Basics of Injection Molding



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E-Trainer「Basics of Injection Molding」目次

1. What is a mold? 1.1 Types of molds - Casting mold
- Forging
- Press mold
- Die cast mold
- Plastic mold
Compression molding, Extrusion, Blow molding, Vacuum molding, RIM molding, FRP molding, Transfer molding
<EXERCISE> - Types of molds
1.2 Injection molding - Closing mold
- Nozzle seating
- Cooling
- Mold opening
<EXERCISE> - Movement of injection molding
2. Mechanism of Mold 2.1 Structure of Molds - Two plate mold
- Three plate mold
- Runnerless mold
Heating methods of molding material
- Names of mold structure
2.2 Function of major parts - Common parts
- Ejector
- Mold base
- Slide core
- Loose core
- Common parts, Ejector, Mold base, Slide core, Loose core
2.3 Movement of Mold - Opening mold(start)
- Opening mold(Complete)
- Ejecting part(start)
- Ejecting part(Complete)
- Ejecting part, closing mold(start)
- Closing mold(Complete)
- One cycle
- Sequence of mold movement
3. Role of Parts 3.1 Cavity and Core - Cavity and Core
- Type of Insert
- Making Inserts
- Position of Inserts
- Type of Inserts
3.2 Runner System - Runner
Shape of Runner, Size of Runner, Layout of Runner
- Gate
Restricted Gate, Non-restricted Gate, Determining Gate Position
- Parts of Sprue
Locate Ring, Sprue Bush
<EXERCISE> -Shape of Runner, Name of Gate
3.3 Undercut Process - Outer Slide Core Method
Slide Core Body Unit,Push Back Spring
- Inner Slide Method, Loose core Method, Method to Push Out Undercut, Inner Slide Core Method
- Hydraulic Cylinder Method
Movement of Hydraulic Cylinder, Calculation of Hydraulic Cylinder
<EXERCISE> - Slide Core Setting, Loose Core Setting, Hydraulic Cylinder Calculation
3.4 Ejecting Parts - Pin Ejection
Pin Ejection, Boss Ejection, Shoulder Pin Ejection, Disk Pin Ejection
- Sleeve Pin Ejection
- Stripper Plate Ejection
- Compressed Air Ejection
- Two-Stage Ejection
- Hydraulic Ejection
- Ejector Plate
Weight Calculation, Coil Spring, Gas Spring
<EXERCISE> - Type of Ejection, Selecting Ejector Plate Ejection Spring, Selecting Gas Spring
3.5 Mold Cooling - Position of Cooling Channel
- Cavity Cooling
- Core Cooling
<EXERCISE> - Core Cooling Method
3.6 Degassing and Air Venting - What is Degassing and Air Venting?
- Design of Degassing and Air Venting
<EXERCISE> - Defect by Degassing and Air Venting
3.7 Considering Mold Dimension - Mold Dimension
- Possibility of Part Removal
- Ejector Rod Position
< EXERCISE> - Mold Dimension
3.8 Determining Material of Mold - Material Criteria
- Types and Use of Material of Mold
- Heat Treatment of Material
Heat Treatment of Steel Material, Surface Hardening of Steel Material
<EXERCISE> -Types for Material of Mold
3.9 Mold for Screw Thread Forming - Type of Screw
- Molding Inner Screw
Fixed Screw Core Molding, Force Ejection Molding, Removable Screw Core Molding, Rotating Screw Molding(1)(2)(3)
- Positioning of Rotating Screw Core
- Molding Outer Screw
Fixed Screw Cavity Molding, Force Ejection Molding, Slide Core Screw Molding
<EXERCISE> -Name of Screw Thread Molding
4. Quality of Molded Parts 4.1 Quality of Molded Parts - Quality of Molded Parts
- Molding Process
- How to improve the Quality?
<EXERCISE> - Quality of Molded Parts
4.2 Dimension of Parts - Part Shrinkage Rate
- Draft Angle
- Flow Path Ratio
<EXERCISE> - Calculation of Part Shrinkage, Flow Path Ratio
5. Operation of Molding Machine 5.1 Installation of Mold - Mold Installation
- Mold Installation Steps
- Mold Installation Bolt
<EXERCISE> - Mold Installation Steps
5.2 Setting Molding Condition - Injection Condition
Injection Pressure, Injection Speed
- Temperature Condition
Resin Temperature, Mold Temperature
- Ejection Condition
<EXERCISE> - Caution for Molding Condition
5.3 Mechanical Structure of Molding Machine - Injection Device
Screw Diameter and Injection Pressure, Injection Volume and Injection Load(Weight), Injection Rate, Plasticating Ability, Screw Rolling Rate, Others
- Clamping Device
Calculation of Clamping Force, Mold Opening/Closing Stroke
- Force and Transferring System
- Electric Control Device
<EXERCISE> - Calculation of Clamping Force
6. Characteristic of Plastic Work 6.1 Type of Plastic - Thermoplastic
- Thermosetting Plastic
- Difference between Crystalline plastic and Non-crystalline plastic
<EXERCISE> - Type of Plastic
6.2 Property of Plastic - Property of Plastic
- Characteristics of Molding Material in processing
Polyamide(NYRON), Polypropylene, Polyethylene, Acrylonitrile butadienstylene, Polycarbonate, Polystyrene, Polyvinyl chloride, Epoxy resin, Phenol resin
<EXERCISE> - Property of Plastic
7. Molding Problems and Solution - Sink Mark
- Warp
- Whitening
- Weld Line
- Flash
- Incomplete Filling
- Jetting
- Flow Mark
<EXERCISE> - Cause and Solution of Molding Problems