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    Manual Injection Molding

    Uploaded by

    M. Ahmad
    The document discusses manual injection molding of polymers to produce specific shapes. It explains that polymers require high injection pressure to properly flow into molds due to their high viscosity when molten. The process involves melting polymer pellets and injecting the molten material into a mold under pressure. Proper injection and holding pressures are needed to completely fill the mold cavity and avoid defects. Samples produced with correct pressures were properly shaped, while those with incorrect pressures were improperly shaped.

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    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd

    Manual Injection Molding

    Uploaded by

    M. Ahmad
    218 views5 pages
    The document discusses manual injection molding of polymers to produce specific shapes. It explains that polymers require high injection pressure to properly flow into molds due to their high viscosity when molten. The process involves melting polymer pellets and injecting the molten material into a mold under pressure. Proper injection and holding pressures are needed to completely fill the mold cavity and avoid defects. Samples produced with correct pressures were properly shaped, while those with incorrect pressures were improperly shaped.

    Original Description:

    Process of MIM

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    The document discusses manual injection molding of polymers to produce specific shapes. It explains that polymers require high injection pressure to properly flow into molds due to their high viscosity when molten. The process involves melting polymer pellets and injecting the molten material into a mold under pressure. Proper injection and holding pressures are needed to completely fill the mold cavity and avoid defects. Samples produced with correct pressures were properly shaped, while those with incorrect pressures were improperly shaped.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    218 views5 pages

    Manual Injection Molding

    Uploaded by

    M. Ahmad
    The document discusses manual injection molding of polymers to produce specific shapes. It explains that polymers require high injection pressure to properly flow into molds due to their high viscosity when molten. The process involves melting polymer pellets and injecting the molten material into a mold under pressure. Proper injection and holding pressures are needed to completely fill the mold cavity and avoid defects. Samples produced with correct pressures were properly shaped, while those with incorrect pressures were improperly shaped.

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    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
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    To study the flow behavior of molten polymeric material and mold it into

    specific shape by Manual Injection Molding Machine.


    Principle:
    Thermoplastic materials in their melt state, experience very high viscosity and they require very
    high external force or injection pressure for their proper flow into the mold cavity.

    Theory:

    Injection moulding is a manufacturing process for producing parts by injecting molten 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.

    Defects in Injection Molding:

    Flash fin:

    Flash, also called “spew” or “burrs”, is an excess of molding material that appears as a thin lip
    or protrusion at the edge of a component. Flash appears because material has flowed outside of
    the intended flow channels and into the space between the tooling plates or at the injector
    pin. Flash is usually subtle but might be considered a major defect if particularly obvious on a
    product. The process for reworking a molded product with flash often includes trimming the
    excess material.

    1
    Weld lines:

    Weld lines can appear on the surface of a molded part where the molten material has converged
    after splitting off into two or more directions in a mold. The hair-like weld line is the result of
    weak material bonding, which lowers the strength of the part.

    2
    Die:
    A die is a specialized tool used in manufacturing industries to cut or shape material mostly using
    a press. Like molds, dies are generally customized to the item they are used to create. Products
    made with dies range from simple paper clips to complex pieces used in advanced technology.

    Apparatus:

     Polymeric materials (PE, PVC, PS) in the form of small pallets.


     Manual Injection molding machine and its accessories.

    Procedure:

    1. The power supply was switched on and the melting temperature was set according the
    type of material which was needed to be melted.
    2. The machine was allowed to achieve the required temperature.
    3. The temperature was maintained automatically to the set value by the machine’s
    thermostate.
    4. The metallic die was placed in front of the nozzle opening of the manual injection
    molding machine and properly tightened.
    5. The plunger was lifted up by the screw and the pallets were pour down in the barrel of the
    manual injection machine by the hopper.

    3
    6. The plunger was lowered down and the pallets were allowed to melt down by the
    resistive heating effect of the heater around the barrel.
    7. Then screw was rotated and injection pressure was inserted on the molten melt.
    8. The molten material was allowed to enter the metallic mold cavity by the nozzle and
    through the gate of the mold.
    9. Proper holding pressure was maintained for complete filling and to avoid the backing
    pressure.
    10. The material in the mold cavity was allowed to cool down then removed.
    11. The complete cycle was repeated for the next sample/samples.

    Results:

    Properly shaped injection molded samples were collected as a result of the application of exact
    injection pressure and holding pressure.

    Sample # Result
    1 (injection pressure and holding pressures are properly applied)

    2 (injection pressure and holding pressures are not properly applied)

    3 (injection pressure and holding pressures are not properly applied)

    4
    Conclusion:

    The polymeric materials are low melting materials and do not suffer high temperature. High
    temperature disintegrates their structure. On the hand they have high viscosity between the layers
    of melt. For proper molding to the desired shape, proper injection pressure and holding pressure
    is necessary. Super heating cannot be utilized because of the nature of their structure that is
    destroyed upon over heating. So, the viscosity if overcome by external pressure for proper
    filling.

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