This seminar provides comprehensive information about the injection
molding process, and covers both the underlying engineering principles
as well as their application in the molding environment. Classroom
lectures cover the basics of the injection molding process and provide
practical analyses that yield results and can be applied in the molding
Injection molding workshops supplement the class material to provide
experience with actual machine operation and practical molding
techniques. Machine start-up, operation and shutdown procedures are
demonstrated. Molding trials that show the relationships
between processing variables and part quality are conducted.
Workshop emphasis is on practical setup procedures that optimize molding
cycle and product requirements. Troubleshooting techniques and solutions
to practical molding problems are also addressed.
This course is appropriate for sales managers, account managers, sales
and applications engineers, new product development specialists, product
marketing professionals, product designers and engineers, industrial
designers and industrial engineers, mechanical engineers, materials
purchasing managers, manufacturing personnel and technicians, plant
managers, production supervisors, quality assurance and quality control
personnel, and anyone involved in plastic part or mold procurement.
Overview of the Injection Molding Process
- Molding behavior of thermoplastics; molding functions: plastication and injection, forming and solidification; machine and mold operations; machine sequence; process sequence and variables: plastication, injection, packing and holding, cooling
Plastics Materials and Their Molding Requirements
- Molecular structure: polymer types, amorphous vs. crystalline; thermal characteristics: transitions and energy requirements; flow characteristics: non-Newtonian effects
Plastic Melting, Filling, Holding and Cooling
- Processing mechanisms: feeding, melting and mixing; screw problems and solutions; special screw options: mixing, multi-stage
- Isothermal cavity filling: filling modes, filling problems; thermal effects: flow length, orientation, stresses; runner and gate flows; flow balancing; pressure requirements: pressure traces; packing/holding and cooling-heat transfer effects; pvT applications
Elements of Injection Molds
- Mold types and configurations: 2-plate, 3-plate, stack, etc.; ejection systems; cooling systems; thermal systems/hot runners
Injection Molding Machinery
- Injection units: variants and options; clamp systems: toggle, hydraulic, hydromechanical; hydraulic/electrical systems; energy saving features; specialized machines: multicomponent, coinjection, gas-assist, etc.
Process Setup and Troubleshooting
- Scientific and decoupled molding concepts; troubleshooting; cycle-time minimization and yield
Process Monitoring and Control
- Machine and mold sensors; proportional and servo valves; closed-loop control; velocity and temperature profiling; statistical process monitoring
Attendees will use both electric and hydraulic molding machines, and
non-instrumented and instrumented molds.