1. PLASTIC INJECTION MOLDING
AKASH DEEP.B.N
1SJ03ME121

2. Plastic Injection Molding
· Overview
· Injection Molding
· Injection Molding machine
· Injection molding processes
· Injection molding materials
· Injection molding problems and solutions
· Typical applications and Products

3. Overview
Injection molding is the most widely used polymeric fabrication process.
It is the primary process for manufacturing thermo plastic products.
Injection molding can be used to form a wide variety of products. Complexity is virtually unlimited, sizes may range from very small to very large, and excellent control of tolerances is also possible.
The major reasons that injection is so popular is that it produces light weight parts of specific color with built in surface texturing.
Most polymers may be injection molded, including thermoplastics, fiber reinforces thermoplastics, thermosetting plastics, and elastomers.

4. Injection molding
Injection molding is a method to obtain molded products by injecting plastic materials molten by heat into a mold, and then cooling and solidifying them. The method is suitable for the mass production of products with complicated shapes, and takes a large part in the area of plastic processing.
Advantages of Injection Molding
High production rates
Wide range of materials can be used
Low labor costs
Minimal scrap losses

5. Types of Injection Molding Machines
Hand injection molding machine
Piston type injection molding machine
Reciprocating type injection molding machine

6. Injection Molding Machine

7. Injection molding machine is divided into 3 units i. e
Injection molding machine is divided into 3 units i.e. a clamping unit, an injection unit and mold.
The functions of the clamping unit are opening and closing a die, and the ejection of products. There are 2 types of clamping methods, namely the toggle type shown in the figure below and the straight-hydraulic type in which a mold is directly opened and closed with a hydraulic cylinder. The functions of the injection unit are to melt plastic by heat and then to inject molten plastic into a mold.

9. Machine components
Injection system The injection system consists of a hopper, a reciprocating screw and barrel assembly, and an injection nozzle, as shown in Figure 1. This system confines and transports the plastic as it progresses through the feeding, compressing, degassing, melting, injection, and packing stages.
FIGURE 1. A single screw injection molding machine for thermoplastics, showing the plasticizing screw, a barrel, band heaters to heat the barrel, a stationary platen, and a movable platen.

10. The hopper
The barrel
The reciprocating screw The reciprocating screw is used to compress, melt, and convey the material. The reciprocating screw consists of three zones (illustrated below)
the feeding zone
the compressing (or transition) zone
the metering zone

11. FIGURE 2. A reciprocating screw, showing the feeding zone, compressing (or transition) zone, and metering zone.

12. The nozzle
FIGURE 3. (a) Nozzle with barrel in processing position. (b) Nozzle with barrel backed out for purging.
Mold system
The mold system consists of tie bars, stationary and moving platens, as well as molding plates (bases) that house the cavity, sprue and runner systems, ejector pins, and cooling channels, as shown in Figure 4. The mold is essentially a heat exchanger in which the molten thermoplastic solidifies to the desired shape and dimensional details defined by the cavity.

13. Mold System
3 plate mold
2 plate mold

14. Hydraulic system
Control system
Clamping system
The delivery system
The delivery system, which provides passage for the molten plastic from the machine nozzle to the part cavity, generally includes:
a sprue
cold slug wells
a main runner
branch runners
gates.
FIGURE 6. The molded system
includes a delivery system and molded parts.

15. Injection molding processes
The Injection molding process basically is divided into 6 major steps
1. Clamping
2. Injection
3. Dwelling
4. Cooling
5. Mold Opening
6. Ejection

16. Cycle time in injection molding
The injection molding cycle can be divided into several stages. They aremold closing, filling, packing, cooling, mold opening and ejection as shown here.
Cooling Time is a major fraction of the total cycle time.
Materials for injection molding
Acrylonitrile butadiene styrene (ABS)
Polyethylene
Polypropelene
Polystyrene

17. Typical Applications
Injection molding is widely used in a wide variety of industries: automotive, appliance, computer, communication and industrial equipment. Examples of injection molded parts in the automotive industry include sail panels, radiator end caps, door panels, lamp housings, and fuel rails.
Radiator End Cap
Automobile parts
Automotive Sail Panel
 Fuel Rails with Injectors

18. Injection Molding Problems and Solutions
Fault
Air trap
Black streaks
Flash
Short shot
Sink mark
Solution
Reduce injection speed,
Proper venting.
Lower the barrel temp.
Clean the injection unit.
Adjust the clamp force.
Reduce the injection pressure.
Increase the injection value.
Increase the cooling time.

19. Conclusion
As the injection molding technology is now living its most rapid development times. The most important factors behind this situation is
There is no potential competitors
Injection molding is especially suitable for mass production.
The profitable molding in today’s competitive market depends on precise clamping action coupled with both high plasticizing performance and reliability integrated with complete plant operating performance.

20. References Injection Molding Hand Book Theory of Molds WWW.Google.com
Dominick V Rosato
Donald V Rosato
Theory of Molds
R S Nagesh