TRAINING - INJECTION

DRAFT
 INDEX
1- PLASTIC
TYPES OF MATERIALS
2- INJECTION MACHINE
CLOSING GROUP
INJECTION GROUP
SEQUENTIAL
NOYOS
Refrigeration
AUTOMATIC FEEDING
3- MOLDS
4- INJECTION CYCLE
5- DEFECTS OF INJECTED PARTS
6- MACHINE OPERATION
MACHINE STOPPAGE DUE TO DEFECT
MACHINE STOPPED DUE TO MALFUNCTION
7- MACHINE SAFETY DATA SHEET
THE PLASTIC
PLASTIC MATERIALS
PLASTIC MATERIALS
PLASTIC MATERIALS
PLASTIC MATERIALS
PLASTIC MATERIALS
PLASTIC MATERIALS
PLASTIC MATERIALS
INJECTION MACHINE
 THE CLOSING GROUP
It is ahydraulic presso mechanics, with a strengthenough closure to counteract the
force exerted by the molten polymer when injected into the mold.
If the closing force is insufficient, the mold will tend to open and the material will escape through the
mold union.

The fundamental parameter for sizing a closing unit is its force to maintain
the closed mold. This value is usually given in tons (t).

Closing unit data necessary for mold sizing:

✓ the minimum distance between plates

✓ the maximum opening distance
✓ the dimensions of the plates
✓ the distance between columns, the race of the expulsion system.
✓ PLACE A PHOTO OF EACH POSITION
THE CLOSING GROUP
 THE INJECTION GROUP

The main function of the unit of

injection is to melt, mix, and inject
the polymer.

The fusion process requires a

increase in the temperature of the polymer,
What results from heating and friction
from this with the camera and the spindle.

The dosing in the screw retracts, transporting the material towards the front of
the chamber. It is where the molten polymer accumulates to be injected. This chamber
acts like that of a piston; the screw then behaves like the plunger that
push the material
THE INJECTION GROUP
 SEQUENTIAL
The sequential: it is a normally hydraulic drive that through small
internal hydraulic cylinders in the mold open and close the different injection points
what it carries. This system is used to eliminate the different injection defects in lines of
union, burned, etc.
Since these cylinders are small and are exposed to high temperatures from the channel
hot, the maximum working pressure is 50 bar. If it operates at higher levels, it produces leaks and
continuous breakages.
A delicate and sensitive point of oil leakage in a sequential gearbox is the machine connections.
mold since there are several hydraulic circuits, with many nozzles and connection hoses.
Quick plug for sequential

Sequential of a mold
with hydraulic circuit and
hydraulic cylinders
 NOYOS
The noyo: It is a drive, normally hydraulic, that is mainly used for the
expulsion of pieces by means of hydraulic cylinders. The base and for what it was conceived a
it is not for the movement of any internal part of the mold that cannot be moved with
guides.
The nozzles can reach the maximum pressure of the machine even though it is not
recommended because it must be adjusted to the pressure that the cylinders can withstand
bring the mold.
The hydraulic hoses are susceptible to leaks occurring.
oil especially on the connection between machine and mold.

Quick male plug Quick female plug

Internal core of the mold
noyos machine mold of noyos
 REFRIGERATION
Cooling circuit: The function of cooling is to try to keep the temperature of the
two semi-molds to be homogeneous and suitable for the injection of the piece to be molded.
The placement of the cooling circuits will vary depending on the mold and the shape.
Each half-mold (cavity and core) will have one or more cooling channels.
independents with their respective inputs and outputs as close as possible to the
cavity, adhering to the manufacturing standards.

S1

And 1

In this example, there is a circuit.

in each part of the mold one in
the cavity and one in the nucleus.
S1

And 1
INJECTION MACHINE
INJECTION CYCLE
INJECTION CYCLE
INJECTION PARAMETERS

DRAFT
INJECTION PARAMETERS
INJECTION PARAMETERS
 DEFECTS IN INJECTED PARTS
During manufacturing, different defects can appear in the parts. These can
having different origins, they can come from:

✓ the design phase of the piece

✓ design and conception of the mold
✓ of the mold manufacturing
✓ due to inadequate mold maintenance
✓ they can be defects attributable to the improper functioning of some
injection machine component
✓ they can also be caused by an inadequate selection of material or
attributable to the worker

Even in the ideal situation where defects cannot be attributed to any of the
previous causes, these may appear and their origin will then be due to the
process conditions (times, pressures, speeds, temperatures, ...).
Identifying the cause of a defect is not a simple task due to the multitude of factors.
that intervene.

The main defects that can appear are described below.

injected parts, their causes and possible corrective actions.
 TPM INJECTION TRAINING

EMPTY / UNFILLED
Description :
Absence of 100% filling of the cavity where the piece is formed, appears mainly in
the outer profiles, ribs, and legs of the piece.
Possible causes that produce it:
Lack of material in the injection machine feeding.
Inadequate injection parameters (speeds, pressures, temperatures).
Clogging of one of the injection points.
Bad gas exit.
Correction:
Adjust the injection parameters to the machine data sheet.
-Clean or improve, if possible, the gas outlets of the molds.
 TPM INJECTION TRAINING

REBABAS
Description :
Excess material outside the cavity where the piece is molded, usually has a thickness of
lower resistance.
Possible causes that produce it:
Existence of any material particle between the closing surfaces of the mold or in the movements.
interiors of the same.
Lack of adjustment in the mold closure.
Excessive temperature of the material.
Injection speed or pressure too high.
Insufficient clamping force of the injection machine.
Correction:
Check that there are no remnants of material in the seals or in the interior movements of the mold.
Adjust injection parameters according to the specification.
Adjustment of the mold closures.
 TPM INJECTION TRAINING

GUSTS
Description:
Flashes of whitish spots, generally shaped like a comet's tail, that cross the
part in the sense of filling the flow of the material.
Possible causes that produce it:
Wet raw material.
Degraded material (due to excess temperature or time on the spindle).
Mix of materials.
Defective injection nozzle.
Correction:
Condition the raw material using dehumidifiers, dryers, etc.
Adjust injection parameters according to the data sheet.
Handle the material carefully and ensure the cylinder is purged of the previous material.
Periodic review of the nozzle.
 TPM INJECTION TRAINING

BURNED

Descripción :
Dark spots with the appearance of degraded material, even with the possibility of lack of material.

Possible causes that produce it:

High injection speeds.
High speed in spindle rotation.
Blocked gas escapes, causing their trapping and the burning of plastic that
is located close to the gas outlet.
Correction:
Adjust the injection parameters to the machine data sheet.
Clean or improve, if possible, the gas outlets of the molds.
 TPM INJECTION TRAINING

DEFORMATION
Descripción :
Piece that presents a geometry different from the defined, twisted, flattened.
Possible causes that produce it:
Bad demolding of the piece (due to excessive injection pressure or insufficient cooling time).
Grip of the part in the mold (due to impacts on cars or cavities of the mold).
Excess heat in the mold (short cooling time).
Apprehension of the incorrect handler.
Lack of cooling in the mold.
Correction:
Injection parameter review.
Repair by maintenance.
Check handler.
Check cooling in the mold or tempering machine.
 TPM INJECTION TRAINING

OVERINJECTED
Descripción :
Injection of excessive material onto a part, in multi-material injections occurs when one of
the components are mounted or introduced into the mold area of the other component.

Possible causes that produce it:

Leftover materials from the previous injection cycle.
In multimaterial injections, it is produced by an imbalance in the injection parameters.

Correction:
Adjust the injection parameters to the machine data sheet
 TPM INJECTION TRAINING

INJECTION BRANDS
Descripción :
Parts with injection flow marks (striations appear in the direction perpendicular to the flow).
Possible causes that produce it:
Leftover materials from the previous injection cycle.
Low injection temperature or speed
Correction:
Adjust the injection parameters to the machine data sheet
 TPM INJECTION TRAINING

LINES OF UNION
Description :
Mark the line on the part coinciding with the area of the material flow joint.
Possible causes that produce it:
Incorrect injection parameters.
Low material temperature
Dirty mold gas outlet.

Correction:
Adjust the injection parameters to the machine data sheet. Retest.
injection and update the machine data sheet.
Clean the gas outlet of the mold.
 TPM INJECTION TRAINING

BUBBLES
Descripción :
Holes or caverns appear inside the molded piece.

Possible causes that produce it:

The outer areas of the piece solidify before the central ones, creating internal voids.
Moisture in the material.

Correction:
Increase the sections for entries, channels, and mazarotes.
Increase the temperature of the mold.
Drying or dehumidifying of the material.
 TPM INJECTION TRAINING

Descripción :
RECHUPES
Surfaces with depressions appear at certain points, especially in areas that have more
thickness (nerves, sideburns...).
Possible causes that produce it:
The channels and openings are very small or uneven compared to the thickness of the piece.
Insufficient or irregular cooling in the mold.
Maintenance pressure too low.
Mattress made of very low material.
High injection speed.
Correction:
Increase the dimensions of channels, inputs, and if possible, redesign the thicknesses.
Check the cooling circuit.
Increase the cooling time, the maintenance time, or both.
Increase the material run in the second phase.
Reduce the injection speed.