Injection Molding

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

5 DAY LECTURE/WORKSHOP
OFFERED FOUR TIMES:
January 9-13, 2012 (CRS# 00.716-001) Andy Routsis
March 12-16, 2012 (CRS# 00.716-002)

June 18-22, 2012 (CRS# 00.716-011) Dr. Stephen Johnston
August 13-17, 2012 (CRS# 00.716-021)
8:30am-5:00pm

TUITION: $1495

OVERVIEW
This seminar provides comprehensive information about the injection molding process, and covers both the underlying engineering principles as well as their application in the molding environment. Classroom lectures cover the basics of the injection molding process and provide practical analyses that yield results and can be applied in the molding shop.

Injection molding workshops supplement the class material to provide experience with actual machine operation and practical molding techniques. Machine start-up, operation and shutdown procedures are demonstrated. Molding trials that show the relationships between processing variables and part quality are conducted.

Workshop emphasis is on practical setup procedures that optimize molding cycle and product requirements. Troubleshooting techniques and solutions to practical molding problems are also addressed.

AUDIENCE
This course is appropriate for sales managers, account managers, sales and applications engineers, new product development specialists, product marketing professionals, product designers and engineers, industrial designers and industrial engineers, mechanical engineers, materials purchasing managers, manufacturing personnel and technicians, plant managers, production supervisors, quality assurance and quality control personnel, and anyone involved in plastic part or mold procurement.

CONTENT

Overview of the Injection Molding Process

Molding behavior of thermoplastics; molding functions - plastication & injection, forming & solidification; machine & mold operations, machine sequence; process sequence & variables - plastication, injection, packing & holding, cooling

Plastics Materials and Their Molding Requirements

Molecular structure - polymer types, amorphous vs. crystalline; thermal characteristics - transitions & energy requirements; flow characteristics - non-Newtonian effects

Plastic Melting, Filling, Holding and Cooling

Processing mechanisms - feeding, melting & mixing; screw problems & solutions; special screw options: mixing, multi-stage
Isothermal cavity filling - filling modes - filling problems; thermal effects - flow length, orientation, stresses; runner & gate flows, flow balancing; pressure requirements - pressure traces; packing/holding & cooling-heat transfer effects; pvT applications

Elements of Injection Molds

Mold types & configurations: 2-plate, 3-plate, stack, etc.; ejection systems; cooling systems; thermal systems/hot runners

Injection Molding Machinery

Injection units - variants & options; clamp systems - toggle, hydraulic, hydromechanical; hydraulic/electrical systems, energy saving features; specialized machines: multicomponent, coinjection, gas-assist, etc.

Process Setup and Troubleshooting

Scientific and decoupled molding concepts; troubleshooting; cycle time minimization and yield

Process Monitoring & Control

Machine and mold sensors; proportional & servo valves; closed-loop control; velocity and temperature profiling; statistical process monitoring

WORKSHOPS
Attendees will use both electric and hydraulic molding machines, and non-instrumented and instrumented molds.

ENROLLMENT LIMIT
Course enrollment is limited to 12 students.

INSTRUCTORS
Dr. Stephen Johnston or Mr. Andy Routsis