Injection Molding

This introduction covers all aspects such as materials behavior, machine and mold design, and the process.

Introduction to the Technology of Injection Molding

1

(13)

The Injection Molding Process

1

(2)

Components of the Injection Molding Process

3

(9)

Injection Molding Machine

3

(1)

Plasticating Unit

3

(1)

Clamping Unit

4

(2)

Mold

6

(1)

Runner System

7

(1)

Cavity

8

(1)

Ejector System

9

(1)

Tempering System

10

(2)

Machine Control System

12

(1)

References

12

(2)

Injection Molding Materials

14

(43)

Properties of Plastics

14

(2)

Classification of Plastics

16

(2)

The Molecular Structure of Plastics

18

(1)

Processing Behavior of Plastics

19

(25)

Rheological Behavior

19

(1)

Fundamentals

19

(3)

Measuring Methods

22

(4)

Results of Viscosity Measurements

26

(2)

Mathematical Approximation of Rheological Behavior

28

(3)

Application of Viscosity Data

31

(2)

Thermal and Thermodynamic Material Behavior

33

(4)

Measurement of Thermal Properties

37

(1)

PVT Determination

37

(1)

Differential Scanning Calorimetry (DSC)

38

(2)

Thermomechanical Analysis (TMA)

40

(1)

Thermogravimetric Analysis (TGA)

41

(1)

Dynamic-Mechanical Analysis (DMA)

42

(1)

Density Measurement

43

(1)

Mechanical Behavior of Plastics

44

(8)

Amorphous Thermoplastics

44

(1)

Semicrystalline Thermoplastics

45

(1)

Cross-Linked Polymers

46

(1)

Time- and Stress-Dependent Mechanical Behavior

47

(3)

Methods for Measurement of Mechanical Properties

50

(2)

References

52

(5)

The Injection Molding Machine

57

(23)

Injection Unit

58

(7)

Hopper

58

(1)

Screw

59

(2)

Nonreturn Valves (Check Valves)

61

(1)

Nozzle

62

(2)

Barrel Tempering

64

(1)

Guidance and Drive of the Injection Unit

64

(1)

Clamping Unit

65

(5)

Mechanical Clamping Units

66

(2)

Hydraulic Clamping Units

68

(1)

Hydraulic Mechanical Clamping Units

69

(1)

Deformation Characteristics of Mold and Clamping Unit

69

(1)

Comparison of Different Clamping Systems

70

(1)

Machine Hydraulics

70

(3)

Control System

73

(1)

Special Types of Injection Molding Machines

74

(3)

References

77

(3)

The Injection Mold

80

(30)

Tasks of the Injection Mold

80

(1)

Introduction and Classification of Molds

81

(4)

Functional Units in Injection Molds

85

(20)

Mold Mounting, Alignment, and Guiding

85

(4)

Runner System

89

(1)

Conventional Runner Systems

90

(3)

Hot Runner Systems

93

(4)

Cavity

97

(2)

Heat Transfer System

99

(1)

Design of Heat Transfer Units

99

(3)

Ejector System

102

(3)

References

105

(5)

Course of Process and Process Control in Injection Molding

110

(35)

Course of Process in Injection Molding

110

(1)

Phases of the Injection Molding Cycle

110

(1)

Injection Phase

111

(7)

Flow Process in the Mold

112

(2)

Frozen Layer and Orientation

114

(3)

Pressure Course in the Cavity

117

(1)

Holding Pressure Phase

118

(9)

Switching to Holding Pressure

118

(2)

Influence of Process Parameters on Pressure Curves

120

(2)

Course of State in the PVT Diagram

122

(2)

Influence of Different Parameters on the Course of State

124

(3)

Cooling Phase

127

(8)

Residual Stresses

127

(1)

Cause of Residual Stresses

128

(2)

Influence of Process Parameters on Residual Stresses

130

(1)

Crystallization

131

(1)

Dependence of the Degree of Crystallinity on Various Process Parameters

132

(3)

Influence of Internal Properties on External Properties

135

(5)

Influence of Internal Structure on Final Part Properties

136

(4)

References

140

(5)

Automation

145

(20)

Mold Changing Systems

146

(9)

Quick Clamping Devices

147

(3)

Quick Coupling Systems

150

(1)

Mold Changing Devices

151

(2)

Mold Transport System

153

(1)

Stepwise Automation of Mold Changing Systems

153

(1)

Requirements for Injection Molds

154

(1)

Automation of the Injection/Plasticating Side

155

(2)

Raw Material Supply

157

(1)

Handling of the Parts

158

(2)

Computer Control in Automation

160

(3)

References

163

(2)

Quality Assurance

165

(6)

Quality Control in Production

165

(4)

Control Chart

165

(1)

Machine Process Capability

166

(1)

Process Capability

167

(1)

Controlling Production with Statistical Process Models

168

(1)

Incoming Inspection

169

(1)

Acceptance Sampling Inspection

169

(1)

References

170

(1)

Special Processes

171

(20)

Intrusion Injection Molding

171

(1)

Injection/Compression Molding

171

(1)

Injection Press-Stretching Process (IPS Process)

172

(1)

Lost-Core Process

172

(2)

Push/Pull Process (Live-Feed Injection Molding)

174

(1)

In-Mold Decoration (IMD)

175

(1)

In-Mold Lamination

175

(1)

Overmolding

176

(1)

Multicomponent Injection Molding

176

(2)

Gas-Assisted Injection Molding

178

(2)

Injection Molding of Thermoplastic Foam

180

(1)

Insert/Outsert Process

180

(1)

Metal/Ceramic Powder Injection Molding

181

(1)

Reaction Injection Molding (RIM)

182

(1)

Resin Transfer Molding (RTM)

183

(1)

Compression Molding

184

(1)

Transfer Molding

185

(1)

References

186

(5)

Index

191

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