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1、Molding Process Introduce,Daniel zuo,Process Selection,Processing of Engineering Thermoplastics:,Injection Molding Extrusion Compression Molding Thermoforming Blow Molding Secondary Operations Comparisons,Injection Molding Extrusion Compression Molding Thermoforming Blow Molding Secondary Operations
2、 Comparisons,Processing of Engineering Thermoplastics:,Process Selection - Injection,Injection Molding Introduction,Injection molding makes possible mass production of intricate, high performance, tight tolerance parts with very little secondary labor and minimal waste.,Process Selection - Injection
3、,Hopper,Mold,Clamp,Extruder Barrel with Heating Bands,Injection Molding Machine,Process Selection - Injection,Injection Unit The Reciprocating Screw,Pellets,Feed Section,Melt,Process Selection - Injection,Injection Unit The Reciprocating Screw,Screw Pushes Forward: Inject,Screw Slides Back: Feed, Me
4、lt,(Filling) Throat,Rotation Injection Force Back Pressure,Process Selection - Injection,Injection Unit The Reciprocating Screw,Screw Slides Back: Feed, Melt,Process Selection - Injection,Injection Unit The Reciprocating Screw,Ready for Injection,Process Selection - Injection,Injection Unit The Reci
5、procating Screw,Screw Pushes Forward: Inject,Process Selection - Injection,Feed Section: Picks up pellets and carries them forward. Transition Section: central portion of the screw with reduced channel depth which compresses plastic, eliminating air between pellets and heating and melting them. Mete
6、ring Section: Final plasticizing of melt.,Screw Description,Process Selection - Injection,Clamping System,Mold,Movable Platen,Stationary Platen,Provides motion and force to open and close mold Clamping Force: maximum holding force in tons that a machine can maintain,Nozzle,Process Selection - Inject
7、ion,Standard Injection Molding,Fast Cycle Times Complex Parts High Volume Aesthetics,Advantages,Disadvantages,High Pressure Process Limited Large Part Capability High Tooling Cost,Process Selection - Injection,Co- Injection Molding,Two - Component,Co- Injection Molding,Co- Injection Molding,Three Co
8、mponent,Co- Injection Molding,Co- Injection Molding,Four Component,Co- Injection Molding,LEXAN FOAMABLE RESIN Business Machine Chassis,Structural Foam Part,High Strength and Rigidity in Larger Parts,Process Selection - Injection,Mucell微孔发泡设备,01 Needle valve nozzle 02 Gas injector 03 MuCell-plasticiz
9、ing screw (L/D ratio: 22:124:1) 04 Homogenizing section for gas/melt mixture 05 Plastics granules without blowing agent,01,05,03,02,04,Mucell微孔发泡工艺的塑化单元,Mucell微孔发泡的产品表现形式,Structural Foam Injection Molding,Large Part Capability Low Pressure Process High Stiffness to Weight Ratio,Advantages,Disadvanta
10、ges,Longer Cycle Time Aesthetics Blending Required,Inert Gas,Blowing Agent with Resin,Relative to Standard Injection Molding,Process Selection - Injection,Structural Foam,Increases the attainable wall thickness Gas expands inside plasticized material to create foam core,SKIN,SKIN,CORE,Process Select
11、ion - Injection,Gas Assist Injection Molding,Gas Introduced After Short Shot to Pack out Part,Improved Aesthetics Low Pressure Process Lower Part Weight Reduced Cycle Time,Advantages,Disadvantages,Defect on Every Part More Complex Process High Tooling Costs Licensing Costs,Process Selection - Inject
12、ion,Gas Assist Injection Molded Shipping Container,Gas Assist Molded Rib,Injection Molded Rib,Gas Created Cavity,Gas Injection Defect,Sink,Gas Assist Injection Molding,Process Selection - Injection,Vicat Softening point,Mold Temperature,Process,close,inject,plasticization,cool,open,temperature rise,
13、close,inject,plasticization,cool,Valve unit,hot water,hot water,hot water,wait,wait,cold water,cold water,Heat & Cool System,Process Selection - Injection,Heat & Cool Equipments,Valve Unit,1,2,3,Boiler,Cooling Water,： Channel,Part,Cooling Channel,Need special equipment,Process Selection - Injection,
14、Advantage of Heat & Cool,Heat & Cool,Good Surface Finishing with Filled Material,No Weld line,Increase Weld strength,Eliminate Jetting & Flow mark,Paint less,No stress,Increase Flowability,Note PC Handphone,Door mirror Door handle,Bezel Housing,Housing,Lens Light guide plate,Thin wall,Process Select
15、ion - Injection,G,Compression,Preset Gap,Injection,Time,Position,Screw Clamp,Injection Compression Molding,Time,Screw Core,Compression,Preset Gap,G,o,Go,Injection,Position,Selective ICM or Coining,Feature,Process Benefits,Filling at a larger effective thickness,Compression assisted filling and pack,
16、Short shot process,Lower shear,Longer fill length,Lower fill pressure,Lower clamp force,Thinner wall capability,Bi-axial flow,Reduction of residual stresses,Material savings,Weight reduction,Cycle time reduction,Better impact properties,Advantages, Warpage, Dimensional stability, Optical Quality,Wel
17、d line strength,Lower Cavity Pressure,In-mold decorating with “soft touch”,Why Use ICM?,Injection,ICM,Nozzle Pressure,Nozzle Pressure,Cavity Pressure,Cavity Pressure,Mold Position,Mold Position,25k,15.5k,PSI,PSI,2.0,0.004,Inch,Time (sec),Time (sec),0.040,0.3,21k,Inch,3.7k,Experimental Cavity Pressur
18、e Profile,Lexan 141 - 1.5mm thickness,ICM,IM,Improved Flow in Wheel Covers,Decrease Molded-in Stress,Injection Molding Extrusion Compression Molding Thermoforming Blow Molding Secondary Operations Comparisons,Processing of Engineering Thermoplastics:,Process Selection - Extrusion,Extrusion,Extrusion
19、 is the act of squeezing, pressing, or pushing material through a die in order to make a shape.,Process Selection - Extrusion,The Extruder,Pellets,Part,Heating Coils,Screw,Die,Continuous Process,Process Selection - Extrusion,The Profile Extrusion Die,Continuous Flow Uniform Cross-Section,Process Sel
20、ection - Extrusion,Extruded Through Die Supported and Cooled by a Stack of Polishing Rolls Cut and Trimmed Once Below Glass Transition Temperature Sheet May be Used in Thermoforming and Compression Molding,Sheet Extrusion,Die,Extrusion Cutaway View,Roll Stack,Process Selection - Extrusion,Other Roll
21、 Stack Options,Process Selection - Extrusion,Thermoplastic and Glass Composite Sheet,Glass Fiber Mat,Glass Impregnated Sheet,Sheet Extruder,A Combination of Glass Mat and Thermoplastic Resin Having Both High Stiffness and Good Impact Strength.,Process Selection - Extrusion,The Extruder,Pellets,Part,
22、Heating Coils,Screw,Die,Low Tooling Die Costs Large Part Capability Continuous Process,Advantages,Disadvantages,High Set-up Cost Constant Cross Section Limited Complexity,Process Selection - Extrusion,Injection Molding Extrusion Compression Molding Thermoforming Blow Molding Secondary Operations Com
23、parisons,Processing of Engineering Thermoplastics:,Process Selection - Compression,Softened sheet is placed in a mold then pressed into shape by compressive force.,Process Selection - Compression,Compression Molding,2,3,1,Soft Sheet,Trimming,Compressive Force,Part,Process Selection - Compression,Com
24、pression Molding,Large Part Capability Variable Wall Thickness Uses Conventional Stamping Equipment Low Warpage and Distortion,Advantages,Disadvantages,High Tooling Cost (Cheaper than Injection Molding) Secondary Trimming Aesthetics,Process Selection - Compression,Compression Molding,Injection Moldi
25、ng Extrusion Compression Molding Thermoforming Blow Molding Secondary Operations Comparisons,Processing of Engineering Thermoplastics:,Process Selection - Thermoforming,Vacuum Forming,Atmospheric Pressure(14.7 psi),Softened Sheet,Mold,Part,Vacuum,Process Selection - Thermoforming,Pressure Forming,So
26、ftened Sheet,Compressed Air,Pressure Formed Part, atm pressure,Process Selection - Thermoforming,Low Tooling Cost Large Part Capability Low Pressure Process,Advantages,Disadvantages,Low Part Complexity Longer Cycle Times,Vacuum,Process Selection - Thermoforming,Thermoforming,Compressed Air,Injection
27、 Molding Extrusion Compression Molding Thermoforming Blow Molding Secondary Operations Comparisons,Processing of Engineering Thermoplastics:,Double Walled, Hollow parts,Process Selection Blow,Pinch Bar,Parison Drop,Pre Blow,Full Pressure,Release,Mold,Part,1,2,3,4,5,Process Selection Blow,Blow Moldin
28、g,Mandrel,Parison,Controlling Wall Thickness,Raised Mandrel,Lowered Mandrel,Thinner Wall,Thicker Wall,Process Selection Blow,Double Wall Geometry (Hollow Parts) Good Stiffness to Weight Ratio Low Tooling Cost Large Part Capability,Advantages,Disadvantages,Longer Cycle Times Secondary Trimming Purgin
29、g Start-up Cost,Process Selection Blow,Blow Molding,Injection Molding Extrusion Compression Molding Thermoforming Blow Molding Secondary Operations Comparisons,Processing of Engineering Thermoplastics:,Process Selection Sec.Operation,Injection Molding Extrusion Compression Molding Thermoforming Blow
30、 Molding Secondary Operations Comparisons,Injection Molding Extrusion Compression Molding Thermoforming Blow Molding Secondary Operations Comparisons,Processing of Engineering Thermoplastics:,Process Selection,Size Part Complexity Wall Thickness Production Quantity Costs,Process Selection Criteria,Process Selection,Part Complexity vs. Part Size,Process Selection,.300 .250 .200 .150 .100 .050 0,BM IM FM CM EX TF,Wall Thickness,Process Selection,Tooling Cost Ranking,Extrusion Thermoforming Blow Molding Foam Molding Compression Molding Injection Molding,Process Selection,