Injection Molding Equipment

Injection molding machine:

Injection molding machines, also known as presses, consist of a hopper, injection plunger or screw-type piston, and heating. The mold is clamped to the mold of the molding machine, where the plastic is injected into the mold through the sprue holes. Presses are rated in tonnage, the amount of clamping force that the computer machine can apply. This force keeps the mold closed during injection molding. Tonnage can be set from under 5 tons to 6000 tons, although presses of higher tonnage are rarely used. The total clamping force required is determined by the projected area of the molded custom part. 2 to 8 tons of clamping force per square inch of projected area. As a rule of thumb, most products can use 4 or 5 t/in. If the plastic material is very strong, more injection pressure is required to fill the mold, and therefore more clamping tonnage is required to keep the mold closed. The required force can also be determined by the material used and the size of the part, the larger the plastic part, the higher the clamping force required.

Mold:

Cavity dies or stamping dies are tools used to produce plastic parts during molding. Traditional injection molds are expensive to manufacture and are only used in high-volume production applications where thousands of parts are produced. Dies are typically constructed of hardened steel, pre-hardened steel, aluminum and/or beryllium copper alloys. The choice of material for making the mold is mainly based on economic factors. Steel molds are generally more expensive to construct, but have a longer life, which will offset the higher initial cost by having more parts manufactured before they wear out. Pre-hardened steel tooling is less wear resistant and is primarily used for lower volume requirements or larger components. The hardness of pre-hardened steel is usually between 38 and 45 on the Rockwell-C grade. Hardened steel molds are heat treated after machining to make them more excellent in terms of wear resistance and service life. Typical hardness ranges from 50 to 60 Rockwell-C (HRC).

Aluminum tooling costs far less than steel tooling, and when used with higher grades of aluminum such as QC-7 and QC-10 aircraft aluminum and machined using modern computerized equipment, they can economically shape hundreds of thousands of parts. Aluminum molds also provide quick turnaround and faster cycles due to better heat dissipation. They can also be coated for abrasion resistance against glass fiber reinforcement. Beryllium Copper is used in areas of the mold where rapid heat dissipation is required or where the most shear heat is seen.

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