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Injection moulding is one of the most important methods of manufacturing plastics products. Through the development of sophisticated micro processor control systems, the modern injection moulding machine is capable of producing precision mouldings with close tolerances in large numbers and with excellent reproducibility. This capability, however, is often limited by the lack of a proper appreciation of mould design. The mould, or tool as it is often called, is at the heart of the injection moulding process. Its basic function is to accept the plastic melt from the injection unit and cool it to the desired shape prior to ejection. It is not, however, simply a matter of the mould having an impression of the shape to be moulded. Many other factors have to be taken into account - for example, the ability to fill the mould impression properly and efficiently without inducing weaknesses in the moulding and the efficient cooling of the moulding in order to maximise production rates without diminishing the quality of the moulding. In addition, the type of mould, gate and runner system, and ejection system which will best meet the needs of a particular job specification have to be determined. In our experience lack of attention to such factors leads to the mould limiting the ability of the injection moulding machine and preventing the process as a whole from achieving its true potential.
The goal of the book is to assist the designer in the development of parts that are functional, reliable, manufacturable, and aesthetically pleasing. Since injection molding is the most widely used manufacturing process for the production of plastic parts, a full understanding of the integrated design process presented is essential to achieving economic and functional design goals. Features over 425 drawings and photographs.
Special Injection Molding Techniques covers several techniques used to create multicomponent products, hollow areas, and hard-soft combinations that cannot be produced with standard injection molding processes. It also includes information on the processing techniques of special materials, including foaming agents, bio-based materials, and thermosets. The book describes the most industrially relevant special injection molding techniques, with a detailed focus on understanding the basics of each technique and its main mechanisms, i.e., temperature, mold filling, bonding, residual stresses, and material behavior, also providing an explanation of process routes and their variants, and discussions of the most influencing process parameters. As special molding technologies have the potential to transform plastics processing to a highly-efficient, integrated type of manufacturing, this book provides a timely survey of these technologies, putting them into context, accentuating new opportunities, and giving relevant information on processing. Provides information about the basics needed for understanding several special injection molding techniques, including flow phenomena, bonding mechanisms, and thermal behavior Covers the basics of each technique and its main mechanisms, i.e., temperature, mold filling, bonding, residual stresses, and material behavior Discusses the most relevant processing parameters for each injection molding technique Presents a variety of techniques, including gas and water assisted injection molding, multi component injection molding, hybrid injection molding, injection molding of bio-based materials, and techniques for thermoset
This work focuses on the factors critical to successful injection moulding, including knowledge of plastic materials and how they melt, the importance of mould design, the role of the screw, and the correct use of the controls of an injection moulding machine. It seeks to provide operating personnel with a clear understanding of the basics of injec
An injection mold is the heart of any plastics molding workcell. Understanding the principles of an injection mold design and its importance is fundamental to the success of the product. This book takes the reader through the process of conceptualizing and designing an injection mold that will produce the desired plastic part.
This book provides design engineers, toolmakers, moulding technicians and production engineers with an in depth guide to the design and manufacture of mould tools that work successfully in production. It highlights the necessity to design a mould tool that allows overall production to make an acceptable profit, and whilst it is recognised that not all design engineers will be able to influence the profitability factor it is an important aspect to consider.The guide focuses on designs that will produce the required production rate and quality of mouldings in a consistent and reliable fashion; the key components of a successful mould tool. The introductory chapters outline the injection moulding process, basic moulding parameters and overall machine construction. Dedicated chapters give a full account of all the variables that should be taken into account.
This third edition has been written to thoroughly update the coverage of injection molding in the World of Plastics. There have been changes, including extensive additions, to over 50% of the content of the second edition. Many examples are provided of processing different plastics and relating the results to critiCal factors, which range from product design to meeting performance requirements to reducing costs to zero-defect targets. Changes have not been made that concern what is basic to injection molding. However, more basic information has been added concerning present and future developments, resulting in the book being more useful for a long time to come. Detailed explanations and interpretation of individual subjects (more than 1500) are provided, using a total of 914 figures and 209 tables. Throughout the book there is extensive information on problems and solutions as well as extensive cross referencing on its many different subjects. This book represents the ENCYCLOPEDIA on IM, as is evident from its extensive and detailed text that follows from its lengthy Table of CONTENTS and INDEX with over 5200 entries. The worldwide industry encompasses many hundreds of useful plastic-related computer programs. This book lists these programs (ranging from operational training to product design to molding to marketing) and explains them briefly, but no program or series of programs can provide the details obtained and the extent of information contained in this single sourcebook.