GT ME 4210 - Process Description (27 pages)

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Process Description



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Process Description

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Pages:
27
School:
Georgia Tech
Course:
Me 4210 - Mfg Processes & Engr
Mfg Processes & Engr Documents
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Injection MoldingMolding Process Description ver 1 ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 1 Overview Equipment Process ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 2 Extruder ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 3 Extruder and die ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 4 Injection molding machine Cl Clamp M ld Mold B Barrel l Hopper ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 5 KrausMaffei at Ford 4000 tonnes ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 6 Injection j molding g machine schematic ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 7 Mold ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 8 Mold ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 9 Modular molds ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 10 Mold schematic ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 11 Mold schematic runner sprue cavity gate sprue p nozzle front ejection pin side ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 12 Process ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 13 Process Pellets placed in hopper Pellets fall into barrel through throat Pellets P ll t packed k d tto fform solid lid b bed d air forced out through hopper Pellets melted by mechanical shear between barrel and screw ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 14 Process Melted plastic forms shot in front of screw screw moves back b k as plastic l ti moves forward reciprocating screw ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 15 Process Screw moves forward to inject j p plastic into mold cavity Part P t cools l and d solidifies lidifi next shot is made ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 16 Process Mold opens Ejection pins move forward to eject part Mold closes Process starts again ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 17 Feed zone Solid bed Pellets crushed together Air ejected ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 18 Compression zone Melting Solid bed melted by mechanical shear barrel secondary mixing flow screw flight solid bed ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 19 Metering zone Homogenization Melted polymer is homogenized thermally y and color wise ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 20 Injection pressure Typically 15 000 psi Ranges from 3 3 000 000 to 40 40 000 000 psi Hydraulic pressure is about 10x less ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 21 Process time Open and eject part p Close mold Injection j 1 33 35 5 Pack and hold Part cooling 15 ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 22 Pressure historyy Cycle time Part ejjection Mold closed time Cooling Pack Gate freezze off 2 25 Injection Fasst closing 50 0 0 5 15 33 35 Time s ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 23 Temperature history Cooling Part ejjection 200 gate Pack Gate freezze off 100 Injection Fasst closing part p 0 0 5 15 33 35 Time s ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 24 Gates and freeze freeze off off Filling Packing Cooling ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 25 Summary Equipment Process ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 26 ME 6222 Manufacturing Processes and Systems Prof J S Colton GIT 2009 27


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