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This two day, total 16 hours, course offers a concise review of the essentials one ought to know when dealing with the
injection molding processes. Emphasis is on obtaining a condensed overview on rheology,
molding machinery, cycle elements, energy transfer (heating, cooling, thermal expansion)
need to know of runnerless tooling and mold base, cavity, core and slide alignments.
This fact-filled presentation is considered a general overview and
"wrap-up", which combines the highlights of our other injection molding and tool
design programs. It is a fast-paced compact seminar covering methods generally known,
yet less understood. This seminar reveals why many innovations should or have become the
industry standard.
This course is intended for those individuals who like to
"brush up" on their overall knowledge in the injection molding field. It
is not a beginners seminar, therefore a sound knowledge and understanding
of the injection molding process is a prerequisite.
At this seminar you will....
- Understand polymer flow and behavior and learn about the
heat content of plasticized materials.
- Witness several mold filling scenario's and observe crystal
structure and spherulites growth.
- Understand the effect of molding conditions and wall
thickness on mold shrinkage.
- Learn how to interpret the molding machine specifications.
- Come to know the high dynamic forces on a mold and hot
runner system (which just appear to be a static assembly).
- Apprehend heat coefficient versus flow of the cooling media.
- Receive a comprehensive custom-developed instruction manual,
provided only to participants of this seminar, which will serve as a valuable source in
the future.
Seminar Outline
I Plastic flow and
behavior:
- Overview of thermoplastics, amorphous and crystallinity
materials, polymerization process and intermolecular forces.
- Polymer flow and mold filling studies.
- Viscosity versus shear rate.
- Crystal structure & spherulites growth during the
cooling process.
- Shrinkage from mold dimensions of molded plastics.
- Discussion on computer aided mold filling analysis.
II Cycle elements
- Dependent and independent variables.
- Hydraulic pressure versus cavity pressure.
- Intensifying ratio, shot weight and plasticizing capacity.
- Clamping mechanism (parallelism of the platen, tie bar
elongation).
III Mold types
- Two plate mold; Stripper plate mold; Three plate mold; Stack
mold, etc.
IV Cam Actions
- Projected areas on the slide, and resultant forces projected
against the clamping mechanism.
- Slides and cam activation, sliding mechanisms, etc.
V Hot runner systems
- Advantages and disadvantages of hot runner systems.
- Annular versus cylindrical flow in runnerless tooling.
- Application of heating elements; power requirements and
thermocouples.
- Calculations required in order to install the correct
capacity heating element(s).
- Gating methods and material suitability.
- Thermal conductivity of tool steels and other non-ferrous
materials used in the mold making industry.
- Coefficient of thermal expansion of materials used in the
mold making industry.
- When, why and where to use insulator sheets.
- Mechanical stability of the mold base and components.
VI Mold base alignment
- The application, position, and alignment of parting line
interlocks.
- Guided ejector mechanism.
- Cavity - core alignment.
VII Cooling theory
- Cooling system(s) for the injection molding shop.
- Basic water cooling theory and energy removal.
- Importance of metering the cooling media.
- Discussion on computer aided mold cooling analysis.
VIII Mold cooling
circuits
- Uniform heat transfer circuits.
- Applications of cooling inserts, baffles, bubbles and heat
pipes.
- Typical common errors in cooling line layouts.
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