Injection Molding for Practitioners / Christoph Jaroschek.

Format:

• Book

Author/Creator:

• Jaroschek, Christoph, author.

Language:

English

Subjects (All):

• Engineering design.

Physical Description:

1 online resource (262 pages)

Edition:

First edition.

Place of Publication:

Munich, Germany : Carl Hanser Verlag GmbH & Co. KG, [2024]

Summary:

Practical and easy to understand, this book describes the injection molding process and the settings of the injection molding machine to produce high-quality injection molded parts. It is intended as a guide for the machine operator and provides clear instructions for process optimization. How exactly does injection molding work? How do you set up the machine optimally? How do you produce a high-quality injection molded part? The book conveys all of this in an easy-to-understand form. The common special processes are described in detail and the necessary additional physical principles are explained. The chapter "Optimization of Quality" describes how quality can be documented and which tools are available for quality optimization. This also includes artificial intelligence (SPC, EVOP). The ever-more important topic of sustainability is also covered in a separate chapter.

Contents:

• Intro
• The Author
• Preface
• Contents
• 1 The Injection Molding Process
• 1.1 Process Flow
• 1.2 The Machine and Plant Technology
• 1.2.1 Clamping Unit
• 1.2.2 Injection Unit
• 1.2.3 Drive
• 1.2.4 Controls
• 2 Technical Jargon
• 2.1 Injection Molding Machine
• 2.2 Mold
• 2.3 Injection Molding Process
• 2.4 Plastic Material
• 3 Setting the Process Variables
• 3.1 Basic Information for the Initial Settings
• 3.1.1 Shot Weight
• 3.1.2 Flow Path Length
• 3.1.3 Average Wall Thickness
• 3.1.4 Plastic to Be Processed
• 3.1.5 Class of Molded Part
• 3.1.6 Projected Area of the Molded Part
• 3.2 Initial Setting
• 3.2.1 Temperature
• 3.2.1.1 Melt Temperature, Processing Temperature
• 3.2.1.2 Mold Temperature
• 3.2.1.3 Nozzle Temperature/Hot Runner Temperature
• 3.2.2 Metering
• 3.2.3 Injection and Holding Pressure
• 3.2.3.1 Injection Process
• 3.2.3.2 Switchover to Holding Pressure
• 3.2.3.3 Holding Pressure Process
• 3.2.4 Cooling Time
• 3.3 Correcting the Initial Settings
• 3.3.1 First Correction Step (without Holding Pressure)
• 3.3.2 Second Correction Step (with Holding Pressure)
• 3.4 Optimization of the Initial Settings
• 3.4.1 Incomplete Cavity Filling
• 3.4.2 Sink Marks
• 3.4.3 Flash
• 3.4.4 Visible Weld Lines
• 3.4.5 Jetting
• 3.4.6 Grooves (Vinyl Record Effect)
• 3.4.7 Surface Streaks
• 3.4.8 Burn Marks (Diesel Effect)
• 3.4.9 Dull Spots Near the Gate
• 3.4.10 Differences in Surface Gloss
• 4 Plastic Properties Relevant to Injection Molding
• 4.1 Flow Properties of Plastics
• 4.1.1 Relationship between Pressure and Velocity (Hagen-Poiseuille)
• 4.1.2 Viscosity
• 4.1.2.1 Influence of the Shear Rate on the Viscosity
• 4.1.2.2 Influence of Temperature on Viscosity
• 4.1.3 Combined Influence of Speed and Temperature (Bathtub Curve)
• 4.1.4 Fountain Flow.
• 4.1.5 Troubleshooting with Flow Trace Analysis
• 4.2 Process Sequence for Injection and Holding Pressure
• 4.2.1 Relationship between Specific Pressure, Volume and Temperature (pvT Diagram)
• 4.2.2 Pressure-Time Graph, Pressure Curves
• 4.2.3 Injection Speed
• 4.2.4 Holding Pressure Phase
• 4.2.4.1 Holding Pressure Time
• 4.2.4.2 Holding Pressure Level
• 4.3 Design of Molded Parts
• 4.3.1 Flow-Path/Wall-Thickness Ratio
• 4.3.2 Filling Pattern
• 4.3.2.1 Weld Lines and Flow Lines
• 4.3.2.2 Folds
• 4.3.2.3 Burners/Diesel Effect
• 4.3.2.4 Poorly Filled Areas
• 4.4 Inner Properties of Plastics
• 4.4.1 Orientations
• 4.4.2 Stresses
• 4.4.3 Crystallization
• 4.5 Temperatures and Heat Processes in Plastics
• 4.5.1 Cooling (Calculation)
• 4.5.2 Cooling Properties, Weld Line Strength
• 4.5.3 Influence of Mold Temperature on Molded Part Dimensions
• 4.5.4 Temperature Equilibrium
• 4.5.5 Melting Temperature, Processing Temperature
• 4.5.6 Influence of Temperature on Demolding and General Demolding Problems
• 4.5.7 Dwell Time and Material Degradation
• 5 Special Injection Molding Processes
• 5.1 Injection Molding with Blowing Agents
• 5.1.1 Thermoplastic Foam Injection Molding (TFI)
• 5.1.2 Gas Counter-Pressure Process
• 5.1.3 System Equipment for Blowing Agent Injection Molding
• 5.2 Gas-Assisted Injection Technique (GIT)
• 5.2.1 Pressure Curve for the Internal Gas Pressure Technique
• 5.2.2 Standard GIT Process
• 5.2.2.1 Design of GIT Parts
• 5.2.2.2 Process Engineering for the Standard GIT Process
• 5.2.3 Blow-Out Process
• 5.2.3.1 Secondary Cavity Process
• 5.2.3.2 Melt Push-Back Method
• 5.2.4 Troubleshooting the GIT Process
• 5.3 External Gas Pressure Technique
• 5.4 Injection Compression Molding
• 5.4.1 General Information on the Process
• 5.4.2 Large-Area Injection Compression Molding.
• 5.4.3 Partial Injection Compression Molding
• 5.4.4 Passive Injection Compression Molding
• 5.4.5 Process Control for Large-Area Injection Compression Molding
• 5.4.6 Process Control for Injection Compression Molding with Displacement Cores
• 5.4.7 Process Control for Passive Injection Compression Molding
• 5.5 Multi-Component Injection Molding
• 5.5.1 Overmolding
• 5.5.1.1 General
• 5.5.1.2 Material Combination for Multi-Component Injection Molding
• 5.5.1.3 Special Process Engineering Knowledge
• 5.5.2 Sandwich Molding
• 5.5.2.1 General
• 5.5.2.2 Injection Sequence in the Sandwich Process
• 5.5.2.3 Special Product-Related Knowledge
• 5.5.2.4 Process Technology
• 5.5.2.5 Standard Sandwich Technology
• 5.5.2.6 Mono-Sandwich Technology
• 5.5.2.7 General Troubleshooting
• 5.6 Plasticizing with Degassing
• 6 Optimization of Quality
• 6.1 Documentation and Monitoring
• 6.1.1 Continuous, Chronological Monitoring
• 6.1.1.1 The Significance of Individual Actual Process Parameters
• 6.1.1.2 Possible Defect Frequency
• 6.1.2 Statistical Process Control (SPC)
• 6.1.2.1 Documentation with Statistical Parameters
• 6.1.2.2 Control Charts
• 6.1.2.3 Strategy for Regulating Quality
• 6.1.2.4 Parameter Selection
• 6.1.3 Monitoring with Process Models
• 6.2 Optimization with External Intelligence
• 6.2.1 Design of Experiments (DOE)
• 6.2.2 Evolutionary Operation (EVOP)
• 6.2.3 Comparison of EVOP and DOE
• 6.3 Special Process Strategies
• 6.3.1 pvT Strategy
• 6.3.2 Adaptive Process Control
• 6.3.2.1 Correlation Analysis
• 6.3.2.2 Adaptive Machine Control
• 6.3.2.3 Flow Rate Control
• 6.3.2.4 APC and IQ Weight Control
• 7 Sustainability in Injection Molding
• 7.1 Use of Recycled Materials
• 7.2 Reduction in Energy Requirements
• 7.2.1 Saving Drive Energy
• 7.3 Saving Heating Power
• 7.4 Use of Blowing Agents.
• 8 Procedure for Standardized Presetting of an Injection Molding Machine
• 8.1 Basic Molded-Part Data
• 8.2 Settings
• 8.3 Tables and Diagrams
• 9 Further Reading
• Index.

Notes:

• Includes index.
• Description based on publisher supplied metadata and other sources.
• Description based on print version record.

ISBN:

1-56990-292-5