INJECTION MOULDING MACHINE

1. Turn power on to heaters and chiller [180°C for PP]

2. Turn on pump using touch screen - ON/OFF 5X before leaving on
3. Leave for 30 minutes to reach temperature
4. Got to Manual operation and Ensure Nozzle retracted
5. Injection - move screw fwd and bwd
6. Leaving screw fwd (but not max fwd)
7. Oil Motor - start and stop to rotate screw
8. Open mould move to left
9. Operate Ejector pins fully
10. Mould close to retract ejector pins and set up
11. Check sensors for mould position
i. Closed -check light on [realign to 0.5mm max behind fully closed] High
Pressure
ii. Centre – Ensure ejected part with riser is free to eject
iii. Open –open mold
12. Leave mold Open
13. Check material in hopper must be dry PP and PE best
14. Open material valve
15. Add paper between nozzle and die
16. Purge auto turn on to complete 5 cycles and fill up barrel with molten material
17. Turn purge off
18. Metering - OM return screw to back position
19. Open safety cover and clean nozzle of plastic
20. Adjust shot count to number required and ensure shot count ON [if required]
21. Goto Menu and operate on semi automatic mode for first off
22. Goto Auto start

Turn off machine

i. Set auto to semi auto and wait for completion of next cycle OR
ii. Shut off material to barrel
iii. Let auto empty barrel of material [34 samples to purge full barrel]
iv. Alarm sounds due to time out on auto cycle (reset machine)
v. Open mold manually
vi. Eject part fully from mold
vii. Close mold manually but not at high pressure (check pressure gauge reading is zero)
viii. Move nozzle RHS
ix. Inject material out of barrel
x. OM – return screw
xi. Inject material fwd and backward
xii. OM – return
xiii. Inject fwd and bwd
xiv. Screw fwd
xv. Inject fwd and bwd
xvi. Stop pump
xvii. Turn off machine and chiller

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Moulding Cycle Process see manual cycle time chart
i. High speed Mould close
ii. Low pressure clamp
iii. High pressure clamp
iv. Injection unit forward
v. Injection first speed first pressure
vi. Injection second speed second pressure
vii. Measuring [screw rotation]
viii. Decompression [reverse screw]
ix. Injection unit backward
x. Mould open
xi. Ejector forward
xii. Ejector backward

Touch Screen Manual Mode

Mold open and close mold

EJT operate ejector forward and backward

Nozzle operate injection unit forward and backward

Inject operate screw forward and screw backward

OM operate screw rotation clockwise and anticlockwise

Purge Clean barrel of material

1st pressure setting fills 90+% cavity and related to speed of screw

2nd pressure setting fills last bit of cavity

E stop on machine

Open mold and clear all parts

Screw back
Reset

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Maintenance

Lubricate tie bars of mould with WD 40

If purge plastic does not clean barrel then remove barrel from machine and clean {see Manual pg
4-16}

When machine hot

i. Remove safety covers and hopper
ii. Replace safety sensor to operate screw
iii. Remove nozzle heater, thermocouple and unit
iv. Open mold to maximum
v. Remove heater from barrel
vi. Remove O ring from barrel and pin drops out
vii. Pull screw fwd or operate screw if tight so screw removed from mold side
viii. Screw and barrel still very hot
ix. Clean screw with cotton or natural cloth/ tissue
x. Clean barrel steel wool or brass brush
xi. Replace all parts when temperature cooled to normal

For use of Polycarbonate material - screw and barrel both polished

Shunt wire PLC 69 and XO 7

Pin in mold needs to see ejector pin backward

7.0 ton clamp force

Max capacity is 5.5 g per shot

Tensile specimen is 1.04 g per shot

New Mold assembly [see manual Pg 4-4 and 4-7]

Ensure ejector pins well greased
Ensure guide pins well greased

Operate at slow speed for first 5,000 cycles before increase speed

Problems and solutions

To reduce Flashing Reduce Injection Time

Reduce holding pressure

To reduce Bowing Reduce ejection force

Increase cooling time (1 sec intervals)

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Touch Screen and Settings (see Manual pg 5-4 for value changes or section B-1)

MENU>
ADJ> MOLD > Decomp Tm (mold decompression time) 0.5
Mold Cls St Tm (mold closing start time) 0.25
Hi Prs Chg St Tm (High pressure select start timing) 0.25

NOZZLE> Cl Nzl Incr Prs Tm (injection unit pressure increase time) 0.2
Nzl Bwd St Tm (start of injection unit backward time) 0.1
Nzl Bwd Tm (injection unit backward time) 0.0

INJECT> Inject Tm (Auto cycle time) 2.7

Inject St Tm (injection start time) 0.1
Inject 2nd Prs Chg Tm (change to 2nd pressure) 0.75 (2.0)
Inject Decomp Tm (injection decompression time after end injection) 0.05 (0.0)

EJECT > Ejt St Tmg (ejector start decompression) 0.05

Ejt Fwd Tm (to set ejection stroke) 0.4
Ejt Count (set number of times for one operation) 2.0
Cyc St Tm (intermediate time before next cycle starts) 0.3

MTG> Cool Tm (set product cooling time auto) 8.0 (6.0)

Mtg St Tm (metering start time after injection) 0.5
Decomp St Tm (decompression start time) 0.05
Decomp Tm (decompression time) 0.2

SHOT COUNT> Planned Shots 99999

Shot XX
Grand Total 10546

Select> Eject ON Mold set OFF

Count over ON Power off OFF
Mold sweep OFF Mold sweep Manual

Monitor> ` STD (sec) Before 1(sec)

Cycle time 18.0 0
Clamp time 2.50 0
Mtg tm max 20.0
Mtg tm min 2.00

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Control Settings

Tensile sample 1.04g per shot Barrel capacity 5.5 g per shot

Metering control value 1.4 mm

Eject speed adj 4.2 mm/sec

Injection Panel
1. Low pressure close [V3] x = 11.1mm (fixed nut to knurled boss)
2. Injection 1st pressure [V18] x = 10.0mm
3. Injection 2nd pressure [V19] x = 10.5mm

4. Screw rotation speed 2.2 r.p.m.

5. Back pressure [V21] 2.5 Kg/cm³

6. Injection speed [V17] 3.0 mm/sec [lutfi 4.1]

Pressure values during automatic cycle

Clamp P1 = 0 Kg/cm³
P2 = 145 Kg/cm³

Injection Pressures 65 Kg/cm³

Pump Pressures [45, 65, 100, 15, 40-150] Kg/cm³

Mold - moves tool open or closed

3 sensors 1, back position 2,Change speed from fast to slow 3, Stop position

196.0

144.0

112.5
Machi
48.5 ne
frame
115.0
00
132.0

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Thermocouple wires for nozzle and barrel are tied together
Heater wires for nozzle and barrel are tied together`

When running molding machine with no material

INJECT Inject Tm 0.0

Inject St Tm 0.0
Inject 2nd Prs Chg Tm 0.0
Inject Decomp Tm 0.0

MTG Cool Tm 3.0

Mtg St Tm 0.0
Decomp St Tm 0.0
Decomp Tm 0.0

Material MSI supplier

Manufacturer BASELL Polyolefins :
Polyethylene PE
Polypropylene PP
Polycarbonate PC

Polypropylene PP MOPLEN EP54OP

Net wt 25 Kg 03 21 016 502693N

PE-LD 36001424 04/27/334920

400 + 150

Regrinding Machine

Ensure particle size filter

Ensure magnetic filter to remove burrs from grinding blades
Maximum number of times material can be reground before damage moulding machine
See manufacturers data and previous work

Industrial machine @ £2,500.00

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Testing of plastic Lutfi 11/1/05

Material PP

Injection speed Screw Speed RPM Temp Monitor Actual

Y=75.5x-68.9 cycle time time
4.17 1.3 30 190 23 20
4.17 1.6 50 225 18 17
4.17 2.25 100 260 16.5 15

Machine left running over dinner with temp set at 90

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