A M COMPONENTS L .L.

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Injection moulding is a manufacturing
process for producing parts by injecting
material into a mould . Injection moulding can
be performed with a host of materials mainly
including metals, glasses, elastomers, confections,
and most commonly thermoplastic
and thermosetting polymers. Material for the
part is fed into a heated barrel, mixed, and
forced into a mould cavity, where it cools and
hardens to the configuration of the cavity.
 Clamping unit
 Injection unit
 Drive unit
 Mould
 Hydraulic system
 Control system
 Hopper
 Heaters
 Cooling channels
 Material
 Machine
 Mould
 Manpower
 PVC
 ABS(Acrylonitrile Butadiene Styrene)
 Polypropylene
 Polystyrene
 HDPE( High density poly ethylene)
 LDPE(Low density poly ethylene)
 Rubber Thermoplastic
 Epoxy
 Material preparation
 Feeding into hopper
 Injection
 Mould holding and cooling
 Ejection
 Material granules are fed into hopper then
melted down in barrel which is surrounded by
the heaters.
 Melted material is injected into mould cavity and
mold is held under pressure until the material
cools and hardens.
Once the material hardens, the mold is opened
and the component is ejected by runner plate.
 Moulds are the common terms used to describe
the tool used to produce components in moulding .
 Moulds are constructed from hardened steel,
prehardened steel, aluminium , beryllium-copper
alloy.
 In general, steel moulds cost more to construct ,
but their longer lifespan will offset the higher
initial cost over a higher number of parts made
before wearing out.
 The moulds can be manufactured either by CNC
machining or by using electrical discharge
machining processes.
The mould consists of two primary components,
the injection mould (A plate) and the ejector
mould (B plate).
 Shrinkage allowance: Depends on shrinkage
property of material core and cavity size.
 Cooling circuit: In order to reduce the cycle
time, water circulates through holes drilled in
both the core and cavity plates.
 Ejection gap: The gap between the ejector
plate face and core back plate face should hold
dimension within the core. It must allow
component to be fully removed from the mold.
 Mould polishing : The core, cavity, runner and
sprue should have good surface finish and
should be polished along material flow
direction.
 Mould filling : The gate should be placed such
that the component is filled from the thicker
section to thinner section.
 Draft : Required in both the core and cavity for
easy ejection of the finished component.
 Constant mould temperature for uniform
quality.
 Reduced cycle time for productivity.
 Improved surface finish without defects.
 Long mould life.
 Avoiding warpage by uniform mold surface
temperature (warpage caused by non uniform
cooling).
 Short moulding
 Sink marks and Voids
 Warpage
 Flash
 Knit or Weld lines
Short Moulding: Short shot defect in injection moulding appears if
sufficient material is not injected into the mould. And
mold is not filled completely.

 Increase wall thickness or provide rib in molten plastic in solidifying

section.
 Selection of low viscous plastic with higher flow-ability.
 Increase injection plastic temperature and pressure.
 Reduce mold clamping Force.
 Increase core and cavity Temperature
 Increase Gate and Runner Size.
Sink Marks and Voids:  Sink Marks are small craters or depressions that
develop in thicker areas of the injection molded
parts.

 Voids are pockets of air trapped inside or close to

the surface of an injection molded component

 Reduce the maximum part wall thickness. That ensures faster cooling.
Therefore sink marks will be reduced.
 Select a material with reduced volumetric shrinkage.
 Increase dwelling time and pressure
 Lower Mold temperatures and increased holding pressure and holding
time allows more adequate cooling and curing.
Warpage: It is the deformation due to uneven shrinkage in the different
areas of the moulded part.

 Ensure part uniform wall thickness. That results in the plastic flows in
a single direction.

 Ensure cooling time is sufficiently long and that it is slow enough to

avoid the development of residual stresses being locked into the part.
Flash: This injection molding defect occurs when molten plastic escapes
from the mold cavity.

 Increase the clamp pressure.

 Avoid Over-packing
 Ensure that the mold is properly maintained and cleaned.
Knit / Weld Lines:
Weld / Knit lines are actually more like a plane than a line that appears in a
part where molten plastics meet each other as they flow from two different
parts of the Injection Mold.

 Change part thickness.

 Switch to a less viscous plastic or one with a lower melting
temperature.
 Raise the temperature of the mold or molten plastic.
 Increase the injection speed.
 Dew-point measurement is a common and
important metric in the plastic drying process.
 A good dew point meter can tell you whether
your dryer is working normally or if it’s in
need of repair.
 Dew point meters do this by measuring the
humidity in the air that flows through the
dryer.
Traditional moulding:
 A part or component is produced at one constant pressure across the fill and
pack/hold stages. Due to the non-Newtonian flow of thermoplastics, this method
of moulding is often inconsistent, allowing for large variations between shots.

Scientific Injection Moulding:

 The fill and pack/hold stages are separated (i.e. the molding process is
“Decoupled”). This minimizes variation between shots and improves consistency
by utilizing the non-Newtonian fluid behavior of the thermoplastic material.
Scientific Injection Molding can be broken down into three distinct phases:

 Fill: During the Fill phase, the cavity of the molding tool is filled between 95-99%
of the total available volume. This partial filling of the tool establishes the
foundation for consistency between shots.

 Pack/Hold: During the Pack/Hold phase the remaining volume is filled and the
plastic is compressed to fully “pack” the cavity.
 Cooling/Recovery: During the final phase, Cooling/Recovery, the part is allowed
to cool and become dimensionally stable. It is during this time that the next shot is
metered.
 Molding Cycle Time to:
The molding cycle time on the machine consists of the injection time, which
depends on the shot size and machine power, but is usually small (1–2 sec.); and
the cooling time—usually dominates respectively.

tc=h max 2π 2αloge4 (Ti−Tm)π (T x−Tm)

where
H max = maximum wall thickness of part, mm
T x = recommended part ejection temperature, °C
Tm = recommended mold temperature, °C
Ti = polymer injection temperature, °C
α = thermal diffusivity coefficient, mm2/s
 Fast production.
 Low labour costs.
 Design flexibility.
 High-output production.
 Multiple materials can be used at the same time.
 Can be used to produce very small parts.
 Leaves little post-production scrap.
 Ability to include inserts.
 Good colour control.
 Good product consistency.
 Reduced requirements for finishing.
 Good dimensional control.
 High initial tooling and machinery cost.
 Part design restrictions.
 Small runs of parts can be costly.
 Injection moulding is used to create many
things such as Cups, Containers, tools,
Mechanical parts (Including gears).
 Injection moulding is the most common
modern method of manufacturing parts. It is
ideal for producing high volumes of the same
object.
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