Industry News

The working principle of injection mold molding

2021-11-16
Injection molds are parts that give plastic shapes and dimensions during molding. Although the structure of the mold may vary widely due to the variety and performance of plastics, the shape and structure of plastic products, and the type of injection machine, the basic structure is the same. The mold is mainly composed of three parts: the pouring system, the forming parts and the structural parts. Among them, the pouring system and the molded parts are the parts that are in direct contact with the plastic and change with the plastic and the product. They are the most complex and the most variable parts in the plastic mold, requiring the highest processing finish and precision.
The gating system refers to the part of the runner before the plastic enters the cavity from the nozzle, including the main runner, cold material cavity, runner and gate, etc. Molded parts refer to the various parts that constitute the shape of the product, including movable molds, fixed molds and cavities, cores, molding rods, and vents.
1)
1. Injection steps:
The screw rotates at a high speed to melt the raw materials. The rotation speed is very important for melting. If it is too slow, the plastic will not melt completely, and if it is too fast, the plastic will be carbonized. Of course, the barrel is also important for heating.
2. Injection molding steps:
After the raw material is melted, the melted material is injected into the mold. And an injection molding machine is required to provide injection pressure to inject the molten raw material into the mold.
Then it takes some time to hold and form.
After that, cool the mold and close the gate of the mold. Finally, the mold is cooled by air and water.
Pick up the product: This is the last step. Some customers need to use a robot to pick up the products, and some let the products fall off automatically after molding.
2) Main road
It is a passage in the mold that connects the nozzle of the injection machine to the runner or cavity. The top of the sprue is concave to connect with the nozzle. The diameter of the main runner inlet should be slightly larger than the nozzle diameter (0.8mm) to avoid overflow and prevent the two from being blocked due to inaccurate connection. The diameter of the inlet depends on the size of the product, generally 4-8mm. The diameter of the main runner should be expanded inward at an angle of 3° to 5° to facilitate the demolding of the runner.
It is a cavity at the end of the main runner to trap the cold material generated between two injections at the end of the nozzle to prevent the clogging of the runner or gate. Once the cold material is mixed into the cavity, internal stress is likely to occur in the manufactured product. The diameter of the cold material cavity is about 8-10mm, and the depth is 6mm. In order to facilitate demolding, the bottom is often borne by the demolding rod. The top of the stripping rod should be designed in a zigzag hook shape or set with a recessed groove, so that the sprue can be pulled out smoothly during demolding.
3) Diversion channel
It is the channel connecting the main channel and each cavity in the multi-slot mold. In order to make the melt fill the cavities at the same speed, the arrangement of the runners on the mold should be symmetrical and equidistant. The shape and size of the cross-section of the runner have an impact on the flow of the plastic melt, the product demolding and the difficulty of mold manufacturing. If the flow of the same amount of material is used, the flow channel resistance with a circular cross-section is the smallest. However, because the specific surface of the cylindrical runner is small, it is unfavorable for the cooling of the runner redundant, and the runner must be opened on the two mold halves, which is laborious and easy to align. Therefore, trapezoidal or semicircular cross-section runners are often used, and they are opened on half of the mold with a stripping rod. The runner surface must be polished to reduce flow resistance and provide a faster filling speed. The size of the runner depends on the type of plastic, the size and thickness of the product. For most thermoplastics, the cross-section width of the runners does not exceed 8m, the extra-large ones can reach 10-12m, and the extra-small ones are 2-3m. On the premise of meeting the needs, the cross-sectional area should be reduced as much as possible, so as to avoid adding debris in the runner and prolonging the cooling time.
4) Gate

It is the channel connecting the main runner (or branch runner) and the cavity. The cross-sectional area of the channel can be equal to the main flow channel (or branch channel), but it is usually reduced. So it is the smallest cross-sectional area in the entire runner system. The shape and size of the gate have a great influence on the quality of the product. The function of the gate is: A. Control the material flow speed: B. Prevent backflow due to the early solidification of the melt stored in this part during injection: C. Make the passing melt subject to strong shear and increase the temperature , Thereby reducing the apparent viscosity to improve fluidity: D, to facilitate the separation of the product and the runner system. The design of the gate shape, size and position depends on the nature of the plastic, the size and structure of the product. Generally, the cross-sectional shape of the gate is rectangular or circular, and the cross-sectional area should be small and the length should be short. This is not only based on the above effects, but also because it is easier for small gates to become larger, and it is difficult for large gates to shrink. The gate location should generally be selected where the product is thickest without affecting the appearance. The design of the gate size should take into account the properties of the plastic melt. 





sam@erbiwa.com.cn
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