Injection of test specimen for tensile test

This master thesis deals with the literature survey on injection molding machine construction, working and process parameters. And also, optimizing process parameters of the injection molding machine in plastic manufacturing technology to analyze and measure the data experiments and simulations on mold flow in the Injection molding machine. The main aim of this thesis is to perform simulations and compare them with machine settings to understand the principle parameters of the injection molding machine by both theoretically and practically for the study of improving product quality. This involves comparing the Practical results of the parameters of the injection molding machine (flow time, injection pressure, mold temperature, Melting temperature, etc.) by the results of software simulation. Hence we get to know the parameters to be changed to get better quality of the product.This master thesis deals with the literature survey on injection molding machine construction, working and process parameters. And also, optimizing process parameters of the injection molding machine in plastic manufacturing technology to analyze and measure the data experiments and simulations on mold flow in the Injection molding machine. The main aim of this thesis is to perform simulations and compare them with machine settings to understand the principle parameters of the injection molding machine by both theoretically and practically for the study of improving product quality. This involves comparing the Practical results of the parameters of the injection molding machine (flow time, injection pressure, mold temperature, Melting temperature, etc.) by the results of software simulation. Hence we get to know the parameters to be changed to get better quality of the product

Perancangan Mold Base Dengan Sistem Two Plate Mold Untuk Produk Spesimen Uji Tarik

A mold is a tool for printing plastic products. The way it works is by installing the mold on a plastic injection machine, and then the machine does the injection process to put molten plastic material into the mold. In the mold, there is a cavity that matches the shape of the product to be made. Before a mold can be used, it must be designed and manufactured. ATK Polytechnic of Yogyakarta has one injection molding machine with several molds available. The available molds do not yet have a design based on various information, analysis, and calculations, so this research will make a mold design that is expected to be a guideline for making plastic injection molds and is expected to be able to analyze the needs for cavities, gates, ejector systems, cooling system. In this study, the design and calculation of mold construction, including the cavity, parting line, gate, ejector, cavity plate, core plate, runner, and cooling, were discussed. The purpose of this study is to determine how to design a basic mold construction with a two-mold plate system, with the resulting product being a tensile test specimen. The result of this tensile test specimen mold design is a mold base design drawing with a mold size of 350mm x 500mm x 255mm, the number of cavities being 4 cavities per mold, and the volume of the tensile test specimen mold being 33.0122 cm3

Identifikasi Flashing Pada Mold Alat Cukur

Molding is a process utilized by industries to shape plastic products. One of the plastic molding processes involves injection molding. Injection molding is a procedure where plastic pellets are placed into a hopper or channel and subsequently fed into a barrel. The injection is propelled by a screw mechanism through a machine nozzle and a sprue bushing enters the mold cavity. All of this occurs within a closed mold. A flashing defect in a product refers to an excess material flaw located at the product's edges. To identify the causes of flashing defects in shaving tools, a fishbone diagram is employed, categorizing factors into five: machine factors, material factors, method factors, human factors, and mold factors. The identification results show that flashing defects in shaving tools are primarily attributed to mold factors, where 37 cavities exhibit flashing defects.Molding adalah proses yang digunakan oleh industri untuk mencetak produk plastik. Salah satu proses pencetakan plastik dilakukan melalui injection molding. Injection molding merupakan proses di mana bijih plastik dimasukkan ke dalam hopper atau lorong, lalu dialirkan ke dalam barrel. Injection didorong menggunakan mekanisme screw melalui nozzle mesin dan sprue bushing masuk ke dalam cavity atau cetakan. Semua ini dilakukan dengan mold yang telah tertutup. Cacat produk flashing adalah cacat yang muncul akibat material berlebih yang terdapat di tepi produk. Untuk mengidentifikasi penyebab terjadinya cacat produk flashing pada alat cukur, digunakanlah diagram fishbone yang terbagi menjadi lima faktor: faktor mesin, faktor material, faktor metode, faktor manusia, dan faktor mold. Hasil identifikasi menunjukkan bahwa flashing pada alat cukur paling banyak disebabkan oleh faktor mold, di mana 37 cavity mengalami cacat flashing

Composite-based additive manufacturing applications in the polymer injection molding cycle

“The experimental method utilized in this research was the application of composite-based additive manufacturing (CBAM) mold plates in the injection molding process. The mold plates comprised carbon fibers and polyether ether ketone (PEEK) matrix. Modifications were made to the mold plates post manufacturing in order to properly adapt to the rest of the injection molding die. A custom cooling system was engineered and integrated into the injection molding machine for the CBAM mold plates. The polymer processed in the injection molding cycle for this study was Lustran 348 acrylonitrile butadiene styrene (ABS). The result of the trials conducted in this research demonstrated that polymer injection molding with CBAM mold plates was feasible and comparable to metal molds. However, adverse effects noted from using these parts made via the CBAM mold plates were rougher surface finishes and high adhesion between the polymer/tooling surface interface. In fact, the adhesion was so great that upon removal of the part from the mold, some regions of the PEEK matrix were torn from the tooling surface leaving a visibly unsmooth manifold behind. Further research and applications of CBAM mold plates could demonstrate promise in replacing the expensive, subtractive computer numerically controlled (CNC) metal mold plates for relatively small cycles”--Abstract, page iii

Direct Injection Molding Tooling Inserts from the SLS Process with Copper Polyamide

The "RapidTool" Short Run (SR) Tooling Process using the Copper Polyamide material provides a route to mold inserts for injection molding made directly in the Selective Laser Sintering machine. The STL files for the mold inserts are shelled and conformal cooling lines and ejector pin guides are added before SLS processing. Sintering of the material in the SLS machine provides quick metal/plastic tooling with good thermal conductivity. Final preparation of the tooling inserts includes sealing the surface with epoxy, final finishing using sandpaper, and backing up the shells with a metal alloy. The Copper Polyamide SR Tooling inserts are used to mold several hundred parts with common plastics with injection cycle times similar to conventional molding cycle times.Mechanical Engineerin

Additively Manufactured Carbon Fiber- Reinforced Thermoplastic Composite Mold Plates For Injection Molding Process

Polymer injection molding processes have been used to create high-volume parts quickly and efficiently. Injection molding uses mold plates that are traditionally made of very hard tool steels, such as P20 steel, which is extremely heavy and has very long lead times to build new molds. In this study, composite-based additive manufacturing (CBAM) was used to create mold plates using long-fiber carbon fiber and polyether ether ketone (PEEK). These mold plates were installed in an injection molding machine, and rectangular flat plates were produced using Lustran 348 acrylonitrile butadiene styrene (ABS). Tensile and flexural testing was performed on these parts as well as parts produced using traditional P20 steel mold plates with the same geometry to compare the performance of the different mold plates. The parts produced using the carbon fiber mold plates were within 5% of the tensile strength and 10% of the flexural strength of the traditionally manufactured parts. However, the parts produced using the carbon fiber mold plates required additional cooling time due to the lower conductivity of the carbon fiber composite compared to the P20 steel. This allows additively manufactured composite molds to be a good substitute for conventional molds in low-volume injection molding production

Tapered LIGA mold insert

The applications of microstructures produced by the LIGA process are useful in a broad range of fields including: microfluidics, heat transfer, and mechanics. The Microsystems Engineering Team at Louisiana State University has used the LIGA process as a foundation for the team’s productivity in these areas. Many advances in the processes involved in producing these microstructures have been made in the past increasing the efficiency of the entire process. A modified exposure technique in the lithography stage of the LIGA process is being developed to produce microstructures with a draft angle as opposed to the standard straight walled structures. Electroformed mold inserts produced previously have encountered high ejection forces causing deformation or tearing of the molded products. The tapered sidewalls produced in the modified exposure mirror those already used in macro-scale injection molds, and will dramatically reduce the forces resulting in superior parts with improved cycle times. The two objectives that define this research project are: i) to successfully manufacture a LIGA high aspect ratio microstructure mold insert with tapered features, and ii) to use the manufactured mold insert and successfully mold and eject parts using a injection molding machine. A LIGA based mold insert approximately one millimeter in depth was produced with a three degree draft angle. This insert was then used with a injection molding machine to produce and efficiently eject cyclic olefin copolymer (COC) plastic parts

Experimental Study on the Demolding Force in Micro Metal Injection Molding

In this paper experimental study on the demolding force needed to eject micro structures in Micro Metal Injection Molding (μMIM) is conducted. Injection molding is done on a variotherm mold mounted on a Battenfeld injection molding machine and demolding force measurement is done on an Instron tensile testing machine. Green part is a round disc of φ16 mm and thickness 1.5 mm with an array of φ100 μm × height 200 μm micro structures at the center. The experimental results are in good accordance with the previous analysis results.Singapore-MIT Alliance (SMA

Warpage characterization of microchannels fabricated by injection molding

Cataloged from PDF version of article.Mass-production of microfluidic devices is important for biomedical applications in which disposable devices are widely used. Injection molding is a well-known process for the production of devices on a mass scale at low-cost. In this study, the injection molding process is adapted for the fabrication of a microfluidic device with a single microchannel. To increase the product quality, high-precision mechanical machining is utilized for the manufacturing of the mold of the microfluidic device. A conventional injection molding machine is implemented in the process. Injection molding was performed at different mold temperatures. The warpage of the injected pieces was characterized by measuring the part deformation. The effect of the mold temperature on the quality of the final device was assessed in terms of the part deformation and bonding quality. From the experimental results, oneto-one correspondence between the warpage and the bonding quality of the molded pieces was observed. It was found that as the warpage of the pieces decreases, the bonding quality increases. A maximum point for the breaking pressure of the bonding and the minimum point for the warpage were found at the same mold temperature. This mold temperature was named as the optimum temperature for the designed microfluidic device. It was observed that the produced microfluidic devices at the mold temperature of 45 !C were able to withstand pressures up to 74 ba

ANALISIS PRODUK SPION PS 135 DENGAN PENGATURAN PARAMETER MELT TEMPERATURE MATERIAL PLASTIK POLYPROPYLENE (PP) PADA PROSES INJECTION MOLDING(STUDI KASUS PT. SINAR AGUNG SELALU SUKSES KARANGANYAR JAWA TENGAH)

Rizka Zahra Wulansari. ANALISIS PRODUK SPION PS 135 DENGAN PENGATURAN PARAMETER MELT TEMPERATURE MATERIAL PLASTIK POLYPROPYLENE (PP) PADA PROSES INJECTION MOLDING (STUDI KASUS PT. SINAR AGUNG SELALU SUKSES KARANGANYAR JAWA TENGAH). Skripsi, Fakultas Keguruan dan Ilmu Pendidikan Universitas Sebelas Maret Surakarta. Juli 2013. Tujuan penelitian ini adalah untuk mengetahui: (1) pengaruh parameter melt temperature terhadap kualitas produk injection molding yang dihasilkan. (2) parameter melt temperature yang menghasilkan produk dengan kualitas terbaik pada proses injection molding produk plastik Polypropylene (PP) menggunakan software simulasi. (3) kesesuaian antara software simulasi dengan aplikasi produksi di industri untuk desain parameter kerja melt temperature pada proses injection molding produk plastik Polypropylene (PP). Penelitian ini dilakukan dengan analisis kualitas produk injection molding (Spion PS 135). Analisis produk dengan simulasi menggunakan software Autodesk Inventor 2013. Parameter kerja injection molding digunakan adalah mold temperature 50°C, maximum machine injection pressure 85 MPa, injection time 2 s, clamp open machine time 7 s, dengan memvariasikan parameter melt temperature yaitu 200°C, 210°C, 220°C, 230°C, 240°C, 250°C, 260°C, 270°C dan 280°C, 290°C. Beberapa variasi parameter melt temperature dieksekusi menggunakan mesin injection molding Haitian HTF 160X. Data hasil penelitian dianalisis menggunakan teknik analisis deskriptif. Data dan analisis hasil penelitian menunjukkan parameter melt temperature mempengaruhi total part weight, quality prediction, cacat shrinkage dan sink mark produk Spion PS 135. Peningkatan melt temperature menyebabkan penurunan total part weight. Quality prediction terbaik produk Spion PS 135 adalah pada parameter melt temperature 210s/d280°C, mold temperature 50°C, maximum machine injection pressure 85 MPa, injection time 2 s, clamp open machine time 7 s, dengan kualitas terbaik pada nilai melt temperature 210°C dan 220°C. Analisis secara visual produk, menggunakan software Autodesk Inventor 2013, sesuai dengan hasil eksekusi menggunakan mesin injection molding dari PT.SASS Karanganyar. Kata kunci: injection molding, polymer melt temperature, Autodesk Inventor, polypropylene, quality prediction Rizka Zahra Wulansari. ANALYSIS OF REARVIEW MIRROR CASE PRODUCT OF PS 135 BY THE REGULATION OF MELT TEMPERATURE PARAMETER OF THE POLYPROPYLENE (PP) PLASTIC MATERIAL ON INJECTION MOLDING PROCESS (A CASE STUDY AT THE LIMITED LIABILITY COMPANY OF PT.SINAR AGUNG SELALU SUKSES, KARANGANYAR, CENTRAL JAVA) Skripsi: the Faculty of Teacher Training and Education, Sebalas Maret University, July 2013) The objectives of this research are to investigate: (1) the effect of melt temperature parameter on the quality product resulting from the injection molding, (2) the melt temperature parameter resulting in the best rearview mirror case on the injection molding process of polypropylene (PP) plastic product by using the simulation software, and (3) the correspondence between the simulation software and the production application in industry for the work parameter design of melt temperature on the injection molding process of polypropylene (PP) plastic product. This research was conducted by analyzing the quality product injection molding of the rearview mirror case product of PS 135. The analysis with simulation used the software of Autodesk Inventor 2013. The work parameter of the injection molding included the mold temperature of 50°C, the maximum machine injection pressure of 85 MPa, the injection time of 2 s, and the clamp open machine time of 7 s, with the variations of melt temperature of 200°C, 210°C, 220°C, 230°C, 240°C, 250°C, 260°C, 270°C, 280°C, and 290°C. The variations of melt temperature were executed by using the injection molding machine of Haitian HTF 160X. The data of the research were analyzed by using the descriptive technique of analysis. The result of the research shows that the melt temperature parameter influence the total part weight, quality prediction, shrinkage defect, and sink mark defect of the rearview mirror case product of PS 135. The increase in the melt temperature causes the decrease in the total part weight. The best quality prediction of the rearview mirror case product of PS 135 result from parameter of the melt temperatures ranging 210°s/d280°C, the mold temperature of 50°C, the maximum machine injection pressure of 85 MPa, the injection time of 2 s, and the clamp open machine time of 7 s with the best quality of the product at melt temperature of 210°C and 220°C. The visual analysis on the rearview mirror case product used the software of Autodesk Inventor 2013 has a correspondence with the execution of the injection molding machine at the limited liability company of PT.Sinar Agung Selalu Sukses, Karanganyar. Keywords: injection molding, polymer melt temperature, Autodesk Inventor, Polypropylene, quality prediction