TABLE OF CONTENTS

1.0 TITLE ................................................................................................................................................... 3

2.0 OBJECTIVES ....................................................................................................................................... 3

3.0 INTRODUCTION ................................................................................................................................ 4

3.1 Theory ............................................................................................................................................... 5

4.0 APPARATUS ....................................................................................................................................... 6

4.1 Industrial Apparatus .......................................................................................................................... 8

5.0 PROCEDURE ....................................................................................................................................... 9

6.0 RESULT ............................................................................................................................................. 11

7.0 DISCUSSION ..................................................................................................................................... 12

8.0 CONCLUSION ................................................................................................................................... 13

9.0 RECOMMENDATIONS .................................................................................................................... 14

10.0 REFERENCES ................................................................................................................................. 15

 TABLE OF FIGURES

Figure 1: Injection Moulding Machine ....................................................................................................... 4

Figure 2: Example of injection of molded part ........................................................................................... 5

Figure 3: Polypropylene Homopolymer ..................................................................................................... 6

Figure 4: Clamping unit .............................................................................................................................. 6

Figure 5: Injection unit................................................................................................................................ 6

Figure 6: Hydraulic injection molding ........................................................................................................ 8

Figure 7: Hybrid injection molding ............................................................................................................ 8

Figure 8: Inserting the granule into the hopper. .......................................................................................... 9

Figure 9: Control anel for injection moulding ........................................................................................... 9

Figure 10: Computerized Control Unit ..................................................................................................... 10

Figure 11: Safety gate that has been closed .............................................................................................. 10

Figure 12: Finished Products .................................................................................................................... 10

Figure 13: Different type of defects occurred ........................................................................................... 11

1.0 TITLE

Title: Plastic Injection Moulding

2.0 OBJECTIVES

1. To study the principle operation of a plastic injection moulding machine

2. To produce a simple plastic product using the mould and machine
3. To inspect the quality of product generated using the machine
3.0 INTRODUCTION

The innovative of manufacturing technology over the last 50 years allow us to produce wide variety of
products either simple or complex components at low time processing. These products are manufactured
using injection moulding typically used for thermoplastic materials which consisted of three basics
methods which is melting, reshaping, cooling. The plastic material is melted and then injected into the
mold that consist variety of pattern in the injection moulding. After that, the plastic material will cool
down its temperature and solidifies into the final part. Below is the figure that consists few sections of
injection moulding machine.

Figure 1: Injection Moulding Machine

One common things that can be seen in every manufacturing industry is their mass production of products.
It is undeniable the mass production has been an important aspect to their revenue. Therefore, the biggest
advantages of injection moulding machine is its capability to mass produce of thin walled plastic for wide
variety of applications such as plastic housings. Plastic housing is un-thick wall enclosure, usually consists
of ribs on the inside. These plastic housing are used in many products including consists of household
appliances, automotive bumpers, and electronics parts. Injection moulding also used in everyday items
such as plastic cups and toys.
3.1 Theory

In this section will be described details of the process cycle for injection moulding. The overall
processes are actually very short, typically between 2 seconds and 2 minutes that consists of four stages:

1. Clamping

The clamping unit consists of two halves of the mold that need to securely close first before injection of
the material into the mold. First half of the mold is built into the molding machine and the second half
can slide. The clamping unit is hydraulically powered pushed the mold half together with sufficient
force to keep the mold securely closed when injecting the material.

2. Injection

The pellets form of the raw plastic material is fill into the hopper and move towards the mold by the
injection unit. Heating and pressuring of material is occurred during this process. The molten material is
then injected quickly into the mold.

3. Cooling

The molten plastic inside the mold start to cool as soon it contacted to the interior mold surfaces. When
the plastic cool, it also starting to solidify itself. During that time, the mold cannot be opened until it
fully solidified and cooled.

4. Ejection

The cooled part will be ejected from the mold into the other half of the mold. To eject the part sufficient
amount of force must be applied to prevent the part from defect of part shrinking and stick to the mold.
Once the part is ejected, the system will clamp back the mold for the next injection

Figure 2: Example of injection of molded part

 4.0 APPARATUS

Material Description

 Combination of:
 Plastic
 Rubber
 The material is in granule form.

Figure 3: Polypropylene Homopolymer

Mold Mold cavity Barrel (heater) Hopper Screw Motor Drive

Figure 4: Clamping unit Figure 5: Injection unit

Safety gate

Computerized
Control Unit
Below is the description of each components:
HOPPER : Hold the propylene homopolymer (PPH) and transfer to the
rotating and reciprocating screw.
BARREL : It is used to supports the reciprocating screw and heat the PPH
by using the electric heater bands.
SCREW MOTOR DRIVE : Supply the power to rotate the reciprocating screw
SAFETY GATE : As a finishing step to produce the product. Opening and closing
the gate again to produce another same product.
CONTROL UNIT : It is used to monitor and control the process such as the
pressure, speed, temperature, and position.
MOLD : To form a pattern of a product where the heated polymer
granule is injected into.
4.1 Industrial Apparatus

Types of injection molding Description

The advantages:
 Lower price
 Cheaper parts
 Stronger parts
Figure 6: Hydraulic injection molding  High power

The advantages:
 Diversity
 Energy saving
 Less downtime
 Replaceable motor
Figure 7: Hybrid injection molding
5.0 PROCEDURE

1) Insert the material (Polypropylene homopolymer) to the hopper.

Figure 8: Inserting the granule into the hopper.

2) Closed the lid of the hopper.

3) Turn on the motor.
4) Switch on the panel.

Figure 9: Control anel for injection moulding

5) Press advance mover button and make sure the nozzle is in front of the sprue.

Figure 10: Computerized Control Unit

6) Switch on the semi auto button.
7) Close safety gate.

Figure 11: Safety gate that has been closed

8) Clamping process started.
9) Product has been fabricated.

Figure 12: Finished Products

6.0 RESULT

Figure 13: Different type of defects occurred

7.0 DISCUSSION

The result had shown plenty of defection that would develop many discontinuities. Its maybe been caused
by the machine which may be uncalibrated or flaw by the operator. Some of the major defects of the result
are shown below;

1) Flash

When the molten plastic escapes the cavity, it is called flash. It is usually escapes through the parting
line and ejector pins. This extra shape will remain on the final product. It is caused when the mould is
not tightened together (clamped) with enough force. This allows the molten plastic to slip pass. Mould
that already reached it time also the cause of flash to appear. Not just that, too much injection pressure
also pushes the plastic to came out from resistance.

2) Burn Marks

Black marks which are discolorations, usually in black (burn) or rust in colour which appears on the
surface of the product after the injection process. The main reason of burn marks to happen because
of too much heating or the speed of the injection is too fast. Overheating of trap air is also one of the
cause for burn marks to appear.

3) Short Shot

Short shot is something to be avoided as it is where the product is incomplete as it falls short. This
shows that the molten plastic did not fill the mould fully. This is the result where the product become
unfinished. Some of the reason that effects the product to become short is when incorrect calibration
of the mould can result the molten plastic didn’t fill the cavity fully. Not enough degassing gas also
became the reason short shot as there are no way the trapped air to escape.

4) Vacuum Void

When bubbles are seen on the product it is called vacuum void as it is the pocket of trapped air on the
surfaces. It is because the surface and the inner section of the product receive uneven solidification
process. When this happens the molten plastic in the mould receive less pressure and causing air to be
trapped unless it could be flown out. Two halves of mould that are not correctly aligned will also cause
void to develop in such way.
8.0 CONCLUSION

Before we end the report, we can conclude that the objectives were achieved. The machine must be
well calibrated and maintained to avoid more defects. By using the knowledge on learning the common
principal, injection moulding and the effects of defects will be applied in the future. The product had
been fabricated and the report were completed perfectly as injection moulding is one type of a casting
that is easy to be learn and used by both students or engineers.

Moreover, injection moulding process can be improved in the future to be one of the simplest casting
process to be used and will be improved more as it will become a great asset for engineers and students.
9.0 RECOMMENDATIONS

From studies that have been made, some recommendations are made to avoid or lessen the defects on the
product. Some of the ways are shown below;

1) Flash
a. Increase the pressure on the clamp so that the mould shuts completely
b. Be familiar with the optimum injection cases such as speed, pressure and temperature.

2) Burn Marks
a. Slows the speed of the injection
b. Decrease the temperature of the mould and melt

3) Short Shot
a. Choose lesser viscous as it will become easier to flow
b. Change to a machine with more higher material feed

4) Vacuum Voids
a. Make sure the mould is tight and neatly aligned.
b. Give more holding time and the holding pressure to the mould.
10.0 REFERENCES

1. Azom, Apr 2001. The injection Moulding Cycle. Retrieved from

https://www.azom.com/article.aspx?ArticleID=265

2. Tony Rogers, December 2015. Mechanism of injection moulding. Retrieved from

https://www.creativemechanisms.com/blog/everything-you-need-to-know-about-injection-
molding

3. Defects of injection moulding. Retrieved from

https://www.toray.jp/plastics/en/amilan/technical/tec_014.html

4. Types and benefits of injection moulding. Retrieved from

https://www.midstatemold.com/injection-molding-machines/

5. Details causes of injection moulding defects. Retrieved from

https://www.decaturmold.com/wp-content/uploads/Molding-Defects-Causes-Corrective-Actions-
Glossary.pdfTony Rogers, December 2015. Mechanism of injection moulding. Retrieved from

6. Introduction of injection moulding. Retrieved from

http://www.aimprocessing.com/blog/a-brief-introduction-to-plastic-injection-molding

7. Mechanism of injection moulding. Retrieved from

https://www.toray.jp/plastics/en/amilan/technical/tec_008.html

8. Process of injection moulding machine. Retrieved from

http://www.custompartnet.com/wu/InjectionMolding

9. Polypropylene definitions. Retrieved from

https://www.emcoplastics.com/pp-homopolymer/

10. Process of plastic injection moulding machine. Retrieved from

http://visionplastics.net/resources/what-is-plastic-injection-molding/