Injection molding handbook:
Gespeichert in:
| Format: | Buch |
|---|---|
| Sprache: | English |
| Veröffentlicht: |
Munich [u.a.]
Hanser
2008
|
| Ausgabe: | 2. ed. |
| Schlagworte: | |
| Online-Zugang: | Inhaltsverzeichnis |
| Beschreibung: | XVII, 764 S. zahlr. Ill. und graph. Darst. 25 cm |
| ISBN: | 9783446407817 9781569904206 |
Internformat
MARC
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| 008 | 071205s2008 gw ad|| |||| 00||| eng d | ||
| 016 | 7 | |a 983192014 |2 DE-101 | |
| 020 | |a 9783446407817 |9 978-3-446-40781-7 | ||
| 020 | |a 9781569904206 |9 978-1-56990-420-6 | ||
| 035 | |a (OCoLC)170057853 | ||
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| 044 | |a gw |c XA-DE-BY | ||
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| 084 | |a 660 |2 sdnb | ||
| 084 | |a CIT 735f |2 stub | ||
| 245 | 1 | 0 | |a Injection molding handbook |c Tim Osswald ... With contributions from J. Beaumont ... |
| 250 | |a 2. ed. | ||
| 264 | 1 | |a Munich [u.a.] |b Hanser |c 2008 | |
| 300 | |a XVII, 764 S. |b zahlr. Ill. und graph. Darst. |c 25 cm | ||
| 336 | |b txt |2 rdacontent | ||
| 337 | |b n |2 rdamedia | ||
| 338 | |b nc |2 rdacarrier | ||
| 650 | 4 | |a Injection molding of plastics |v Handbooks, manuals, etc | |
| 650 | 0 | 7 | |a Spritzgießen |0 (DE-588)4056561-0 |2 gnd |9 rswk-swf |
| 689 | 0 | 0 | |a Spritzgießen |0 (DE-588)4056561-0 |D s |
| 689 | 0 | |5 DE-604 | |
| 700 | 1 | |a Osswald, Tim A. |d 1958- |e Sonstige |0 (DE-588)1062689453 |4 oth | |
| 700 | 1 | |a Beaumont, John P. |d 1952- |e Sonstige |0 (DE-588)124071295 |4 oth | |
| 856 | 4 | 2 | |m HBZ Datenaustausch |q application/pdf |u http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=016239627&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |3 Inhaltsverzeichnis |
| 999 | |a oai:aleph.bib-bvb.de:BVB01-016239627 | ||
Datensatz im Suchindex
| _version_ | 1804137262646034432 |
|---|---|
| adam_text | Contents
Preface vii
Contributors xix
1 Introduction 1
P. J. Gramann, T. A. Osswald
1.1 Historical Background 1
1.2 The Reciprocating Screw Injection Molding Machine 9
1.2.1 The Plasticating and Injection Unit 9
1.2.2 The Clamping Unit 10
1.2.3 The Mold Cavity 11
1.3 The Injection Molding Cycle 13
1.4 Related Injection Molding Processes 17
References 18
2 Injection Molding Materials 19
T. A. Osswald
2.1 Historical Background 19
2.2 Macromolecular Structure of Polymers 23
2.3 Molecular Weight 27
2.4 Conformation and Configuration of Polymer Molecules 30
2.5 Thermoplastic Polymers 34
2.5.1 Amorphous Thermoplastics 34
2.5.2 Semi Crystalline Thermoplastics 36
2.5.3 Examples of Common Thermoplastics 43
2.6 Thermosetting Polymers 46
2.6.1 Cross Linking Reaction 46
2.6.2 Examples of Common Thermosets 48
2.7 Copolymers and Polymer Blends 49
2.8 Elastomers 51
M. DeGreiff
2.9 Efficient Vulcanizing Systems 52
2.10 Thermoplastic Elastomers 53
G. Holden
2.10.1 Service Temperatures 54
2.10.2 Examples of Common Thermoplastic Elastomers 55
References 61
x Contents
3 Processing Fundamentals 63
T. A. Osswald
3.1 Processing Data 63
3.1.1 Temperature Settings 64
3.1.2 Injection and Pack Hold Pressure Settings 64
3.1.3 Drying 66
3.1.4 Processing Data for Thermoplastic Elastomers 66
G. Holden
3.1.5 Processing Data for Thermosets 71
3.1.6 Processing Data for Elastomers 72
3.2 Rheology of Polymer Melts 72
3.2.1 Shear Thinning Behavior of Polymers 73
3.2.2 Simplified Flows Common in Injection Molding 75
3.2.3 Estimating Injection Pressure and Clamping Force
(Stevenson Model) 78
3.2.4 Nonisothermal Flows in Polymer Processing 83
3.2.5 Normal Stresses in Shear Flow 83
3.2.6 Deborah Number 84
3.2.7 Rheology of Curing Thermosets 85
3.2.8 Suspension Rheology 87
3.3 Rheometry 87
3.3.1 The Melt Flow Indexer 88
3.3.2 The Capillary Viscometer 88
3.3.3 Viscosity from the Capillary Viscometer 89
3.4 Anisotropy Development During Processing 91
3.4.1 Orientation in the Final Part 91
3.4.2 Fiber Damage 100
3.5 Solidification and Curing Processes 102
3.5.1 Solidification of Thermoplastics 103
3.5.2 Solidification of Thermosets 112
3.5.3 Residual Stresses, Shrinkage, and Warpage 117
References 122
4 Plasticating 125
C. Rauwendaal, P. J. Gramann
4.1 The Plasticating Unit 125
4.1.1 The Ram Extruder 126
4.1.2 The Reciprocating Screw 127
4.2 Functions of the Plasticating Unit 140
4.2.1 Solids Conveying 140
4.2.2 Melting or Plasticating 144
4.2.3 Melt Conveying 151
4.2.4 Degassing or Devolatilization 157
4.2.5 Mixing 158
4.3 Conclusion 177
References 178
Contents xi
5 Clamping Unit 181
R. Farrell
5.1 Metal Fatigue and Its Importance in Clamp Design 181
5.1.1 Importance in Clamp Design 181
5.1.2 A Brief History of Metal Fatigue 182
5.1.3 The Three Phases of Metal Fatigue 182
5.1.4 Determination of Design Stress for Metal Fatigue 183
5.1.5 Determination of Survival Factor (SF) 191
5.1.6 Conclusion of Discussion of Metal Fatigue 193
5.2 Functions of the Clamping System 193
5.3 The Three Types of Clamping Systems 194
5.3.1 Hydraulic 194
5.3.2 Hydromechanical 195
5.3.3 Mechanical 196
5.3.4 Types of Toggle Systems 198
5.4 Key Elements of a Clamp 200
5.4.1 Platens 200
5.4.2 Tie Rods and Nuts 213
5.4.3 Toggle Pins and Bushings 217
5.4.4 Tie Rod Bushings 221
5.4.5 Moving Platen Support 222
5.4.6 Shut Height Adjustment 222
5.4.7 Ejector Systems 226
5.5 A Special Discussion of Tie Rod Design 227
5.5.1 Why This Element Is So Important 227
5.5.2 Thread Load Distribution 227
5.5.3 Thread Bending Stress 230
5.5.4 Thread Axial Stress 232
5.5.5 Combined Stresses 232
5.5.6 Mitigating Factors 233
5.5.7 Ways to Improve the Design 234
5.6 Understanding Clamp Spring Rate (Stiffness) 236
5.6.1 How to Determine Clamp Spring Rate 237
5.6.2 The Importance of Clamp Spring Rate 238
5.7 Math Model for a Toggle Clamp 239
5.8 The Farrell Square Root Rule 243
5.8.1 Relationships That Follow from the Farrell Square Root Rule 244
5.8.2 The Whole Machine Can Follow the Square Root Rule 246
References 246
6 Mold Design 249
J. Beaumont
6.1 Standard Mold Assembly 250
6.2 Cold Runner Molds 252
6.2.1 Two Plate Cold Runner Mold 252
6.2.2 Three Plate Cold Runner Mold 254
6.3 Hot Runner Molds 257
6.3.1 Externally Heated Manifold and Drops 259
xii Contents
6.3.2 Externally Heated Manifold with Internally Heated Drops 259
6.3.3 Internally Heated Manifold and Internally Heated Drops 261
6.3.4 Insulated Manifold and Drops 262
6.3.5 Miscellaneous Hot Runner Systems Design 263
6.3.6 Hot Sprues 264
6.3.7 Hot Drops (Nozzles) 265
6.3.8 Special Considerations in the Operation of Hot Runner Molds 268
6.3.9 Stack Molds 271
6.4 Runner Design 272
6.4.1 Cold Runner Design 274
6.4.2 Runner Balancing in Geometrically Balanced Runners
(Cold and Hot Runners) 276
6.4.3 Nongeometrically Balanced Runner Layouts 284
6.5 Gate Design 286
6.5.1 Gate Types 286
6.5.2 Positioning Gates 295
6.6 Structural Design of a Mold for Long Life and Rigidity 296
6.6.1 Mold Material Selection 296
6.6.2 Fatigue 297
6.6.3 Deflection of Side Walls 298
6.6.4 Core Deflection 298
6.6.5 Deflection of Support Plates 300
6.7 Mold Cooling 302
6.7.1 Practical Considerations 303
6.7.2 Thermal Expansion 305
6.7.3 Parallel versus Series Cooling Circuits 305
6.7.4 Baffles and Bubblers 307
6.8 Mold Ejection Systems 309
6.8.1 Basic Ejection Problems 309
6.8.2 Means of Ejection 312
6.8.3 Ejection Considerations 315
6.8.4 Ejection Design 316
6.9 Vent Design 320
References 323
7 Material Handling and Auxiliary Equipment 325
S. Collins
7.1 Bulk Material Handling 325
7.2 Pneumatic Conveying Systems 326
7.3 Receivers and Loaders 329
7.3.1 Self Contained Loaders 331
7.4 Material Handling Controls 332
7.5 Feeders and Blenders 333
7.6 Dryers 336
7.7 Inntegrated Drying and Conditioning System 338
7.8 Mold and Process Temperature Control 339
7.9 Automation 341
7.10 Granulators 344
Contents xiii
8 Statistical Process Control 347
C. Rauwendaal
8.1 Statistical Process Control 347
8.1.1 Implementing Statistical Process Control 347
8.1.2 Basic Statistical Concepts 350
8.2 Control Charts 357
8.2.1 Introduction 357
8.2.2 Control Charts for Variables Data 357
8.2.3 Control Charts for Attributes Data 364
8.3 Process Capability and Special SPC Tools for Molding 365
8.3.1 Introduction 365
8.3.2 Capability Indexes 366
8.3.3 Use of Computers 369
8.3.4 Special SPC Techniques for Injection Molding 370
References 374
9 Special Injection Molding Processes 375
L. S. Turng
9.1 Coinjection (Sandwich) Molding 376
9.1.1 Process Description 378
9.1.2 Process Advantages 380
9.1.3 Process Disadvantages 383
9.1.4 Applicable Materials 383
9.1.5 Typical Applications 383
9.2 Fusible (Lost, Soluble) Core Injection Molding 385
9.2.1 Process Description 385
9.2.2 Process Advantages 388
9.2.3 Process Disadvantages 388
9.2.4 Applicable Materials 388
9.2.5 Typical Applications 389
9.3 Gas Assisted Injection Molding 389
9.3.1 Process Description 390
9.3.2 Process Advantages 393
9.3.3 Process Disadvantages 395
9.3.4 Applicable Materials 395
9.3.5 Typical Applications 395
9.4 Injection Compression Molding 398
9.4.1 Process Description 398
9.4.2 Process Advantages 399
9.4.3 Process Disadvantages 400
9.4.4 Applicable Materials 400
9.4.5 Typical Applications 401
9.4.6 Computer Simulation for Injection Compression Molding 401
9.5 In Mold Decoration and In Mold Lamination 402
9.5.1 Process Description 402
9.5.2 Process Advantages 404
9.5.3 Process Disadvantages 404
9.5.4 Mold Design and Processing Considerations 405
xiv Contents
9.5.5 Applicable Materials 406
9.5.6 Typical Applications 407
9.6 Insert and Outsert Molding 409
9.6.1 Insert Molding Process Description 409
9.6.2 Outsert Molding Process Description 410
9.7 Lamellar (Microlayer) Injection Molding 412
9.7.1 Process Description 412
9.7.2 Process Advantages 412
9.7.3 Process Disadvantages 415
9.7.4 Applicable Materials 415
9.7.5 Typical Applications 416
9.8 Low Pressure Injection Molding 416
9.8.1 Process Description 416
9.8.2 Process Advantages 420
9.8.3 Process Disadvantages 420
9.8.4 Applicable Materials 420
9.8.5 Typical Applications 420
9.9 Microinjection Molding 421
9.9.1 Process Description 421
9.9.2 Process Advantages 426
9.9.3 Process Disadvantages 426
9.9.4 Applicable Materials 427
9.9.5 Typical Applications 427
9.10 Microcellular Molding 427
9.10.1 Process Description 427
9.10.2 Process Advantages 430
9.10.3 Process Disadvantages 431
9.10.4 Applicable Materials 431
9.10.5 Typical Applications 431
9.11 Multicomponent Injection Molding (Overmolding) 431
9.11.1 Process Description 432
9.11.2 Process Advantages 433
9.11.3 Process Disadvantages 434
9.11.4 Applicable Materials 434
9.11.5 Typical Applications 435
9.12 Multiple Live Feed Injection Molding 436
9.12.1 Process Description 436
9.12.2 Process Advantages 438
9.12.3 Process Disadvantages 440
9.12.4 Applicable Materials 441
9.12.5 Typical Applications 441
9.13 Push Pull Injection Molding 441
9.13.1 Process Description 441
9.13.2 Process Advantages and Disadvantages 442
9.13.3 Applicable Materials 442
9.13.4 Typical Applications 444
9.14 Powder Injection Molding 444
9.14.1 Process Description 445
9.14.2 Process Advantages 447
Contents xv
9.14.3 Process Disadvantages 447
9.14.4 Typical Applications 448
9.15 Reaction Injection Molding 448
9.15.1 Process Description 448
9.15.2 Process Advantages 450
9.15.3 Process Disadvantages 450
9.15.4 Applicable Materials 450
9.15.5 Typical Applications 451
9.16 Resin Transfer Molding and Structural RIM 451
9.16.1 Process Description 451
9.16.2 Process Advantages 453
9.16.3 Process Disadvantages 453
9.16.4 Applicable Materials 453
9.16.5 Typical Applications 453
9.17 Rheomolding 454
9.17.1 Process Description 455
9.17.2 Process Advantages 456
9.17.3 Process Disadvantages 457
9.18 Structural Foam Injection Molding 457
9.18.1 Process Description 457
9.18.2 Process Advantages 460
9.18.3 Process Disadvantages 461
9.18.4 Applicable Materials 461
9.18.5 Typical Applications 464
9.19 Thin Wall Molding 464
9.19.1 Process Description 464
9.19.2 Process Advantages 466
9.19.3 Process Disadvantages 466
9.19.4 Applicable Materials 468
9.19.5 Typical Applications 468
9.20 Vibration Gas Injection Molding 468
9.20.1 Process Description 468
9.21 Water Assisted Injection Molding 469
9.21.1 Process Description 469
9.21.2 Process Advantages 470
9.21.3 Process Disadvantages 471
9.21.4 Applicable Materials 471
9.22 Rubber Injection 471
M. DeGreiff, N. Castano
9.22.1 Rubber Molding Processes 471
9.22.2 Curing Systems in Rubber Injection Process 474
9.23 Injection Molding of Liquid Silicone Rubber 476
Acknowledgement 478
References 479
xvi Contents
10 Part Design 483
J. Beaumont
10.1 The Design Process 483
10.2 The Four Building Blocks of Plastics Part Design 487
10.2.1 Material 487
10.2.2 Product Design 497
10.2.3 Mold Design and Machining 499
10.2.4 Process 501
10.3 Part Design Guidelines for Injection Molded Plastic Parts 514
10.3.1 Designing the Primary Wall 516
10.3.2 Ribs, Gussets, and Bosses 519
10.3.3 Bosses 522
10.3.4 Corners, Fillets, and Radii 525
10.3.5 Taper and Draft Angles 526
10.3.6 Undercuts and Holes 526
10.3.7 Gating and Process Considerations 529
10.3.8 Cores 530
10.3.9 Avoid Picture Frame Features 531
10.3.10 Integral Hinges 531
10.4 Sample Part Design 533
10.5 Estimating Part Costs 536
References 539
11 Simulation in Injection Molding 541
B. A. Davis, A. C. Rios, V. Yang
11.1 Introduction 541
11.2 History 542
11.3 Governing Equations 545
11.3.1 Flow Models 545
11.3.2 Orientation Models 548
11.3.3 Heat Transfer Models 549
11.3.4 Constitutive Equations 551
11.4 Numerical Methods 553
11.4.1 Finite Difference Method 554
11.4.2 Finite Element Method 554
11.4.3 Boundary Element Method 555
11.4.4 Finite Volume Method 556
11.5 Simplified Calculations 557
11.5.1 Finite Difference Based Calculations 557
11.5.2 Midplane Model Based Calculations 558
11.5.3 Solid Model Based Calculations 559
11.5.4 True 3 D Claculations 563
11.6 Advanced Calculations 564
11.6.1 Commercial Software 565
11.6.2 Specialty Calculations 570
11.7 Injection Compression Molding 574
11.7.1 IC Molding of Thermoplastic Materials 576
11.7.2 IC Molding of Thermoset Materials 577
Contents xvii
11.8 Molding Process Optimization 578
11.8.1 Optimal Gating 578
11.8.2 Active Process Control 578
11.9 Conclusions 579
Acknowledgements 580
References 580
12 Process Troubleshooting 581
12.1 Introduction to Troubleshooting 581
/ Wickman, T. Springett, and R. Vadlamudi
12.2 Troubleshooting Guide 586
12.2.1 Troubleshooting Table 586
/ Bozzelli
12.2.2 Troubleshooting on Injection Molding of Rubber 627
M. DeGreiff
12.2.3 Important Troubleshooting Considerations 631
T. Osswald
12.3 Technology and Process Troubleshooting 632
J. Wickman, T. Springett, and R. Vadlamudi
12.3.1 Technology Implications 633
12.3.2 Injection Molding Process and Sensors 634
12.3.3 Pressure Sensors 636
12.3.4 Temperature Sensors 638
12.3.5 Process Monitoring 638
12.3.6 Automatic Troubleshooting 638
12.3.7 Design of Experiments 639
12.3.8 Factorial Design of Experiments 640
12.4 Conclusions 642
J. Wickman, T. Springett, and R. Vadlamudi
References 642
13 Materials Troubleshooting 645
M. Sepe
13.1 Composition Problems 646
13.1.1 Diagnostic Tools for the Polymer 647
13.1.2 Diagnostic Tools for Fillers and Reinforcements 668
13.1.3 Diagnostic Tools for Additives 675
13.2 Molecular Weight Problems 682
13.3 Performance Problems 708
13.3.1 Material Selection Process 708
13.3.2 Use of Fillers 715
13.3.3 Deflection Temperature Under Load 717
13.3.4 Impact Properties 720
13.4 A Brief Discussion of Viscoelasticity 725
13.5 Conclusion 754
References 754
Index 755
|
| adam_txt |
Contents
Preface vii
Contributors xix
1 Introduction 1
P. J. Gramann, T. A. Osswald
1.1 Historical Background 1
1.2 The Reciprocating Screw Injection Molding Machine 9
1.2.1 The Plasticating and Injection Unit 9
1.2.2 The Clamping Unit 10
1.2.3 The Mold Cavity 11
1.3 The Injection Molding Cycle 13
1.4 Related Injection Molding Processes 17
References 18
2 Injection Molding Materials 19
T. A. Osswald
2.1 Historical Background 19
2.2 Macromolecular Structure of Polymers 23
2.3 Molecular Weight 27
2.4 Conformation and Configuration of Polymer Molecules 30
2.5 Thermoplastic Polymers 34
2.5.1 Amorphous Thermoplastics 34
2.5.2 Semi Crystalline Thermoplastics 36
2.5.3 Examples of Common Thermoplastics 43
2.6 Thermosetting Polymers 46
2.6.1 Cross Linking Reaction 46
2.6.2 Examples of Common Thermosets 48
2.7 Copolymers and Polymer Blends 49
2.8 Elastomers 51
M. DeGreiff
2.9 Efficient Vulcanizing Systems 52
2.10 Thermoplastic Elastomers 53
G. Holden
2.10.1 Service Temperatures 54
2.10.2 Examples of Common Thermoplastic Elastomers 55
References 61
x Contents
3 Processing Fundamentals 63
T. A. Osswald
3.1 Processing Data 63
3.1.1 Temperature Settings 64
3.1.2 Injection and Pack Hold Pressure Settings 64
3.1.3 Drying 66
3.1.4 Processing Data for Thermoplastic Elastomers 66
G. Holden
3.1.5 Processing Data for Thermosets 71
3.1.6 Processing Data for Elastomers 72
3.2 Rheology of Polymer Melts 72
3.2.1 Shear Thinning Behavior of Polymers 73
3.2.2 Simplified Flows Common in Injection Molding 75
3.2.3 Estimating Injection Pressure and Clamping Force
(Stevenson Model) 78
3.2.4 Nonisothermal Flows in Polymer Processing 83
3.2.5 Normal Stresses in Shear Flow 83
3.2.6 Deborah Number 84
3.2.7 Rheology of Curing Thermosets 85
3.2.8 Suspension Rheology 87
3.3 Rheometry 87
3.3.1 The Melt Flow Indexer 88
3.3.2 The Capillary Viscometer 88
3.3.3 Viscosity from the Capillary Viscometer 89
3.4 Anisotropy Development During Processing 91
3.4.1 Orientation in the Final Part 91
3.4.2 Fiber Damage 100
3.5 Solidification and Curing Processes 102
3.5.1 Solidification of Thermoplastics 103
3.5.2 Solidification of Thermosets 112
3.5.3 Residual Stresses, Shrinkage, and Warpage 117
References 122
4 Plasticating 125
C. Rauwendaal, P. J. Gramann
4.1 The Plasticating Unit 125
4.1.1 The Ram Extruder 126
4.1.2 The Reciprocating Screw 127
4.2 Functions of the Plasticating Unit 140
4.2.1 Solids Conveying 140
4.2.2 Melting or Plasticating 144
4.2.3 Melt Conveying 151
4.2.4 Degassing or Devolatilization 157
4.2.5 Mixing 158
4.3 Conclusion 177
References 178
Contents xi
5 Clamping Unit 181
R. Farrell
5.1 Metal Fatigue and Its Importance in Clamp Design 181
5.1.1 Importance in Clamp Design 181
5.1.2 A Brief History of Metal Fatigue 182
5.1.3 The Three Phases of Metal Fatigue 182
5.1.4 Determination of Design Stress for Metal Fatigue 183
5.1.5 Determination of Survival Factor (SF) 191
5.1.6 Conclusion of Discussion of Metal Fatigue 193
5.2 Functions of the Clamping System 193
5.3 The Three Types of Clamping Systems 194
5.3.1 Hydraulic 194
5.3.2 Hydromechanical 195
5.3.3 Mechanical 196
5.3.4 Types of Toggle Systems 198
5.4 Key Elements of a Clamp 200
5.4.1 Platens 200
5.4.2 Tie Rods and Nuts 213
5.4.3 Toggle Pins and Bushings 217
5.4.4 Tie Rod Bushings 221
5.4.5 Moving Platen Support 222
5.4.6 Shut Height Adjustment 222
5.4.7 Ejector Systems 226
5.5 A Special Discussion of Tie Rod Design 227
5.5.1 Why This Element Is So Important 227
5.5.2 Thread Load Distribution 227
5.5.3 Thread Bending Stress 230
5.5.4 Thread Axial Stress 232
5.5.5 Combined Stresses 232
5.5.6 Mitigating Factors 233
5.5.7 Ways to Improve the Design 234
5.6 Understanding Clamp Spring Rate (Stiffness) 236
5.6.1 How to Determine Clamp Spring Rate 237
5.6.2 The Importance of Clamp Spring Rate 238
5.7 Math Model for a Toggle Clamp 239
5.8 The Farrell Square Root Rule 243
5.8.1 Relationships That Follow from the Farrell Square Root Rule 244
5.8.2 The Whole Machine Can Follow the Square Root Rule 246
References 246
6 Mold Design 249
J. Beaumont
6.1 Standard Mold Assembly 250
6.2 Cold Runner Molds 252
6.2.1 Two Plate Cold Runner Mold 252
6.2.2 Three Plate Cold Runner Mold 254
6.3 Hot Runner Molds 257
6.3.1 Externally Heated Manifold and Drops 259
xii Contents
6.3.2 Externally Heated Manifold with Internally Heated Drops 259
6.3.3 Internally Heated Manifold and Internally Heated Drops 261
6.3.4 Insulated Manifold and Drops 262
6.3.5 Miscellaneous Hot Runner Systems Design 263
6.3.6 Hot Sprues 264
6.3.7 Hot Drops (Nozzles) 265
6.3.8 Special Considerations in the Operation of Hot Runner Molds 268
6.3.9 Stack Molds 271
6.4 Runner Design 272
6.4.1 Cold Runner Design 274
6.4.2 Runner Balancing in Geometrically Balanced Runners
(Cold and Hot Runners) 276
6.4.3 Nongeometrically Balanced Runner Layouts 284
6.5 Gate Design 286
6.5.1 Gate Types 286
6.5.2 Positioning Gates 295
6.6 Structural Design of a Mold for Long Life and Rigidity 296
6.6.1 Mold Material Selection 296
6.6.2 Fatigue 297
6.6.3 Deflection of Side Walls 298
6.6.4 Core Deflection 298
6.6.5 Deflection of Support Plates 300
6.7 Mold Cooling 302
6.7.1 Practical Considerations 303
6.7.2 Thermal Expansion 305
6.7.3 Parallel versus Series Cooling Circuits 305
6.7.4 Baffles and Bubblers 307
6.8 Mold Ejection Systems 309
6.8.1 Basic Ejection Problems 309
6.8.2 Means of Ejection 312
6.8.3 Ejection Considerations 315
6.8.4 Ejection Design 316
6.9 Vent Design 320
References 323
7 Material Handling and Auxiliary Equipment 325
S. Collins
7.1 Bulk Material Handling 325
7.2 Pneumatic Conveying Systems 326
7.3 Receivers and Loaders 329
7.3.1 Self Contained Loaders 331
7.4 Material Handling Controls 332
7.5 Feeders and Blenders 333
7.6 Dryers 336
7.7 Inntegrated Drying and Conditioning System 338
7.8 Mold and Process Temperature Control 339
7.9 Automation 341
7.10 Granulators 344
Contents xiii
8 Statistical Process Control 347
C. Rauwendaal
8.1 Statistical Process Control 347
8.1.1 Implementing Statistical Process Control 347
8.1.2 Basic Statistical Concepts 350
8.2 Control Charts 357
8.2.1 Introduction 357
8.2.2 Control Charts for Variables Data 357
8.2.3 Control Charts for Attributes Data 364
8.3 Process Capability and Special SPC Tools for Molding 365
8.3.1 Introduction 365
8.3.2 Capability Indexes 366
8.3.3 Use of Computers 369
8.3.4 Special SPC Techniques for Injection Molding 370
References 374
9 Special Injection Molding Processes 375
L. S. Turng
9.1 Coinjection (Sandwich) Molding 376
9.1.1 Process Description 378
9.1.2 Process Advantages 380
9.1.3 Process Disadvantages 383
9.1.4 Applicable Materials 383
9.1.5 Typical Applications 383
9.2 Fusible (Lost, Soluble) Core Injection Molding 385
9.2.1 Process Description 385
9.2.2 Process Advantages 388
9.2.3 Process Disadvantages 388
9.2.4 Applicable Materials 388
9.2.5 Typical Applications 389
9.3 Gas Assisted Injection Molding 389
9.3.1 Process Description 390
9.3.2 Process Advantages 393
9.3.3 Process Disadvantages 395
9.3.4 Applicable Materials 395
9.3.5 Typical Applications 395
9.4 Injection Compression Molding 398
9.4.1 Process Description 398
9.4.2 Process Advantages 399
9.4.3 Process Disadvantages 400
9.4.4 Applicable Materials 400
9.4.5 Typical Applications 401
9.4.6 Computer Simulation for Injection Compression Molding 401
9.5 In Mold Decoration and In Mold Lamination 402
9.5.1 Process Description 402
9.5.2 Process Advantages 404
9.5.3 Process Disadvantages 404
9.5.4 Mold Design and Processing Considerations 405
xiv Contents
9.5.5 Applicable Materials 406
9.5.6 Typical Applications 407
9.6 Insert and Outsert Molding 409
9.6.1 Insert Molding Process Description 409
9.6.2 Outsert Molding Process Description 410
9.7 Lamellar (Microlayer) Injection Molding 412
9.7.1 Process Description 412
9.7.2 Process Advantages 412
9.7.3 Process Disadvantages 415
9.7.4 Applicable Materials 415
9.7.5 Typical Applications 416
9.8 Low Pressure Injection Molding 416
9.8.1 Process Description 416
9.8.2 Process Advantages 420
9.8.3 Process Disadvantages 420
9.8.4 Applicable Materials 420
9.8.5 Typical Applications 420
9.9 Microinjection Molding 421
9.9.1 Process Description 421
9.9.2 Process Advantages 426
9.9.3 Process Disadvantages 426
9.9.4 Applicable Materials 427
9.9.5 Typical Applications 427
9.10 Microcellular Molding 427
9.10.1 Process Description 427
9.10.2 Process Advantages 430
9.10.3 Process Disadvantages 431
9.10.4 Applicable Materials 431
9.10.5 Typical Applications 431
9.11 Multicomponent Injection Molding (Overmolding) 431
9.11.1 Process Description 432
9.11.2 Process Advantages 433
9.11.3 Process Disadvantages 434
9.11.4 Applicable Materials 434
9.11.5 Typical Applications 435
9.12 Multiple Live Feed Injection Molding 436
9.12.1 Process Description 436
9.12.2 Process Advantages 438
9.12.3 Process Disadvantages 440
9.12.4 Applicable Materials 441
9.12.5 Typical Applications 441
9.13 Push Pull Injection Molding 441
9.13.1 Process Description 441
9.13.2 Process Advantages and Disadvantages 442
9.13.3 Applicable Materials 442
9.13.4 Typical Applications 444
9.14 Powder Injection Molding 444
9.14.1 Process Description 445
9.14.2 Process Advantages 447
Contents xv
9.14.3 Process Disadvantages 447
9.14.4 Typical Applications 448
9.15 Reaction Injection Molding 448
9.15.1 Process Description 448
9.15.2 Process Advantages 450
9.15.3 Process Disadvantages 450
9.15.4 Applicable Materials 450
9.15.5 Typical Applications 451
9.16 Resin Transfer Molding and Structural RIM 451
9.16.1 Process Description 451
9.16.2 Process Advantages 453
9.16.3 Process Disadvantages 453
9.16.4 Applicable Materials 453
9.16.5 Typical Applications 453
9.17 Rheomolding 454
9.17.1 Process Description 455
9.17.2 Process Advantages 456
9.17.3 Process Disadvantages 457
9.18 Structural Foam Injection Molding 457
9.18.1 Process Description 457
9.18.2 Process Advantages 460
9.18.3 Process Disadvantages 461
9.18.4 Applicable Materials 461
9.18.5 Typical Applications 464
9.19 Thin Wall Molding 464
9.19.1 Process Description 464
9.19.2 Process Advantages 466
9.19.3 Process Disadvantages 466
9.19.4 Applicable Materials 468
9.19.5 Typical Applications 468
9.20 Vibration Gas Injection Molding 468
9.20.1 Process Description 468
9.21 Water Assisted Injection Molding 469
9.21.1 Process Description 469
9.21.2 Process Advantages 470
9.21.3 Process Disadvantages 471
9.21.4 Applicable Materials 471
9.22 Rubber Injection 471
M. DeGreiff, N. Castano
9.22.1 Rubber Molding Processes 471
9.22.2 Curing Systems in Rubber Injection Process 474
9.23 Injection Molding of Liquid Silicone Rubber 476
Acknowledgement 478
References 479
xvi Contents
10 Part Design 483
J. Beaumont
10.1 The Design Process 483
10.2 The Four Building Blocks of Plastics Part Design 487
10.2.1 Material 487
10.2.2 Product Design 497
10.2.3 Mold Design and Machining 499
10.2.4 Process 501
10.3 Part Design Guidelines for Injection Molded Plastic Parts 514
10.3.1 Designing the Primary Wall 516
10.3.2 Ribs, Gussets, and Bosses 519
10.3.3 Bosses 522
10.3.4 Corners, Fillets, and Radii 525
10.3.5 Taper and Draft Angles 526
10.3.6 Undercuts and Holes 526
10.3.7 Gating and Process Considerations 529
10.3.8 Cores 530
10.3.9 Avoid Picture Frame Features 531
10.3.10 Integral Hinges 531
10.4 Sample Part Design 533
10.5 Estimating Part Costs 536
References 539
11 Simulation in Injection Molding 541
B. A. Davis, A. C. Rios, V. Yang
11.1 Introduction 541
11.2 History 542
11.3 Governing Equations 545
11.3.1 Flow Models 545
11.3.2 Orientation Models 548
11.3.3 Heat Transfer Models 549
11.3.4 Constitutive Equations 551
11.4 Numerical Methods 553
11.4.1 Finite Difference Method 554
11.4.2 Finite Element Method 554
11.4.3 Boundary Element Method 555
11.4.4 Finite Volume Method 556
11.5 Simplified Calculations 557
11.5.1 Finite Difference Based Calculations 557
11.5.2 Midplane Model Based Calculations 558
11.5.3 Solid Model Based Calculations 559
11.5.4 True 3 D Claculations 563
11.6 Advanced Calculations 564
11.6.1 Commercial Software 565
11.6.2 Specialty Calculations 570
11.7 Injection Compression Molding 574
11.7.1 IC Molding of Thermoplastic Materials 576
11.7.2 IC Molding of Thermoset Materials 577
Contents xvii
11.8 Molding Process Optimization 578
11.8.1 Optimal Gating 578
11.8.2 Active Process Control 578
11.9 Conclusions 579
Acknowledgements 580
References 580
12 Process Troubleshooting 581
12.1 Introduction to Troubleshooting 581
/ Wickman, T. Springett, and R. Vadlamudi
12.2 Troubleshooting Guide 586
12.2.1 Troubleshooting Table 586
/ Bozzelli
12.2.2 Troubleshooting on Injection Molding of Rubber 627
M. DeGreiff
12.2.3 Important Troubleshooting Considerations 631
T. Osswald
12.3 Technology and Process Troubleshooting 632
J. Wickman, T. Springett, and R. Vadlamudi
12.3.1 Technology Implications 633
12.3.2 Injection Molding Process and Sensors 634
12.3.3 Pressure Sensors 636
12.3.4 Temperature Sensors 638
12.3.5 Process Monitoring 638
12.3.6 Automatic Troubleshooting 638
12.3.7 Design of Experiments 639
12.3.8 Factorial Design of Experiments 640
12.4 Conclusions 642
J. Wickman, T. Springett, and R. Vadlamudi
References 642
13 Materials Troubleshooting 645
M. Sepe
13.1 Composition Problems 646
13.1.1 Diagnostic Tools for the Polymer 647
13.1.2 Diagnostic Tools for Fillers and Reinforcements 668
13.1.3 Diagnostic Tools for Additives 675
13.2 Molecular Weight Problems 682
13.3 Performance Problems 708
13.3.1 Material Selection Process 708
13.3.2 Use of Fillers 715
13.3.3 Deflection Temperature Under Load 717
13.3.4 Impact Properties 720
13.4 A Brief Discussion of Viscoelasticity 725
13.5 Conclusion 754
References 754
Index 755 |
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| id | DE-604.BV023035845 |
| illustrated | Illustrated |
| index_date | 2024-07-02T19:18:53Z |
| indexdate | 2024-07-09T21:09:30Z |
| institution | BVB |
| isbn | 9783446407817 9781569904206 |
| language | English |
| oai_aleph_id | oai:aleph.bib-bvb.de:BVB01-016239627 |
| oclc_num | 170057853 |
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| owner_facet | DE-210 DE-29T DE-91G DE-BY-TUM DE-1050 DE-12 DE-703 DE-92 DE-83 |
| physical | XVII, 764 S. zahlr. Ill. und graph. Darst. 25 cm |
| publishDate | 2008 |
| publishDateSearch | 2008 |
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| publisher | Hanser |
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| spelling | Injection molding handbook Tim Osswald ... With contributions from J. Beaumont ... 2. ed. Munich [u.a.] Hanser 2008 XVII, 764 S. zahlr. Ill. und graph. Darst. 25 cm txt rdacontent n rdamedia nc rdacarrier Injection molding of plastics Handbooks, manuals, etc Spritzgießen (DE-588)4056561-0 gnd rswk-swf Spritzgießen (DE-588)4056561-0 s DE-604 Osswald, Tim A. 1958- Sonstige (DE-588)1062689453 oth Beaumont, John P. 1952- Sonstige (DE-588)124071295 oth HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=016239627&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Injection molding handbook Injection molding of plastics Handbooks, manuals, etc Spritzgießen (DE-588)4056561-0 gnd |
| subject_GND | (DE-588)4056561-0 |
| title | Injection molding handbook |
| title_auth | Injection molding handbook |
| title_exact_search | Injection molding handbook |
| title_exact_search_txtP | Injection molding handbook |
| title_full | Injection molding handbook Tim Osswald ... With contributions from J. Beaumont ... |
| title_fullStr | Injection molding handbook Tim Osswald ... With contributions from J. Beaumont ... |
| title_full_unstemmed | Injection molding handbook Tim Osswald ... With contributions from J. Beaumont ... |
| title_short | Injection molding handbook |
| title_sort | injection molding handbook |
| topic | Injection molding of plastics Handbooks, manuals, etc Spritzgießen (DE-588)4056561-0 gnd |
| topic_facet | Injection molding of plastics Handbooks, manuals, etc Spritzgießen |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=016239627&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
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