ARBURG Practical Guide to Injection Moulding

Contents......Page 5
Dear Reader......Page 11
Preface......Page 13
1.2 Introduction to Injection Moulding......Page 15
1.3.1 Piston Injection Unit......Page 17
1.3.2 Reciprocating Screw Machine......Page 18
1.3.3 Breaking Down the Injection Moulding Cycle......Page 19
1.4.1 Extrusion......Page 20
1.4.3 Transfer Moulding......Page 21
1.4.4 Blow Moulding......Page 22
1.4.5 Film Blowing......Page 23
1.4.7 Injection-Compression Moulding......Page 24
Further Reading......Page 25
2.1 Introduction......Page 27
2.3 Formation of Macromolecules......Page 28
2.5.1 Thermoplastic......Page 30
2.5.2 Thermosets......Page 31
2.5.3 Elastomers......Page 32
2.5.4 The Formulation of Plastics......Page 33
2.6.1 Rheology......Page 34
2.6.3 Physical and Chemical Change......Page 35
2.6.4 Fountain Flow......Page 36
2.7 Conclusion......Page 37
3.1 Injection Units......Page 39
3.3.2 Plasticising Capacity......Page 40
3.3.4 The Injection Cylinder......Page 41
3.4 Selection of the Injection Unit......Page 42
3.5 L/D Ratio......Page 43
3.5.1 Mixing Screws for Additives and Fast Cycling Machines......Page 45
3.5.2 Non-Return Valve......Page 46
3.7 Unit Hardening Treatment......Page 47
3.8 The Nozzle......Page 48
3.9 Clamping Units......Page 51
3.9.2 Mould Weights......Page 52
3.10 Selection of the Clamping Unit......Page 54
3.11.3 Setting Mould Closing and Clamping Force......Page 55
3.12 Data for Mould Closing Force......Page 56
3.14 International Standard for the Designation of Injection Moulding Machines......Page 59
4.1.2 Stripper Mould......Page 61
4.1.3 Slide Mould......Page 62
4.2.1 Introduction......Page 63
4.2.3 Runner Shape......Page 65
4.2.4 Runner Layout......Page 66
4.3.2 Restricted Gate......Page 71
4.3.5 Fan Gate......Page 72
4.3.8 Spider Gate......Page 73
4.3.10 HOT TIP Gating......Page 74
4.4 Mould Temperature Control......Page 75
4.5 Ejection Systems......Page 77
4.7 Conclusion......Page 78
Further Reading......Page 79
5.2.3 Cylinder......Page 81
5.2.4 Directional Valves......Page 82
5.2.6 Flow-Regulator Valves......Page 84
5.2.7 Location and Setting of Proportional Valves......Page 85
5.2.9 Receivers......Page 87
5.3.3 Screw with Position Regulator......Page 88
5.3.4 Injection Process Regulation......Page 89
5.4.1 Multitronica Control Unit – Standard Equipment......Page 91
5.4.3 Selogica Control Unit – Standard Equipment......Page 92
6.1 Introduction......Page 95
6.2.1 Overview and Common Properties......Page 96
6.2.3 Styrene Copolymers......Page 97
6.2.4 Modified Polyphenylene Oxide (PPO mod.)......Page 98
6.2.5 Polyvinyl Chloride (PVC)......Page 99
6.2.7 Polymethyl Methacrylate (PMMA)......Page 100
6.2.8 Polycarbonate (PC)......Page 101
6.2.9 Polyacrylates (PAR, PAE, APE, PEC)......Page 102
6.2.11 Polyetherimide (PEI)......Page 105
6.2.12 Polyamide-Imide (PAl)......Page 106
6.3.1 Overview and Common Properties......Page 107
6.3.2 Polyethylene (PE)......Page 108
6.3.3 Polypropylene (PP)......Page 109
6.3.4 Polyamide (PA)......Page 110
6.3.5 Polyacetals (POM)......Page 112
6.3.6 Polyterephthalates (Linear Polyesters)......Page 113
6.3.8 Polyfluoroolefins......Page 114
6.3.9 Polyacrylic Acid (PAA)......Page 115
6.3.10 Polyphthalamide (PPA)......Page 116
6.3.11 Polyaryl Ether Ketones (PAEK)......Page 117
6.3.12 Liquid Crystal Polymers (LCP)......Page 118
6.4 Conclusion......Page 119
7.1.2 Materials for Screw Injection Moulding Machines......Page 121
7.1.3 Processing Procedures for Thermoset Plastics......Page 122
7.1.6 Guide Values for Cylinder and Mould Temperature Settings......Page 123
7.1.9 Nozzle Temperature (if nozzle heating is applied)......Page 125
7.1.10 Common Thermoset Materials: Properties and Applications......Page 126
7.2.1 Processing Procedures for Elastomeric Materials......Page 129
7.2.2 Silicone Elastomers – Liquid Silicone Rubber (LSR) Systems......Page 130
7.2.3 Processing Components for LIM......Page 136
7.2.4 Application of LSR Parts in Food Production......Page 146
7.2.5 Summary......Page 147
7.3.1 Introduction......Page 148
7.3.2 Binder......Page 149
7.3.3 Processing......Page 150
7.3.5 The Process Requirements......Page 151
7.4 A Growing Market for Moulders......Page 152
8.2 Examples of Moulding Parameters of Selected Materials......Page 153
8.3 Injection Moulding Process Parameters and Quality of Moulded Parts......Page 154
8.4 Injection and Mould Cavity Pressure......Page 157
8.7 Filling Speed and Orientation......Page 160
8.8 Effects of Too High Filling Speed......Page 161
8.10.1 Compound Temperature......Page 162
8.10.3 Nozzle Temperature......Page 163
8.10.4 Temperature Profile Guideline for Plasticising Cylinder......Page 164
8.10.5 Recommended Temperatures for Cylinder and Mould......Page 165
8.10.7 Screw Speed......Page 167
8.11.1 Filling to Packing......Page 168
8.11.2 The Mould......Page 171
8.13 Cycle Time......Page 175
8.14 Setting the Injection Moulding Machine......Page 176
9.2.1 Detection and Classification of Defects......Page 177
9.2.2 Flow Charts for Troubleshooting......Page 178
9.2.3 Sink Marks......Page 197
9.2.4 Streaks......Page 198
9.2.5 Gloss/Gloss Differences......Page 203
9.2.7 Jetting......Page 205
9.2.8 Diesel Effect (Burns)......Page 206
9.2.9 Record Grooves Effect......Page 207
9.2.10 Stress Whitening/Stress Cracks......Page 208
9.2.11 Incompletely Filled Parts......Page 209
9.2.12 Oversprayed Parts (Flashes)......Page 210
9.2.13 Visible Ejector Marks......Page 211
9.2.15 Flaking of the Surface Layer......Page 212
9.2.16 Cold Slugs/Cold Flow Lines......Page 213
9.2.17 Entrapped Air (Blister Formation)......Page 214
9.2.18 Dark Spots......Page 215
9.3.1 Using the Data Acquisition Record......Page 216
9.3.2 Data Acquisition Record for Optimising Moulded Parts......Page 217
9.4.1 Threaded Connecting Sleeves for Ink Drafting Apparatus......Page 218
9.4.3 Wristwatch Glass......Page 219
9.4.5 Glass Cover for Digital Gauge......Page 220
9.4.6 Plug Boards with Insert Pins......Page 221
9.4.8 Toothbrush Components......Page 222
9.4.9 Screw Cap with Conical Nipple......Page 223
9.4.11 Battery Housing......Page 224
10.2.1 Co-Injection Moulding......Page 227
10.6 Business Trends......Page 228
10.7 Material Selection......Page 229
10.8.2 Co-Injection Moulding......Page 231
10.8.4 Interval Injection Moulding......Page 243
10.9.1 Gas Injection Moulding Technology (GIT)......Page 245
10.10 Multi-Shot Moulding......Page 255
10.10.1 Machine Technology......Page 256
10.10.2 Core Back Moulding......Page 258
10.10.3 Rotating Tool......Page 259
10.10.4 Transfer Moulding......Page 260
10.10.6 Materials for Muti-Shot Moulding......Page 261
10.10.8 Limitations to Multi-Shot......Page 263
10.12 The Future?......Page 264
Further Reading......Page 265
Appendix 1 Abbreviations and Acronyms......Page 267
Appendix 2 Trade Names, Specific Weight and Suppliers of Some Plastic Materials......Page 271
Index......Page 273