this is very useful slide for cipet

1. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
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006
V 
CENTRAL INSTITUTE OF PLASTICS
ENGINEERING AND TECHNOLOGY

2. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
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V 
INJECTION MOULDING PROCESS -
RESOURCES
MATERIAL
MACHINE
MOULD
MAN POWER

3. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
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MATERIAL
THERMOPLASTIC
MATERIAL
THERMOSET
MATERIAL
PLASTIC MATERIAL

4. ISO 9001
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QUALITY
MANAGEMENT
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•HEAT •COOL •SOLID
•PRESS.
IT CAN BE RECYCLED
THERMPLASTIC MATERIAL
•SOFT

5. ISO 9001
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•HEAT •HEAT
•SOLID
•PRESS.
•IT CAN NOT BE RECYCLED
•SOFT
•CHARCOAL
THERMOSET MATERIAL

6. ISO 9001
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QUALITY
MANAGEMENT
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Injection Moulding
Definition
Process whereby heat softening, plastics material
is forced (injected) from a cyclinder into a cavity
which is a replica of article. After allowing for
cooling finished article can be ejected out from
the cavity.

7. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
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Injection Moulding
Product
Batch process of constant dimension with close
dimensional control. Such as
• video cassettee,
• fuel pumps,
• gear box,
• small gears,
• automobile parts,
• pipe fittings disposable
syringes &
• other medical
equipments.
• bucket,
• mug,
• dustbin,
• cups,
• crates,
• moulding luggauge,
• cabinate for radios,
• taperecorders,
• housing for domestic
appliances,

8. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
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Injection Moulding
Material
All thermoplastics like LDPE, HDPE, PVC, ABS,
Polycarbonate, etc.
Thermoset on specific requirement & cost
effective basis, Recommended MFI 8 to 10 and
above.

9. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
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V 
Injection Moulding
Rating
• Clamping Capacity in Tonnes

10. ISO 9001
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QUALITY
MANAGEMENT
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Injection Moulding
Major factor for consideration
• Type of Clampings
• L/D ratio and compression ratio,
• Shot weight
• Minimum and Maximum day light
• Size of platen and distance tie rod/
• Type of Drive.

11. ISO 9001
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U K A S
QUALITY
MANAGEMENT
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MACHINE
 HEATING
 PRESURISING AND CONVEYING
 MOULD CLAMPING
Figure - The basic Injection Moulding Cycle

12. ISO 9001
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U K A S
QUALITY
MANAGEMENT
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MOULD
 THE MOLD HAS 4 MAIN FUNCTIONS
RECEIVE & DISTRIBUTE THE MATERIAL
SHAPE FORMING
COOLING(Water & oil)
DISPOSAL

13. ISO 9001
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QUALITY
MANAGEMENT
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MANPOWER
TO SET UP A PROCESS
TO MONITOR AND TROUBLE SHOOT
TO OPARATE MACHINE

14. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
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V 
Injection Moulding
Types of Injection Unit
•Plunger
•Preplasticising
•Reciprocating screw

15. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
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V 
PLUNGER TYPE MACHINE
TYPES OF I.M MACHINES

16. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
Qi
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V PLUNGER-PLUNGER TYPE

17. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
Qi
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V 
SCREW – PLUNGER TYPE

18. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
Qi
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V IN LINE RESIPROCATING SCREW TYPE

19. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
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V 
Screw Rotation

20. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
Qi
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V 
The rotation of the screw produces
frictional and shear together with the
heat input from heater bands around
the barrel cause the material to melt.
These two sources of heat , combined
with the mixing effect of the screw ,
provide a homogenous melt
Screw Rotation

21. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
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NOZZLE
It provides thermal & mechanical connection
from hot cylinder to cold injection mold
TYPES OF NOZZLES
An open channel with no mechanical
valve
An internal check - valve held closed by
spring
A shut off valve

22. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
Qi
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V 
SCREW-L/D RATIO
It is the ratio of the flight length to the dia.
of the screw
 Generally L/D ratio varies 20:1 to 30:1
 Generally L/D ratio for PVC is 16:1
 The larger the L/D ratio greater opportunity
for mixing, resulting in better homogeneity of
melt
 Greater the resident time of the plastic in the
barrel permitting faster cycles of larger shots
& more output

23. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
Qi
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V 
FEED ZONE: Promotes pumping/output rate
adequately-It can be 50 to 60% of L
COMPRESSION ZONE: Promotes shearing
and hence melting of polymers at the output
rate of feed zone-It can be 20 to 25% of L
METERING ZONE: Promotes homogenization
of entire melt stream emerging from
compression zone- It can be 20 to 25% of L
SCREW- VARIOUS ZONES IN SCREW

24. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
Qi
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V 
SCREW
SIGNIFICANCE OF LENGTH OF EACH ZONE
 Longer feed zone creates greater potential
throughput
 Longer compression zone results in less
shear heat & more to compress & melt the
plastic
 Longer meter zone allows screw to develop
more pumping pressure and greater
opportunity to homogenize
 Shorter meter zone allows less time to assure
uniform melt temperature and viscosity

25. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
Qi
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V 
CLAMPPING-TYPES
 HYDAULIC CLAMPING
 TOGGLE CLAMPING
 PNEUMATIC CLAMPING

26. ISO 9001
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QUALITY
MANAGEMENT
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V 
Hydraulic Clamping
Toggle Clamping

27. ISO 9001
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U K A S
QUALITY
MANAGEMENT
Qi
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V 

28. ISO 9001
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U K A S
QUALITY
MANAGEMENT
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V 
HYDRAULIC Vs TOGGLE-COMPARISION
 Much higher original
cost
 Higher horse power
needed.Therefore
more expensive to
run
 Unlimited stroke
potential
 Direct readout of
clamp force
 Lower original cost
 Lower horse power
needed.More
economical to run
 Limited stroke
potential
 No Direct readout of
clamp force

29. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
Qi
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V 
HYDRAULIC Vs TOGGLE-COMPARISION
 Easy adjustment of
clamp force
 Easy mold setup
 Varies stroke to mold
height
 Clamp speed easily
controlled or stopped
at any point
 Low maintenance as
parts are self
lubricated
 More difficult
 More involvement in
mold setup
 Constant mold stroke
 Clamp speed more
difficult to control and
stop
 Higher maintenance
cost

30. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
Qi
006
V 
POLYMER
MATERIAL
TEMP.RANGE 0
C
MOLD TEPMP.
Nylon-6 230-260 80-90
Nylon-6 with GF 230-280 70-90
Nylon-66 270-290
80-90
Nylon11 210-240 30-60
Polysulphon 33-400 100-160
LDPE 160-240 30-50
LLDPE 200-280 30-50
HDPE 160-220 30-50
EVA copolymer 160-230 30-50
PP homopolymer 220-280 20-70
PP,20% Talc 200-280 20-70
PP,copolymer 170-230 20-60
PP,20% glass 220-280 20-80
GPPS 170-280 20-70
GPPS with GF 210-280 60-80
HIPS 190-260 50-80
SAN 200-280 30-80
ABS 240-280 40-80

31. ISO 9001
B
U K A S
QUALITY
MANAGEMENT
Qi
006
V 
POLYMER MATERIAL TEMP.RANGE 0 C MOLD TEPMP.
PVC,Rigid 190-220 30-60
PVC,Soft 140-200 20-40
Acrylic 220-250 60-90
PET 280-295 5-15
PET,Not reinforced 235-280 20-70
PBT,30%GF 235-280 20-90
PET/PBT copolymer 235-280 20-90
PC 280-310 80-120
PC 40% GF 270-310 80-120
PPS 300-360 120-180
POM copolymer 180-230 60-120
PPO modified with GF 250-280 110-13
PPS/PS 270-300 70-110
PUR 170-220 10-30