low flow rate
Causes:
Symptom:
shrinkage near the end of fill decrease pressure at transfer
change in fill weight
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Sinks and Voids

What Changed:
decreased fill time due to a high transfer setpoint
Causes:
insufficient material enters mold during fill
Symptom:
shrinkage near the end of fill decrease pressure at transfer
decrease in fill weight
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Sinks and Voids

What Changed:
decreased pack and hold pressure
Causes:
inadequate pressure within mold
Symptom:
shrinkage anywhere on part decreased pack weight decreased final weight
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Sinks and Voids

What Changed:
poor gate seal due to a low hold time
Causes:
material exits the cavity through the gate
Symptom:
shrinkage near the gate decreased final weight
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Sinks and Voids

What Changed:
high mold temperature
Causes:
excessive shrinkage occurs
Symptom:
shrinkage anywhere on the part decreased pressure at transfer
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Voids
What Changed:
low mold temperature
Causes:
polymer freezes to mold surface as part shrinks
Symptom:
voids anywhere on the part increased pressure at transfer
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Short Shots
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Short Shots
What Changed:
Causes:
Symptom:
increased pressure at transfer
decreased fill weight decreased pack weight decreased final weight
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Short Shots
What Changed:
increased fill time due to low flow rate
Causes:
Symptom:
decrease pressure at transfer
change in fill weight decreased pack weight decreased final weight
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Short Shots
What Changed:
decreased fill time due to a high transfer setpoint
Causes:
insufficient material enters mold during fill
Symptom:
decrease pressure at transfer
decrease in fill weight decreased pack weight decreased final weight
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Short Shots
What Changed:
decreased pack pressure
Causes:
inadequate pressure to complete mold filling after transfer
Symptom:
decreased pack weight decreased final weight
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Jetting
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Jetting
What Changed:
Causes:
high viscosity prevents fountain flow
Symptom:
increase pressure at transfer
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Jetting
What Changed:
decreased fill time due to high flow rate
Causes:
high flow rate prevents fountain flow
Symptom:
increase pressure at transfer
increased fill weight decreased fill time
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Jetting
What Changed:
low mold temperature
Causes:
poor adhesion to mold surface prevents fountain flow
Symptom:
increased pressure at transfer
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Causes/Symptoms for Common Defects as you can see if the process is documented, the scientific troubleshooter can quickly identify what changed
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Troubleshooting Methods Again A Scientific Troubleshooter:

knows the history of the process, mold, machine, material, and technology determines what has changed acts on knowledge (intelligence) verifies the results of any change
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Troubleshooting Methods Step 1: Examine the Part to Ensure:

proper diagnosis no other defects are present
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Troubleshooting Methods Step 2: Rule Out Obvious Causes:

check the simple causes
where applicable
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Troubleshooting Methods Step 3: Compare with Documented Process Outputs

focus on related outputs process of elimination
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Troubleshooting Methods Step 4: Return Process to Documented Standard

change one parameter at a time allow each change time to affect the process
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Troubleshooting Methods Step 5: Verify Other Process Outputs

verify any relevant parameters a full verification may be necessary if cause not found, check the mold, machine, & material
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Troubleshooting Methods Step 6: Document Any Changes Made

record actions and causes ensures others can follow
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Scientific Troubleshooting
In conclusion: it is not only about troubleshooting a process All factors such as material, mold, machine, part design and technology must be documented.
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FREE 10-Day Online Training Offer Intelligent Molder Series: Process Evaluation
In-Mold Rheology Test Gate Seal Worksheet Decoupled II Process Worksheet
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FREE 10-Day Online Training Offer Follow-Up Email Will Contain:

Instructions to Download Worksheets Instructions to Receive Free Trial Webinar Notes & Special Offer
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Scientific Troubleshooting of Common Defects
Q&A Session
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Troubleshooting For Injection Molding by IDES

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Scientific Troubleshooting of Common Injection Molding Defects

www.traininteractive.com | (tel) 978.957.0700

FREE Information Please visit: www.IDES.com

FREE Information Please visit: www.traininteractive.com

2009 Upcoming Webinars

Part Design for Reducing Cycle Time

2009 Upcoming Webinars

Practical Scientific Molding Techniques

2009 Upcoming Webinars

10 Easy Ways to Analyze Your Plastic Parts

2009 Upcoming Webinars 10 Procedures to Fine-Tune Any Molding Process

2009 Upcoming Webinars

Best Molding Practices

Scientific Troubleshooting of Common Defects

Real-Life Troubleshooting Scenarios Case #1 Material Issue - Problem

Real-Life Troubleshooting Scenarios Case #1 Material Issue Solution

Resulting in a cycle time under 9 seconds!

Real-Life Troubleshooting Scenarios Case #2 Part Design Issue - Problem

Real-Life Troubleshooting Scenarios Case #2 Part Design Issue Solution

Resulting in a cycle time under 12 seconds!

Real-Life Troubleshooting Scenarios Case #3 Machine Issue - Problem

Real-Life Troubleshooting Scenarios Case #3 Machine Issue Solution

Real-Life Troubleshooting Scenarios Case #4 Mold Issue - Problem

Real-Life Troubleshooting Scenarios Case #4 Mold Issue Solution

Real-Life Troubleshooting Scenarios Case #5 Technology Issue - Problem

Real-Life Troubleshooting Scenarios Case #5 Technology Issue Solution

Who is a Scientific Troubleshooter?

trou ble shoot er

1 : a skilled worker employed to locate

trouble and make repairs in machinery and technical equipment

Who is a Scientific Troubleshooter? A Typical Troubleshooter:

Who is a Scientific Troubleshooter?

1 : the state of knowing : knowledge as

distinguished from ignorance or misunderstanding

Who is a Scientific Troubleshooter?

sci ence + trou ble shoot er =

Who is a Scientific Troubleshooter? A Scientific Troubleshooter:

Process Documentation Machine Inputs vs. Process Outputs

Process Documentation Setup Technicians Typically Document:

Process Documentation Scientific Troubleshooters Document:

Process Documentation Process Outputs - Temperatures:

Process Documentation Process Outputs - Times:

Process Documentation Process Outputs - Plastic Pressures:

pack pressure hold pressure

Process Documentation Process Outputs - Weights:

Process Documentation Process Outputs - Additional Data:

Process Documentation The Scientific Troubleshooter Uses Documentation To:

Causes/Symptoms for Common Defects The Typical Troubleshooter Asks:

'what buttons do I push to correct the defect?

Causes/Symptoms for Common Defects The Scientific Troubleshooter Asks:

what change occurred to cause this defect?

increased fill weight change in screw recovery time

decreased fill weight

Sinks and Voids

Sinks and Voids

increased fill weight

Sinks and Voids

decreased fill weight

Sinks and Voids

change in fill weight

Sinks and Voids

decrease in fill weight