Scientific Processing for Injection Molding
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2 DAY LECTURE/WORKSHOP
OFFERED TWICE:
June 11-12, 2012 (CRS# 00.755-011)
August 13-14, 2012 (CRS# 00.755-021)
8:30am-5:00pm
TUITION: $1045
OVERVIEW
This seminar 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
melt 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
INSTRUCTOR
Suhas Kulkarni