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    02injection Moulding Machine

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    S Karthick Keyan
    The document discusses injection moulding processes and machines. It describes key parameters that must be controlled in plastic injection including melt temperature, viscosity, injection speed and pressure. It explains the two main plasticizing methods - screw and plunger types. The main components and functioning of injection moulding machines are outlined including the hopper, barrel, screw, heating zones, injection unit and mould. Machine specifications like clamping force, shot capacity and plasticizing rate are also covered.

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    02injection Moulding Machine

    Uploaded by

    S Karthick Keyan
    197 views31 pages
    The document discusses injection moulding processes and machines. It describes key parameters that must be controlled in plastic injection including melt temperature, viscosity, injection speed and pressure. It explains the two main plasticizing methods - screw and plunger types. The main components and functioning of injection moulding machines are outlined including the hopper, barrel, screw, heating zones, injection unit and mould. Machine specifications like clamping force, shot capacity and plasticizing rate are also covered.

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    Original Title

    02INJECTION MOULDING MACHINE(27)

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    The document discusses injection moulding processes and machines. It describes key parameters that must be controlled in plastic injection including melt temperature, viscosity, injection speed and pressure. It explains the two main plasticizing methods - screw and plunger types. The main components and functioning of injection moulding machines are outlined including the hopper, barrel, screw, heating zones, injection unit and mould. Machine specifications like clamping force, shot capacity and plasticizing rate are also covered.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    197 views31 pages

    02injection Moulding Machine

    Uploaded by

    S Karthick Keyan
    The document discusses injection moulding processes and machines. It describes key parameters that must be controlled in plastic injection including melt temperature, viscosity, injection speed and pressure. It explains the two main plasticizing methods - screw and plunger types. The main components and functioning of injection moulding machines are outlined including the hopper, barrel, screw, heating zones, injection unit and mould. Machine specifications like clamping force, shot capacity and plasticizing rate are also covered.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 31

    INJECTION MOULDING

    • Plastic Injection Moulding process demands


    precise control of melt temperature, melt viscosity,
    injection speed, injection follow-up pressure,
    switch over point from speed to pressure, cycle
    time. It is found that different polymers have
    different characteristics and different limitations in
    processing. Shear rate and shear stress influence
    melt temperature, viscosity, density and flow
    behavior of polymer.
    • Some polymers are hygroscopic, some polymer
    have limited thermally stable time which is
    different at different temperature. Such polymers
    have limited residence time. The changes in each
    parameter has its own influences on other
    parameters. Hence, process control becomes very
    intricate. This calls for critical analysis of the
    machine specifications and capabilities while
    ordering the machine.
    INJECTION MOULDING MACHINE
    The main functions of an injection moulding
    machine is to take preheated granules from
    hopper, heat it in a progressive way in the barrel,
    mix the material homogenously by screw rod and
    then inject the hot melt under high pressure
    through a nozzle into a closed mould.
    PLASTICISING

    There are two types of plasticising


    methods adopted in injection molding
    machines ,viz. Plunger plasticising and
    Screw plasticising.Most efficient out of the two is the
    Screw type which can produce high pressure and
    homogenous melt by screw rotation as well as
    reciprocation. Plunger types are used for easy flow
    materials and for smaller capacity machine upto 5 Tons.
    Plunger Injection Machine
    Reciprocating Screw
    Injection Machine
    NOZZLE

    MOLD HEATERS SCREW SCREW DRIVE


    MOTOR
    PLUNGER TYPE INJ. MOULDING MACHINE

    MOVING HOPPER
    PLATEN
    TIE RODS BAND HEATER
    AUTO
    FEEDER

    TEMP.
    CONTROLLERS

    NOZZL
    E SPREADER
    SCREW TYPE INJECTION MOULDING
    MACHINE
    (INJECTION UNIT)

    FIXED
    PLATEN

    INJECTION BAND
    CHAMBER HEATER
    Mechanical Nozzle between
    Toggle barrel and mold
    (not shown)
    Hopper
    Heater
    bands

    Clamping
    Unit Hydraulic
    Unit

    Mold cooling fed Barrel Screw


    Hyd. from external unit (Ram)
    Cylinder

    SCREW TYPE INJ. MOULDING


    MACHINE PARTS & WORKING
    30 ton, 1.5 oz (45 cm3) Engel

    Injection Molding Machine


    for wheel fabrication
    Process & machine schematics
    *

    Schematic of thermoplastic Injection molding machine

    * Source: http://www.idsa-mp.org/proc/plastic/injection/injection_process.htm
    SCREW ROD DESIGN

    1.General purpose screw rod length is divided into


    three sections viz.
    a)FEED b) TRANSITION and c) METERING

    Feed section controls the quantity of granules


    taken from Hopper every cycle.

    Transition section converts efficiently the solid


    granules into homogenously melted liquid.

    Metering section controls the amount of material


    that can be injected every shot.
    TYPES OF SCREW RODS

    GENERAL PURPOSE SCREW

    BEARING
    PITCH FLIGHT WIDTH
    METERING
    DIA. DEPTH

    KEY
    FEED SECTION TRANSITION METERING
    SECTION SECTION
    OVERALL LENGTH
    INJ. MOULDING SCREW ROD
    WITH BARREL ASSEMBLY
    L METERIN
    Feed MELTING G Section
    Section (Transition) (25%L)
    (25%L) Section(50%L)

    Ds Ø S Hm
    pitch
    Hf
    Hm = 0.22 minimum flight depth
    DS = Nominal Screw Dia. ( Metering)
    L = Overall length
    Ø = 17.8 0 Helix angle (one turn
    per screw dia.) δ = 0.005 flight clearance (Radial)
    L / D = 16 : 1 to 24 : 1
    Hf = Flight depth at Feed Hf / Hm = 2.0 to 2.2 Compression
    ratio
    TYPICAL METERING TYPE INJECTION MOLDING SCREW &
    BARREL
    STANDARD NOZZLE

    Thermo Cople
    R

    Dia.

    Band Heater
    NEEDLE SHUT OFF NOZZLE

    NEEDLE

    PLATE
    SPRING

    USED FOR NYLON MATERIAL


    TO AVOID DROOLING
    NON RETURNVALVE
    (RING TYPE)

    NON RETURN VALVE


    (RING TYPE)

    BACK PRESSURE
    NON RETURN
    VALVE
    (BALL TYPE)

    ROTATIO
    N STAGE

    STOP PIN BALL

    RECIPROCATION
    STAGE
    MACHINE CLAMPING SYSTEMS

    1. PURE HYDRAULIC CLAMPING SYSTEM


    SHUT HT.

    TIE BAR

    DAY LIGHT
    DOUBLE TOGGLE CLAMPING

    CLAMPED
    POSITION

    OPENED
    POSITION
    SINGLE TOGGLE
    CLAMPING

    CLAMPED
    POSITION

    OPENED
    POSITION
    DOUBLE TOGGLE CLAMPING

    CLAMPED
    POSITION

    OPENED
    POSITION
    INJECTION MOULDING MACHINE
    SPECIFICATION

    1.SHOT CAPACITY : --
    MAX.VOLUME OF PLASTIC, MACHINE
    CAN
    INJECT IN ONE
    SPECIFIED SHOT, VOLUME V IN
    AS SWEPT S,
    C.C.
    DEPENDS ON DENSITY AND MELT
    TEMPERATURE OF THE PLASTIC.
    INJECTION MOULDING MACHINE
    SPECIFICATION

    • 2 PLASTICISING CAPACITY :
    MAX. AMOUNT OF PLASTIC
    (POLYSTYRENE), THE MACHINE
    CAN BRING TO MOULDING
    CONDITION IN A GIVEN TIME.

    EXPRESSED AS Kg. / HOUR OF


    POLYSTYRENE
    INJECTION MOULDING MACHINE
    SPECIFICATION
    3.CLAMPING TONNAGE : ---
    Max. force machine can hydraulically
    develop to clamp the two halves of mould against
    the internal force due to injection of plastic,
    expressed in tonnes.

    4. INJECTION PRESSURE : ---


    Max. pressure with which machine can inject
    plastic through nozzle, specified in kg/cm2
    DEPENDS ON THE L / D RATIO OF SCREW ROD
    SPECIFICATIONS OF SP80 WINDSOR M/C
    INJECTION UNIT
    Plasticising Capacity * 20 Kg/ Hr.

    Maximum Shot Capacity


    With Injection chamber Ф34 @ 1800 rpm 75 Cm3
    With Injection chamber Ф42 @ 1200 rpm 110 Cm3
    Screw Diameter 34 mm

    Screw L/ d ratio 18 : 1

    Injection stroke 80 mm Hopper capacity

    30 Kg.

    * Depends on material + Shot


    SPECIFICATIONS OF SP80 WINDSOR M/C

    LOCKING UNIT

    Mould Clamping force 80 Tonnes


    Size of Mould Plates ( h x v ) 500 x 500 mm
    Distance between Tie bars 330 x 330 mm
    (hxv)

    Diameter of Tie bars 65 mm


    Max. Mould opening 450 mm
    Min. Mould Height 150 mm
    Max. Daylight 600 mm
    WINDSOR MACHINE SPECIFICATIONS

    MOD PLASTI MAX. MAX. MAX. DIST. MIN. MAX.


    EL CISING SHOT CLAM. BETWEE SHUT DAY
    CAPACITY CAPA FORCE INJ. N HT. LIGH
    Kg/ hr cm3 Tonnes PRESS. TIE mm. Tmm.
    Kg./cm2 BARS
    (H X V)
    mm
    SP 15 44 30 1950 280X280 100 470
    30
    SP 20 75 80 1800 330X330 150 600
    80
    SP 50 190 130 1800 380X380 200 750
    130
    SP 90 320 180 1800 430X430 350 900
    180
    MACHINE SPECIFICATIONS
    WINDSOR SP 80
    Specifications – Fixed Platen SP80

    0 .0
    12 7
    Ø H
    Specifications – Moving Platen SP80

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