1、Pacific ADS Design Training November 20031Molding Process IntroduceDaniel zuoPacific ADS Design Training November 20032Process SelectionProcessing of Engineering Thermoplastics:Injection MoldingExtrusionCompression MoldingThermoformingBlow Molding Secondary OperationsComparisonsPacific ADS Design Tr
2、aining November 20033Injection MoldingExtrusionCompression MoldingThermoformingBlow MoldingSecondary Operations ComparisonsProcessing of Engineering Thermoplastics:MaterialsProcessingProcessingProcess Selection-InjectionPacific ADS Design Training November 20034Injection Molding IntroductionInjectio
3、n molding makes possible mass production of intricate,high performance,tight tolerance parts with very little secondary labor and minimal waste.Process Selection-InjectionPacific ADS Design Training November 20035HopperMoldClampExtruder Barrel withHeating BandsInjection Molding MachineProcess Select
4、ion-InjectionPacific ADS Design Training November 20036Injection UnitThe Reciprocating ScrewPelletsFeed SectionMeltProcess Selection-InjectionPacific ADS Design Training November 20037Injection UnitThe Reciprocating ScrewScrew Pushes Forward:InjectScrew Slides Back:Feed,Melt(Filling)ThroatHeating Co
5、ilsNozzleRotationInjection ForceBack PressureProcess Selection-InjectionPacific ADS Design Training November 20038Injection UnitThe Reciprocating ScrewScrew Slides Back:Feed,MeltProcess Selection-InjectionPacific ADS Design Training November 20039Process Selection-InjectionPacific ADS Design Trainin
6、g November 200310Injection UnitThe Reciprocating ScrewScrew Pushes Forward:InjectProcess Selection-InjectionPacific ADS Design Training November 200311Feed Section:Picks up pellets and carries them forward.Transition Section:central portion of the screw with reduced channel depth which compresses pl
7、astic,eliminating air between pellets and heating and melting them.Metering Section:Final plasticizing of melt.Screw DescriptionMeteringCompressionFeedProcess Selection-InjectionPacific ADS Design Training November 200312Clamping SystemMoldMovablePlatenStationaryPlaten Provides motion and force to o
8、pen and close mold Clamping Force:maximum holding force in tons that a machine can maintainNozzleProcess Selection-InjectionPacific ADS Design Training November 200313Standard Injection MoldingFast Cycle TimesComplex PartsHigh VolumeAestheticsAdvantagesDisadvantages High Pressure Process Limited Lar
9、ge Part Capability High Tooling CostProcess Selection-InjectionPacific ADS Design Training November 200314Co-Injection MoldingPacific ADS Design Training November 200315Co-Injection MoldingPacific ADS Design Training November 200316Co-Injection MoldingPacific ADS Design Training November 200317LEXAN
10、 FOAMABLE RESIN Business Machine ChassisStructural Foam PartHigh Strength and Rigidity in Larger PartsProcess Selection-InjectionPacific ADS Design Training November 200318Mucell微孔发泡设备微孔发泡设备Pacific ADS Design Training November 20031901 Needle valve nozzle02 Gas injector03 MuCell-plasticizing screw(L
11、/D ratio:22:124:1)04 Homogenizing section for gas/melt mixture05 Plastics granules without blowing agent0105030204Mucell微孔发泡工艺的塑化单元微孔发泡工艺的塑化单元Pacific ADS Design Training November 200320Mucell微孔发泡的产品表现形式微孔发泡的产品表现形式Pacific ADS Design Training November 200321Structural Foam Injection Molding Large Part
12、 Capability Low Pressure Process High Stiffness to Weight RatioAdvantagesDisadvantages Longer Cycle Time Aesthetics Blending RequiredInert GasBlowing Agent with ResinRelative to Standard Injection MoldingProcess Selection-InjectionPacific ADS Design Training November 200322Structural Foam Increases
13、the attainable wall thickness Gas expands inside plasticized material to create foam coreSKINSKINCOREProcess Selection-InjectionPacific ADS Design Training November 200323Gas Assist Injection MoldingGas Introduced After Short Shot to Pack out Part Improved Aesthetics Low Pressure Process Lower Part
14、Weight Reduced Cycle TimeAdvantagesDisadvantages Defect on Every Part More Complex Process High Tooling Costs Licensing CostsProcess Selection-InjectionPacific ADS Design Training November 200324Gas Assist Injection Molded Shipping ContainerGas Assist Molded RibInjection Molded RibGas Created Cavity
15、Gas Injection DefectSinkGas Assist Injection MoldingProcess Selection-InjectionPacific ADS Design Training November 200325Vicat Softening pointMold TemperatureProcesscloseinjectplasticizationcoolopentemperature risecloseinjectplasticizationcoolValve unithot waterhot waterhot waterwaitwaitcold waterc
16、old waterHeat&Cool SystemProcess Selection-InjectionPacific ADS Design Training November 200326BoilerNeed special equipmentProcess Selection-InjectionPacific ADS Design Training November 200327Heat&CoolGood Surface Finishing with Filled MaterialNo Weld lineIncrease Weld strengthEliminate Jetting&Flo
17、w markPaint lessNo stressIncrease FlowabilityNote PCHandphoneDoor mirrorDoor handleBezelHousingHousingLensLight guide plateThin wallProcess Selection-InjectionPacific ADS Design Training November 200328GCompressionGoPreset GapInjectionTimePositionScrewClampf=0GoInjection Compression MoldingPacific A
18、DS Design Training November 200329TimeScrewCoreCompressionPreset GapGf=0GoGoInjectionPositionSelective ICM or CoiningPacific ADS Design Training November 200330FeatureProcess BenefitsFilling at a larger effective thicknessCompression assisted filling and packShort shot processLower shearLonger fill
19、lengthLower fill pressureLower clamp forceThinner wall capabilityBi-axial flowReduction of residual stressesMaterial savingsWeight reductionCycle time reductionBetter impact propertiesAdvantages Dimensional stability Optical QualityWeld linestrengthLower CavityPressureIn-mold decorating with“soft to
20、uch”Why Use ICM?Pacific ADS Design Training November 200331InjectionICMNozzle PressureNozzle PressureCavity PressureCavity PressureMold PositionMold Position25k15.5kPSIPSI2.00.004InchTime(sec)Time(sec)0.0400.321kInch3.7kExperimental Cavity Pressure ProfilePacific ADS Design Training November 200332L
21、exan 141-1.5mm thicknessICMIMImproved Flow in Wheel CoversDecrease Molded-in StressPacific ADS Design Training November 200333Injection MoldingExtrusionCompression MoldingThermoformingBlow Molding Secondary OperationsComparisonsProcessing of Engineering Thermoplastics:MaterialsProcessingProcessingPr
22、ocess Selection-ExtrusionPacific ADS Design Training November 200334ExtrusionExtrusion is the act of squeezing,pressing,or pushing material through a die in order to make a shape.Process Selection-ExtrusionPacific ADS Design Training November 200335The ExtruderPelletsPartHeating CoilsScrewDieContinu
23、ous ProcessProcess Selection-ExtrusionPacific ADS Design Training November 200336The Profile Extrusion DieContinuous FlowUniform Cross-SectionProcess Selection-ExtrusionPacific ADS Design Training November 200337 Extruded Through Die Supported and Cooled by a Stack of Polishing Rolls Cut and Trimmed
24、 Once Below Glass Transition Temperature Sheet May be Used in Thermoforming and Compression MoldingSheet ExtrusionDieExtrusion CutawayViewRigidSheetRollStackProcess Selection-ExtrusionPacific ADS Design Training November 200338DieDieOther Roll Stack OptionsProcess Selection-ExtrusionPacific ADS Desi
25、gn Training November 200339Thermoplastic and Glass Composite SheetGlass Fiber MatGlass Impregnated SheetSheet ExtruderA Combination of Glass Mat and Thermoplastic Resin Having BothHigh Stiffness and Good Impact Strength.Process Selection-ExtrusionPacific ADS Design Training November 200340The Extrud
26、erPelletsPartHeating CoilsScrewDie Low Tooling Die Costs Large Part Capability Continuous Process AdvantagesDisadvantages High Set-up Cost Constant Cross Section Limited ComplexityProcess Selection-ExtrusionPacific ADS Design Training November 200341Injection MoldingExtrusionCompression MoldingTherm
27、oformingBlow Molding Secondary OperationsComparisonsProcessing of Engineering Thermoplastics:MaterialsProcessingProcessingProcess Selection-CompressionPacific ADS Design Training November 200342Softened sheet isplaced in a mold thenpressed into shape bycompressive force.Process Selection-Compression
28、Compression MoldingPacific ADS Design Training November 200343231Soft SheetTrimmingCompressive ForcePartProcess Selection-CompressionCompression MoldingPacific ADS Design Training November 200344 Large Part Capability Variable Wall Thickness Uses Conventional Stamping Equipment Low Warpage and Disto
29、rtionAdvantagesDisadvantages High Tooling Cost (Cheaper than Injection Molding)Secondary Trimming AestheticsProcess Selection-CompressionCompression MoldingPacific ADS Design Training November 200345Injection MoldingExtrusionCompression MoldingThermoformingBlow MoldingSecondary Operations Comparison
30、sProcessing of Engineering Thermoplastics:MaterialsProcessingProcessingProcess Selection-ThermoformingPacific ADS Design Training November 200346Vacuum FormingAtmospheric Pressure(14.7 psi)Softened SheetMoldPartVacuumProcess Selection-ThermoformingPacific ADS Design Training November 200347Pressure
31、FormingSoftened SheetCompressed AirPressure FormedPart atm pressureProcess Selection-ThermoformingPacific ADS Design Training November 200348 Low Tooling Cost Large Part Capability Low Pressure ProcessAdvantagesDisadvantages Low Part Complexity Longer Cycle TimesVacuumProcess Selection-Thermoforming
32、ThermoformingCompressed AirPacific ADS Design Training November 200349Injection MoldingExtrusionCompression MoldingThermoformingBlow Molding Secondary OperationsComparisonsProcessing of Engineering Thermoplastics:MaterialsProcessingProcessingDouble Walled,Hollow partsProcess Selection BlowPacific AD
33、S Design Training November 200350Pinch BarParison DropPre BlowFull PressureReleaseMoldPart12345Process Selection BlowBlow MoldingPacific ADS Design Training November 200351MandrelParisonControlling Wall ThicknessRaised MandrelLowered MandrelThinner WallThicker WallProcess Selection BlowPacific ADS D
34、esign Training November 200352 Double Wall Geometry(Hollow Parts)Good Stiffness to Weight Ratio Low Tooling Cost Large Part CapabilityAdvantagesDisadvantages Longer Cycle Times Secondary Trimming Purging Start-up CostProcess Selection BlowBlow MoldingPacific ADS Design Training November 200353Inject
35、ion MoldingExtrusionCompression MoldingThermoformingBlow MoldingSecondary Operations ComparisonsProcessing of Engineering Thermoplastics:MaterialsProcessingProcessingProcess Selection Sec.OperationInjection MoldingExtrusionCompression MoldingThermoformingBlow MoldingSecondary Operations ComparisonsP
36、acific ADS Design Training November 200354Injection MoldingExtrusionCompression MoldingThermoformingBlow MoldingSecondary Operations ComparisonsProcessing of Engineering Thermoplastics:MaterialsProcessingProcessingProcess SelectionPacific ADS Design Training November 200355 Size Part Complexity Wall
37、 Thickness Production Quantity CostsProcess Selection CriteriaProcess SelectionPacific ADS Design Training November 200356Part Complexity vs.Part SizeIMFMCMBMTFEXPart SizePARTCOMPLEXITYProcess SelectionPacific ADS Design Training November 200357.300.250.200.150.100.050 0BM IM FM CM EX TFWall ThicknessProcess SelectionPacific ADS Design Training November 200358Tooling CostRankingExtrusionThermoformingBlow MoldingFoam MoldingCompression MoldingInjection MoldingLeast ExpensiveProcess Selection
