Essay On Injection Molding

Abstract— In this project the process parameters of injection molding process was found and comparing the surface roughness values of polycarbonate material with polyvinyl chloride which has been already in use in our lab. Polycarbonate is in this experiment because it’s having high tensile strength and high melting point than PVC. In this project the process parameters of injection molding process like melt temperature, mold temperature, filling time, clamping force, ram speed and etc… was found out and from this results we can find out which one is the best one in given conditions and results were discussed and graphs are plotted.

Key words: - polycarbonate, poly vinyl chloride, surface roughness, melting point, process parameters…

I. INTRODUCTION

Injection molding is a manufacturing technique for making parts thermoplastic material. The injection molding process was studied extensively in attempt to create plastic component at the highest quality possible. This project is to get optimize parameter in injection molding process. The present study analyses the Wear behavior of polycarbonate reinforced with 20 wt. % short glass fibers. The specimens were prepared under different molding conditions, with varied filling time, melt temperature, and mould temperature.

Injection molding, a cyclic process, is completed in an injection molding machine fig 1. The machine comprises a clamping unit, an injection unit, a hydraulic unit and a control unit. The clamping unit holds, opens and closes the mold automatically

Process parameters

Fill time = 4.9000 s

Cooling time = 20.0000 s

Velocity/pressure switch-over by = Automatic

Packing/holding time = 10.0000 s

Ram speed profile:

% shot volume % ram speed

---------------------------------

100.0000 100.0000

0.0000 100.0000

Pack/hold pressure profile:

Duration % filling pressure

---------------------------------

0.0000 s 80.0000

10.0000 s 80.0000

20.0000 s 0.0000

Ambient temperature = 25.0000 C

Inlet melt temperature = 270.0000 C

Ideal cavity-side mold temperature = 66.0000 C

Ideal core-side mold temperature = 66.0000 C

From these results and values we have obtained process parameters of injection molding process for a given specimen.

4. Graphs and model simulation

In this experiment there are different steps involved in a simulation of model using mold flow plastics insight.

4.1 Material selections

4.2. Meshing of model

4.3. Temperature distribution of model

4.4. Clamping force

4.5. Pressure injection

4.6. Ram speed

III. CONCLUSION

Surface roughness testing for PVC:-

In this test the PVC specimen was been tested and the different roughness values (Ra) were obtained by using different locations of the model.

Top surface:- locations Roughness in μm,

1

3.14

2

3.78

3

3.16