1. Injection Molding & Advanced Process Control
SPE Automotive TPO Global Conference 2009
What video or avi goes here???
1 - BasM 1

2. Polymer Basics
What video or avi goes here???

3. Material selection is part of the design process and can directly cause failure
A key element in a successful plastic part program is the selection of the
appropriate material for the application.
The process of material selection is complicated by the fact that there are literally
thousands of polymers, blends, alloys, and compounds available.
The selection process can be simplified by comprehending:
The performance requirements of the part
How materials are classified
Testing methods

4. POLYMERIZATION PROCESS
From the Greek Poly meaning many, and Meros (mer), meaning part(s)
Chemical Composition: Example
Polyethylene: Crack crude oil to ethylene then polymerized (linked together) to form 500-1,000,000 ethylene units
Transfer System
Silo
Esterifier 1°
Esterifier 2°
High Polymerizer
Low Polymerizer
Pump
Manifold Extrusion
I still need this graphic. Chris is supposed to be looking for it.
Feedstock:
Crude Oil
Natural Gas
Agriculture

5. Chemical Composition: Example
Polymer:
From the Greek Poly meaning many, and Meros (mer), meaning part(s)
Chemical Composition: Example
Polyethylene: Crack crude oil to ethylene then polymerized (linked together) to form 500-1,000,000 ethylene units
Key Points:
Polymers can have the same carbon backbone but drastically different properties
Polymers with Oxygen (O), Nitrogen (N), Chlorine (CI), Bromine (Br), or Fluorine (F) probably have to be dried
Time and space do not allow us to review each polymer composition and its
properties. An excellent source for basic polymer descriptions can be found
in the first pages of the yearly Modern Plastics Encyclopedia.

6. Chain Lengths At room temperature C1 = Methane, a gas
C6 = Hexane, a liquid
C17 = Kerosene
C50 = Wax
C500-1,000, = Polyethylene
For strength
Long molecules are preferred
For processability
Short molecules are preferred
Easy flow
Low viscosity
Transmits pressure more hydrostatically
Long molecules
Difficult to flow
High viscosity
Viscosity changes dramatically with changes in flow rate
Dynamic: flow rate during filling
Static: flow rate during pack and hold
Large static pressure losses along the flow path
Resin manufacturing must compromise/balance chain length vs. strength vs. flow.
Most polymers that find commercial use as plastics or rubbers have molecular weights
between 10,000 and 1,000,000.

7. Molecular Weight (Mw):
Molecular Weight = (Molecular Weight of Repeat Unit x Number of Units)
In practice, when polymers are made, chains or the number of units linked together varies
Within the same polymer family molecular weight is a measure of molecular length:
High Molecular Weight = Long Molecules = Stronger
Low Molecular Weight = Short Molecules = Weaker

8. Molecular Length Polymers are mixtures of various length molecules
Not all chains are the same length
Molecular weight distribution

9. Batch to Batch Variations Cause Changes in Viscosity
Effects of Molecular Weight
Generally as molecular weight increases, physical properties increase at the expense of processing ease
Short chains - easy flow
Long chains - difficult to flow

10. Polymer Chain Degradation
Polymer chains are strong
Aramide fibers (flack jackets, tires)
Chains can be broken by improper processing
Too much heat
Too much time at elevated temperatures (drying and melt)
Too much shear force
Presence of a chain-breaking chemical (e.g., water)
Polyester
Polycarbonate
Nylon
Proper drying is essential for these materials

11. How can this be detected?
Degradation
Improper processing can degrade polymer chains and provide poor part performance
Chain degradation will provide a regrind that is easier flowing (lower viscosity)
Shorter molecules = poor strength
How can this be detected?

12. Polymers Plastics Plastics = Polymer + Additives Additives:
Impact modifiers (rubber)
Fillers
Nucleating agents
Flame retardants
Mold release agents
Antioxidants
Wetting agents
Plasticizers
Fiber reinforcements
Heat stabilizers
Lubricants
Antistatic agents
Coloring agents
Slip aids

13. Material is going to vary folks –
Additive Degradation:
Additive chain size is small relative to the polymer
May become volatile during processing which can result in:
Accumulation in vents, mold surfaces, etc.
Change in physical properties (often an increase)
Stiffer flow (higher viscosity plastic)
Change in Additive Content is a Prime Difference Between Virgin and Early Generations of Regrind.
Material is going to vary folks –
that's no excuse!

14. Polymer Morphology Two families of thermoplastics
Amorphous Semi-crystalline
Random Structure
Broad Melting Point
Often Solvent Sensitive
Poor Fatigue/wear
Low Shrink
No Molecular Cuddling
More Forgiving on dimensional
Control
Ordered Structure
Sharp Melting Point
Solvent Resistant
Excellent Fatigue Wear
High Shrink
High Molecular Cuddling
Problematic on dimensional Control

15. Cooling and Crystallinity
Extremely important for semi-crystalline materials
Crystals are non-existent above melting temperature
Low mold temp, faster cooling, smaller/less crystals, less shrinkage, but may not be suitable for application
High mold temp, slower cooling, larger/more crystals, more shrinkage
Mold and Melt temperatures are critical to maintain dimensional tolerances
New Slide.
Need to add graphics to this page. See Shane when you get here.

16. Decoupled MoldingSM Strategies
16 - APT 16

17. Injection Molding Approaches
Train2.jpg
Injection Molding Approaches
Traditional Molding:
The original method of molding
Fill and pack on first stage
Use only enough first stage pressure to pack the mold
Train1.JPG
DECOUPLED MOLDINGSM:
Train2 a fill pack only.jpg
Use abundant first stage pressure
Separate the filling or velocity phase of molding from the packing or pressurization phase
Helping Injection Molders Succeed
17 - AF 17

18. DECOUPLED MOLDINGSM Definition:
A process control method that addresses how the machine controls are
used to fill and pack plastic into the mold.
Objectives:
Injection speed reacts only to the machine’s velocity setting(s)‏
Constant and repeatable injection speed shot to shot, year to year, regardless of any effective viscosity changes
Reduce part variation due to effective viscosity variations
Gain the ability to fill fast to minimize effective viscosity variations
Make the process capable of always making good parts
Reduce cycle time due to increased fill rates
Train2 a fill pack only.jpg
18 - AF 18

19. Plastic Temperature Screw Configuration Barrel & Nozzle Heats
Screw R.P.M.
Back Pressure
Feed Throat Condition
19 - APT 19

20. The Screw Inside the barrel is a screw.
Barrel 1a 001
Inside the barrel is a screw.
Most injection molding screws are divided into three zones each with its own task:
Move plastic - Feed Zone (conveying)‏
Melt plastic - Compression Zone (transition)‏
Mix plastic - Metering Zone
The difference between the zones is in the channel depth which creates a space for plastic.
The channel depth on the feed end of the screw is larger than the depth of the metering end. The ratio of depth difference is called Compression Ratio.
Example - 3:1 Compression ratio screw means the channel depth in the feed zone is three times larger than the channel depth in the metering zone.
When the screw is rotated, drawing plastic into the barrel, it is conveyed forward and compressed. This action converts screw work into shear heat.
20 - APT 20

21. What other features of a screw are important?
Compression Ratio
The proper compression ratio screw for the application is a key component for proper plastic melting and mixing.
Low to 2.5:1 - Shear sensitive materials (PVC)‏
Medium to 3.0:1 - General purpose
High to 5.0:1 - Crystalline materials (Nylon)‏
How do you know if you have the correct compression ratio for your job?
What other features of a screw are important?
21 - APT 21

22. What is a good guide for residence time? How can we know what it is?
Screws come in different lengths and diameters. The flight length in relationship to the outside diameter of the flights is called the L/D.
A high L/D indicates a long screw relative to its diameter; therefore, the plastic will have a greater distance to travel from the feed port to the nozzle
The time to travel this distance is called the residence time
Conversely a low L/D is a short screw which will provide faster throughput and a lower residence time
The profile of a screw describes the number of turns in each zone from the feed zone through the metering zone.
Example: (20/1 L/D screw) = 10 turns feed, 5 turns transition, 5 turns metering
The exact screw type and configuration needed depends on the application; however, generally speaking:
Amorphous resins need long transition sections
Crystalline resins need long feed sections
What is a good guide for residence time?
How can we know what it is?
22 - APT 22

23. Mixers
Mixing Screw
Breaks up tornado-like flow of melted plastic in the screw flights
Is placed in the metering zone to mix melted plastic
Must not cause high localized shear
Provides more uniform melt temperature
Provides more uniform color dispersion
Faster purging / quicker color change
Mixing Screw.jpg
23 - APT 23

24. Screw RPM determines the maximum shear rate of the plastic
SCREW RPM: Should be as slow as possible without
increasing cycle time.
Reduces maximum and overall shear rate
Shears material more uniformly
Reduces fiber breakage in filled material
Provides more melt homogeneity
Think circumferential speed when moving to another machine
Screw RPM determines the maximum shear rate of the plastic
24 - APT 24

25. 25 - APT 25

26. Back Pressure
Injection cylinder works as a pump pushing oil back to tank
Changes the amount of heat added by shear
Changes temperature of the melt quickly (temporary)
The change will not be totally sustained unless zone temperatures are also changed
Changes the amount of shear mixing or homogenization
May increase fiber breakage in fiber-filled materials
26 - APT 26

27. Feed throat temperature effects melting and moisture splay
Must be cold enough to prevent clumping and hot enough for dew not to form (105 °F or 35 °C minimum)
27 - APT 27

28. If screw recovery problems exist, do step 6
Set all zones at the desired melt temperature
Run the machine on cycle
Take the melt temperature
Adjust the center and rear zones to achieve desired melt temperature
This may not be possible on machines with an incorrect screw for the material being molded
Set the rear zone to make the plastic stick to the barrel and to obtain faster screw recovery (temperature at which minimum screw recovery time is achieved with a constant RPM)
If screw recovery problems exist, do step 6
28 - APT 28

29. Plastic Flow Injection Speed and Distance 29 - AF 29
plasticbarrel jpg
29 - AF 29

30. During filling two things must be available:
Pressure in abundance (Ri)‏
Flow sufficient to achieve the desired flow rate (pumps or accumulators)‏
On electric machines available plastic pressure and injection rate are analogous to Ri and flow rate
plastic flow rate key jpg
30 - AF 30

31. Force can be intensified in a hydraulic system
The determining factor for force intensification is the square inch area on which the hydraulic pressure is applied
If the piston in a cylinder has more area than the area where the force is being applied then the output force will be greater than the input force
Pressure increases inversely proportional to the area ratios.
For example, if two pistons of different size are connected by a rod, the pressure existing on the smaller area will always be greater A1
= ? A2
psip?
Force=Pressure a 001.jpg
This principle also applies to the cap side and the rod side of a normal double acting piston

32. 32 - AF 32

33. 33 - AF 33

34. NonNewtonian.JPG
34 - AF 34

35. 35 - AF 35

36. THE RUNNER Best Two are almost as good Better Better Good
The main purpose of the runner is to distribute the plastic to all the cavities in such a way as to fill all the cavities at the same shear rate and direction, at the same temperature, and at the same pressure gradient.
Good
Best
Two are almost as good
Better
Better
36 - AF 36

37. Hot Runner Manifold System - 2 Drops
The runner can be kept liquefied through the use of a hot runner manifold.
What are the video icons for?????
The mold a jpg
37 - AF 37

38. If the mold does not treat the plastic material the same in each cavity. This fact may render the process uncontrollable.
This is why no mold can be more controllable than a single cavity mold.
No header???? What is this page supposed to convey?
38 - AF 38

41. How can we complete the fill of these two glasses at the same rate (time)? What must be adjusted?
This slide is about if you block a cavity obviously you must change your shot size. A lot of people I have found do not understand why you must also adjust the speed in order to duplicate you flow rate. This picture shows if I have a smaller shot (Smaller Glass) compared to the original full shot (Larger Glass).
Question: What must you do to complete the fill at the same time?
Answer: Adjust the orifice of the funnel on the right. This is what a machine does when you slow down the fill speed.
41 - AF 41 41

42. What is the primary reason for using a valve gate?
Heated systems require the use of a valve gate to seal the gate.
Of critical importance is the number of gates and their location.
What is the primary reason for using a valve gate?
42 - AF 42

46. Complex 8-Cavity Independent

48. Most part failures occur at the weld lines
Always remember that the weld lines are the weakest area of a plastic part
Varies with material
Difference in strength is greater in fiber-filled material
Always determines the strength of screw bosses and depressions where knit lines are present
Improper venting enhances the effect
Weld line strength varies with how the part is packed
Most part failures occur at the weld lines
48 - AF 48

49. Dynamic Pressure Loss 16,490 psip 9,628 psip 8,345 psip 5,245 psip
Parts psi a 002
5,245 psip
49 - AF 49

50. DECOUPLED MOLDINGSM 50 - AF
Decouple injection speed from first stage hydraulic pressure.
Make sure abundant hydraulic pressure is available to the injection cylinder - at least 10% more than the peak hydraulic pressure observed at the injection cylinder gauge
Use the speed control to exclusively control injection speed
Any adjustment of fill speed should change the fill time
The peak hydraulic pressure must not reach the maximum setting
Separate filling the cavity from packing and/or holding
Fill to 95-99% full (not packed)‏
Fill at a constant “CONTROLLED” rate.
Fill time should remain constant
Peak hydraulic pressure should vary as viscosity varies from all causes
Fill as fast as far as possible.
May need to be relatively slow
Lens molding
Shear sensitive material like PVC
Poor mold venting (not acceptable in the long run)‏
The best fill set up fills the mold quickly with as few speeds as possible to make good parts.
Sometimes a slow start is necessary
Jetting in hot runner molds
Reducing some types of splay or blush at the gate
Cut off or end filling by:
Stroke
Cavity pressure
Don’t flash!
Speed doesn’t flash a properly built, properly clamped mold
The sudden, complete filling of the cavity flashes the mold
50 - AF 50

51. How many programmed injection steps are required?
As few as possible
Normally no more than three (3)‏
Ten (10) is overkill
How should these programming steps be
determined?
Equal divisions over the shot size
Each step size determined by the set-up person
Preferred
Fewer steps
Simpler setup
Should be able to cancel unused steps (KIS)‏
Should be able to change overall fill speed with one command
Injection Steps.jpg
51 - AF 51

52. Fill consistent with quality Purpose:
To fill the cavity and produce part(s) that are 95-99% filled
Goal:
Fill as fast as possible under control
Separate speed from pressure
Have adequate pressure available
During Fill:
The injection unit is brought forward so the nozzle is in contact with the mold sprue
bushing
The moving platen is brought forward, the mold halves meet and clamping force is built
When the proper force is built, oil is directed to the injection cylinder, pushing the
piston forward
Since the screw is attached to the piston in the cylinder, the screw is also pushed
forward
As the screw moves forward, without rotation, the ring on the non-return valve is
pushed back into the closed position and the screw acts as a plunger, pushing plastic out of the barrel
consistent with quality
52 - AF 52

53. The material is forced through the nozzle of the machine and into the
part of the mold called the sprue bushing.
The stream of melt can be divided and distributed into different areas of the mold via the runner system
The plastic then flows through the gates and across the cavity(s)‏
At the end of fill, the part is 95 to 99% filled, or “short”
Speed of fill can be “constant” or “programmed”. First stage pressure setting must never be reached.
53 - AF 53

54. Plastic Pressure
54 - APG 54

55. 55 - APG 55

56. 56 - APG 56

57. Plastic Pressure Gradient
(Static Not Dynamic)
Pack and Hold
Packing Pressure Over Time
Packing Velocity to a Cavity Pressure
Holding Pressure & Time
57 - APG 57

58. Decoupled ІІ Molding
Objective: fill the mold fast, transfer by screw position when the cavities are 95-98% full. The ram inertia is used up just before the cavities fill out, and 2nd stage hold pressure is used to complete the filling and pack out the parts
58 - APG 58

59. 59 - APG 59

61. Example of Decoupled II Molding (2-Stage Control)
Better
But Not
The Best
What effect will a +/- 10% viscosity change have inside the mold? Can parts be contained if a viscosity change happens which requires re-centering the process?
How?
61 - APG 61

62. 62 - APG 62

63. Decoupled II Process 23.76% 34.10%
14.45% Viscosity Change
Activity: In groups of two answer the two questions using the attached formula.
Tell: Give instruction on how to use data box to answer questions.
Ask: If advanced group, further questions could be asked about what other curves are demonstrating inconsistencies.
What is the post gate peak cavity pressure variation? __________
What is the end of cavity peak cavity pressure variation? __________
Formula: ((High - Low) divided by Original) X 100 =% change
23.76%
34.10%
63 - MM II ALM

64. Plastic is compressible 1/2 to 3/4 percent per 1,000 psip.
This means overall dimensions will change on average 1/2 to 3/4 percent per 1,000 psi of plastic variation.
REMEMBER:
A short shot is zero pressure in the cavity
at the end-of-cavity.
Other factors:
Direction of flow vs. transverse to flow direction
Long fillers such as glass
Crystallinity
Controlling pressures
in the mold cavity is the
key to minimizing part variation.
64 - APG 64

65. Group Practice Pressure Loss 10,000 Post Gate psip 12,000 .500 ± .002
EOC 2,000 psip
Material Highly Nucleated Polypropylene ABS
Morphology Crystalline Crystalline Amorphous
+10% viscosity change % viscosity change % viscosity change
What is the Pressure Loss?
What are the New Dimensions?
11000
12000
11000
.495
Short
.4975
65 - APG 65

66. Variations Pressure Cause Short Shots Flash Sinks
Dimensional Variations
Warp
Gloss Gradient
Strength
66 - APG 66

67. Decoupled III: Three stage molding
Objective: fill the mold fast, profile by screw position. When the cavities are 85-95% full, transfer to a slow, controlled velocity pack stage. Packing is complete when the cavity pressure or screw position transfer completes packing the part(s)
67 - APG 67

68. Decoupled III Molding
68 - APG 68

69. Process Pivot Point 2a.jpg
69 - APG 69

70. Example of Decoupled III Molding
The BEST!
What effect will a +/- 10% viscosity change have on the end of cavity pressure of this mold? How much better is this than Decoupled II in the previous example?
70 - APG 70

71. What is the post gate peak cavity pressure variation? __________
Decoupled III Process
14.49% Viscosity Change
Activity: In groups of two answer the two questions using the attached formula.
Tell: Give instruction on how to use data box to answer questions.
Ask: If advanced group, further questions could be asked about other what curves are demonstrating inconsistencies.
Ask the students to compare the results of their calculations from the prior page to the current page and discuss the advantages.
Which process is the most stable?
Which process is the most repeatable?
Which process would have the potential for repeatable parts?
What is the post gate peak cavity pressure variation? __________
What is the end of cavity peak cavity pressure variation? __________
2.82%
11.81%
71 - APG 71

72. How do we know when cooling in a mold is adequate?
Mold Cooling
How do we know when cooling in a mold is adequate?
72 - AC 72

73. COOLING IS THE LONGEST PORTION OF THE MOLDING CYCLE
Cool The Plastic
Design for mold temperature uniformity
The hottest spot in the cavity determines the cycle time
Locate coolant lines to adequately cool critical area
Inside sharp corners
Around the gate, runner and sprue
Thick part sections
Cooling lines should be in the mold inserts
Sliding cores, as well as lifters, must be cooled
Coolant channels and connectors should be standardized
All coolant circuits should have provisions to detect flow problems for process control
COOLING IS THE LONGEST PORTION OF THE MOLDING CYCLE
73 - AC 73

74. We are filling something with heat, then removing it.
How do we know when the cooling or heating system in our home is adequate?
When every area is at the temperature we want it to be
We are filling something with heat, then removing it.
In order to optimize cooling we must understand what limits it
Heat and heat content
Heat conductivity and flow
74 - AC 74

75. Heat Content of Each Shot The mold is a leaky heat bucket.
This total heat content multiplied by the shot weight is transferred into the mold each shot.
The mold is a leaky heat bucket.
75 - AC 75

76. If the cycle is interrupted heat continues to flow out of this leaky heat bucket called a mold until the mold reaches room temperature.
During startup heat flow starts when the plastic contacts the surface of the mold. The temperature difference between the plastic and the mold is the thermal pressure causing heat flow from the plastic into the mold.
To understand how fast heat can flow, we must understand thermal conductivity and thermal impedance or resistance.
76 - AC 76

77. Heat Flow Heat flows through matter like water seeps through soil
Temperature difference is a measure of thermal pressure
In the winter the temperature difference between the inside of a wall and the outside is the thermal pressure making heat flow out through the wall
The ability of a material to conduct heat is called it’s thermal conductivity
77 - AC 77

78. BTU’s have a hard time passing through plastic or air.
To compare polypropylene to tool steel:
(from Table 5) = 300 times more conductivity
12” tool steel size of conductivity = .040” thickness of polypropylene
12” x = Equivalent Thickness 1
300
BTU’s have a hard time passing through plastic or air.
To compare tool steel to air:
(from Table 5) = 1500
12” = .008” of dead air space has the same thermal impedance as 12” of tool steel
78 - AC 78

79. A dirty mold surface or reduced cavity pressure can reduce cooling rates by as much as 20%
A mold with scale in cooling lines can reduce cooling rate by as much as 50%
Scale
79 - AC 79

80. Plastic Cooling General piping rule:
Use the fewest flow circuits that will provide turbulent flow in all channels with a maximum coolant T between the inlet and the outlet of 4°F (2°F on critical jobs)
Monitor or control the flow in all parallel flow channels
Without turbulent flow in the channels, the outer layers of coolant near the walls insulate the center of flow and efficiently reduce the volume of fluid available to carry the heat away
80 - AC 80

81. The ability to transfer heat is increased with turbulent flow as shown below:
Heat transfer can be done without turbulent flow. More turbulent is better than less.
81 - AC 81

82. FLOW THROUGH MOLD COOLING LINES FOR TURBULENT FLOW:
The following tables show the flow necessary in commonly used mold cooling lines to obtain turbulent flow.
FLOW THROUGH MOLD COOLING LINES FOR TURBULENT FLOW:
Flow in GPM for water to obtain turbulent flow:
RN = 
Where V = Kinematic Viscosity
(Centistokes)
D = Diameter in inches
3160 x GPM
V D
Note: Twice the flow rate is needed for 50/50 ethylene glycol/water mix for turbulent flow.
82 - AC 82

83. GPM NEEDED FOR TURBULENT FLOW:
The tables below show the flow necessary in commonly used mold cooling lines to obtain turbulent flow:
GPM NEEDED FOR TURBULENT FLOW:
Note: Twice the flow rate is needed for
50/50 ethylene glycol mix for turbulent flow.
1. For the top graphic change the temperature column to be first and 50/50 column last.
83- MMI

84. Computers Programs Make It Easy!
Note that ethylene glycol increases the viscosity and doubles the flow
necessary to achieve turbulent flow.
Ethylene glycol should not normally be used in cooling circuits but it is OK if abundant capacity exists. (Reduces efficiency)
Thermal conductivity of coolant changes with temperature.
Viscosity of coolant changes with temperature.
Calculating the potential heat transfer coefficient is complex and time
consuming and makes understanding the finer points of heat transfer at the
coolant interface difficult.
Computers Programs Make It Easy!
84 - AC 84

85. System is more efficient Eliminates need for use of ethylene glycol
When possible, use higher flow rates and coolant no colder than 50°F to obtain
required cooling.
System is more efficient
Eliminates need for use of ethylene glycol
Remember the potential cooling capacity depends on the total cooling impedance
of the system which includes:
The plastic
The plastic mold interface
The mold material
Any air gaps
The scale or lack of scale in the cooling channels
All must be optimized and maintained for continued constant cooling rates and
times.
85 - AC 85

86. How to pipe a mold: Strategy Treat each cavity the same
Pipe the mold the same each time
Separate cooling circuits for each cavity or:
Use enough flow so that the temperature difference between in and out will create essentially uniform temperature throughout the mold
Same size lines
Same length lines
Same size disconnect fittings
Same manifold position to each mold circuit
86 - AC 86

87. Critical dimensions for cooling channels are:
Diameter (should they be round?)
Depth (the average distance from the center of a cooling channel to the surface of the part)
Pitch (the average distance between the cooling channels)
As in a building, the criteria for judging if the environmental system is adequate
is if all areas are at the desired temperature for the intended use or result.
87 - AC 87

88. Temperature Map of the Molded Part+
300° +
280° +
190° +
70° +
160° +
210°
88 - AC 88

89. How should cooling channels be connected?
Series
Parallel
Uses least coolant
Has largest pressure loss
Largest temperature differential
All channels get the same coolant flow
Provides maximum cooling if coolant is available
Uses the most coolant
Lowest pressure loss
May waste resources
Flow channels with highest restrictions get least cooling
89 - AC 89

90. Combination of series and parallel
Best: A balance of the two
90 - AC 90

91. This allows easy detection of cooling problems. Blocked line
Insufficient available coolant
Coolant interruption
Coolant line breaks (auto shut-off)
Coolant can be prioritized to
areas where it is needed.
Hard to cool areas
Smaller lines
Areas far away from coolant surface
Q = KA P
For a given flow rate Q there is a specific P if all channels are open. If not, A changes and P will change.
K = A flow constant
A = Area of all flow channels
If a line is plugged, piped wrong, or the flow to the manifold from the central system changes, then the P or pressure difference will change.
91 - AC 91

92. Trouble killing
92 - Troublekilling 92

93. Plastic’s Point of View
Short Shots
Plastic’s Point of View
Shorts shots mean zero pressures at the end-of-fill. There was no packing phase in the cycle. If no machine changes of pressures or flow rates were evident, this generally means a viscosity change has occurred. The viscosity is increased to a condition where the plastic will no longer flow.
93 - Troublekilling 93

94. Short Shots, cont. Causes for Short Shots Possible Corrective Action
Plastic temperature is too low.
Injection rate is too slow
During fill, insufficient injection pressure was available to maintain fill speed set.
During fill, pressure is abundant and fill time is too slow.
Material is too high viscosity.
Possible Corrective Action
Measure melt temperature using the 30/30 approach.
Monitor fill time and compare it to correct fill time.
Raise first stage pressure.
Check for nozzle obstruction.
Purge into the air and observe the injection pressure.
Change material.
Increase pack and hold pressures to compensate for material increase in viscosity.
94 - Troublekilling 94

95. Splay Plastic’s Point of View Possible Corrective Action
Splay is plastic road kill!
Splay is a gas or liquid disbursed over the surface of a plastic part and manifests itself as tracks. Splay can be caused by several liquids or gases which can be moisture from undried material, trapped air, degraded polymer molecules, or degraded additives. Splay can be generated by moisture condensing on the surface of the mold and smearing across the mold surface by the plastic flow.
Possible Corrective Action
Dry material.
Increase back pressure to remove trapped air.
Change the screw type to remove trapped air.
Check material temperature and residence time to eliminate molecular degradation and additive degradation.
Keep moisture from condensing on the mold surface.
Remove sprue break.
Reduce or eliminate decompression.
Check L/D of screw; if lower than 16:1, try higher L/D or different screw design.
95 - Troublekilling 95

96. Flash and Short Shots at the Same Time
Plastic’s Point of View
This generally indicates a change in the pressure distribution during fill due to a dramatic viscosity change. It can also be caused by insufficient clamp tonnage.
Possible Corrective Action
Check clamp tonnage availability.
Check viscosity (Injection Fill Integral).
Check fill time.
Check melt temperature using 30/30 approach.
Check mold temperature.
Determine that the material is correct.
96 - Troublekilling 96

97. SINKS AND VOIDS Plastic’s Point of View
As material cools and shrinks in a mold, insufficient packing will become evident as either sinks on the outer portion of the part or voids in the center. Sinks and voids are evident in thick sections which are the last to cool or in areas extremely remote from the gate or very near the gate. Classic sinks in thick areas and away from the gate indicate insufficient packing and possibly increased viscosity of material. Sinks near the gate generally indicate lack of gate seal and possibly decreased viscosity, which is many times due to increased plastic temperature causing lack of gate seal. Decreased packing generally causes sinks away from the gate while increased packing can cause sinks at the gate end of the part if the increased pressure in the part causes the gate discharge after injection.
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98. Causes of Sinks and Voids Increase in viscosity of plastic
Packing and holding pressures are too low (end of fill sinks and thick sections only).
Injection time is too short to allow gate seal.
Mold temperature is too high to affect gate seal.
Voids are sometimes mistaken for bubbles. Bubbles are trapped gas while voids are vacuum voids due to a lack of material during cooling. SEE BUBBLES for further information.
Possible Corrective Action
Improper melt temperature -check using 30/30 approach.
Raise pack and/or hold pressure.
Increase injection forward/hold time.
Lower mold temperature.
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99. Dimensional Variations
Dimensional variations in plastics are caused by changes in the pressure distribution throughout the cavity and, for semi-crystalline materials, changes in cooling rate. Dimensional variations in both types of material can also be caused by changes in the post mold, cooling, and stabilization environment. In order to best analyze dimensional variations, the problem should be specifically categorized as on the next page:
Good Part Template
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100. Dimensional Variations, cont.
Good Part Template
Part is too small all over:
Plastic’s Point of View
Plastic pressure throughout the cavity is too low.
Possible Corrective Action
Increase packing pressure to obtain required in-mold pressures.
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101. Dimensional Variations, cont.
Part is too large all over:
Plastic’s Point of View
The pressure distribution throughout the cavity is too high.
Possible Corrective Action
Reduce packing pressure to obtain cavity pressure required.
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102. Dimensional Variations, cont.
Part is too small near the gate:
Plastic’s Point of View
The effective plastic pressure near the gate is too low while the pressure in the rest of the part is okay. This generally is caused by the gate being unsealed.
Possible Corrective Action
Increase injection forward/holding time or determine the root cause, such as possible increase of plastic temperature.
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103. Part is too large at the gate:
Dimensional Variations, cont.
Part is too large at the gate:
Plastic’s Point of View
Possible Corrective Action
The pressure distribution in the mold at the gate end is too large; the rest of the pressure is okay.
Reduce packing pressure; possibly change the pack rate if possible.
Check melt temperatures; may be too high.
Check material viscosity (Injection Fill Integral).
Allow discharge by reducing injection forward/hold time.
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104. Dimensional Variations, cont.
Part is too small at the end of cavity:
Plastic’s Point of View
Plastic’s Point of View
Pressure distribution is okay at the gate but is reduced from normal at the end of fill. This generally indicates a change in plastic viscosity.
Check fill time.
Check melt temperature using 30/30 approach and adjust as appropriate.
Check viscosity (Injection Fill Integral). If viscosity is too high, increase fill speed until the viscosity is correct.
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105. Dimensional Variations, cont.
Part is too large at the end of cavity:
Plastic’s Point of View
Possible Corrective Action
This means that the pressure distribution in the cavity is okay at the gate and too high at the end-of -fill. This indicates a lowering of viscosity.
Check melt temperature by using 30/30 approach.
Check fill time.
Check viscosity (Injection Fill Integral). If viscosity is too low, reduce injection speed until viscosity number is correct.
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106. Dimensional Inconsistency
Plastic’s Point of View
Inconsistent dimensions mean inconsistent pressure gradients throughout the part. This could indicate that on some shots, the gate is sealing or not sealing. Otherwise the pressure distribution in the cavity is varying on a shot-to-shot basis. If this is the case, check to see if there are large variations in parts shot-to-shot or if there are trends over time. Trends over time indicated temperature variations or material lot variations, whereas shot-to-shot inconsistencies indicating packing fluctuations over short periods are either caused by gate seal changes or pressure changes due to check ring leaks, etc.
Possible Corrective Action
Run a series of short shots to check the check ring consistency.
Monitor hydraulic pressure consistency.
Do a gate seal analysis and possibly increase injection forward time.
Monitor viscosity fluctuations (Injection Fill Integral).
Monitor in-mold pressure to determine variability.
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107. Warp Plastic’s Point of View
Warp is an inconsistent deformation of the part making it nonconforming to the shape of the cavity. This is generally caused by some kind of stress induced in the part during filling, packing, or cooling. Warp is a complex phenomena and is often caused by a summation of many forces, a few of which are dominant.
In amorphous material, the effect of crystallinity does not exist. Therefore there is an extra dimension in the crystalline or semi-crystalline materials. Parts filled with long thin fibers, such as glass, have another factor; the orientation of which is not present in unfilled materials.
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108. Warp, cont. Crystalline Materials Possible Corrective Action
In crystalline materials, a large portion of warp is crystallinity induced, caused by non-uniform cooling. In amorphous materials compressive stress gradients caused by non-uniform packing pressures throughout the part are generally predominant. In addition, the orientation stresses caused by flow and subsequent relaxation of the stresses during cooling can cause non-uniform stresses in parts. In analyzing warp problems, it is important to categorize them as crystalline or amorphous, fiber-filled or unfilled, and then proceed. In the semi crystalline material, comparing the first shot out of a cold or uniformly-temperatured mold to one run later as the mold warms up will give an understanding of whether or not this is the problem. If the first part out of the mold is not warped, then the issue of non-uniform cooling is probably the predominant situation.
Another quick check is to run the part using an amorphous material. Many times an easy flow ABS can be substitutes for polypropylene. If the ABS part does not warp and the polypropylene part does, crystallinity issues are probably the cause.
Possible Corrective Action
Redesign the cooling to minimize hot spots and cold spots in the mold.
Change the material to an amorphous resin.
Redesign the part to a more rigid structure using complex shapes or ribs (ribs are least desirable).
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109. Warp, cont. Plastic’s Point of View Crystalline Materials con’t.
Analyzing warp in parts made of high aspect (long) fiber-filled materials involves comparing parts molded with the fiber to that of the unfilled resin to determine the degree of change. Flow during fill orients fibers in the direction of flow, but they do not de-orient as many molecules do during cooling. Most often, warp caused by orientation of fibers can only be corrected by changing the flow directions in the part or changing the design of the part.
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110. Warp, cont. Amorphous Unfilled Materials Possible Corrective Action
Generally, amorphous warp is caused by a combination of orientation stresses and a packing stress gradient. A packing stress gradient can be reduced by reducing viscosity, generally by increasing fill rates and/or temperatures.
Also, when Decoupled III is being used, optimizing pack speed can minimize the packing stress gradient.
Orientation stress can be reduced by raising the plastic temperature, slowing the fill, and/or reducing the cooling rate. If the packing stress gradient is the predominant factor, increasing speed will generally reduce warp. If orientation stress is the primary effect, increasing speed will cause the warp to worsen.
Another important factor is whether or not the gate is sealed. Many times the packing stress gradient can be reduced by intentionally not sealing the gate which will reduce the compressive stress gradient by allowing back flow, thus making the part flat. This is especially true in center-gated parts, both semi-crystalline and amorphous.
Possible Corrective Action
Increase fill speed.
Decrease fill speed.
Increase melt temperature.
Increase mold temperature.
Reduce injection time to allow gate to back flow or discharge.
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111. Knitline Weakness or Cosmetic Problems
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112. Knitline Weakness or Cosmetic Problems, cont.
Plastic’s Point of View
A knitline is truly a glue joint in that the two plastic flow fronts join and do not generally re-entangle. The exceptions are some crystalline materials which are welded together above their melting point. In a classic knitline formation, the same problems apply to a knitline as that of making a good glue joint. The material must be at a low enough viscosity, the flow front must be clean, there must be sufficient pressure to cause bonding, and the pressure must be held for a sufficient time to allow the material to solidify. Also, there is often air entrapment. Knitlines must be well vented. If all of the elements are available, knitline integrity should exist.
Possible Corrective Action
Check viscosity (Injection Fill Integral) and correct if necessary.
Check melt temperature.
Check fill time.
Check mold temperature.
Be sure the part is properly packed.
Raise packing pressure. Be sure that the gate is sealed.
Check gate seal time.
Maintain proper cycle.
Be sure that the cavity is adequately vented at the knitline area.
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