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Injection Molding MFG 355. 15 Ton Injection Molding Machine Click on frame to start video.

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Presentation on theme: "Injection Molding MFG 355. 15 Ton Injection Molding Machine Click on frame to start video."— Presentation transcript:

1 Injection Molding MFG 355

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4 15 Ton Injection Molding Machine Click on frame to start video

5 77 Ton Injection Molding Machine Click on frame to start video

6 150 Ton Injection Molding Machine

7 Equipment Injection Unit Screw drive arrangement Feed hopper Barrel heaters Nozzle Tool Screw Check valveScrew tip

8 Equipment Injection Unit

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11 Injection Parts of the injection screw –Screw –Head and check ring

12 Equipment Molds

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14 Mold Materials Aluminum filled epoxy Aluminum Tool steel Stainless steel Hotwork die steel Beryllium-copper

15 Mold Materials Choice based on critical properties –Machinability –Coefficient of thermal expansion –Specific heat capacity –Thermal conductivity –Density –Hardness (abrasion resistance) –Yield strength –Weldability

16 Mold Parts Bases –Standard sizes –Hold mold inserts –Can decrease overall mold costs

17 Mold Parts Guide pins –Align mold cavities Guide pins

18 Mold Parts Sprue Bushing –Hot sprue –Cold sprue

19 Mold Parts Sprue Bushing –Hot sprue

20 Mold Parts Sprue Bushing –Cold sprue –Sprue puller

21 Mold Parts Sprue Bushing –Cold sprue –Sprue puller

22 Mold Parts Runner

23 Mold Parts Runner –Layout Conventional ImprovedBalanced HCircular

24 Mold Parts Runner –Layout Conventional ImprovedBalanced HCircular

25 Mold Parts Runner –Cold well

26 Mold Parts Runner

27 Mold Parts Gates Submarine Gate Pinpoint Gate Fan or Edge Gate

28 Mold Parts Gates Sprue Gate Tab Gate Flash Gate

29 Mold Parts Gates Internal Ring Gate External Ring Gate

30 Mold Parts Gate

31 Mold Parts Gate

32 Mold Parts Gate

33 Mold Parts Cavity –Where the part is made –Layout is critical to material flow

34 Mold Parts Cavity –Knit/weld lines This shows where the weld lines (shown in red) will most likely occur with the part gated in the center (yellow cone).

35 Mold Parts Cooling –Reduce cycle time –Control formation of crystalline areas –Freeze part Mold cavity Cooling lines

36 Mold Parts Ejector system Ejector Plate Ejector pins Return Springs

37 Equipment Clamping Unit

38 Equipment Clamping Unit –Toggle clamping –Hydraulic clamping –Hybrid hydraulic-toggle clamping

39 Equipment Clamping Unit

40 Equipment Clamping Unit –Toggle system Click on frame to start video

41 Plant Concepts

42 Safety High clamping forces High pressure lines High voltage High temperatures

43 Safety Position switches –Mechanical, hydraulic and electrical Shields Lock out/tag out

44 Material and Product Considerations Shapes –Possible to do very complex shapes Structural features –Pins, ribs, bosses, threads, holes –Deep parts are possible –Internal or external threads –Undercuts require sliding mold sections

45 Sliding Mechanism

46 Material and Product Considerations Part design –Uniform wall thickness Helps reduce dimples, shrink marks and distortion –Ribs Save weight at given strength –No sharp bends Helps to fill the mold cavity easier –Oversize the mold Shrinkage amount is dependant on material and additives/fillers

47 Operations and Control Temperature of melt Temperature of mold Pressure of injection and hold Injection or fill rate and time Dwell time Freeze time Ejection (dead time)

48 Special Injection Molding Processes Coinjection molding –Two separate screws –Two different material selections Color, strength, flexibility

49 Special Injection Molding Processes Coinjection molding 123

50 Special Injection Molding Processes Coinjection molding Part 1 Part 2

51 Special Injection Molding Processes Flow-controlled injection processes –Sometimes called Scorim

52 Special Injection Molding Processes Flow-controlled injection processes –Sometimes called Scorim

53 Special Injection Molding Processes Gas injection molding –Employs gas to create hollow parts

54 Special Injection Molding Processes Injection-compression molding Injection-Compression Molding Injection Molding Parts were made with the same mold. The only difference between the two parts is the use of the compression cycle

55 Modeling and Computer-Aided Mold-Flow Analysis Used to help identify potential problems with the mold/part design Models based on the CAD part Adjusted by resin

56 Thank You


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