Scientific Processing for Injection Molding

To register, fill out the registration form and fax it to (978) 934-2028. For more information about registering, click here.

2 DAY LECTURE
OFFERED THREE TIMES:
March 16-17, 2010 (CRS# 00.755-002)
June 13-14, 2010 (CRS# 00.755-012)
August 10-11, 2010 (CRS# 00.755-021)
8:30am-5:00pm

TUITION: $1045

OVERVIEW
This class is designed for those who have a basic working knowledge of polymers and injection molding. It reviews the important aspects of the factors required to develop a robust injection molding process, using the techniques of scientific molding and scientific processing. Scientific principles related to the complete molding process, from the storage and drying of the resin to the packaging of the finished product will be discussed. Design of Experiments (DOE) and rheological shear imbalances specifically for injection molding will be covered. Plastic pressure in the mold cavity is the final indication of the quality of the part and the repeatability of the process. A section of the course will explore this concept. Finally, statistical quality and process control will be discussed. The hands on workshop will include development of a process using scientific molding principles, a Design of Experiments exercise and evaluation of cavity pressure data. Examples of shear imbalances will be shown.

CONTENT

1) Overview of The Six Pillars to Successful Injection Molding

• The Part and Part Design
• The Plastic Resin
• The Mold and Mold Design
• The Molding Machine
• The Injection Molding Process
• The Personnel

2) Scientific Processing

• What is scientific processing?
• Drying and overdrying of plastics
• Molding machine considerations
• Scientific molding
• Post mold shrinkage
• Cavity filling imbalances

3) Scientific Molding

• The injection molding cycle and its process parameters
• In-mold rheology or viscosity curves
• Cavity filling balances
• Pressure drop studies
• Gate seal tests
• Molding area diagram
• Cooling study

4) Advanced Techniques

• Understanding shear imbalances
• Design of Experiments for injection molding
• Cavity pressure information

5) Statistical Process and Quality Control

• Variation and normal distributions
• X-bar and R charts, histograms
• Control limits and control charts
• What is Cp and Cpk?
• Understanding process capability
• Statistical quality control
• Statistical process control

6) Troubleshooting

• A “must have” list of accessories for troubleshooting
• Common molding defects and their solutions
• What to do when there is a problem – a step-by-step guide
• Common mistakes made in part design, mold design and construction
• Tapping available resources for further troubleshooting

WORKSHOPS

Day 1: Hands-on demonstration at the molding machine

• Setting up the machine parameters
• Developing a viscosity curve
• Determining cavity balances
• Determining the pressure drop
• Determining the process window
• Determining the gate seal time
• Determining the cooling time

Day 2: Troubleshooting

• Performing a DOE for injection molding
• Collecting and interpreting cavity pressure data

INSTRUCTOR
Suhas Kulkarni