1. INTRODUCTION TO INJECTION MOULDING OVERVIEW OF BASIC IMM

2. SESSION PLAN 9:00am to 9:30pm PROGRAM INTRODUCTION 9:30am to 10:00am IMM INTRODUCTION 10:00am to 10:30am REFRESHMENT 10:30am to 12:45pm PROGRAM CONTINUE 12:45pm to 2:00pm LUNCH 2:00pm to 3:15pm BASIC CONSTRUCTION OF MOULD 3:15pm to 3:45pm BREAKTIME 3:45pm to 4:00pm PROGRAM CONTINUE 4:00pm Q & A

3. IMM INTRODUCTION

7. Inventions By the mid 20 th century bakelite was invented as the first synthetic resin to use as engineering material by Baekeland. In 1950s the new raw material found and lead to the changes from coal to oil as our energy source created a light alkane fraction as a by product. (Ethylene group).

8. The Making Of Plastics Most synthetic plastics come from crude oil but coal and natural gas is also used. When crude oil is refined gasses are given off . The gasses are broken down into Monomers. These are chemical substances consisting of a single molecule. Thousands of these are linked together in a process called Polymerization to form new compounds called Polymers.

9. Polymerization A chemical reaction in linking the molecules of a simple substance (monomer) together to form large molecules whose molecular weight is a multiple of that monomer. A+A+A+A+A+A+A+A+A+A+A+A+A+A+A+A+A+A A Monomer (Functional group) REACTION

10. Degree of Polymerisation Each polymer molecule incorporates large numbers of monomer units.The degree of polymerization determined the numbers of monomer units in the molecular chain.The higher mean the greater number of monomers and the length of the chain. Molecular weight is the term referred to as the length of the polymer chain.

11. Chains arrangement Polymerisation also has an affect on the shape of polymer molecules: Linear chain arrangement. Branched chain arrangement. Cross linked chain arrangement.

12. Linear Chain Arrangement Linear molecules basically form a straight molecule chain.They are considered to be long and flexible Monomer unit

13. Branched Chain Arrangement The long chain with intermittent off shoots is referred to as Branching or Branched polymer.

14. Cross link Chain Arrangement The polymer chain are linked by a chemical reaction that physically bonds the chains together.

15. General Characteristics of polymers Hygroscopic Having the tendency to absorb moisture from the air. Some resins are hygroscopic, thus requiring drying before molding. Homopolymer A polymer resulting from the polymerization of a single monomer; a polymer consisting substantially of a single type of repeating unit. Copolymer/Terpolymer Polymer resulting from the polymerization of a different monomer; a polymer consisting substantially of a 2 or 3 type of repeating unit .

19. Machine Toggle clamping system With 5 point locking Injection Unit Screw unit Non return valve Fixed platen Moving platen Control Cabinet

20. Nozzle Nozzle contact with the sprue bush of the mould Materials flows inside the mould through Sprue bush

21. Injection Screw

23. Screw

24. Shut off Valve Nozzle and Shut off valve

25. Injection Screw

26. Injection and Holding pressure phase Plasticising-Dosage Injection Screw

30. Types Of IMM

34. Types Of IMM Electric motor and pump arrangement

38. Types Of IMM Synchronous Motors High torque motors

42. Rotor Stator Slow turning, water cooled high-torque motors Water cooling system Space to integrate ball spindel

45. Types Of IMM Electric screw-drive

46. COMPONENTS OF IMM

53. Comparison between toggle and full hydraulic Toggle system Hydraulic system S 2 H 2 H 3 = 950 S 2 H 2 H 1 S 1 H 3 S 1 Mould opening stroke remains the same, maximum platen distance H 3 changes Mould opening stroke changes with mould height, maximum platen distance H 3 remains the same H 1 = 200 S 1 = 550 H 2 = 500 S 2 = 250 H 3 = 750 H 1 = 200 S 1 = 450 H 2 = 500 S 2 = 450 H 1 H 3 = 650

59. tie bars are fully forward Automatic Set-Up After Mould Change clamp opens to align calipers with notches calipers locks clamp closes by retracting tie bars clamp opens - ready for cycle mode calipers unlocks clamp closes until mould halves touch

60. tie bars are fully forward Automatic Set-Up After Mould Change

61. clamp closes until mould halves touch Automatic Set-Up After Mould Change

62. clamp opens to align callipers with notches Automatic Set-Up After Mould Change

63. calipers locks Automatic Set-Up After Mould Change

64. clamp closes by retracting tie bars Automatic Set-Up After Mould Change

65. clamp closes by retracting tie bars Automatic Set-Up After Mould Change

66. Automatic Set-Up After Mould Change Calipers unlocks

67. clamp opens - ready for cycle mode Automatic Set-Up After Mould Change

68. tie bars are fully forward Automatic Set-Up After Mould Change

69. clamp closes until mould halves touch Automatic Set-Up After Mould Change

70. clamp opens to align calipers with notches Automatic Set-Up After Mould Change

71. calipers locks Automatic Set-Up After Mould Change

72. clamp closes by retracting tie bars Automatic Set-Up After Mould Change

73. Automatic Set-Up After Mould Change Calipers unlocks

74. Automatic Set-Up After Mould Change clamp opens - ready for cycle mode

86. Components Of IMM Mechanical ejector on electric machine

87. Components Of IMM Variable pump system Ejector bar Movable platen Clamping cylinder Ejector valve Mechanical ejector on hydraulic machine

88. Peripheral / Auxiliary Equipment

92. Material Drying System Air Exhaust Plastic Pellets Dried Moist Return Air Desiccant Drying Unit Drying Hopper Air Dispersion Cone Hot Dry Air Peripheral / Auxiliary Equipment

94. Hopper Loader Compressed Air Vacuum Feed Tube Container for Plastic Pellets Peripheral / Auxiliary Equipment

95. Additive Metering System Auger Feeder Feed Throat Virgin Plastic Color Concentrate Peripheral / Auxiliary Equipment

98. Safety In IMM

99. MOULD

100. MOULD

101. MOULD 2-plate mould

102. MOULD 3-plate mould

103. MOULD 2-plate mould with slider/split mould

104. MOULD Stack mould

105. MOULD

106. SPRUE SYSTEM SPRUE BUSH It channels the molten Materials from the plasticising Unit/barrel of the moulding machine And guide its to the cavity

107. SPRUE SYSTEM

108. SPRUE SYSTEM

109. SPRUE SYSTEM

110. RUNNER SYSTEM

111. RUNNER SYSTEM Hot runner system

112. RUNNER SYSTEM Cold slug is referring to contaminations or cold materials. Cold slug are formed when: The material at nozzle tip is trapped by the cold well before it enter the cavity. The residual material at Nozzle loses heat and Solidify before next cycle.

113. GATING SYSTEM

114. GATING SYSTEM Gating system can be divided into 2 categories:- 1.Unrestricted Gate (Direct Gate) Where the pressure loss is low,however the defects such as deformation and loss of impact strength may occur,due to residual stress. 2.Restricted Gate (All types of gate except direct gate) Where molten plastic passed at high velocity,generating a large pressure drop where by its then converted to frictional heat which used to heat the molten plastic.

115. GATING SYSTEM Direct Gate Also known as sprue gate. Disadvantages of using this method: -Required secondary process -Impression of sprue mark -Take time to cool the sprue

116. GATING SYSTEM Edge Gate Also known as side gate.The product is gated at parting line Cross section of the gate is usually tapered or semi circular for ease of ejection

117. GATING SYSTEM Fan Gate Gate width is more than 3 times the height of the cross section. Often used in thin wall product that required good surface finish.

118. GATING SYSTEM Disk Gate Also known as diaphragm gate.Allow uniform filling for cylindrical parts. Advantage of using this system product remain round and concentric. Dis advantages gates need to machined off.

119. GATING SYSTEM Pin point Gate Generally used in 3 plate mould. Advantages of using this method,part and runner is separated automatically.

120. GATING SYSTEM Tab Gate Used in thick walled products.To avoid moulding defect for example like jetting. Disadvantages required secondary process.

121. GATING SYSTEM Film Gate Also known as flash gate.Primarily used in moulding part with large surfaces and thin walls. Disadvantages required secondary process.

122. GATING SYSTEM Ring Gate Used for tubular moulding product. Gate is in form of a concentric film between the runner and the cavity.

123. GATING SYSTEM Tunnel Gate Also known as submarine gate Commonly used in multi-cavity mould and for small parts. Cross section of gate is conical Provide automatic degating.

124. MOULD Sample pictures of cavity plate and inserts

125. MOULD

126. RUNNER & CAVITY LAYOUT All cavities should be filled at the same time,to avoid short shot and flashing. Runner flow length should be short as possible,to avoid pressure loss and material waste. There should be sufficient space between cavities for proper cooling and ejection.

127. MOULD POLISHING METHOD

128. MOULD Venting

129. COOLING SYSTEM

130. COOLING SYSTEM

131. COOLING SYSTEM

132. COOLING SYSTEM

133. COOLING SYSTEM

134. LOCATING RING /GUIDE PIN

135. LOCATING RING /GUIDE PIN

136. LOCATING RING /GUIDE PIN

137. EJECTOR SYSTEM

138. EJECTOR SYSTEM Mechanical ejector system

139. EJECTOR SYSTEM

140. EJECTOR SYSTEM Standard ejector pin pin Standard ejector blade pin Standard ejector sleeve

141. EJECTOR SYSTEM Stripper plate ejector

142. EJECTOR SYSTEM Air Valve system

143. EJECTOR SYSTEM Poppet Valve system

144. MOULD MOUNTING Direct machine clamping

145. MOULD MOUNTING Mould clamp

146. MOULD MOUNTING

147. MOULD MAINTENANCE

148. MOULD MAINTENANCE

149. MOULD MAINTENANCE

150. MOULD MAINTENANCE

151. MOULD MAINTENANCE Method of labeling for identification and storage

152. MOULD MAINTENANCE Application of anti rust after production To prevent mould from rust.

153. MOULD MAINTENANCE Preventive maintenance during production and after production

154. MOULD MAINTENANCE Spare parts availability Workshop practice

155. END OF SESSION THANK YOU