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Injection Molding

Injection Molding. MFG 355. 15 Ton Injection Molding Machine. Click on frame to start video. 77 Ton Injection Molding Machine. Click on frame to start video. 150 Ton Injection Molding Machine. Click on frame to start video. Feed hopper. Barrel heaters. Nozzle. Screw drive

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Injection Molding

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  1. Injection Molding MFG 355

  2. 15 Ton Injection Molding Machine Click on frame to start video

  3. 77 Ton Injection Molding Machine Click on frame to start video

  4. 150 Ton Injection Molding Machine Click on frame to start video

  5. Feed hopper Barrel heaters Nozzle Screw drive arrangement Tool Screw Check valve Screw tip Equipment • Injection Unit

  6. Equipment • Injection Unit

  7. Injection • Parts of the injection screw • Screw • Head and check ring

  8. Equipment • Molds

  9. Molds

  10. Mold Materials • Aluminum filled epoxy • Aluminum • Tool steel • Stainless steel • Hotwork die steel • Beryllium-copper

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

  12. Mold Parts • Bases • Standard sizes • Hold mold inserts • Can decrease overall mold costs

  13. Mold Parts • Guide pins • Align mold cavities Guide pins

  14. Mold Parts • Sprue Bushing • Hot sprue • Cold sprue

  15. Mold Parts • Sprue Bushing • Hot sprue

  16. Mold Parts • Sprue Bushing • Cold sprue • Sprue puller

  17. Mold Parts • Sprue Bushing • Cold sprue • Sprue puller

  18. Mold Parts • Runner

  19. Mold Parts • Runner • Layout Improved Balanced “H” Circular Conventional

  20. Mold Parts • Runner • Layout Improved Balanced “H” Circular Conventional

  21. Mold Parts • Runner • Cold well

  22. Mold Parts • Runner

  23. Mold Parts • Gates Submarine Gate Fan or Edge Gate Pinpoint Gate

  24. Mold Parts • Gates Tab Gate Sprue Gate Flash Gate

  25. Mold Parts • Gates Internal Ring Gate External Ring Gate

  26. Mold Parts • Gate

  27. Mold Parts • Gate

  28. Mold Parts • Gate

  29. Mold Parts • Cavity • Where the part is made • Layout is critical to material flow

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

  31. Mold Parts • Cooling • Reduce cycle time • Control formation of crystalline areas • Freeze part Mold cavity Cooling lines

  32. Mold Parts • Ejector system Ejector pins Return Springs Ejector Plate

  33. Equipment • Clamping Unit

  34. Equipment • Clamping Unit • Toggle clamping • Hydraulic clamping • Hybrid hydraulic-toggle clamping

  35. Equipment • Clamping Unit

  36. Equipment • Clamping Unit • Toggle system Click on frame to start video

  37. Plant Concepts

  38. Safety • High clamping forces • High pressure lines • High voltage • High temperatures

  39. Safety • Position switches • Mechanical, hydraulic and electrical • Shields • Lock out/tag out

  40. 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

  41. Sliding Mechanism

  42. 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

  43. 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)

  44. Special Injection Molding Processes • Coinjection molding • Two separate screws • Two different material selections • Color, strength, flexibility

  45. Special Injection Molding Processes • Coinjection molding 1 2 3

  46. Special Injection Molding Processes • Coinjection molding Part 1 Part 2

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