Injection Molding Advanced Troubleshooting Guide : The 4M Approach / Randy Kerkstra, Steve Brammer.

Format:

Book

Author/Creator:

Kerkstra, Randy.

Contributor:

Brammer, Steve.

Language:

English

Subjects (All):

Injection molding of plastics.

Physical Description:

1 online resource (526 pages)

Edition:

2nd ed.

Place of Publication:

Munich : Hanser, 2021.

Summary:

This highly practical troubleshooting guide solves injection molding problems systematically and quickly. The rigorous but user-friendly approach employs the authors' proven "STOP" methodology, considering molding process, mold, machine, and material (4M's) as possible sources of part defects. Importantly, the interaction between tooling, processing, and material is emphasized, allowing successful resolution of difficultproblems where "by-the-books" approaches fail. Starting from troubleshooting methodology and tools, there is a focused discussion of key areas impacting troubleshooting, in particular the 4M's, followed by an in-depth troubleshooting guide for various molding defects, structured logically by type of problem / solution. Insightful case studies throughout show the strengths of the STOP method to get real processes to run smoothly and reliably, producing quality parts with optimal cycle time and cost. Drawing on a wealth of hands-on experience, this book serves as an ideal reference to be consulted at the machine, or as a learning and training manual, suitable for both beginners and experienced molders. With valuable information on robust process windows, cycle time evaluations, scrap savings, and runners / gates with no existing standard in the industry, no other book provides the unique insights found here. The 2nd edition is updated with new discussion and case studies on topics including additive manufactured inserts, unmelts, buildup, burns, cycle time, gloss variation, and read-through.

Contents:

Intro

Preface

About the Authors

Contents

1 Troubleshooting Methodology

1.1 Troubleshooting

1.2 What Makes an Effective Troubleshooter?

1.3 What Makes an Ineffective Troubleshooter?

1.4 Troubleshooting Methodology

1.4.1 STOP: Systematically

1.4.2 STOP: Think

1.4.3 STOP: Observe

1.4.4 STOP: Proceed

1.4.5 STOP: Troubleshooting Cycle

1.4.6 Hard Fix versus Processing around Problem

1.4.7 Troubleshooting Tools

1.4.8 Troubleshooting Methodology Summary

2 Troubleshooting Tool Kit

2.1 Lockout/Tagout

2.2 Hand Tools

2.3 Pyrometer

2.4 Spotting Blue

2.5 Measurement Tools

2.6 Multimeter

2.7 Process Monitoring Equipment

2.8 Moisture Analyzer

2.9 Dew Point Meter

2.10 Flashlight

2.11 Microscope/Magnifying Glass

2.12 Silly Putty

2.13 Inspection Mirror

2.14 Thermal Imaging Camera

2.15 Aluminum Tape

2.16 Dial Indicator

2.17 Purging Compound

2.18 Grinder/Stones

2.19 Camera

2.20 Material Data

2.21 Scale

2.22 Flow Meter

2.23 Mold Cleaning Supplies

2.24 Miscellaneous Supplies

3 Decoupled® or Scientific Molding

4 Gating Details

4.1 Gating

4.2 Gate Size, Shape, and Taper

4.3 Mental Picture Volume versus Pressure

5 Mold Hydraulics

5.1 Hydraulic Uses

5.2 Set and Pull Pressure

5.3 Cylinder Sizing

5.4 Hydraulic Cores or Slides

5.5 Multiple Sequences

5.6 Mounting

5.7 Switches

6 Mold Texture and Polish

6.1 Mold Texture

6.2 Mold Polish

7 Venting

7.1 Venting Basics

7.2 Alternate Venting

7.3 Venting Conclusion

8 Machine Performance

8.1 Load Sensitivity

8.2 Dynamic Check Valve Study

8.3 Velocity Linearity

8.4 10-Cycle Overlay

8.5 Cycle Variation

8.6 Velocity to Pressure Transfer

8.6.1 Machine Control

8.7 Machine Documentation

9 Drying

9.1 Introduction.

9.2 Keys to Drying

9.2.1 Temperature

9.2.2 Dry Air

9.2.3 Air Flow

9.2.4 Time

9.3 Moisture Analysis

9.4 Material Handling

9.5 Material Concerns

10 Purging

10.1 Purging Impact

10.2 Purging Method Example

10.3 Purging Compounds

11 Hot Runners

11.1 Hot Runner Advantages

11.2 Heaters and Thermocouples

11.3 Hang Up Areas

11.4 Hot Drop Tips

11.5 Drooling, Stringing, and Sprue Sticking

11.6 Freeze Off

11.7 Orifice Size

11.8 Leakage

11.9 Zones and Wiring

11.10 Hot Runner Troubleshooting

12 Cavity Balance

12.1 Flow Length

12.2 Flow Diameter

12.3 Shear

12.4 Cooling

12.5 Venting

12.6 Clamp Pressure

12.7 Cavity Fill Balance Study

12.8 Artificial Balance

12.8.1 Family Molds

13 Cavity Instrumentation

13.1 Cavity Pressure Technology

13.2 Cavity Thermocouples

13.3 Process Documentation

13.4 Process Control

13.5 Additional Monitoring Options

14 Mold Cooling

14.1 Mold Cooling Importance

14.2 Water Flow

14.3 Documentation

14.4 Tooling Techniques

14.5 Additive Manufacturing

14.6 Other Cooling Concerns

15 Black or Brown Specks

15.1 Description

15.2 Black Specks Troubleshooting Chart

15.3 Black Specks Troubleshooting

15.3.1 Black Specks Troubleshooting Molding Process Issues

15.3.2 Black Specks Troubleshooting Mold Issues

15.3.3 Black Specks Troubleshooting Machine Issues

15.3.4 Black Specks Troubleshooting Material Issues

16 Blush

16.1 Description

16.2 Blush Troubleshooting Chart

16.3 Blush Troubleshooting

16.3.1 Blush Troubleshooting Molding Process Issues

16.3.2 Blush Troubleshooting Tooling Issues

16.3.3 Blush Troubleshooting Machine Issues

16.3.4 Blush Troubleshooting Material Issues

17 Brown Streaks

17.1 Description

17.2 Brown Streak Troubleshooting Chart.

17.3 Brown Streak Troubleshooting

17.3.1 Brown Streak Troubleshooting Molding Process Issues

17.3.2 Brown Streak Troubleshooting Mold Issues

17.3.3 Brown Streak Troubleshooting Machine Issues

17.3.4 Brown Streak Troubleshooting Material Issues

18 Bubbles

18.1 Description

18.2 Bubbles Troubleshooting Chart

18.3 Bubbles Troubleshooting

18.3.1 Bubbles Troubleshooting Molding Process Issues

18.3.2 Bubbles Troubleshooting Mold Issues

18.3.3 Bubbles Troubleshooting Machine Issues

18.3.4 Bubbles Troubleshooting Material Issues

19 Buildup

19.1 Description

19.2 Buildup Troubleshooting Chart

19.3 Buildup Troubleshooting

19.3.1 Buildup Troubleshooting Molding Process Issues

19.3.2 Buildup Troubleshooting Mold Issues

19.3.3 Buildup Troubleshooting Machine Issues

19.3.4 Buildup Troubleshooting Material Issues

20 Burns

20.1 Description

20.2 Burns Troubleshooting Chart

20.3 Burns Troubleshooting

20.3.1 Burns Troubleshooting Molding Process Issues

20.3.2 Burns Troubleshooting Mold Issues

20.3.3 Burns Troubleshooting Machine Issues

20.3.4 Burns Troubleshooting Material Issues

21 Cloudiness

21.1 Description

21.2 Cloudiness Troubleshooting Chart

21.3 Cloudiness Troubleshooting

21.3.1 Cloudiness Troubleshooting Molding Process Issues

21.3.2 Cloudiness Troubleshooting Mold Issues

21.3.3 Cloudiness Troubleshooting Machine Issues

21.3.4 Cloudiness Troubleshooting Material Issues

22 Color Swirls

22.1 Description

22.2 Color Swirls Troubleshooting Chart

22.3 Color Swirls Troubleshooting

22.3.1 Color Swirls Troubleshooting Molding Process Issues

22.3.2 Color Swirls Troubleshooting Mold Issues

22.3.3 Color Swirls Troubleshooting Machine Issues

22.3.4 Color Swirls Troubleshooting Material Issues

23 Contamination

23.1 Description.

23.2 Contamination Troubleshooting Chart

23.3 Contamination Troubleshooting

23.3.1 Contamination Troubleshooting Molding Process Issues

23.3.2 Contamination Troubleshooting Mold Issues

23.3.3 Contamination Troubleshooting Machine Issues

23.3.4 Contamination Troubleshooting Material Issues

24 Cracking

24.1 Description

24.2 Cracking Troubleshooting Chart

24.3 Cracking Troubleshooting

24.3.1 Cracking Troubleshooting Molding Process Issues

24.3.2 Cracking Troubleshooting Mold Issues

24.3.3 Cracking Troubleshooting Machine Issues

24.3.4 Cracking Troubleshooting Material Issues

25 Delamination

25.1 Description

25.2 Delamination Troubleshooting Chart

25.3 Delamination Troubleshooting

25.3.1 Delamination Troubleshooting Molding Process Issues

25.3.2 Delamination Troubleshooting Mold Issues

25.3.3 Delamination Troubleshooting Machine Issues

25.3.4 Delamination Troubleshooting Material Issues

26 Dimensions

26.1 Description

26.2 Dimensions Troubleshooting Chart

26.3 Dimensions Troubleshooting

26.3.1 Dimensions Troubleshooting Molding Process Issues

26.3.2 Dimensions Troubleshooting Mold Issues

26.3.3 Dimensions Troubleshooting Machine Issues

26.3.4 Dimensions Troubleshooting Material Issues

27 Excessive Cycle Time

27.1 Description

27.2 Excessive Cycle Time Troubleshooting Chart

27.3 Excessive Cycle Time Troubleshooting

27.3.1 Excessive Cycle Time Troubleshooting Molding Process Issues

27.3.2 Excessive Cycle Time Troubleshooting Mold Issues

27.3.3 Excessive Cycle Time Troubleshooting Machine Issues

27.3.4 Excessive Cycle Time Troubleshooting Material Issues

28 High Fill Pressure

28.1 Description

28.2 High Fill Pressure Troubleshooting Chart

28.3 High Fill Pressure Troubleshooting.

28.3.1 High Fill Pressure Troubleshooting Molding Process Issues

28.3.2 High Fill Pressure Troubleshooting Mold Issues

28.3.3 High Fill Pressure Troubleshooting Machine Issues

28.3.4 High Fill Pressure Troubleshooting Material Issues

29 Flaking

29.1 Description

29.2 Flaking Troubleshooting Chart

29.3 Flaking Troubleshooting

29.3.1 Flaking Troubleshooting Molding Process Issues

29.3.2 Flaking Troubleshooting Mold Issues

29.3.3 Flaking Troubleshooting Machine Issues

29.3.4 Flaking Troubleshooting Material Issues

30 Flash

30.1 Description

30.2 Flash Troubleshooting Chart

30.3 Flash Troubleshooting

30.3.1 Flash Troubleshooting Molding Process Issues

30.3.2 Flash Troubleshooting Mold Issues

30.3.3 Flash Troubleshooting Machine Issues

30.3.4 Flash Troubleshooting Material Issues

31 Flow Lines

31.1 Description

31.2 Flow Lines Troubleshooting Chart

31.3 Flow Lines Troubleshooting

31.3.1 Flow Lines Troubleshooting Molding Process Issues

31.3.2 Flow Lines Troubleshooting Mold Issues

31.3.3 Flow Lines Troubleshooting Machine Issues

31.3.4 Flow Lines Troubleshooting Material Issues

32 Glass Fibers on Surface

32.1 Description

32.2 Glass Fibers on Surface Troubleshooting Chart

32.3 Glass Fibers on Surface Troubleshooting

32.3.1 Glass Fibers on Surface Troubleshooting Molding Process Issues

32.3.2 Glass Fibers on Surface Troubleshooting Mold Issues

32.3.3 Glass Fibers on Surface Troubleshooting Machine Issues

32.3.4 Glass Fibers on Surface Troubleshooting Material Issues

33 Gloss Variation

33.1 Description

33.2 Gloss Variation Troubleshooting Chart

33.3 Gloss Variation Troubleshooting

33.3.1 Gloss Variation Troubleshooting Molding Process Issues

33.3.2 Gloss Variation Troubleshooting Mold Issues.

33.3.3 Gloss Variation Troubleshooting Machine Issues.

Notes:

Description based on publisher supplied metadata and other sources.

ISBN:

9781523145065

1523145064

9781569908358

1569908354

OCLC:

1249471040