NEW!
Scientific Processing for Injection Molding
2 DAY LECTURE
OFFERED THREE TIMES:
January 8-9, 2008 (CRS# 00.753-001)
June 10-11, 2008 (CRS# 00.753-012)
August 12-13, 2008 (CRS# 00.753-021)
TUITION: $1045
OVERVIEW
This class is designed for those who have a basic working knowledge about 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
Day 1: Hands-on demonstration at the molding machine
Suhas Kulkarni
Scientific Processing for Injection Molding
2 DAY LECTURE
OFFERED THREE TIMES:
January 8-9, 2008 (CRS# 00.753-001)
June 10-11, 2008 (CRS# 00.753-012)
August 12-13, 2008 (CRS# 00.753-021)
TUITION: $1045
OVERVIEW
This class is designed for those who have a basic working knowledge about 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
- What is scientific processing?
- Drying and overdrying of plastics
- Molding machine considerations
- Scientific molding
- Post mold shrinkage
- Cavity filling imbalances
- 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
- Understanding shear imbalances
- Design of Experiments for injection molding
- Cavity pressure information
- 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
- 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
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
- Performing a DOE for injection molding
- Collecting and interpreting cavity pressure data
Suhas Kulkarni
© 1995-2007 University of Massachusetts Lowell,
Continuing Studies, Corporate & Distance Education
Continuing Studies, Corporate & Distance Education