16. Wildcard week
WILDCARD WEEK
This week for the wild card i was asked to choose something that i am interested , for that as part of this week i chose Injection molding machine to do work for the week .
Machine Description
The TY-7003 is a compact, desktop micro injection molding machine designed for small batch production, classroom teaching, and making test samples (like tensile bars). It features: Small mold compatibility (easy and low-cost to make and replace) AC 220V operation with pneumatic and servo controls PLC touchscreen interface for easy operation Mechanical and electronic safety features Single screw feeding for better plasticization than plunger types
No oil, no hydraulic power, low noise, and minimal pollution
We are using TY-7003 small injection moulding machine . TY-7003 .
I think the machine company is shut so there is no proper videos or documentations available . The link to there site is attached here TY-7003.But the site is not functional fully .
INJECTION MOLDING
Injection molding is a manufacturing process widely used for producing plastic parts in large volumes. The process involves injecting molten plastic material into a mold cavity where it cools and hardens to create the final product. This versatile manufacturing method is essential in various industries, from automotive and consumer goods to medical devices and packaging.
Injection Moulding Process Explained | ArpTech-Blog
Raw Material is feeded into the hopper dryer and then it pass through the screw barrel , the screw barrel has thermisters attached which heats the the screw barrel and melts the material and and passes the material throgh the nozzle block and then it is feeded through the injection point of the mould . You should suit the injection point with nozzle and make sure the nozzle is in align with injection point and make sure there is no gaps and the nozzle is not hitting the injection point .
SAFTY
General safety measures:
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Always keep hands clear of the mold area and moving parts.
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Never bypass machine safety interlocks or guards.
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In case of any abnormal noise, smell, or machine alarm, press the emergency stop button immediately and inform the supervisor.
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Do Not put You Hand inside the Mould while the Machine Doors are Closed .
Material safety:
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Polypropylene (PP) can release fumes when overheated. Always operate the machine in a well-ventilated area or with a fume extractor.
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Avoid inhaling fumes; use a mask if needed.
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Personal Protective Equipment (PPE):
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Safety glasses or face shield
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Heat-resistant gloves
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Long-sleeve clothing
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Closed-toe shoes
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(Optional) Respirator mask if ventilation is poor
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Use Gloves for Taking the hot injection moulded Component
INJECTION MOLDING USING POLYPROPLENE
Polypropylene (PP) is one of the most commonly used thermoplastic polymers in injection molding due to its excellent properties and versatility. The material offers good chemical resistance, high temperature tolerance, and mechanical strength, making it ideal for manufacturing various products. The injection molding process with PP typically involves heating the material to around 180 -220 before injecting it into the mold cavity under high pressure.
This is the material that i used .
MOULD1
I Used a prebuilt Mould . Which was Already Placed Inside the machine , So it was Kinda easy for me , but i need to know the different parameters of the machine , which is shown below .
MOULD DESIGN USING FUSION 360
I Have tried to replicate the design of the MOULD .
Below i have shown the sample mould thaa i have designed , its not complete there are many things to consider . the cooling the ejection etc etc .
here i have shown the part model and the mould design .
First i Turned on the machine by connecting the wires then i turned on the Air inlet .
Then Turn On the Machine by Pressing the Red Button .
Back pressure is one of the important concepts that would help you to acquire the required finish of the product without flash . It helps to set the tonnage .
Above i have shown the temperature and other setting that i have used . since i have used PP , i have set the temperature as 200 . ( i was knowing the temperature that is used in my company since i already did have previous experience in using similar materials in my company Supertech Industries).
Understanding Injection Molding Machine Parameters
When setting up an injection molding machine, several critical parameters need to be carefully configured to ensure optimal production quality:
Stroke (mm): This represents the distance the screw moves forward during injection. It determines the amount of material injected into the mold cavity.
Shot Size: The total volume of material that will be injected, typically measured in cubic centimeters or grams.
2. Speed Settings
Screw Speed (RPM): Controls how fast the screw rotates during plasticization. Higher speeds increase output but may cause material degradation.
Injection Speed: The rate at which the material is injected into the mold. This affects the filling pattern and surface quality.
3. Pressure Controls
Injection Pressure: The force applied to inject the material into the mold cavity.
Holding Pressure: Pressure maintained after filling to compensate for material shrinkage.
Back Pressure: Resistance applied during screw recovery, affecting material mixing and density.
4. Timing Parameters
Injection Time: Duration of the injection phase.
Holding Time: How long the holding pressure is maintained.
Cooling Time: Time allowed for the part to solidify before ejection.
Overall Cycle Time: Total time for one complete molding cycle.
Important Considerations When Setting Parameters:
Material Properties: Different materials require different processing parameters. For PP (as used in this case), temperatures around 200°C are typical. Part Design: Complex geometries may require slower injection speeds and higher pressures. Quality Requirements: Higher quality standards might necessitate longer cooling times and more precise pressure control.
When Clicking The Data settings A tab like this would Open Up .
Here you could set the Important Parameters like Holding time , Cooling Time etc …
The Doors should be Closed For the machine to work . There is a limit switch that helps to enable soo .
You Could use The Below guidelines too make Your Molding process More smoother . Where you could find the solution to your commonly occured problems . This was prepared by Me and My staff For the Proper Working of my Company . So the Workers Could Easily analyse and solve the issue . For More Detailed PDF You could download Our Booklet From
Supertech Industries: Kerala's Leading Injection Molding Workshop
In The PDF You Could See the Detailed Analysis of Every common Defects and its solutions .
Below video shows The ejection using ejector Pin .
Below i have attached the video where i am injection Moulding .
This is the Part That I injection Moulded .
INJECTION MOLDING USING 3D PRINTED MOULD
3D printed molds offer an innovative and cost-effective solution for low-volume injection molding production. While traditional steel molds are expensive and time-consuming to manufacture, 3D printed molds can be produced quickly and at a fraction of the cost. However, special considerations must be taken regarding material selection and processing parameters when using 3D printed molds due to their different thermal and mechanical properties compared to traditional metal molds.
I wanted to try this Out , since Our resin printer is not working i was unable to manufacture . i will be looking into it forward .
CONCLUSION
I was able to look into small injection moulding machine and understand its basic working and i did understood how good its for moulding small components .
REFERENCES
injection-moulding-process-parameters
injection-speed-and-injection-pressure