Comprehensive

Injection Moulding

R.C.Batra

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Dedicated to Mr. T.G. Punwani
The unforgettable pioneer.

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 Contents
Preface
Introduction
Acknowledgements
1. Plastics
2. Injection Moulding of Thermoplastics, the Equipment
3. Injection Moulding of Thermoplastics, the Process
4. Design of Injection Moulds for Thermoplastics
5. Mould Making
6. Intrusion Injection Moulding
7. Compression Injection Moulding
8. Multi-Component Injection Moulding
9. Sandwich Injection Moulding
10. Fusible Core Injection Moulding
11. Foam Injection Moulding
12. Gas Assisted Injection Moulding
13. Powder Injection Moulding
14. Injection Moulding of Thermosets
15. Injection Moulding of Liquid Silicon Rubber
16. Reaction Injection Moulding
Bibliography

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 Introduction

Among all industrial manufacturing processes, injection moulding is probably the

only one which, starting with the raw material, delivers a finished product in the final
shape, colour and finish in one shot. Initially developed for moulding of
thermoplastics, it has made forays into many alien fields hitherto unthought of and
has brought accuracy, efficiency and economy to them. The scope of the injection
moulding process has widened much beyond the limited field of thermoplastics and
has contributed enormously towards bringing most modern appliances and comforts
within the reach of everyone. The trend in development of materials and equipment
indicates that the injection moulding process would overshadow all other related
manufacturing methods.

Injection moulding constitutes the main theme of the book which aims at explaining
the process of conventional injection moulding in all practical details because it
forms the basis for all other variations. Special attention has been paid to the rules
of mould design which are a key to successful processing. These guidelines are also
applicable to the tooling for other related processes directly or indirectly. The
description of the equipment has been handled as much as necessary to understand
the process.

The guideline, while compiling the book, has been the practical application of the
contents. A large number of illustrations, diagrams and tables should help the reader
in understanding and application of the knowledge collected from widely diverse
sources like plastics processors, manufacturers of raw materials, machinery and
moulds, research theses, journals, books, seminars, workshops, lectures,
exhibitions, experience gathered by the author in the German plastics industry and
advice of many well wishers.

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 Acknowledgements

Compiling a book covering over a dozen, widely diverse versions of the Injection
moulding process has been an ambitious venture which would not have been
possible without the active support of numerous organisations, predominantly
German, who provided me generously with literature, illustrations and advice and
permitted me free use of the contents.

Arburg
BASF
Battenfeld
Dr.Boy
BAYER
Engel
E.O.S
Ewikon
Guenther
HASCO
Heitech
HS-Heitzelemente GMBH
IKV
Schoenthaler Dr.W. SKZ, Wuerzburg.
Strack
Sulzer
Vogel-Verlag
Xintech

I must point out that the source of some information, especially the older one, was
impossible to trace as the data had been acquired in seminars, lectures, technical
fairs or journals. Likewise, publishers of some older books did not exist any more
and could not be contacted. I am nevertheless equally thankful to all unknown
donors.

I do not wish to miss expressing my sincere gratitude to my learned friends, Mr.

A.P.Sharma, Mr.Goswami, Mr. Satya Prakash and Prof. Chaturvedi among many
others who have helped me to realise this project.

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 Chapter 1

Plastics

1.1 History of plastics

1.2 Formation of plastics
1.3 Types of plastics
1.4 The molecular structure and properties.
1.5 Common plastics and their properties
1.6 Classification of thermoplastics
1.7 The form of raw material
1.8 Preparation of plastics for processing
1.9 Recycling
1.10 Acronyms

1.1 History
Plastics is a generic term applying to a wide range of materials with long chains of
molecules. While solid in the finished state, at some stage during their
manufacturing, plastics are soft enough to be formed into various shapes, most
commonly through the application, either singly or in combination, of heat and
pressure. They may be natural or be produced either by modification of some natural
material by chemical means or by synthesis of elements such as carbon, hydrogen,
nitrogen, oxygen etc. into compounds of long chains.

Mankind has known and used natural plastics since time immemorial. Vedas, the
ancient holy books of Hindus, dwell upon shellac, a natural resin from a tree and its
application. Also Mahabharata, the great epic of Aryans, mentions its employment for
building of a palace which was later set on fire to kill the inhabitants. More recently,
that is in 1596, John Hyglen undertook a scientific mission to India on behest of the
king of Portugal to investigate this material unknown to the west. He has left
descriptions about its various applications being practiced by Indians in those days.

Five centuries ago, Columbus saw Red Indians playing with lumps of rubber. Later,
in 1731, La Codamine observed South American natives using rubber for
waterproofing of fabrics and shoes. It has been recorded that the king of Potugal
sent his shoes with the next expedition to be waterproofed. The properties of natural
rubber, that is latex, were later improved by treating it with sulphur and it achieved a
worldwide importance when automobiles became a major means of transport.

In the middle of the seventeenth century, the English traveller John Tradescant
observed Malayens heating up a tree resin and forming knife handles out of it. Gutta
Percha, as the material was called, proved of great value to the west as a coating for
electrical cables and held sway in this application till polyethylene was developed
during the second world war.

Till 1860, the only plastics known were those obtained from nature, viz. wax, shellac,
gutta percha and rubber. Only the later had been modified so that it could also be
turned to a hard substance called ebonite. However, they had whetted the appetite
and the hunt for more had begun. The search for a substitute for silk proved another

6
impetus for experimentation. Efforts to treat natural cellulose with chemicals bore
fruit and cellulose nitrate was born. It yielded silk-like garn but was highly
inflammable. The fabric woven from the new material could catch fire from its own
static charge. However, further developments turned it into a mouldable resin.
Celluloid became synonymous with thermoplastics and was moulded indiscriminately
into all sorts of utility articles. Celluloid toys became the rage of the period, but some
other applications failed and brought bad name to “plastics”.

A fully synthetic material, developed with phenol and formaldehyde, started the era
of plastics in the first decade of the twentieth century. It was the first man-made
synthetic material and its uses were still to be found. The inventor, Leo Hendrik
Baekland, christened it Bakelite and it almost became another name for all
thermosetting plastics. Principally, it found application in electrical field but was also
used for articles like buttons, grips, handles, crockery, telephone sets, car parts etc.
Urea Formeldehyde, which followed soon after, was also a thermosetting resin
distinguished by its transparency.

Two thermoplastics, viz. Cellulose acetate and Polyvinyl chloride, which made their
debut in 1927, paved the path for future plastics. The fact that the process of
injection moulding had also achieved maturity around that time, helped their
exploitation in many fields.

The decade 1930-40 was most eventful for synthetic materials. Many new plastics
were introduced, which helped conquer fields hitherto untouched. Acrylics,
developed in 1936, proved an excellent substitute for glass in automobiles and
aeroplanes. The most sensational find was Nylon, initially developed with an aim to
provide a better substitute for silk for ladies’ stockings, but was found to be an ideal
material for demanding technical applications. The third member of the formeldehyde
family, Melamine formeldehyde, complemented the range of thermosets in 1939. It
brought unbreakable crockery in fancy colours within reach of the common man.

The development of synthetic materials was accelerated during the second world
war with the aim to find substitutes for natural materials needed for military
equipment. The accidental discovery of polyethylene in England in 1942 had its
share in tilting the balance in favour of allies. It helped development of the radar
which made the most dangerous weapon of Germany, viz. the undetectable
submarines, detectable and vulnerable. Another plastics used extensively in the
military hardware was acrylics in place of glass in aeroplanes. Cockpits too were
thermoformed out of this tough thermoplastics.

The development set in motion by the war did not lose its momentum after armistice
and the materials discovered and tried during that period were employed in civilian
applications. More and more synthetic materials appeared on the scene and helped
fill up many gaps besides accelerating development in other fields using plastics.

Although the development of new plastics is continuing unabated, the procedure of

the search has undergone a diametric change. In the initial stages, a plastics was
developed (and in some cases found accidentally) first and then examined for its
properties and utility. Now the research takes place with a definite set of properties
and applications in mind as one has learnt how to manipulate the macromolecules.

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It had been prophesied by a visionary long ago that plastics could one day furnish all
materials needed by the mankind with the exception of cutting edges and materials
which have to withstand direct application of heat. That day does not seem to be far.

Table 1.1 lists some of the more common plastics, processed by injection moulding
in order of their appearance.

Table 1.1
Introduction of plastics

Year Plastics
1868 Cellulose Nitrate
1909 Phenol Formaldehyde
1918 Urea formeldehyde
1927 Cellulose Acetate
1927 Polyvinyl Chloride
1935 Melamine Formeldehyde
1935 Polyamide 6 6
1936 Polymethyl Methacrylate
1936 Polyurethane
1936 Polystyrene
1939 Polyamide 6
1942 Polyester
1942 Low Density Polyethylene
1943 Silicones
1945 Cellulose Propionate
1947 Epoxide
1948 Acrylonitrile Butadiene Styrene
1955 High Density Polyethylene
1956 Polyactal
1957 Polypropylene
1957 Polycarbonate
1964 Polyphenylene Oxide
1964 Polyimide
1964 Ethylene Vinyl Acetate
1965 Polysulfone
1971 Polyphenylene Sulfone
1972 Thermoplastic Elastomer
1972 Polyether Sulfone
1975 Liquid Crystal Polymer
1980 Polyether Ether Ketone
1982 Polyetheramide

The popularity of plastics may be attributed to the following factors:

 They are ideal for mass production
 They can be transparent, opaque and coloured
 They do not rust.

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  They are light and tough
 They are good insulators against heat and electricity
 They can be used with foodstuff
 They are resistant to chemicals
 Their properties can be tailored for particular applications
 They can be processed in the desired colour right away.
 Their surface finish can be matched with the non-plastics parts they are
assembled with.
 Their surface can be decorated in numerous ways.
 Multi-component articles can be produced in one operation
 Most of them can be recycled

1.2 Formation of plastics.

Till middle of the last century, coal had been the main source of the synthetic
materials labelled collectively as plastics. The ingredients of the first fully synthetic
material viz. phenol and formaldehyde were by-products of the destructive distillation
of coal. The derivatives of the by-products of coal also formed the basis for many
other plastics like polystyrene and polyamides. Reaction of coke with calcium oxide
yields calcium carbide which produces acetylene. Acetylene, in turn, is the starting
point for production of acrylonitrile, vinyl chloride, vinyl acetate and other vinyl
monomers.

The development of the petrochemical industry and that of plastics have gone hand
in hand after the second world war. The research work carried on petroleum during
the war also benefited plastics as more direct routes were found for mass production
of these synthetic materials.

It is worth mentioning that research work is going on to find alternative, renewable

sources of plastics. Not only some plant constituents such as proteins, starch,
vegetable oils and cellulose but also some animal products like wool, skins, leather,
gelatine, tallow, feathers, whey and casein may also become potential sources of
plastics. Starch and cellulose are the naturally occurring polymers. Natural fibres like
jute, flax, straw, hemp etc. consist mainly of cellulose which, in turn, has already
been modified to mouldable plastics like cellulose acetate, propionate and butyriate.
Residuals from agricultural crops such as straw, stems, hulls, bran, husks have the
same chemical composition as the wood fibre and form a cheap and abundant
source of cellulose. The process has started and plastics have been produced on
commercial scale out of corn. Plastics from agricultural sources can reduce
dependence on fossil fuels and help reduce carbon dioxide emission. Vegetable oils
and sugar too may become future sources of plastics. It must, however, be pointed
out that natural sources have a lower proportion of carbohydrates than the crude oil
and require more energy for their transformation into plastics in contrast to the fossil
oil.

1.2.1 Fractional distillation of oil.

The crude oil contains hydrocarbons in various combinations like gases, light and
heavy oils, petrol, coal tar etc. These are separated by fractional distillation (Fig.
1.1). Heavy benzene or naphtha is the raw material for plastics. By application of

9
heat (850°C) in presence of catalysts, its molecule is cracked into smaller
compounds of carbon and hydrogen like Ethylene and Ethane (Fig. 1.2).

Fig. 1.1
Fig. 1.2

1.2.2
Polymerisation.
Ethylene, a gas,
is separated by
liquefying the
mixture. It forms
basis for many
plastics as well
as for other
compounds. C2H4 is its monomer or one
building block . By the process of
polymerisation, which is formation of a
long chain or a so-called macromolecule
consisting of many individual building
blocks or monomers, it is converted into polyethylene, which is a solid polymer.

Polymerisation can be represented

Fig. 1.3
graphically by the following diagram
(Fig.1.3):

Figure 1.4 shows a molecule of polyethylene consisting of a

number of monomers, each having a carbon atom (black)
and four
Fig. 1.4 hydrogen atoms
(white).

As mentioned before, the

monomer of Ethylene forms

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Fig. 1.5
the model for many other plastics. For example, the monomer of propylene is similar
to that of Ethylene with the difference that one of the four hydrogen atoms is
replaced by a CH3 group. Through the process of polymerisation, we get the plastics
known as Polypropylene(1.5).

One atom of Chlorine and three of Hydrogen in combination with one atom of
Carbon form the monomer of vinyl
chloride (Fig. 1.6).

Fig. 1.6

The monomer of Acrylonitrile differs

from that of Ethylene in that the former
Fig. 1.7 contains a group of CN in the place of one
atom of Hydrogen (Fig. 1.7).

Similarly, a Benzol ring in place of one

Hydrogen atom represents a molecule of
Styrene (Fig. 1.8).
Fig. 1.8

The monomer of Tetrafluoroethylene has four atoms

of Flourine joined with one atom of Carbon(1.9).
Fig. 1.9

Fig. 1.9

Polymerisation is not limited to formation

of macromolecules out of one type of
monomers only. The process can be
carried out with two or more monomers
such as with Acrylonitrile and Styrene to Fig. 1.10
yield SAN, a copolymer (Fig.1.10).

Or with Acrylonitrile, Styrene and Butadiene (ABS, a terpolymer).

1.2.3 Polycondensation, besides polymerisation, is another process of forming

plastics out of two different types of building blocks. Unlike polymerisation, this
process sets a by-product, mostly H2O free. Nylons (Polyamides) are formed by this

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process. The polycondensation of a polyamide molecule from diamine and
dicarboxylic acid is represented by the figure 1.11

The nomenclature for different polyamides, such as PA 6 6, PA 6 10 etc. is derived

from the number of
Fig. 1.11
carbon atoms in each
part of the combined
monomer. For example, PA 6 10 consists of two groups viz. -NH (CH2 )6 NH- and
-CO (CH2)8 CO-

If three or more groups are joined together by polycondensation, the final product is
a thermosetting plastics. Its molecule is no more linear as with a thermoplastics but
three dimensional.

1.2.4 Polyaddition is the process of

forming a new product out of two
different molecular building blocks
without giving rise to a by-product.
Polyurethanes are produced by
polyaddition of isocynate and
dialcohol. The process differs from
polymerisation in that atoms are
exchanged between the two
monomers as shown in figure 1.12. Fig. 1.12

1.3 Types of plastics.

Plastics are divided into two basic categories:
a) Thermosetting plastics
b) Thermoplastics

1.3.1 Thermosetting plastics “set” with the heat permanently into a shape which
cannot be changed by reheating. Their molecules undergo an irreversible chemical
change and become cross linked once for all with
the first heat to a definite level. Thermosetting
plastics have three-dimensional macromolecules.
The binding force among the molecules is the
chemical valency, which is strong (Fig.1.13). This is
the reason, why the thermosetting plastics are hard Fig.1.13
and do not flow under heat and pressure after
processing.

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1.3.1.1 Elastomers constitute a sub-class of
the thermosets with reversible elastic
properties. Their molecules are partially cross
linked and the polymers retain a degree of
elasticity (Fig. 1.14). Elastomers are rubbery at
room temperature and regain their shape after
the deforming force is removed. Like
thermosets, elastomers too cannot be re-
formed after first reaction. Liquid silicone
rubbers belong to this category. Fig.1.14

1.3.2 Thermoplastics soften and subsequently melt at certain temperature and can
be formed to an intended shape. On cooling, they become solid again but the
process of softening with heat and re-shaping can be repeated because the heat
does not effect any chemical change in their structure. Thermoplastics have linear
macromolecules consisting of monomers, which are
bound together by the strong force of their valencies.
However, the holding force between the
macromolecules is the co-ordinate bond or an
electrostatic force, which is weak and gets weaker
Fig. 1.15
under temperature and pressure (Fig. 1.15).

Based on the molecular structure, Thermoplastics have two distinct sub-classes:

1.3.2.1 Amorphous thermoplastics. The macromolecules of

plastics belonging to this class are not arranged in an orderly
fashion (Fig.1.16). When melted, their volume increases up to
15%.

 Their linear shrinkage is relatively small and varies

between 0.3-0.8%. Fig. 1.16
 Amorphous thermoplastics are rigid and hard.
 They are transparent in their basic form, with a few exceptions.
 Their specific gravity ranges from 1.05 to 1.4
 Amorphous thermoplastics do not have a distinct melting point. They soften at
some stage, called glass transition temperature, when heated. Their heat
content is relatively low.
 The most common amorphous thermoplastics are PS, SAN, PMMA, PC etc.

1.3.2.2 Semi-crystalline thermoplastics have part of their molecular chains

arranged in a parallel mode. The rest is disorderly like those of the amorphous
plastics (Fig. 1.17). Upon melting, all molecular chains become
disorderly.

 Their volume increases by about 30 % or more upon

melting.
 Their linear shrinkage is relatively large; it varies between
1.5-3.5 %
 In their natural state, they are translucent to opaque. Fig.1.17
 Their specific gravity lies between 0.9 and 1.3

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  While melting, they require latent heat. They have a distinct melting point.
Their heat content is relatively high.
 The most common semi-crystalline thermoplastics are: LDPE, HDPE, PP, PA,
POM, PET etc.

There are a few special forms of thermoplastics like:

1.3.2.3 Liquid crystal polymers, though crystalline, form a special class of

thermoplastics. They possess rod like crystals, which retain their form even in the
molten state. LC Polymers have properties, which make them an ideal replacement
of metals in many cases. Their shrinkage is low and even negative along the
direction of flow for some compounds.

1.3.3 Polyblends are a mixture of two or more thermoplastics having different

properties. The resultant blend has properties which are average of those of its
constituents. The blends are created with following aims:

 Improving polymer processability

 Supplementing the physical and mechanical properties
 Developing tailor-made materials for specific applications
 Reducing the material cost by mixing a low cost material with an expensive one
 Recycling the mixed scrap

As most of the blends are immiscible, phase separation occurs during processing. In
order to overcome this difficulty, special coupling agents including some copolymers
called compatibilizers are added to the mixture.

1.3.4 Thermoplastic elastomers. In contrast to the thermosetting elastomers (see

1.3.1.1), the thermoplastics elastomers owe their elasticity to a combination of hard
and soft phases. Butadien, isoprene, butylene etc. form the soft phase whereas
styrene acts as the hard component. The possibilities of combinations are unlimited.

The thermoplastics elastomers are inferior in their elastics properties but possess the
advantage of recycling, typical of thermoplastics.

1.3.5 Biologically degradable Plastics are polymers which can be disintegrated

into natural ingredients like water, carbon dioxide, methane, minerals etc. through
the action of natural agents like enzymes, bacteria, fungus, algae etc. Some plastics
can be disintegrated by natural light, hydrolysis or oxidation.

1.3.6 Additives. Polymers can rarely be processed in their pure form. In order to
create or improve the processability and to modify some characteristics or to
incorporate some missing properties, certain substances, usually chemicals but also
inorganic compounds, are added to them. They do not alter the basic chemical
character of the plastics. Thermosetting polymers are rarely processed in their pure
form; they may contain fillers to the extent of 50-75% by weight. The most common
additives are:

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  Plasticisers lend flexibility and softness to otherwise hard and brittle
polymers. (PVC is one such polymer). The plasticisers also enhance the
impact strength.
 Lubricants help reduce viscosity by creating a film between the melt and the
plasticising equipment as well as between the melt and the die/mould. Thus
the thermally sensitive materials do not get overheated. The internal
lubricants facilitate easy gliding of molecules past one another with the same
effect.
 Antioxidants prevent or minimise the weakening or damaging effect of high
processing temperatures.
 Heat stabilisers protect plastics against high temperatures during
processing. PVC, which is thermally sensitive and unstable, cannot be
moulded without these additives.
 Colorants add the desired colour to the plastics and also provide protection
against light. Some luminous and fluorescent pigments lend visibility to
plastics in the dark. The colorants may be of organic or inorganic origin. Some
of them are harmful and are not allowed in contact with foodstuff.
 Flame Retardants make plastics self-extinguishing.
 UV-Stabilisers provide protection against the damaging effect of ultra violet
rays.
 Blowing agents turn plastics into foams.
 Compatibilizers help make alloys or composites out of different plastics.
 Fillers or extenders are added primarily to increase the volume and reduce
the material cost. They also modify certain properties like tensile strength,
modulus of elasticity, sound absorption, shrinkage behaviour etc. The most
common fillers are carbon black, calcium carbonate, talcum, clay, glass fibres,
mica, wood flour etc. Except wood, all fillers are heavier than the plastics.
 Accelerators are mostly used with thermosets to accelerate curing, i.e. cross
linking of molecular chains, at elevated temperatures.
 Inhibitors perform the function of retarding the process of cross linking of
molecular chains at lower temperatures. They prolong the shelf life of
thermosetting resins. During injection moulding of thermosets, they act
against premature curing of the polymer in the plasticising unit.
 Antistatic Agents are added to make plastics electrically conductive. Carbon
black is the most common additive. Other agents to reduce the electrical
resistance are carbon fibres, stainless steel fibres, polyanin powder etc.

1.3.7 Reinforced Plastics. To enhance certain properties of plastics, reinforcing

components are physically mixed into them. Glass fibres are the most common
addition. The other reinforcing ingredients are glass beads, mineral fibres, talcum,
mica etc. For special applications, steel fibres have also been incorporated. The
reinforcing components show beneficial effect in case of many physical properties
but there are some adverse effects also.

There is an increase in the values of:

Modulus of elasticity, creep resistance, tensile and flexural strength, heat
conductivity, high temperature resistance, specific gravity and impact strength below
the freezing point.

15
Following attributes experience a decrease:
Coefficient of thermal expansion, cooling time as the minerals have lower specific
heat and better heat conductivity, mould shrinkage, impact strength at room
temperature, flowability and weld line strength.

1.4 The molecular structure and properties.

Synthetic materials, called plastics collectively, are built of long chains of molecules
consisting of monomers having atoms of elements like carbon, hydrogen, oxygen,
nitrogen, silicone etc. These long chains of molecules are named macromolecules
and may contain thousands of monomers. This is why, the plastics are referred to as
polymers. The length of the chains is not constant.

The physical and mechanical properties of plastics depend upon the shape and
length of the macromolecules as well as on forces which hold them together. Some
knowledge of their structure is helpful in understanding their basic properties and
behaviour.

Thermoplastics have linear macromolecules, sometimes with side

branches, consisting of monomers bound by the strong force of
their valencies. The holding force between the macromolecules is
the co-ordinate bond or an electrostatic force (see Fig. 1.15),
which is weak and gets weaker with increase in distance, Fig. 1.18
temperature and pressure. The linear structure permits the
polymer segments to get closer to each other than the branched structure so that the
former is denser (Fig. 1.18). The branched side chains, on the
other hand, will keep the main polymer backbones further apart
from each other (Fig. 1.19). The longer the chain, the greater is
the effect. The denser polymer would have higher specific
gravity and higher rigidity.
Fig. 1.19
The two varieties of polyethylene, which have the same chemical
formula, are a specific example of this effect. The molecules of HDPE are linear
without side branches; they lie closer together and their co-ordinate forces are more
effective. LDPE on the other hand has macromolecules with side branches; the
molecules cannot be as close to one another as in the case of HDPE. The co-
ordinate forces are therefore weaker and the plastics is less rigid.

Out of the same reason, the polymer with branched chains and more space
between adjacent chains would have higher permeability to gases.

Linear materials with closely packed chains will have higher intermolecular forces
and therefore higher tensile strength.

Likewise the linear materials, being closely packed, will be stiffer because of less
room for bending of the backbones. Their modulus of elasticity will be higher.

As the molecular forces binding a high density material are higher, it takes a higher
amount of heat energy to separate the linear configuration. Consequently, the heat
distortion temperature of materials with linear macromolecules will be higher.

16
Hardness, which can also be defined as resistance to penetration, will be higher for
materials having closely packed molecular chains.

Creep resistance or the resistance to distorting forces too, is higher with materials
of linear molecular chains because of higher intermolecular forces.

Flowability is lower in case of stronger molecular attraction as the flow is opposed

by the cohesive forces.

Compressibility. Branched chains have space between them. Hence these

materials are more easily compressible than the ones with straight chains.

Impact strength is, however, better with branched materials, which are more
flexible.

Crystalline thermoplastics have a part of their molecules lying closer together in an

orderly fashion. Their physical and mechanical properties are closely linked not only
with their crystalline structure but also with the extent and form of crystallinity. The
compactness as a result of closeness results in better cohesion between the
molecular chains, which increases the density, the stiffness, the heat resistance etc.
The effect is similar to that of the unbranched chains. It may be summed up that:

 The more the crystallinity, the higher the density.

 The more the crystallinity, the greater the stiffness as the closely packed crystals
have less space to rotate.
 The more the crystallinity, the higher the tensile strength as more force is needed
to break the intimate bonds.
 The more the crystallinity, the more the hardness (resistance to penetration)
because of the closely packed molecular chains.
 The more the crystallinity, the less the permeability to gases as there are less
gaps between the chains.
 The more the crystallinity, the higher the softening temperature as more heat
energy is needed to overcome the cohesive forces.
 The more the crystallinity, the more the volume expansion on melting as the freed
compact chains get disorderly and occupy more space.
 The more the crystallinity, the greater the shrinkage on cooling. Ordered
molecules occupy less space.
 The more the crystallinity, the less the impact strength. Crystals propagate
cracks.
 The more the crystallinity, the less the resistance to stress cracking.
 Difference in crystallinity in different sections results in more warpage.

The extent of crystallinity in a moulding out of semi-crystalline thermoplastics

depends upon factors like mould temperature, cycle time, injection and holding
pressure, rate of cooling etc. Slow cooling results in higher degree of crystallisation.
Flowability. Plastics melts are visco-elastic fluids. The characteristic of polymers,
most relevant to the process of injection moulding, is their flowability or the viscosity
at moulding temperatures. It is the inner resistance of the melt to flow. The viscosity

17
of a plastics decides the force needed to plasticise and transport the melt, the extent
of pressure to fill the mould cavity, the time for filling and the force needed to prevent
the mould from opening under the filling pressure. In other words, it influences the
design of the moulding machine as well as that of the mould and the moulding.
The flow process of plastics melt involves shear, which is caused by adherence of
the melt to the adjacent surfaces of the plasticising unit and the walls of the mould
cavity. The force needed to make it move introduces shear and the rate of shear is
proportional to the applied force. Shear is also caused by the resistance of
successive layers of the melt gliding past one another.
Plastics are non-newtonian fluids. Their viscosity decreases with the increasing rate
of shear. In other words, they flow more easily with higher speed. The viscosity of a
particular plastics is therefore, not an absolute factor. It depends upon the rate of
shear. The temperature, too, has an influence on the rate of flow. As the temperature
of the polymer rises, the plastics expands and the distance between the
macromolecules increases which facilitates their movement past one another.
Consequently, less force is needed to make the melt flow. The length of the
macromolecular chains has a direct influence on the flowability. The shorter chains
can glide past one another more easily than the longer ones. This is why, the
material grades with longer chains or higher molecular weights are more viscous.
The grades meant for injection moulding should have lower viscosity.
Viscosity can be measured and expressed in several ways. The method more
commonly employed in practice is that of measuring
melt flow index.
The Melt Flow Index (MFI) is a measure of apparent
dynamic fluidity or flowability of thermoplastics. It is the
weight of the melt in grams, extruded through a
standard die at specific temperature under a specific
force in 10 minutes in a standard plastmeter (Fig.1.20).
The MFI is expressed as a number. A higher number
denotes better flowability, which indicates lower
average molecular weight. The MFI number, however,
holds good only for individual thermoplastics. Melt Flow
Indicii of different plastics cannot be compared with one
another.
The melt flow index number is not an absolute measure of Fig. 1.20
actual viscosity but it is a practical scale to compare the
flowability and suitability of different material grade for a particular application. For
instance, to mould a thin-walled component like a disposable injection syringe, a
grade with a higher MFI will be more suitable than the one with lower MFI, being
employed for making a sturdy household container.
The method of measuring the melt flow index also delivers useful information about
the uniformity of the raw material being produced and delivered. It is employed by
the raw material producers as well as by the buyers to check instantly the
conformance of the material.
Flowability of heat sensitive materials like PVC cannot be measured by the above
process. The measure of their flowability is the so-called K value.

18
The viscosity of a thermally sensitive thermoplastics is measured by dissolving it in
a solvent and determining the speed of flow of the solution in a capillary viscometer
relative to that of the pure solvent.
Relative viscosity = time taken by solution/ time taken by the solvent
Knowing values of the relative viscosity and of the concentration of the solution, the
K-value of the polymer can be read out of a corresponding table. A higher K value
indicates higher viscosity or lower flowability.
The solvent used for PVC for determining the relative viscosity is cyclohexanon.
Molecular weight is another specification which gives information about many
characteristics of the polymer. It is the sum of the atomic weight of all atoms
constituting one macromolecule of a thermoplastics. All chains in a polymer are,
however, not of the same length. Therefore, a particular material grade is known by
its average molecular weight. The grades with higher molecular weight have longer
macromolecules and hence lower flowability but they have properties characteristic
of longer molecular chains such as higher tensile and impact strength, better creep
resistance and chemical resistance due to increase in entanglement and
intermolecular attraction between the adjacent chains.

1.5 Common plastics and their properties

1.5.1 Thermosetting plastics.

It may be stressed upon in the outset that the thermosetting plastics are rarely
moulded in their pure form. They are always mixed with additives like glass, cotton,
and organic fibres, talcum, wood flour, cotton fabric etc. Their properties depend
upon the type and extent of additives.

1.5.1.1 Phenol formaldehyde has not only the distinction of being the first fully
synthetic material; it also became a synonym for the thermosets under the name of
Bakelite. In his search of a synthetic substitute for shellac, Mr. Baekland, an
immigrant to USA, experimented with phenol and formaldehyde and developed, in
1907, a brownish substance which he baptised as Bakelite. It was found that it could
harden irreversibly under the influence of heat and pressure and the reinforced
versions offered unlimited possibilities of its use. The reinforced phenol
formaldehyde has:

 high strength, stiffness and hardness.

 Low cold flow.
 high heat resistance.
 high resistance to organic solvents, neutral chemicals, weak acids and alkalis (it
is attacked by the strong acids and alkalis).
 resistance to stress cracking.
 good electrical insulation.

Phenol formaldehyde burns with a bright sooty flame but extinguishes automatically
outside the source of ignition, emitting a smell of phenol and formaldehyde and,
depending upon the reinforcement, of ammonia too. It is not suitable for use with
foodstuff. It is brownish in its natural form but gets darker in light. Hence it is
available only in dark colours.

19
Following substances are used as reinforcing ingredients, either singly or in
combinations, for different applications:

 Wood flour.
 Wood pulp.
 Cotton fibres/ cotton fabric chips.
 Synthetic fibres.
 Asbestos fibres.
 Stone powder.
 Mica.
 Rubber.

Specific gravity 1,4-1,9

injection unit temperature 60-85°C
Mould temperature 160-190 0C
Service temperature without load
Short time 130-1500C
Long time 110-1300C
Mould shrinkage 0-1,0%
Post shrinkage 0-0,5%
(All values depend upon the type and amount of reinforcement).

Conversion processes. Compression, transfer and injection moulding, extrusion.

Uses. Electrical connectors, switches, meter boxes, spools, handles, knobs, ash
trays, components for pumps, screw caps, gears etc.

1.5.1.2 Urea formaldehyde (UF). The search for a transparent synthetic material
resulted in the development of urea formaldehyde a decade after the creation of
phenol formaldehyde. To maintain the transparency, the urea formaldehyde is
primarily reinforced with bleached cellulose. However, other ingredients such as
stone powder, fibres, asbestos etc. are also added when transparency is not
required. Reinforced UF has the following properties:

 High mechanical strength, stiffness and surface hardness.

 Very good electrical properties.
 High surface gloss.
 Proneness to stress cracking.
 Poor dimensional stability because of variable water absorption.
 Higher shrinkage than phenol formaldehyde.

Urea formaldehyde burns with a yellow flame and is self-extinguishing. It is sensitive

to moisture. It is not suitable for applications involving food articles.

Urea Formeldehyde can be injection moulded in special formulations containing

agents which retard its curing at moulding temperatures.

Specific gravity 1,5

20
Moulding unit temperature 70-80°C
Mould temperature 160-170 0C
Service temperature without load
Short term 1000C
Long term 700C
Mould shrinkage 0,5-0,8%
Post shrinkage 0,7-1,2%

Conversion processes. Compression moulding, transfer moulding, injection

moulding.

Uses. Electrical parts like plugs, sockets, meter boxes, lamps, screw caps and
closures for cosmetic containers, knobs, toilet seats, furniture parts etc.

1.5.1.3 Melamine formaldehyde (MF)

Reinforced with organic and inorganic substances, the melamine formaldehyde
resins have the following properties:

 High surface hardness and scratch resistance

 High surface lustre
 Good heat resistance
 Resistance to moisture
 High post-shrinkage leading to cracks
 Usable with foodstuff
 Prone to stress cracking
 Unsuitable for use with boiling water.

Specific gravity 1,5-1,9

Mould temperature 150-170 0 C
Service temperature without load
Short term 120-1700 C
Long term 80-1200 C
Mould shrinkage 0,1-0,9%
Post shrinkage 0,3-1,2%

Conversion processes. Compression moulding, transfer moulding, injection

moulding.

Uses. Almost same as for UF but due to better creep strength and admissibility for
use in contact with eatables, it is used for crockery, electrical parts needing creep
resistance, housings for gadgets, furniture parts etc.

Special note. Combinations of PF and MF are employed to get:

 good dielectric properties

 better creep resistance
 less shrinkage and better dimensional stability
 lower tendency to form cracks under moisture and heat
 lower cost

21
Apart from some special formulations in pourable powders, Melamine requires
auxiliary equipment for feeding with the injection moulding machine.

1.5.1.4 Unsaturated polyester resin

Usually referred to without the adjective, the polyester resin is transparent in its
natural form but also brittle. This is why, it is always used with reinforcing ingredients,
preferably with glass fibres. It also burns readily with a bright, sooty flame, emitting a
sweetish smell. Hence fire retardant are added. Reinforced polyester resins possess
following characteristics:

 High strength, stiffness and hardness

 High heat resistance
 Very good electrical properties
 Very little water absorption
 Good weathering stability

Specific gravity 1,8-2,0

Mould temperature 160-170 0 C
Service temperature without load
Short term 2000 C
Long term 150-1600 C
Mould shrinkage 0,2-0,7%
Post shrinkage 0-0,1%

Conversion processes. Compression moulding, transfer moulding, injection

moulding.

Uses. Electrical components like plugs, sockets, fuse boxes, insulation material,
spools, lights, housings for electrical tools, car parts like spark plug holders, ignition
distributor, ignition coil etc.

1.5.1.5 Epoxide resins.

The excellent flowability of Epoxide resins makes them ideal for the moulding of
intricate components. Epoxy resins have very good electrical and chemical
properties. The usual reinforcement of glass fibres has a positive influence on
mechanical properties and heat stability.

The epoxy resins get darker in colour with the time and are therefore pigmented in
dark tones. They are combustible and hence need addition of fire retardants when
used for electrical components. Because of their very good flowability and very low
shrinkage, they are highly suitable for:

 thin walled components

 components with close tolerances.
 components with inserts. Epoxy resins adhere well to metals.
 components with inserts. Epoxy resins have low risk of stress cracking.

Specific gravity 1,8-1,9

Mould temperature 125-175 0 C
Service temperature without load

22
 Short term 1800 C
Long term 1300 C
Mould shrinkage 0,2-0,3%
Post shrinkage 0- 0,1%

Conversion processes. Compression and transfer moulding, injection moulding,

casting etc.

Uses. Multi-pole connectors, plugs and sockets, condensers, resisters, winding

spools, diodes, transistors, relays etc.

1.5.2 Thermoplastics

1.5.2.1 Amorphous thermoplastics.

1.5.2.1.1 Cellulose acetate (CA)

Cellulose acetate, cellulose propionate and cellulose acetate butyriate form a family
of thermoplastics from the group of plastics derived from natural resources. CA is still
produced and used in sizeable quantities. It is based on natural cellulose, a
polysaccharide (C6 H10 O5) which forms the main ingredient of all plants.

 CA has high toughness, strength and resilience.

 It is transparent but can be coloured in all hues and shades.
 It has a brilliant surface.
 It is highly scratch resistant.
 It is resistant to stress cracking.
 It is resistant to organic solvents, mineral oils, benzene, fats etc.
 It burns with a green-yellowish flame and emits a pungent smell like burning
paper.
 It is not suitable for outdoor applications.
 It absorbs water and needs pre-drying before processing. Dimensions are
effected by absorbed water.

Special attribute. It takes very little electrostatic charge and does not attract dust.

Specific gravity 1,3

Moulding temperature 180-220° C
Service temperature without load
Short term 0-80° C
Long term 0-70° C
Mould shrinkage 0,4-0,7%

Conversion processes. Injection moulding, extrusion, blow moulding.

thermoforming.

Uses. Telephone sets, microphone housing, tool handles and grips, hammer heads,
buttons, keys, spectacle frames, pens, toys, combs and brushes, shoe heels etc.

23
5.2.1.1.2 Polystyrene (PS), also referred to as the General Purpose Polystyrene, is
an amorphous thermoplastics with a shiny surface. It is transparent in natural state. It
is hard and brittle. The wear resistance is average. As it absorbs water only to a
negligible extent, its dimensional stability is excellent.

 It burns with a sooty flame and smells sweet.

 It is resistant to weak acids and alkalis but swells in gasoline, benzene and
other organic solvents.
 It is not impervious to steam, oxygen, carbon dioxide etc.
 It is prone to stress cracking.
 It emits a metallic sound when dropped on hard surface.

Specific gravity 1,05

Moulding temperature 170-280 0 C
Working temperature without load
Short term 80-850 C
Long term 65-750 C
Mould shrinkage 0,4-0,6%

Conversion processes.
Injection Moulding, Injection Blow Moulding, Extrusion, Thermoforming.

Uses. Packaging for food, medicine, cosmetics, disposable cutlery, disposable

tumblers, transparent covers, drawing instruments etc.

The following copolymers of polystyrene overcome various deficiencies like

brittleness of polystyrene, retaining other attributes.

1.5.2.1.3 High impact polystyrene (H.I.P.)

The G.P.Polystyrene modified with butadiene becomes tough and opaque but loses
much of its shine. The wear resistance is average. It absorbs some water and needs
pre-drying before processing.

 It burns with a sooty flame.

 It is resistant to stress cracking.
 It is resistant to weak acids and alkalis. It is attacked by organic solvents.

Specific gravity 1,05

Moulding temperature 190-280 0 C
Working temperature without load
Short term 60-700 C
Long term 50-600 C
Mould shrinkage 0,4-0,7%

24
Conversion processes.
Injection moulding, blow moulding, extrusion.

Uses. Packaging for food, medicines, cosmetics, housing for small gadgets,
machinery, components for house-hold machines, fans, parts for furniture, toys etc.

1.5.2.1.4 Acrylonitrile styrene (SAN).

This copolymer of Styrene retains the shine and transparency of the parent material.
It is tough and hard and has better heat resistance.

 It absorbs more water and needs pre-drying before processing.

 It burns like G.P.Polystyrene.
 It is resistant to weak acid and alkalis. It is dissolved by organic solvents.
 It is resistant to stress cracking.
 It has better heat resistance than Polystyrene.

Specific gravity 1,08

Moulding temperature 200-260 0 C

Service temperature without load
Short term 950 C
Long term 850 C
Mould shrinkage 0,4-0,7%

Conversion processes.
Injection moulding, blow moulding, extrusion, thermoforming.

Uses. Packaging for food, medicines, cosmetics, parts of household gadgets,

telephone sets, knobs, keys and buttons, covers of car lights, traffic signals, pens,
garden furniture, boat bodies etc.

1.5.2.1.5 Acrylonitrile Butadiene Styrene (ABS).

ABS has better hardness, scratch resistance, toughness, heat resistance and
resistance to chemicals than the other derivatives of styrene.

 It is yellowish opaque in natural state. A special formulation is transparent.

 It absorbs more water and must be pre-dried before processing.
 It is resistant to stress cracking.
 It burns with a sooty flame.

Special attribute. ABS can be metalised.

Specific gravity 1,04-1,06

Moulding temperature 200-260 0 C
Service temperature without load
Short term 90-1000 C
Long term 80-850 C
Mould shrinkage 0,4-0,7%

25
Conversion processes.
Injection moulding, Blow moulding, extrusion, calendering, thermoforming.

Uses. Housings for office and household machines, metalised radiator grills,
dashboard components in automobiles, entertainment electronics, suitcases and
boxes, safety helmets, knobs, keys, buttons etc.

1.5.2.1.6 Unplasticised polyvinyl chloride (uPVC).

Unplasticised polyvinyl chloride or rigid polyvinyl chloride is one of the most widely
used plastics. Basically, it is an unstable polymer but a broad palette of stabilisers,
additives and copolymers have made it the most prolific of synthetic materials so that
it offers formulations for extremely diverse applications.

 It is a transparent thermoplastics with high mechanical strength, stiffness and

hardness.
 It is highly resistant to chemicals.
 It is a good insulator for low voltages.
 It has a narrow temperature range for processing.
 It is resistant to stress cracking.
 It can be used for outdoor applications.
 It burns with a yellowish-orange pungent flame emitting chlorine but is self-
extinguishing.

Specific gravity 1,4

Moulding temperature 180-210 0 C
Service temperature without load
Short term 750 C
Long term 650 C
Mould shrinkage 0,4-0,5%

Conversion processes. Injection moulding, extrusion, blow moulding, calendering.

Uses. Pipes and fittings, medical disposables, transparent bottles and containers,
profiles and sections for windows and furniture, vessels and fittings for the chemical
industry, gramophone records, separators for batteries etc.

1.5.2.1.7 Plasticised polyvinyl chloride (PVC- soft).

Plasticised PVC is made flexible with the help of the chemicals called softeners and
also with copolymers. Although most of the properties of the parent resin viz. the
uPVC are retained, the softeners bestow a degree of flexibility, which is dependent
upon the amount of additives. Certain properties such as resistance to chemicals do
get effected as the softeners may leach out with the passage of time or under
adverse conditions. The flexibility may decrease and the resin may become brittle.
More softener makes PVC more susceptible to attack by chemicals. Like uPVC, the
plasticised PVC is:

 Transparent
 Good insulator
 Self extinguishing by moderate amount of softeners

26
 Resistant to strong chemicals
 Brittle at sub-zero temperatures

Some of the additives may be injurious to health. Only selected additives are
permitted for PVC-formulations meant for use as packaging of foodstuff.

Specific gravity 1,2-1,35

Moulding temperature 170-210°C
Service temperature without load
Short term
Long term ~ 50° C
Mould shrinkage 1,5-2,5%

Conversion processes. Injection moulding, extrusion, calendering, dip coating,

rotational moulding.

Uses. Flexible pipes and tubes, floor tiles, gaskets and seals, curtains and table
cloths, rain coats, artificial leather, straps and bands, cable coating, decorative foils,
packaging films, medical tubing, medical disposables, shoes and shoe soles, tool
grips etc.

1.5.2.1.8 Polymethyl Methacrylate (PMMA).

Also popularly known as acrylics, PMMA is an amorphous thermoplastics with high
stiffness and hardness. It is fairly scratch resistant. Its surface can be polished to a
high brilliance.

 It is transparent like water but copolymers have a yellowish tinge.

 It burns with a crackling flame and a fruity smell.
 It is prone to stress cracking.
 It is resistant to weak acids and alkalis.
 It is attacked by polar organic solvents.
 It is resistant to UV-rays; can be used outdoors.

Specific gravity 1,18

Moulding temperature 190-290 0 C
Service temperature without load
Short term 900 C
Long term 750 C
Mould shrinkage 0,4-0.8%

Conversion processes. Injection moulding, extrusion.

Uses. Geometrical instruments, watch glasses, lenses, skylight covers, window

panes, car tail light covers and reflectors, sanitary fittings, sign boards, costume
jewellery, combs and brushes, handles for cutlery etc.

1.5.2.1.9 Polycarbonate (PC).

Polycarbonate is an engineering thermoplastics, which exhibits very high stiffness,
strength and hardness between extreme temperatures of -150° and +135°C.

27
  It is transparent like glass.
 It is a very good electrical insulator.
 It has very high heat resistance.
 It is resistant to weak acids and alkalis.
 It can be used in contact with foodstuff.
 It burns with a sooty, pungent smell of phenol but is self-extinguishing.
 It is prone to stress cracking.
 It absorbs water and necessitates pre-drying before processing.

Specific gravity 1,2

Moulding temperature 270-320 0 C
Service temperature without load
Short term -135-+1600 C
Long term -135-+1350 C
Mould shrinkage 0,6-0,8%

Conversion processes. Injection moulding, extrusion, blow moulding.

Uses. Electrical and electronics components, Safety covers for electrical

installations, winding spools, lamp covers, machine parts, valves, camera and
projector housings, lenses, office machines' bodies and components, computer
parts, traffic signals, headlight reflectors, car light covers, air conditioner parts,
medical devices and disposable instruments, compact discs etc.

1.5.2.1.10 Polyphenylene oxide (PPO).

PPO is an amorphous thermoplastics with a very high stiffness and hardness. Its
heat resistance is excellent.

 It is transparent in natural state.

 It is highly resistant to chemicals.
 It is highly resistant to hydrolysis.
 It is self extinguishing.
 It absorbs very little water.

Special attribute. It degenerates rapidly in air above 100°C.

It can be metalised.

Specific gravity 1.06

Moulding temperature 260-310 0 C
Service temperature without load
Short term 2000 C
Long term 1000 C
Mould shrinkage 0,4-0,7%

Conversion processes. Injection moulding, extrusion, blow moulding.

Uses. Electronic components, medical technical gadgets, components for washing

machines etc. foils for cable insulation, condensers, drawing paper and drawing foils,
photographic film.

28
Note. Modified PPO as a Polyblends with PS is produced by General Electric under
the name of Noryl. It has all properties of PPO without the disadvantage of
degeneration in the air. Its processability is superior to that of PPO. It is more
commonly used than the unblended polymer.

Uses. Components for radio and TV, electrical parts, spools, electrical water heater,
components for dish washing and clothes washing machines, hair dryers, sanitary
fittings, water meter housing, office machines' parts, cameras, projectors, chromium
plated parts for cars, grills etc.

1.5.2.1.11 Polysulphone (PSU).

Polysulphone is an engineering thermoplastics with very high stiffness, hardness
and mechanical strength.

 It is highly resistant to chemicals.

 It is transparent like glass with a light yellowish tinge.
 It is highly heat resistant.
 It burns with bright smoky flame but is self-extinguishing.
 It is prone to stress cracking when in contact with certain chemicals.
 It is hygroscopic. It must be pre-dried before processing.

Specific gravity 1,24

Moulding temperature 320-380 0 C
Service temperature without load
Short term 2000 C
Long term 150-1700 C
Mould shrinkage 0,7-0,8%

Conversion processes. Injection moulding, extrusion, blow moulding,

thermoforming.

Uses. Components of household and industrial machines, water heaters,

automobiles, aeroplanes, projectors, electrical connectors, battery housing, foils for
printed circuits etc.

Special Note. Another polysulfone, viz. polyarylsulfone (PAS) has similar properties
but can withstand temperatures up to 180°C.

1.5.2.1.12 Polyethyleneterephthalate (PETP)

PETP is a linear thermoplastics polyester of the semi-crystalline variety and as such
it is white opaque. The share of the crystalline structure is about 30-40% but it can
be reduced to such an extent with the help of co-monomers that the resultant
polymer is transparent. Its remarkable properties are:
 Excellent hardness, stiffness
 Very good toughness, also at sub-zero temperatures.
 Good ageing characteristics. Low coefficient of friction.
 Good electrical insulation.
 Resistance to stress cracking.

29
 No reaction with water at room temperature, dilute acids, alcohols, oils and fats
etc.
 Reaction with high temperature steam, alkalis, oxidising acids, and organic
solvents.
 Fire resistant, but burns with a sooty flame. Can be used with foodstuff

 Absorbs very little water but needs pre-drying.

(Data for amorphous PETP)

Specific Gravity 1.33

Moulding temperature 260-300° C
Service Temperature without load
Short term 180° C
Long term 100° C

Mould shrinkage 0.2-0.4 %(1,2-2,0% for linear PETP)

Conversion processes. Injection moulding, blow moulding, extrusion,

thermoforming.

Uses. Moulded parts such as rollers, gears, wheels, bearings, guides, components
for pumps, office machines, valves, telephones etc.
Transparent bottles for aerated beverages, household fluids
Films and foils, monofilaments, foils for audio and video cassettes and electrical
insulation, artificial lawns, garments etc.

1.5.2.1.13 PC+ABS-blend (e.g. Bayblend).

The polyblend of Polycarbonate and Acrylonitrile Butadien Styrene is amorphous in
structure and combines the characteristics of the two polymers. The niveau of its
properties is much higher than that of ABS but lower than of PC. It has:

 High impact and notch strength, even at sub-zero temperatures

 High stiffness
 High temperature resistance
 High dimensional precision
 Low distortion
 Low shrinkage
 Stability to UV-rays

Specific gravity 1,1-1,2

Moulding temperature 230-300°C
Service temperature without load
Short term 112°C
Long term 95°C
Mould shrinkage 0,55-0,75%

Uses: Automobile components, electrical and electronic gadgets, household

appliances, hobby and sports goods etc.

30
1.5.2.2 Semi-crystalline thermoplastics.

1.5.2.2.1 Low density polyethylene (LDPE).

Polyethylenes of different densities along with the polypropylene constitute the

group of polyolefines. One common attribute of these semi-crystalline thermoplastics
is their specific gravity, which is less than one so that they all float in water. The
monomer ethylene is the simplest one, having two atoms of carbon and four of
hydrogen (C2 H4), which is also the basic building block of wax.

There are two distinct forms of polyethylene; the low density and the high density
polyethylene. Most of their properties are similar; the difference lies in the extent.

LDPE is translucent to whitish-opaque, depending upon the thickness. It is flexible.

Its molecules can arrange themselves parallel to one another in crystalline structures
among the mass of randomly scattered molecules, while cooling from molten state to
the solid phase. The degree of crystallisation may reach 40-50% depending upon the
rate of cooling and the linearity of the molecules. The crystalline zones contribute
stiffness. Its macromolecules are mostly branched.

 It possesses very high toughness.

 It has excellent electrical insulation properties.
 It absorbs very little water.
 It has very good resistance to all chemicals at room temperature.
 L.D.Polyethylenes with higher molecular weight are more resistant to stress
cracking.
 It burns without soot and smells like wax.

Specific gravity 0,91-0,93

Moulding temperature 160-270 0 C
Service temperature without load
Short term 80-900 C
Long term 60-700 C
Mould shrinkage 1,5-3%
 The cross-linking varieties of LDPE, which become permanently set after
treatment, have higher working temperatures.

Conversion processes. Injection moulding, extrusion, blow moulding, film blowing,

rotational moulding.

Uses. Packaging for foodstuff and diverse articles as shrink film, bags, tubes and
pipes, insulation for electrical cables, lids and closures for containers, sealing rings
and gaskets, household articles, containers for chemical industry etc.

1.5.2.2.2 High density polyethylene (HDPE).

HDPE has a molecular structure, which is more linear than that of LDPE. It is also
stiffer than the LDPE.

31
In natural state, HDPE is whitish in colour. Very thin layers may appear translucent.
HDPE has poor scratch resistant. Ultra high molecular high density versions possess
very good surface hardness and sliding properties.

 It is resistant to almost all chemicals, except to strong acids, at room

temperature.
 It is an excellent insulator to electricity.
 It burns with a bright, sootless flame, emitting smell of wax.
 It is prone to stress cracking.

Specific gravity 0,94-0,97

Moulding temperature 200-300° C
Service temperature without load
Short term 90-1000 C
Long term 70- 800 C
Mould shrinkage 1,5-4,0%

Conversion processes. Injection moulding, extrusion, blow moulding.

Uses. Household articles, containers for food and general merchandise, petrol tanks
and storage tanks for oils and chemicals, crates and containers for transport, bottles
and closures, toys, films for packaging and insulation etc.

The ultra high molecular varieties are used in textile industry, for rollers and wheels,
sliding chutes, implants in human body etc.

1.5.2.2.3 Polypropylene
Polypropylene (PP) is the lightest member of the polyolefin family.

 It has high toughness, hardness and the tensile strength.

 Its scratch resistance is highest among polyolefins.
 It has high heat resistance. It can withstand boiling water.
 It has very good chemical resistance.
 It is translucent to opaque; some special formulations are transparent in thin
sections.
 It burns with a soot-free flame and smells like wax.
 It becomes brittle at sub-zero temperatures.
 It is sensitive to UV-rays.

Note. With the help of nucleating agents, the pattern of crystallinity can be altered, in
that instead of a few big clusters of crystals, many smaller clusters are formed. This
structure results in less dispersion of light, conferring on the material more
transparency. The nucleated polypropylene shrinks more but also more uniformly.
The warpage is also reduced.

Special attribute. Thin, integral hinge out of PP is practically indestructible.

Specific gravity 0,9

Moulding temperature 220-300 0 C

32
Service temperature without load
Short term 1400 C
Long term 1000 C
Mould shrinkage 1,0-2,5%

Conversion processes. Injection moulding, extrusion, blow moulding.

Uses. Pipes, tubes, profiles, sheets, foils, insulation for cables, components for
electrical, electronic, automobile and chemical industry, sanitary fittings, household
articles, medical equipment, transport boxes and crates, packaging for instruments
and small machines like drills, car parts, toys, bags and sacks, packaging bands,
carpeting, artificial lawns.

1.5.2.2.4 Polyamides.

The specific aim of development of polyamides was the artificial yarn. Patented in
1937, PA 6 6 was introduced in USA in 1940 in the form of Nylon stockings. In
Germany, simultaneous research led to the development of PA 6 and PA 6 6 for
injection moulding and extrusion. They were found to be eminently suitable for
engineering applications because of the following properties:

 Very high strength, stiffness and hardness.

 Very good heat endurance.
 Excellent wear resistance, good sliding characteristics, low friction.
 Very good shock absorption and damping.
 Resistance to solvents, gasoline, oils and fats.

Special attribute. All polyamides absorb moisture, which influences their properties.
The toughness increases considerably but dimensions also increase and the
electrical insulation decreases.

Table 1.2

Attributes PA 6 PA 6 6 PA 6 10 PA 11 PA 12
Specific gravity 1,13 1,14 1,08 1,04 1,02
Moulding temperature 0C 230-290 260-320 230-290 200-270 200-270
Service temp. without load 140-180 170-200 140-180 140-150 140-150
Short term 0C
Long term 0C 80-100 80-120 80-110 70-80 70-80

33
Mould shrinkage % 0,8-2,1 1,0-2,2 0,5-2,8 0,5-1,5 0,4-0,6
Moisture intake % 2,5-3,5 2,5-3,1 1,2-1,6 0,8-1,2 0,7-1,1

Conversion processes. Injection moulding, extrusion, blow moulding.

Uses. PA 6, PA 6 6 and PA 6 10: Components subject to wear like gears, sprockets,

axles, ball bearing races, bushes, couplings, shoe heels, lock parts, load bearing
articles like nuts and bolts, handles, levers, ventilators and machine components,
lamps and battery housing, bobbins, combs etc. (PA 6 10 has better dimensional
stability). Automobile components like oil tubs, fans, pedals, hub caps, sliding roof
frame, airbag housing and technical components under the hood.

PA 11 and PA 12: gears, bearings gaskets, housings and other components coming
in contact with water.

Special note. Polyamides are semi-crystalline and as such opaque but the aromatic
polyamides are transparent.

The number given after the abbreviation PA denotes the number of carbon atoms in
the monomer (PA 6, PA 11, PA 12). The double number indicates a monomer with
two molecules and stands for the number of carbon atoms in each molecule (PA 6 6,
PA 6 10).

1.5.2.2.5 Polyacetal (POM=Polyoxylmethylene).

Polyacetal is an engineering thermoplastics from the semi-crystalline family. Its
distinguishing properties as listed below make it an ideal material for technical
applications.

 High hardness and stiffness.

 High toughness, also up to -400 C
 High heat resistance
 Low water absorption, good dimensional stability
 Good electrical properties
 Resistant to petroleum, oils, fats, alcohols, weak acids and alkalis, detergents.
 Excellent surface hardness and wear resistance
 Very low friction, self-lubricating behaviour
 Polyacetal is whitish in natural state. It burns with a pungent bluish flame
smelling of formaldehyde.

Special attribute. Polyacetal is suitable for long lasting integral hinges.

Specific gravity 1,42

Moulding temperature 180-230 0 C
Service temperature without load
Short term 110-1400 C
Long term 90-1100 C
Mould shrinkage 1,9-2,3%

Conversion processes. Injection moulding, extrusion, blow moulding.

34
Uses. Components for cars, office and household machines, gears, bearings,
screws, parts for pumps, textile machinery, radio, television, aerosol components,
springs, engineering components with snap fittings, parts of conveyor belts etc.

1.5.2.2.6 Polyetheretherketone (PEEK)

Peek is a high performance semi-crystalline thermoplastics. Its high heat resistance
and mechanical properties can be further enhanced by reinforcement with glass or
mineral fibres. The distinguishing properties of PEEK are:

 Very high tensile strength

 Very good fatigue resistance
 Very high heat resistance
 Very good chemical resistance, also at elevated temperatures. (soluble only in
sulphuric acid).
 Excellent electrical properties
 Good wear resistance
 Low friction
 Low water absorption
 Resistant to hydrolysis
 Self extinguishing

Specific gravity 1,32

Moulding temperature 375-450 0C
Service temperature without load
Short term 3150C
Long term 2600C
Mould shrinkage 0,7-1,2%

Conversion processes. Injection moulding, extrusion.

Uses. Electrical and electronic components, connectors, relays, printed circuits,

pumps for aggressive fluids as well as for foodstuff, replacement of metal
components in automobiles, aeroplanes and rockets as well as in military hardware.

Special note. Polyetherketone (PEK) polyaryletherketone (PAEK) have similar

properties.

1.5.2.2.7 Liquid crystal polymers (LCP).

LCPs are a unique class of thermoplastics possessing properties of semi-crystalline
and amorphous plastics and much more. Based on polyester, their molecules are
stiff, rod-like structures, organised in large, parallel arrays in the melted as well as
solid state. Their molecules lend strength like reinforcing fibres and hence LCPs are
also called self reinforcing plastics.

 They are resistant to most solvents, even at elevated temperatures.

 They have a low melt viscosity; their L/T ratio of flow may exceed 350.
 Their cooling time is very short.
 They have the least shrinkage and warpage of all thermoplastics.

35
  They have very high tensile strength, stiffness and hardness.
 They have good creep resistance.
 They retain their physical properties even after repeated heating and cooling.
 Their natural colour is beige.
 They are self-extinguishing.

Special attribute. Some filled grades exhibit negative shrinkage along flow.

Specific gravity 1,4

Moulding temperature 390-410 0C
Service temperature without load
Short term 260-300°C
Long term 220-240°C
Mould shrinkage: 0,3-0,6%

Conversion processes. Injection moulding.

Uses. Components for electrical field such as plugs, connectors, socket switch
components, microwave appliances, coil bobbins.
Components for automotive sector such as parts for fuel, ventilation and air
conditioning.
Components for medical field such as parts for hearing aids, metal substitution in
surgical and dental instruments, sterilisation containers, dosing appliances etc.
General: Gears, computer parts, sensors, parts of printing machines, axle of
photostat machine, pump housing, mobile phone parts, fibre optics, CD players etc.

1.6 Classification of thermoplastics.

On the basis of their properties and application, thermoplastics are classified in three
categories :

1.6.1 Commodity plastics: The group of thermoplastics, which can be safely used
up to 90°C, is known as commodity plastics. It comprises polyvinyl chloride,
polystyrene and its derivatives and the polyolefines. ABS and PP, however can also
be used with boiling water.

Commodity plastics find use in packaging, household articles and home appliances.
Volume wise, commodity plastics form the largest part of processed thermoplastics.
Extrusion, injection moulding and blow moulding are the major processes for their
conversion. The maximum processing temperature for commodity plastics does not
exceed 260° C. Only a few of the commodity plastics, e.g. H.I.P., SAN and ABS are
hygroscopic and call for pre-drying.

1.6.2 Engineering plastics: Thermoplastics, with higher temperature resistance

than the commodity plastics and with better mechanical properties, for example,
polycarbonate, polyethleneteraphthalate as well as polybutyleneteraphthalate and
polyacetal fall in this group, so do polysulphone and polyamides. Engineering
plastics may be subjected to temperatures as high as 140°C. PSU and PA 4.6 can
go up to 160°C.

36
Engineering thermoplastics have much better mechanical properties than the
commodity plastics and are used for manufacturing components for technical
application. They are mainly processed by injection moulding. Their processing
temperatures range between 250-350°C. Most of them need pre-drying before
moulding. The moulds too are maintained at higher temperatures.

1.6.3 High performance thermoplastics: This special class of plastics is superior

to the other two groups not only in very high temperature resistance but also in
electrical, mechanical and chemical properties.

These include Polyetherimide, polyether sulphone, polyphenylene sulphide, liquid

crystal polymers, polyether etheramide and polytetrafluoroethylene. They can
withstand temperatures up to 260°C.

High performance thermoplastics are processed exclusively by injection moulding.

The processing temperatures exceed 400°C in certain cases. The injection
pressures too range from 1000 to 2000 bar. The moulding machines for their
processing must have special plasticising units to withstand high temperatures and
wear. The injection moulds for high performance thermoplastics have to be heated to
120°C and above.

1.7 The form of the raw material.

Plastics are generally compounded by the raw material manufacturer and supplied
ready for processing into desired products. The most common form of the
thermoplastics raw materials is granules or beads, pigmented or in their natural
colour. Their form facilitates easy transport and feeding into the processing
machinery.

Polyvinyl chloride, a thermoplastics, is also supplied as powder. It enables the

processor to make a formulation answering his particular requirement by mixing
various additives in proportions yielding the desired mechanical and thermal
properties. PVC is a very versatile polymer which can be compounded to give
numberless variations in rigidity from brittle hard to soft rubbery state.

Thermosetting plastics are available as granules, powder and dough for various
methods of processing.

1.8 Preparation of thermoplastics for moulding.

1.8.1 Pre-drying.
Some of the thermoplastics are hygroscopic. It is imperative that they be dried before
moulding. The moisture leads to defective mouldings and rejection. All plastics,
however, cannot be pre-dried at the same temperature. Table 1.3 lists the
recommended drying temperatures and the duration for various hygroscopic
thermoplastics.

The reground materials should be dried separately and stored in airtight containers.

The most effective way of drying the polymer granulates is by circulation of pre-dried
hot air.

37
 Table 1.3
Pre-drying of Thermoplastics.

Acronym Polymer Predrying Duration

Temp.°C hours
SB High impact Polystyrene 70 2-3
1.8.2 SAN Styrene Acrylonitrile 70-80 2-3 Col
ABS Acrylonitrile Butadien Styrene 70-80 2-4 our
CA Cellulose acetate 70 3 ing
PMMA Polymethyl Methacrylate 70 4 of
PC Polycarbonate 120 4
PPO Polyphenylene Oxide 100 2
PSU Polysulfone 150 6
PET Polyethylene Terephthlate 130 2-4
PA 6 Polyamide 6 80 2-4
PA 6 6 Polyamide 6 6 80 2-4
LCP Liquid Crystal Polymer 150 1-2
POM Polyacetal 110 2-3
PEEK Polyetheretherketone 150-200 5
PC-ABS-Blend Polycarbonate-ABS-Blend 90-110 2-4
EVA Ethylene Vinyl Acetate 70 1-2
thermoplastics.
Thermoplastics are rarely used in their natural colours. The natural colour of semi-
crystalline thermoplastics is white or pale yellow. The amorphous plastics are
transparent like glass with a yellowish or bluish tinge. A positive attribute of plastics is
their ability to take on almost any colour.

Colorants for plastics are of two types. Pigments are generally inorganic compounds,
mostly compounds of metals like titanium, iron, chromium, cobalt, cadmium etc.
They do not dissolve in plastics melt but lend it the corresponding colour and make it
opaque. They can usually withstand high temperatures during processing and
application. Titanium dioxide is the most commonly used pigment for making plastics
white or opaque. Some of the pigments are toxic in nature and may not be used for
products coming in contact with edibles or the human body.
Some commonly used pigments are:

White- Titanium dioxide, Zinc sulphide

Yellow- Lead chromate
Red- Iron oxide, molybdenum red
Green- Chromic oxide, cobalt green
Brown- Iron oxide
Black- Carbon black

Golden, metallic, pearlescent and fluorescent colours constitute the specialities.

Dyes are organic substances and get dissolved in plastics. They are transparent and
when used with natural amorphous thermoplastics, lend it their colour without
making it opaque. Although more brilliant in colour, dyes are more heat and light

38
sensitive and some may also bleach out gradually in use. Because of these
limitations, dyes are not used as extensively as the pigments.

Thermoplastics are available in their natural colours. They are also supplied by the
producers and compounders in a large range of standard colours at an additional
cost. Even special colours and hues can be ordered if the quantity is large enough.

Inspite of the higher price, the ready for use, coloured plastics assure uniformity,
homogeneity and repeatability from batch to batch because the suppliers have at
their disposal, the expensive machinery for compounding, controlling and testing and
the know-how and experience. Colouring in house is not more economical in most
cases but it may have to be resorted to for out of-the-way colours and shades,
especially when the quantities required are not very large.

Choice of colorants. Colorants effect not only the appearance but also the
morphology of the plastics. Depending upon their own chemical structure, they
influence the melting and rheological behaviour, the crystallinity and the shrinkage.
The colorants must fulfil following criteria:
 be compatible with the polymer
 withstand the processing temperature
 should not plate out leaving a layer of colour on mould surface.
 withstand working temperatures for prolonged periods
 remain unchanged under operating environmental conditions, such as
chemicals, gases and fumes, UV rays, moisture etc.
 should not migrate or bleach out
 should not be effected by light
 should not alter the mechanical properties of the polymer.

1.8.2.1 Colouring in own shop.

Because of the following reasons, the moulders may choose to do the colouring of
plastics themselves:
 The desired colour is non-standard and the quantity required is not large.
 The product has to be moulded out of the same material but in a number of
colours.
 The material in natural colour is cheaper when purchased in bulk.
 The inventory of the raw material in only a few colours is simpler and more
economical.
 Ease of storage. Space saving
Various options for colouring the raw material in house are:

1.8.2.1.1 Dry colouring

It is carried out with pigments in powdered form. A precisely weighed amount of the
colour is added to a predetermined quantity of plastics granules along with a wetting
agent in liquid form. The mixing takes place in a tumbler which consists of one or two
hollow drums with tightly fitting closures . The drums are revolved around in a
vertical plane at slow speed by means of an electrical motor. The design of the
equipment facilitates constant mixing of granules and the powdered colour.

39
Advantage. The apparatus is simple in design and low in cost. The mixing is fairly
uniform. It is quite useful for small quantities which could be used immediately. The
quality of colouring in the product is satisfactory.

Disadvantages. The process must be carried out in isolated rooms, as the powder
may contaminate the surroundings. The apparatus must be kept meticulously clean if
it is to be used for various colours. The pigment may stick to the screw and the barrel
of the plasticising unit and may contaminate the subsequent charges in another
colour.

The colour may separate and settle down during long storage and transport over
long distances. The colouring of the mouldings may not be uniform in case of
separation of pigment. Moreover, the colour may not disperse equally to thin
sections of the moulding.

The mixture cannot be transported to the machine automatically.

1.8.2.1.2 Wet colouring.

Instead of powdered pigment, the colouring substance is in the form of paste. Mixing
with the granulate may be done in a tumbler for small quantities and the mixture
poured in the hopper or the pigment may be added to the granulate right on the
moulding machine. It is effected by a dosing gadget coupled with the hopper. The
predetermined quantity of the paste is pumped in with each cycle.

Advantages. Wet pigmentation is an economical method. The pigment does not

pollute the surroundings. The pigmentation is more uniform. The quality of mouldings
is very good, especially when dosing is carried out accurately on the machine.

Disadvantages. A dosing gadget is necessary for every machine for regular

production. The pigment sticks to all parts of the plasticising unit. The dosing gadget
as well as the injection unit must be thoroughly cleaned before colour changes. By
higher concentrations of the pigment, separation may take place which can bring
colour fluctuations in production. The pigment may not disperse equally to thin
sections of the moulding.

1.8.2.1.3 Colouring with master batches.

Master batches are colour concentrates, consisting of pigments embedded in
thermoplastics. They are prepared by mixing large quantities of the pigment with the
plastics and regranulating it. The percentage of the pigment may be as high as 50%.
The carrier plastics is compatible with the plastics to be coloured.

Granules of the master batch can be mixed with material granulate in required
proportion either in a tumbler or the batch can be metered to the raw material on the
machine with a volumetric dosing gadget.

Advantages. The process is very clean at all stages. It does not pollute the
environment, the mixer, the machine and the mould. Cleaning and change of the
colour are very simple. Dispersion of the colour is uniform. The dosing is simple and
accurate. Through higher dosage, greater colour intensity is possible.

40
Disadvantages. Master batches are more expensive than the dry colours or pastes.
They cannot be set in universally as the carrier plastics in the master batch must
match with the polymer to be coloured. The uniformity of distribution of colour
depends upon the efficacy of the screw. The colour dispersion in thin sections of the
moulding may not be adequate.

It must be remarked in conclusion that the geometry of the screw also plays a crucial
role in satisfactory mixing and dispersion of the pigments. General purpose screws
under 20D length do not deliver adequate results. Either screws with additional
mixing head or those with a length of 25D are recommended for colouring on the
machine.

1.8.2.1.4 Dip dyeing.

Although a post operation, dip dyeing may replace pre-colouring in many cases.
Recently developed by Bayer Material sciences of Germany and christened “Aura”,
the patented process consists of dipping the moulded or extruded article in an
aqueous solution containing the dyes along with specific surficants. The solution may
be prepared by dissolving the solvents and the dyes in deionised water at 50-60°C
and then heating it up to 96°C.

The dyes get diffused in the product in a very short period which may range from a
few seconds to some minutes depending upon the depth of penetration intended.
Variation in wall thickness does not effect the appearance of the treated product.
Special features like metal flakes or sparkle present in the article, are enhanced by
dip dyeing. The last operation in dip-dyeing comprises rinsing of the dyed article in
clear water and drying with hot air.

The process may be applied to most amorphous polymers and to some semi-
crystalline ones too.

The economical advantages of the dip dyeing technology come to the fore when a
product has to be manufactured in a number of colours in small batches. The
conventional moulding process would involve change of material by purging for
every new colour, resulting in wastage of material as well as production time. The dip
dyeing method obviates storage of plastics raw material in numerous colours and
thus reduces inventory costs considerably.

The process can also be employed to impregnate moulded/extruded articles with

UV-stabilisers, antistatic agents etc., also in conjunction with dyeing.

1.9 Recycling.
Theoretically thermoplastics can be remelted and moulded any number of times. It
must, however, be emphasised that some degeneration does take place with each
round of melting, exercising adverse influence on certain properties. Reground
material can be added to the virgin one in certain proportion without discernable
difference in quality of the mouldings. Twenty percent is considered to be the safe
limit. The size of the reground particles should not differ much from that of the virgin
granules and the mixing should be quite thorough so that the resultant melt for each
shot is uniform.

41
Mixing of recycled material is not recommended for applications where any decline
in properties may result in failure of the product or risk of health, such as with articles
for medical application etc.

Thermosetting plastics cannot be recycled for moulding. They can, however, be used
as fillers with materials in other fields.

1.10 Acronyms.
Plastics are generally referred to under their acronyms, a list of which is given below.

Acronyms for some Common Polymers.

ABS Acrylonitrile Butadiene Styrene

ASA Acrylester Styrene Acrylonitrile
CA Cellulose Acetate
CAB Cellulose Acetate Butyrate
CAP Cellulose Acetate Propionate

CN Cellulose Nitrate
EVA Ethylene Vinyl Acetate
FEP Fluorinated Ethylene Propylene
HDPE High Density Polyethylene
HDHMWPE High Density High Molecular Weight Polyethylene
HIPS High Impact Polystyrene
LCP Liquid Crystal Polymer
LDPE Low Density Polyethylene
LLDPE Linear Low Density Polyethylene
MF Melamine Formaldehyde
PA Polyamide
PAI Polyamide Imide
PAN Polyacryle Nitrile
PBTP Polybutylene Terephthalate
PC Polycarbonate
PEEK Polyether Ether Ketone
PEI Polyetherimide
PEN Polyethyleneaphthalate
PES Polyether Sulphone
PET/PETP Polyethylene Terephthalate
PF Phenol Formaldehyde
PI Polyimide
PMMA Polymethyl Methacrylate
POM Polyoxymethylene
PP Polypropylene
PPO Polyphenylene Oxide
PPS Polyphenylene Sulphide
PS Polystyrene
PSU Polysulphone
PTFE Poly Tetra Fluoro Ethylene
PU/PUR Polyurethane

42
PVC Polyvinyl Chloride
PVDC Polyvinylidene Chloride
PVDF Polyvinylidene Fluoride
SAN Styrene Acrylonitrile
SB Styrene Butadiene (HIPS)
TEEE Thermoplastic Ether Ester Elastomer
TPE Thermoplastic Elastomer
TPU Thermoplastic Polyurethane
UHMWHDPE Ultra High Molecular Weight High Density Polyethylene
UF Urea Formaldehyde

Chapter 2

Injection Moulding of Thermoplastics; the Equipment.

2.1 History
2.2 The injection moulding process
2.3 The moulding equipment

2.1 History of injection moulding.

Shellac, a natural tropical resin had been in use in the western countries since the
middle age but it was around 1850 that a method was developed for mass

43
production of articles out of it. It involved liquefying of the solid resin by application of
heat and forcing or “injecting” the melt into a confined cavity having the shape of the
intended product. The “cavity” was usually contained in two metal blocks, which
could be held together during injection and solidifying of the molten resin and then
taken apart to extract the solidified product. The arrangement was called a mould.
The existing process of die casting served as a model.

The first injection moulding device for the natural

thermoplastics was a modified die casting machine. The
range of products was limited to some household utility
articles and decorative items. It was the invention of
celluloid in 1872 which spurred development of the
injection moulding process. The first patent for an
injection moulding machine for thermoplastics was
registered by the Hyatt brothers in the United States in
1872. It was a vertical, manually operated machine, not
much different from that still being used in India for
simple, small mouldings in the cottage industry (Fig. 2.1).
A fact, which helped penetration of the new material in
many areas, was the availability of expertise in mould
making in the field of glass blowing. Celluloid became a
synonym for thermoplastics and many utility articles
appeared in the new material in attractive colours and
affordable prices. Plastics toys became a rage and ruled
the market till the first world war. More than the material, Fig.2.1
the process of its moulding had brought a revolution in
the whole concept of mass production.

44
The next notable development
took place in 1921. Hermann
Buchholz of Germany introduced
an improved version of the
manually operated injection
mouldings machine. Eckert and
Ziegler, German machine
manufacturers, replaced the
manual injection by pneumatic Fig.2.2
force and introduced their
invention in 1925. Essentially, it
was a vertical machine like its predecessor and the mould closing was still manual.
Eckert and Ziegler became leading moulding machine manufacturers though many
more followed soon. The truly automatic era dawned when the plasticising unit was
put in horizontal position in the thirties and the important parameters like pressure
and durations of injection, cooling etc. could be pre-set. The plasticising unit
consisted of a hollow steel barrel, equipped with band heaters for melting the
granules, and a piston or a “plunger” fitting closely in the barrel for injection, powered
pneumatically, electrically or hydraulically. Plasticising was improved by introducing
a torpedo in the barrel in the path of the melt, so that it received heat not only from
outer band heaters but also from inside, though indirectly (Fig. 2.2). Later, the
torpedoes too were equipped with internal heaters.

A revolutionary development was the

invention of reciprocating single screw
plasticising and injection. The screw
fulfilled functions of conveyor,
plasticiser, mixer and of the injection
plunger. The first screw preplasticising
injection moulding machine (Fig. 2.3)
was introduced in 1959 by Ankerwerke
of Germany and the principle has
given a tremendous boost to plastics.

Thermosets had been processed,

Fig.2.3 since their advent in the first decade of
the twentieth century, on vertical
presses by semi-automatic processes of compression and transfer moulding. It was
in 1963 that a screw pre-plasticising automatic machine was introduced for moulding
of thermosetting plastics.

The in-line screw pre-plasticising and injection system has become a norm and has
experienced numerous improvements since its introduction. The in-depth studies
and research in the behaviour of plastics melts have contributed to refinement of the
functions of the screw pre-plasticising and injection. Computerisation has brought
very precise setting, repeatability and control of the parameters. The closing
systems, too, have been refined and extended to electro-hydraulic, servo-hydraulic,
fully electric and combinations. Tiebarless and two platen versions of mould closing
systems and the closed loop injection have extended the scope, productivity and
accuracy of the injection moulding process tremendously.

45
The injection moulding process has not remained confined to thermoplastics, as
would be seen in the ensuing chapters.

2.2 The injection moulding process.

Injection moulding is rightly regarded as the most versatile process for conversion of
thermoplastics. It is perhaps the only process which manufactures even the most
intricate articles, right from the raw material to the final form, in one shot, obviating
after-operations in most cases.

Basically, the injection moulding process consists of two distinct steps.

a. Plasticising or liquefying of the solid plastics
b. Transferring the melt to a mould giving it the shape of the intended product
and stabilising it in that form.

In practical terms, the process comprises the following operations.

 Plasticising the thermoplastics raw material, i.e. converting it from solid to fluid
through heat energy.
 Injecting the plasticised material in a confined cavity of the shape of the article
to be formed.
 Extracting the heat from the injected melt to resolidify the plastics in the given
shape.
 Opening the cavity and extracting the solidified moulded article.

The process is carried out by an injection moulding machine, which performs these
functions and converts the injected plastics into the intended article with the help of a
mould.

2.2 The moulding equipment.

In order to be able to perform various steps involved in the injection moulding
process, the equipment should have the means to:

 plasticise the polymer

 hold and close a mould
 inject the plasticised plastics with pressure in the closed mould
 cool the injected material
 open the mould
 eject the moulding

The equipment viz. the injection moulding machine, consists of several units which
perform the above named tasks. These are:

2.3.1 The plasticising unit

2.3.2 The clamping unit
2.3.3 The Ejection device
2.3.4 The cooling battery
2.3.5 The machine body
2.3.6 The control panel

46
Fig. 2.4 shows above units in Fig.2.4
their usual position.

2.3.1 The plasticising unit.

It transports the material from the source (feeding point) towards the delivery
(nozzle) end.
It plasticisers (melts) the solid polymer and homogenises it while conveying it to the
nozzle end.
It injects the melt into the mould.
It doses or recharges the material for the next injection.
The plasticing unit consists of the following parts:

2.3.1.1 The barrel.

The plasticising unit consists of
a long, hollow metal cylinder
called barrel, which contains a
screw closely fitting in its bore
(Fig. 2.5). The screw can rotate
and reciprocate. The cylinder,
which is generally placed
horizontally, is fixed on one end
to a motor which powers the
screw. The barrel has a vertical
opening at this end of its Fig.2.5
periphery, where a hopper for the
raw material is mounted at right
angles to its axis. It resembles a conical funnel, circular or square in cross section,
and is generally fabricated out of stainless steel sheet. It has a closely fitting lid,
which is sometimes foreseen with electrical heaters on the inside to prevent moisture
deposition on cold plastics raw material. The hopper is a receptacle for the granules
of the thermoplastics to be moulded. It has a glass covered side window to display
the level of the filling. It has also provision for shutting off the aperture to the barrel
and for emptying of the contents.

The barrel is equipped with a number of electrical band heaters controlled by means
of thermocouples, which are placed in holes drilled in the wall of the barrel to a safe
depth but not entering the material bore. However, the section of the barrel around
the hopper (the feeding section) is provided with water cooling to prevent the
material granules from getting heated, melting superficially, sticking together
(bridging) and blocking the passage from hopper to the screw.

2.3.1.2 The cylinder head.

The end of the barrel opposite to the feeding zone is closed by a flange like
component called the cylinder head, centred and fixed onto the barrel with screws.
Its function is to reduce the bore of the barrel gradually to that of the nozzle placed
on its exit end. The nozzle is generally screwed into the cylinder head. Like the
barrel, the head and the nozzle are also equipped with band heaters and
thermocouples. The cylinder head for machines processing PVC and thermosets is
designed to be readily detachable.

47
The barrel, the cylinder head, the nozzle and the hopper form the outer components
of the plasticising unit. The barrel and its head are made of nitriding steels for
processing of common polymers without abrasive fillers. Stainless steel is preferred
for aggressive polymers like PVC and POM and a bi-metal hard sleeve inside the
barrel is used for materials containing abrasive fillers.

The nozzle forms the end of the barrel and represents the link between the
plasticising unit and the injection mould. Its inner bore tapers down to a small orifice
in the range of 3-6 mm., through which the molten plastics is injected into the mould.
The plasticising unit assembly is generally placed horizontally. It can be moved
linearly to and fro.

Special purpose machines may have the plasticising unit in positions other than
horizontal also.

2.3.1.3 The nozzle.

The machine nozzle forms the exit end of a plasticising unit and is fitted onto the
cylinder head. It is the link between the source of the melt and the receiver viz. the
mould. Its functions are:
1. reducing the size of the melt channel from the bore of the cylinder head to
that of the entry in the mould.
2. establishing a leak proof link between the plasticising unit and the mould.
3. enabling a smooth transfer of the melt from the plasticising unit to the mould
with least possible loss of heat and pressure.
4. separating the fluid melt in its body from the frozen material of the sprue in the
mould.
5. preventing drooling of the melt from the plasticising cylinder, when the unit is
not resting on the mould.

There are a few designs of the nozzle for general and specific requirements. The
most common types are:

2.3.1.3.1 The open nozzle

(Fig.2.6). An open nozzle is the
standard outfit for an injection
moulding machine and is used with
most plastics. It is centred and
screwed in the barrel head. As the
figure shows, its internal bore,
starting from the internal diameter
of the cylinder head, tapers down
to a smaller hole to match with the Fig.2.6
sprue. The small hole runs straight
for 3-5 mm. and then funnels out. This measure forms a distinct tear-off point where
the cold material in the tip of the nozzle resting against the sprue bush of the cooled
mould would tear off from the hot melt on the right and go out with the frozen sprue.

The open nozzle, besides being the simplest and the cheapest, provides a smooth,
interruption-free passage to the melt, causing very little pressure loss. It does not

48
have any dead corners where the melt could stagnate and degenerate. It is suitable
for almost all materials, particularly for the heat sensitive ones. Polymers with very
low viscosity, such as the polyamides, pose a problem of drooling with the open
nozzle. Special nozzles with shut-off mechanisms have been developed for use in
such cases. These are:

2.3.1.3.2 The spring operated shut-off nozzle. The nozzle is closed by a spring
loaded needle or pin placed in the central path of the melt. The closing end of the pin
is tapered so that at the time of injection, the melt pressure pushes it back and sets
the passage free for the melt. As the needle has to be placed on the central axis in
line with the bore of the nozzle, the melt from the barrel must be diverted around it.
The flow is no more streamlined as in an open nozzle.

The version shown in figure

2.7 has an externally placed
compression spring, which
exerts pressure on the needle
through a crossbar. A
shortcoming of the nozzle is
that the material channels
cannot be distributed
uniformly due to the space
occupied by the cross bar. Fig.2.7
However, the spring can be
replaced without taking the
nozzle apart.

Another version, depicted in figure

2.8, differs from the foregoing
design in the location of the spring.
The working principle is identical in
both versions. The spring (a
number of disc springs) is located
inside and the melt goes around
the spring housing through a
Fig.2.8 number of evenly distributed
channels. All material streams
meet again near the central bore of
the nozzle blocked by the conical tip of the needle. The drawback of the design is
that the replacement of springs requires dismantling of the nozzle.

As the spring operated needle valves depend upon the injection/ holding pressure to
open the melt passage, the nozzle can remain partially closed if the pressure is low.
A part of the pressure can also be lost in overcoming the force of the spring.
Charging or refilling for the next shot is possible only with the nozzle pressing on the
sprue bush as otherwise the back pressure may push back the closing spring
leading to drooling. Springs, working constantly at high temperature, may lose a part
of their tension after some time.

49
Spring loaded nozzles separate the hot melt from the colder material in the front
bore which goes out with the sprue. Another advantage offered by these nozzles is
the possibility of charging as well as purging without the support of the mould.

2.3.1.3.3 Hydraulically operated shut-off

nozzle (Fig. 2.9). The blocking of the melt
path is effected by a cylindrical bolt, placed
across the main bore. The bolt has a hole
corresponding to the material passage, which
can be brought in line by turning the bolt in
“open” position, by means of a small
hydraulic cylinder, so that the melt can pass
through unhindered. A modified version
slides the bolt to align its hole with the melt
bore, instead of turning as described before.
Fig.2.9
This design offers the best solution as there are
no divisions, no diversions and no narrow channels which could overheat the
material. The opening and closing is regulated by the machine controls.

2.3.1.3.4 The slider shut-off nozzle.

The main part of this shut-off nozzle is a
tip which can slide linearly in the nozzle
body which, in turn, is fixed onto the
cylinder head. The figure 2.10
demonstrates its mode of functioning.
When the injection unit is not in contact
with the mould, the sliding tip of the
nozzle is kept in the forward position by
the melt pressure so that the angular
passages of the melt to the central outlet Fig.2.10
path in the tip are blocked. When pressed
against the sprue bush of the mould prior
to injection, the tip is pushed to the rear position and the angular channels get
connected to the central bore of the nozzle body. Now the melt can be conveyed to
the mould. When the cylinder is pulled back after the holding phase, the material
pressure pushes the tip forward and shuts off the angular channels.

The nozzle is simple in design and does not require external aids such as springs or
hydraulic cylinders for operation but suffers from the drawbacks caused by diversion.
The melt left in the bore of the sliding tip after the shut off may cool and lead to
blockage or to the defects in the subsequent moulding caused by cold material.
Purging is possible only with some additional device.

It may be mentioned that apart from the designs described above, there are
numerous variations of the shut-off nozzles, developed by different machine
manufacturers.

50
 2.3.1.4 Static Mixers. Although the screw
also effects mixing, static mixers may be
incorporated in the machine nozzle to
enhance the degree of mixing, especially of
the pigments added to the granulate in form
of liquid, powder or master batch. Static
mixers are devices to divide the melt into a
number of smaller streams which join again
at the end. The pineapple mixer (Fig. 2.11) is
the simplest form of a static mixer. The other
designs employ zigzag plates or barriers to
the same end (Fig. 2.12). It proves beneficial Fig. 2.11
with sophisticated products where the surface
finish is one of the prime quality attributes. The more uniform melt temperature
narrows down the dimensional fluctuation
and thus helps reduce rejection rate. Static
mixers are also needed for moulding of
thermoplastic blends.

Fig. 2.12
Depending upon the design of the mixing
channels, there is some loss in the injection
pressure. The temperature of the melt, however, experiences a rise. Generally, the
injection pressure does not require compensation as the melt with more even
temperature distribution flows more easily.
Mixers, however, come in the way of the suck-back.

2.3.1.5 The screw.

The primary function of the plasticising unit, suggested by its name, is executed by
the screw but apart from plasticising, the screw performs a number of tasks as listed
below:

 transporting the raw material from the source (hopper) towards the delivery
point (barrel head).
 compacting the material and expelling air
 plasticising the raw material through friction
 mixing the material
 homogenising and compressing the molten material
 injecting the melt in the mould
 compensating for the shrinkage of the melt in the mould

In order to be able to perform these functions, the screw is given a special

configuration. It is divided in three distinct zones or sections along its length. These
are feed zone, compression or the
transition zone, and the metering
zone, placed one after the other in

Fig.2.13
51
the named order (Fig. 2.13). They differ from each other in their geometry and their
functions.

2.3.1.5.1 The feed zone.

The feed zone of the screw (A) is situated right under the hopper from which it gets
the material and transports it further to the next zone when it rotates. It extends over
half the length of the screw. The threads of the screw have their maximum depth in
the feed zone. It is usually 0,15 times the diameter for the general purpose screws.
The minimum depth of the feed zone, however, is never less than 3 mm. so as to be
able to accommodate plastics granules. This is why, screws of a diameter less than
12 mm. are not feasible. A core diameter of less than 6 mm. will not be able to
withstand the torque acting upon it during operation.

2.3.1.5.2 The compression Zone.

The compression zone (B) starts where the feed zone ends. The depth of the thread
starts decreasing gradually in this zone. This leads to compaction of the granules
and results in expulsion of the included air towards the hopper. As the sectional area
decreases gradually, the material is compressed more and more. Consequently, the
friction between the granules and the barrel and also among the material particles
increases and the plastics starts melting. A part of the heat also comes from the
electrical heaters fitted around the barrel also. A molten film deposits on the bore of
the barrel but the advancing flank of the rotating screw keeps on scraping and
pushing it inwards in a looping motion. This action leads to mixing and uniform
heating of all material particles.

The length of the compression zone is about one fourth of the length of the screw.
The ratio of the thread depth at the start and at the end of the compression zone is
termed as the compression ratio (actually the compression ratio relates to the
reduction in volume but as the pitch of the thread remains constant, the ratio of
depth corresponds to that of the volumes in the beginning and at the end of
compression). This is the factor having the maximum influence on friction and heat
generation. The compression ratio of the general purpose screws ranges from 2,5:1
to 3,5:1. For heat sensitive materials like PVC, it does not exceed 2:1. As a rule, a
higher compression ratio increases the output. For polyolefins, which have a wide
processing temperature range, it may exceed 4:1. It is lower for more viscous
materials such as polycarbonate.

2.3.1.5.3 The metering zone.

The metering zone (C) forms the last section of the screw and begins where the
compression zone ends. It has a uniform depth all along, namely that at the end of
the preceding zone. It is usually about one fourth of the total screw in length. Its main
function is to stabilise and homogenise the melt and bring it to the final temperature
for injection. As the depth of the screw is minimum in this section, there is maximum
friction between the melt and the cylinder wall as well as between various layers of
the melt itself. The sticking and scraping during the rotation leads to constant mixing
and homogeneity of the temperature.

A non-return valve fitted at the end of the metering zone forms the last part of the
screw. As described in the next section, the melt being forwarded over the metering
zone by the rotating screw can pass through the valve towards the barrel head but

52
cannot flow backwards when the screw acts as an injection plunger. As the melt
flows forward during plastication, the screw recedes back, making room for the melt.

The other function of the screw is injection of the melt. It acts as a linearly moving
plunger for performing this task. It is pushed forward to force the molten material out
of the barrel. The non-return valve prevents leakage of the melt in reverse direction.
The screw does not rotate during the injection stroke.

The dimensions of various features of the screw are linked with its diameter. The
pitch of the screw is generally maintained uniform as 1xD throughout its length. The
helix angle works out to about 17.8, which has been found to be most efficient for
transporting the material. The land width of the thread flank is taken as one tenth of
the screw diameter. Its front flank, pushing the material, is kept vertical to the screw
axis and joins the root diameter with a fillet radius whereas the back of the flank is
tapered at an angle of 20-30 degrees to increase its strength. The ratio of the length
to the diameter of the screw may vary from 18 to 24. The larger the L/D ratio, the
more the shear heat generated by friction and better the mixing.

Too long a screw is difficult to support and maintain straight. It may start touching the
barrel due to the overhang. The length influences the plasticising distance and hence
the degree of homogeneity. Too short a distance may effect the homogeneity
adversely. The length of various sections is expressed as a function of the screw
length.

Irrespective of the length, the screw and barrel must have a very close fit. The
maximum clearance aimed at is about 0,2 mm.

Screws with shallow depths are better for homogeneity but lower in output.

The screws are hardened by nitriding. The hardened layer measures about 0,2 mm.
The material used for fabrication of screws is a nitriding steel. Coatings of special
hard alloys are deposited on the screw surface for processing of filled, abrasive
compounds. Wear and tear in the plasticising unit occurs due to removal of metal
particles from the surface by the abrasive action of fillers in the plastics. Adhesive
wear is caused by the strong holding power exercised by plastics like polycarbonate,
polysulfones etc., especially at lower temperatures. The thin nitrided layer from the
surface of the screw gets removed gradually and the clearance thus generated
enhances backward leakage. Subsequently, the efficiency decreases with increasing
wear.

Another serious cause of the wear of the plasticising unit is decomposition of certain
heat sensitive plastics. Some volatile additives, too, decompose at higher
temperatures and corrode the surface of the screw and barrel. For working of
aggressive materials, the screw and barrel must be coated with protective layers of
chromium, nickel etc.

In conclusion, it may be mentioned that special screws have been developed for
specific tasks. Screws for more intensive mixing have another zone added onto the
metering zone which may have mixing devices like staggered pins to part the melt in
a number of streams which join again. The effect is similar to that of the mixers (see

53
Fig. 2.11 & 2.12). A degassing screw, especially meant for hygroscopic
thermoplastics, compresses the melt like a conventional screw and then releases the
pressure in a subsequent decompression zone with greater depth so that the steam
and gases thus released can escape through tiny holes in the barrel. It continues
with a second compression zone and a metering zone. It is obvious that the
degassing plasticising unit will be almost double in length than a normal one.

2.3.1.6 The Screw tip.

During injection, when the screw
acts as a plunger and pushes the
melt through the small orifice of the
nozzle, very high forces act on its
front part which tend to push the
melt backwards. A device called
non-return valve or check valve,
fixed on the tip of the screw, has
the function of allowing the melt to
flow in the forward direction during
plasticising but prevent its
backward flow during injection and Fig.2.14
the hold-on phase. The most
common type of the non-return valve (Fig. 2.14) consists of a sleeve whose external
diameter has a sliding fit in the bore of the barrel head. The other part of the valve is
an arrow like tip which is fitted onto the front face of the screw through the sleeve,
leaving a gap for latter’s linear movement. The inner bore of the sleeve is larger than
the shaft of the arrow head passing through it. The conical arrow head has three or
more cut-outs which allow the melt to pass through and collect in the front part of the
barrel. The opposite face of the sleeve, when pushed back, sits snugly against the
front face of the screw and forms a leak-proof joint.

During plasticising, the melt pushes the sleeve forward and passes through the cut-
outs in the tip towards the front part of the barrel, but during injection, the melt in the
front pushes back the sleeve against the face of the screw. Now the sleeve forms a
piston and prevents passage of the melt backwards.

An improved version of the non-return valve described above integrates a mixing

function in the part. The shaft of the tip, which passes through the bore of the sleeve,
has shallow spiral grooves cut on it, through which melt can pass forward but
partially unmolten granules cannot. Unlike in the first version, the bore of the sleeve
here has a sliding fit on the shaft.

Another design of the non-return valve, shown in

figure 2.15 makes use of a ball in the material
channel which allows the melt movement in one
direction only.

The functioning of the non-return valves entails

passage of the melt through narrow gaps, which
may lead to overheating and degeneration of heat
Fig.2.15 sensitive polymers like PVC. For such materials,

54
specially designed screw tips instead of non-return valves are employed (Fig. 2.16).
The thread continues, with decreasing depth till the end of the screw tip. Some
backwards leakage of the melt is unavoidable but there is no degradation.

2.3.1.7 Plasticising and injection.

As the screw rotates and transports the material
towards the nozzle end plasticising it in the process, it
recedes by the same distance to make room for the
molten material in the front section of the barrel.
However, by throttling the exhaust oil from the injection
cylinder at the back of the screw, pressure can be
applied and maintained on the melt to increase frictional
work and to improve mixing. This is termed as the “back
pressure”. There is provision for the screw to be pulled
back by a short distance at the end of the dosing
process. Called "suck-back" or "decompression", it Fig.2.16
relieves the pressure on the compressed melt in the front
part and thus helps in preventing drooling from the open nozzle. Shut-off nozzles are
employed in case of easy flowing polymers, such as Nylons.

The heat needed for plasticising the solid material originates from the heaters
around the barrel and from the frictional work rendered by the screw. Whereas the
heat provided by the electrical heaters is regulated by the thermocouples, that
contributed by the screw depends upon its surface speed. Too high a speed may
cause overheating leading to degeneration of the polymer.

As described before, the rotating screw makes the granules rub against the barrel
wall and form a molten film there. The advancing flank of the thread scrapes the
stationary molten material adjacent to the barrel wall and forces it towards the screw
root, causing a good mixing and achieving more homogeneity in melt temperature.
All material is turned into a viscous fluid before it reaches the end of the
compression zone. The back pressure drives any air trapped between the granules
back towards the hopper. Finally, the next section viz. the metering zone,
homogenises the melt.

The plasticising unit is capable of linear movement and is held against the mould
with sufficient force during injection to prevent leakage. It can be pulled back after
dosing to break the contact between the cooled mould and the heated nozzle.

The screw needs rotary movement to act as a transporter and plasticiser. It must
also be able to advance axially to inject the melt and to recede during charging to
make room for the melt. The rotary motion is imparted by a hydraulic or an electric
motor. Both have their advantages and disadvantages. The hydraulic motor has a
constant torque but its speed can be varied steplessly. The electric motor is smaller,
more efficient and more economical but requires a gear box for speed adjustment
which cannot be stepless. In contrast to a hydraulic motor, it has an overload
capacity.

A hydraulic cylinder, mounted in line with the screw at the feeding zone end, delivers
the force and the linear movement for injection. Another hydraulic cylinder, placed

55
under the unit and coupled with it, moves the
plasticising unit linearly towards the mould and away
from it. It also delivers the press-on force ( Fig. 2.17).

Another movement needed by the plasticising unit is

closing and opening of the hydraulic shut-off nozzle. A
small hydraulic cylinder performs this operation.

The fully electrical injection moulding machines employ

Fig.2.17
AC-servomotors in conjunction with threaded ball
spindles for the rotation and the linear movement of the
screw. The force and the movement is transferred with the help of belts made of
special elastomers,
making the operation
smooth and noiseless.
The movement of the
injection unit too is
executed in the similar
manner.

Fig. 2.18 illustrates the

arrangement in principle.
Fig.2.18
2.3.1.8 The
Capacity data of an injection Unit.
The parameters which convey the capacity and capability of an injection unit are:

2.3.1.8.1 The maximum injection pressure. It depends upon the diameter of the
screw. It equals the force from the driving system acting on the screw divided by its
cross section.

As a rule, the machine manufacturers offer three different plasticising units for an
Injection moulding machine. All units have same length but screws of different
diameters (and corresponding barrels). Consequently, the specific injection
pressures are also different. The biggest screw has the least pressure but more
output. It is used for easy flowing polymers. The minimum specific pressure is
generally over 1000 bar. The smallest screw offers the maximum injection pressure
and is employed for very viscous plastics such as polycarbonate etc. Its output is the
least among the three sets.

The L:D ratio is obviously different in each case.

2.3.1.8.2 The maximum shot volume. The maximum distance that a screw is
designed to recede while dosing is 4-5 times its diameter. In other words, the
maximum volume of melt plasticised and transported to the front of the barrel for
injection is limited to the cross sectional area of the bore multiplied by the back
stroke. It is, however, advisable to count with about 80% of the rated shot volume.
The shot weight will depend upon the specific gravity of the molten polymer.

56
It may be recalled that all thermoplastics expand when molten. The increase in
volume may be as much as 30% or more for semi-crystalline materials and about
half of that for the amorphous ones. Consequently, the melt will have a lower specific
gravity than that quoted for the solid thermoplastics. The effective shot weight would
depend upon both factors, viz. the expansion as well as the specific gravity. Table
2.1 lists the conversion factor for some molten thermoplastics.

Table 2.1
Conversion factors

Thermoplastics Conversion
Factor
PS 0,91
SB 0,88
SAN 0,88
ABS 0,88
CA 1.02
CAB 0,97
PMMA 0,94
PVC-hart 1.12
PVC-soft 1.02
PC 0,97
PE 0,71
PP 0,73
PP+20% Talcum 0,85
PP+40% Talcum 0,98
PP+20% GF 0,85
PA 0,91
POM 1.15

2.3.1.8.3 The Plasticising Capacity. It is a theoretical parameter which states the

amount of plasticised material if the screw plasticised continuously. Nevertheless, it
furnishes useful information whether the cooling time would suffice for dosing the
next shot.

2.3.2 The mould closing unit.

Placed in line with the plasticising unit is
a set of two vertical plates, also called
mould platen (Fig. 2.19). The one on the
right, closer to the plasticising unit, is
fixed on the machine bed and has a
precise round hole in the middle in line
with the horizontal axis of the
plasticising unit, which allows access to
the nozzle of the later and also serves
as a locating device for the injection
mould. The platen has a number of
Fig. 2.19
threaded holes for clamping of one part of the mould
(usually called the injection or the fixed mould half). The

57
fixed platen also supports four tie bars (two in case of very small machines), which
serve as guides for the other platen, that moves to and fro and carries the other
mould half. The mould is generally loaded from above. The larger machines have the
provision of pulling out one tie bar in order to load the mould from the side. Like the
fixed platen, the moving platen too is provided with threaded holes for clamping of
the other half of the mould (ejection or moving half) and has an accurate circular
opening in the centre, which provides access to the ejection mechanism and serves
as location for the moving mould half.

Fixing of the mould halves on the platen either directly with bolts or with the help of
clamps is the classical method widely in practice. Additional devices like mechanical
or hydraulic clamps can also be added onto the platen for fast fixing. Some
machines are also equipped with electromagnets in the platen with mechanical
safety arrangement so that the mould remains in place even in case of power failure.
The moving platen is moved, by means of hydraulic, mechanical or electrical
systems or by their combination, towards the fixed platen to close the mould (i.e.
bring both mould halves together) and away from it to open it. The tie bars guide it
accurately. In bigger machines, the moving platen is further supported on the bed to
prevent bending of the tie bars. Hydraulic or electrical ejection systems are also
mounted on the back of the moving platen.

A third plate, parallel to the other two and fixed on the bed behind the moving platen
on the same axis, holds the other ends of the tie bars as well as the motive devices
such as toggle lever, hydraulic cylinder etc. In earlier versions, it also held the
ejecting rod (see ejection mechanisms- 2.3.3).

The latest generation of the injection moulding machines has no tie bars, thus
providing better access to the platen, easier loading of the mould horizontally or
vertically and better utilisation of the platen area. Guidance to the moving platen is
provided in an alternative manner, described later.

The closing unit has the function of closing and opening the mould and holding it
closed with a predetermined force during the injection phase. "The clamping force"
counters the force, generated by the injection pressure in the mould, which tends to
open it. This force is the product of the projected area of moulding and the effective
injection pressure per unit area. The maximum area of the article, which can be
moulded on a particular machine, can be derived from the clamping force of the
machine. It also serves as measure of the machine size.

Summing up, the essential parts of the mould closing unit of a moulding machine
are:

a) A fixed platen (injection side).

b) A moving platen (ejection side).
c) Guiding elements (tie bars and bushes).
d) The third platen.
e) Closing and locking mechanism.
f) Ejection system.

It performs the following functions:

58
1. Carry the two mould halves.
2. Bring the two mould halves together-- precise, parallel and coaxial.
3. Move ejection mould half fast close to the fixed half.
4. Close the mould gently.
5. Build up the locking force.
6. Keep the mould locked during injection and hold-on phase.
7. Release the force after the cooling phase.
8. Open the mould gently till the parting of the two mould halves.
9. Move back fast.
10. Slow down before stopping at the pre-set position.
11. Perform additional functions like ejection, core pulling etc.

A sliding safety cover with provision to stop any movement of the platen, if it is
opened inadvertently, shields the clamping unit.

2.3.2.1 The Mould Closing Systems.

There are three distinct systems of closing (moving the platen) and locking in use.
These are:

I. Mechanical (toggle lever)

II. Hydraulicc (hydraulic cylinders)
III. Electrical (electrical motors and threaded spindles)

These systems comprise three platen, viz. the fixed mould platen on the injection
side, the moving mould platen and a third fixed platen behind the moving one, on
which the driving components such as the toggle levers, the hydraulic cylinders or
the electrical parts are anchored.

In addition, there are hybrid closing systems in use which combine the above basic
types.

Two distinctly different mould closing systems are:

IV. Two plate locking system. (hydraulic)

V. Tiebarless locking system. (hydraulic)

2.3.2.1.1 The mechanical closing system.

The system makes use of toggle
lever mechanism to move the middle
platen to and fro and to lock it. As
shown in figure 2.20, it is hinged on
one side on the third plate and on
the moving platen on the other end.
A small, double acting hydraulic
cylinder provides the force and the
movement to the central hinge of the
toggle lever for opening and Fig.2.20
closing.

59
The toggle lever closure has proved suitable for injection moulding machines
because of its natural attributes viz.:
 Gentle start, fast movement and then slow movement at the end.
 High closing force at the end of the closing stroke at the cost of very little work.
 Possibility of positive locking by overstepping the dead point.

The toggle lever mechanism may be of the single type as shown above. It is
connected to the moving platen in the middle. It is simple in construction but has
certain serious drawbacks.
 It does not guarantee absolutely parallel movement.
 It leaves no free space in the centre of the moving platen for placement of the
ejection mechanism.
 The position of the hydraulic cylinder is inconvenient. If placed below, it clashes
with the machine bed. Fixed upwards, the covers have to be extended.

The single toggle lever system, as shown here, is used only with small machines.
The system has been refined to a double toggle lever mechanism to eliminate the
shortcomings.

2.3.2.1.2 The double toggle lever mechanism (Fig. 2.21).

This is an improvement on the
single toggle lever system. It
consists of a pair of toggle levers,
fixed on one end to the third
(stationary) platen and on the other
end to the moving platen, on four
corners. As shown in the diagram,
a hydraulic cylinder placed on the
central horizontal axis moves a
yoke plate, which in turn transfers
the movement to the platen
through the toggle levers.
Fig.2.21
The movement achieved is parallel and
uniform. The platen is loaded on four
corners. The space in the middle is free for accommodating the ejection mechanism.
Now-a-days, the double toggle lever is used in most of the machines having a
mechanical closing system.
The mechanical closing systems generate closing and locking forces by straining two
units, viz. the tie bars and the machine platen. When toggle levers make the closing
movement and bring the two mould halves in contact, they are not yet fully stretched.
The toggle levers can create the locking force only in the fully stretched position. It is
achieved by straining all concerned parts, particularly the tie bars. The magnitude of
the locking force depends upon the amount of stretching of the tie bars. Should there
be any changes in the mould height due to fluctuation of temperatures, the locking
force would also not remain constant as the stretching of the tie bars is also effected.
As the stretched length of the toggle levers is unchangeable, adjustments in mould
height can be effected only by changing the position of the third plate. Larger
machines have the provision to move the plate automatically by means of a motor

60
which operates the four locking nuts holding the plate on tie bars, centrally. The
height adjustment in smaller units is carried out manually.

In the case of machines with mechanical closing, the minimum and maximum mould
height is specified along with the maximum stroke.

2.3.2.1.3 Hydraulic closing systems.

In fully hydraulic mould closing systems, the force for the movement of platen as well
as for locking is brought forth by directly acting hydraulic cylinders. Obviously,
cylinders of considerable diameters are needed to generate the required force with
the given hydraulic pump pressure. Such big cylinders need enormous quantity of oil
for their operation. It will be a waste of energy to execute the long closing and
opening movements of the platen with the main cylinder. In any case, the
movements would be very slow. Because of these reasons, most hydraulic moulding
machines employ a two step closing system:

 Fast cylinder/s with smaller diameter for the movement of platen

 Main cylinder of larger diameter for locking.

A significant difference between the toggle lever and fully hydraulic closing systems
is that the hydraulic cylinders can deliver the full locking force at any point of travel
whereas the toggles produce it when fully stretched. The force generated by the
hydraulic cylinder is directly proportional to the hydraulic pressure from the source.
Consequently, it is very simple to adjust its magnitude by adjusting the pressure of
the incoming oil. This force remains constant even if the mould height changes due o
temperature and also during the injection phase when the pressure of the melt in
the mould tends to open the mould. The closing and the locking force are identical in
fully hydraulic systems. Non-return valves help to save energy after the required
level of locking force has been arrived at.

Unlike the mechanical closing system, the hydraulic closing units have no limitation
on the maximum mould height. Their specifications refer to the minimum mould
height and the maximum daylight.

Figure 2.22 illustrates the working

principle of a fully hydraulic closing
system.

Oil is compressible. This is why,

hydraulic systems generally
employ hydraulic cylinders for the
movement and holding of the
platen, coupled with mechanical
devices for positive locking.

Fig.2.22

61
 2.3.2.1.4 Electrical Closing System.
The closing unit of an all-electric
moulding machine operates the toggle
levers with the help of a threaded ball
spindle, which is rotated by a
synchronous motor (Fig.2.23). Though
the working is same as with the
combination of a hydraulic cylinder and
the toggle levers, there are some
positive side effects. Oil is compressible
Fig.2.23 and the accuracy and consistency of its
power and movement transmission is
dependent upon its composition, purity
and temperature. Leakage also reduces its efficiency. The sizeable volume of oil in
large hydraulic machines requires some time to achieve the working temperature. An
electrical motive device is free of these shortcomings. The mechanism is clean and
drip free and therefore particularly suitable for clean room applications. The machine
can be set in operation instantly.

2.3.2.1.5 Two Platen Closing System.

All foregoing systems employ
a third plate in addition to the
two mould carrying platen.
The third plate is employed for
anchoring of the toggle lever
mechanism, the hydraulic
cylinders or the electrical
motor etc. as otherwise it is
not possible to move and lock
the mould platen. The same
goal can be achieved without
the third plate by employing
tie bars as piston rods of Fig.2.24
hydraulic cylinders as shown in
figure 2.24

The closing movement is imparted by separate cylinders. The tie bar cylinders take
over the locking function. They can be mounted on the back of either the fixed or the
moving platen.

The two plate closing system is being increasingly used in small and medium sized
injection moulding machines. It is, however, practicable only with the fully hydraulic
machines.

The two platen injection moulding machines offer a number of advantages such as:
 Less floor area.
 Less weight
 Less oil, saving in energy
 Fast pressure build-up
 Better access to the ejection mechanism

62
  Fast mould set up

Here too, a number of variations have been developed.

2.3.2.1.5 Tiebarless Closing Systems (Fig.2.25).

Tie bars have been
regarded unavoidable for
the movement and guidance
of the moving platen parallel
and co-axial to the fixed
platen. They perform this
function at the cost of
accessibility and the useful
platen area. Loading and
unloading of moulds, which
has to be carried out from
above, is a time consuming
process. The latest Fig.2.25
development in closing units
of the injection moulding
machines, viz. the tiebarless version, offers a solution to these very drawbacks.

Engel of Austria has been the pioneer in this field. The idea has been adapted from
the C-presses used for sheet metal working. The main problem in deleting the tie
bars has been to find an alternative, which would ensure parallelism of the mould
platen, previously taken care of by the tie bars.

A C-frame would obviously open up on the mouth of C when strained. Incorporation

of compensating elastic elements counters the deformation and keeps the closed
mould halves parallel to each other. It is a complex mechanism.

The tiebarless system offers the following advantages over other systems:

 Less cost
 Excellent accessibility from back, front and top for mounting large moulds and for
fixtures and handling devices for insert inlaying or part removal.
 Possibility of automatic mould loading and unloading
 Larger useable platen area
 Stiffness of platen without deformation in the middle
 No maintenance of tie bars

Another variation of tiebarless closing systems is an H-frame design.

2.3.2.1.6 Comparison of the toggle lever and fully hydraulic closing systems.
Toggle levers act on 4 corners of the moving platen. The injection forces acting on
the mould platen through the mould tend to bend them in a concave form. Excessive
deformation can lead to flashing. The platen are, therefore, designed to counteract
the deforming forces. The permissible deformation ranges from 0,05 mm to 0,3 mm,
depending upon the size of the machine.

63
The hydraulic closing
systems apply the locking
force in the central region of
the moving platen.
Consequently, there is no
deformation on this side.
Excessive injection forces
Fig.2.26
try to bend the fixed platen.
The total deformation is,
therefore, one sided in case
of hydraulic systems. Figure 2.26 illustrates the phenomenon of deformation for both
systems.

Left. Double Toggle Lever Locking

Right. Hydraulic Locking system

Both systems have advantages and disadvantages:

 The toggle lever system moves the platen ideally without any additional devices.
The natural movement of a toggle lever, viz. slow-fast-slow, is what is needed for
closing and opening the mould. The hydraulic systems need additional
arrangements to achieve the same. Especially in case of big hydraulic machines,
with large cylinders and heavy platen, it is a difficult job to accelerate or retard
movements accurately.
 Toggle lever systems apply the force away from the centre of the platen where
the opposing forces act. The deformation will be more than with hydraulic system
acting on the central axis, right in the line of the opposing forces.
 The locking force in case of toggle lever system is dependent upon the extent of
stretching of the tie bars. The force changes if the mould temperature and
consequently its height changes. The locking force in hydraulic machines is
independent of the mould height.
 Toggle lever systems need more space for bigger movements. The machine
length increases.
 Toggle lever systems have more moving parts and hence are more expensive to
maintain. With hydraulic systems, it is mostly seals and gaskets which need
replacement.
 The ejection mechanism can be located conveniently on the central axis with
toggle lever operated machines. In case of hydraulic closing systems, special
configurations are needed to create space. More often, alternative systems or
locations have to be chosen for the ejection mechanism.
 Hydraulic systems are less noisy than the toggle lever systems.
 The toggle levers develop their locking force in fully stretched state. The
minimum and maximum mould heights have to be strictly observed. Hydraulic
systems bring forth their locking force at any point of their travel. Only the
minimum mould height has to be maintained. There is no bar on the maximum
mould height.

2.3.3 The Ejection Mechanism.

As a rule, the injection moulds are designed to retain the mouldings on the moving
side upon opening. Consequently, the ejection mechanism, which forms a part of the

64
machine, is also housed on the moving side. Its function is to to provide the
movement and the force to release the mouldings from the mould parts on which
they are holding and to push them out of the mould.

The forces holding the mouldings in the mould depend upon:

 The shrinkage of plastics

 The surface area and thickness of walls in the direction of ejection
 The modulus of elasticity of plastics
 The coefficient of friction between the mould material and the plastics
 Intended or unintended undercuts (caused by roughness of surface and
inaccuracies in dimensions)

The ejection mechanism is required to overcome the holding force.

There are three variations of the ejection system.

2.3.3.1 Mechanical ejector.

The mechanical system of
ejection consists of a stationary
threaded spindle, housed in the
third plate of the machine, in
line with the central axis (Fig.
2.27). It forms an obstruction to
the ejector bolt of the mould
when the moving platen nears
the end of the opening stroke.
Its protrusion can be adjusted
so that the ejector plates of the
mould are pushed forward by a
pre-set amount. (Actually, the Fig.2.27
ejector plates are stopped by the
spindle while the mould half
moves on backward, thus creating a relative movement of the ejectors.)

The system is very simple but has many drawbacks. It cannot be coupled with the
mould; hence it cannot pull back the mould ejector plates. (This may be necessary to
place inserts in the mould, to avoid collision of protruding ejector pins with sliders
while closing the mould or to enable free fall of the moulding.) The ejector plates of
the mould can be actuated only once, which is a distinct disadvantage if the
mouldings do not fall down with one push. Also the speed of ejection cannot be
adjusted independently.

The ejection force equals the opening force of the machine.

The system is almost obsolete.

65
2.3.3.2 Hydraulic ejector.
It consists of a hydraulic cylinder, fixed centrally
behind the moving platen on the common
horizontal axis of the mould closing unit (Fig.
2.28). The cylinder can be coupled with the ejector
bolt of the mould. The said cylinder has adjustable
stroke, speed and force. It can also be set to
pulsate, that is, to operate a number of times and
made to stop in a particular position to enable
robots to take over the mouldings. Its start of
operation can be initiated through a limit switch or
a sensor. In some cases, mostly with large Fig. 2.28
machines, the system comprises an ejector plate,
placed directly behind the moving platen and
guided by means of guide pillars. It is made to move hydraulically to actuate the
ejection system of the mould.

The hydraulic connections of the ejection system can also be utilised to actuate
hydraulic motors built in moulds for unscrewing or for actuating slides in moulds
through hydraulic cylinders where the core pulling device is not available.

2.3.3.3 Electro-mechanical ejector.

The fully electrical machines employ a threaded
spindle powered by a small electrical servo
motor to generate the movement needed to push
the ejector plates of the mould (Fig. 2.29). Here
too, the stroke, its speed, frequency and position
of stopping can be regulated as in the case of a
hydraulic ejector.
Fig.2.29
2.3.3.4 Pneumatic ejector.
Compressed air is often employed to support other modes of
ejection. The moulding machine is equipped with valves to regulate air jets, the start
and duration of their operation. Compressed air at 6-8 bar, generated by a separate
compressor, is connected to the machine. The air jets may be incorporated in the
mould or placed outside.

2.3.4 The cooling battery (Fig. 2.30).

A distribution system for the mould
cooling water, having a number of
inlets and outlets with valves to
regulate the flow, is generally
situated at the back of the machine.
The common device consists of a
main inlet which divides the
incoming water into a number of
parallel channels. Individual cooling
circuits in the mould can be
connected to these channels which
have transparent sight glasses,
Fig. 2.30
66
floats to indicate the water level and throttles for regulation of the flow quantity. The
exit channel is common for all streams. Fresh water may come to the cooling
system from a cooling tower or from a refrigeration system. It is used to cool the
mould as well as the hydraulic oil tank and the feeding zone of the barrel. One circuit
from the cooling arrangement is permanently connected to the feeding section of the
barrel of the plasticising unit to prevent melting of raw material close to the entrance,
as described earlier.

The used water is generally returned to the initial source through the common exit
channel and is cooled again in a closed loop system.

The system, though simple in operation and maintenance, suffers from some severe
shortcomings which may effect the quality and productivity adversely. The
temperature and the heat conducting capacity of the in-coming coolant depends
upon the ambivalent conditions, such as seasonal fluctuations in temperature and
humidity as well as from chemical and physical contents of the source water.
Depending upon the type of cooling towers, there is some loss of the fluid as well as
pollution from surroundings. The simple throttle valves regulate the flow in an
unrepeatable way and may often be adjusted without a precise record.

A more reliable system ensuring independence from ambient conditions is the

controlled temperature mould cooling gadget, which supplies the coolant at a
constant temperature to the mould. It is portable and has a pump, heaters and
thermostats and also controlled cooling/ heating arrangement for the coolant coming
back from the mould. The fluid used is water for lower and oil for higher
temperatures. The sophisticated gadgets can supply fluids at temperatures as high
as 250°C for processing of engineering polymers.

2.3.5 The Machine Body.

The three essential units of the injection moulding machine responsible for
processing of the melt described above, are mounted atop a frame which houses the
hydraulic system of the machine. It consists of an oil tank, a motor, a pump or
pumps, a pressure accumulator, hydraulic valves, oil distribution lines etc. The pump,
driven by the electrical motor, generates pressurised hydraulic oil, which serves as
the conveyor of power to actuate various processes such as screw rotation, injection,
closing and opening of platen, ejection etc. by means of suitable devices like
hydraulic motors and cylinders. Directional valves direct pressurised oil to various
units as commanded by timers.

Hydraulic systems have proved to be most efficient for the purpose of distributing
power. Oil is fairly incompressible and obviates the use of rods, levers, racks, cables
and gears for transmitting motion. It also permits high switch-over speeds.

The major disadvantage of oil is the change in its viscosity with temperature. Efficient
cooling systems and temperature controls can keep this drawback within narrow
limits. Leakage is another problem which has been overcome by gaskets and seals
made of special synthetic materials, developed specifically for the purpose.

67
2.3.6 The Control Panel.
The moulding operation involves many variables as described before, which must be
individually set and controlled for each mould. These are temperatures of various
zones of the plasticising unit and sometimes, also of the mould. There are pressures
such as injection, holding and back pressure and a number of movements and
speeds. The sequence and durations of various steps in the moulding process must
be set and maintained precisely. A control panel houses the devices to set and
control different parameters like temperatures of different sections of the plasticising
unit, speeds of injection, opening and closing of the mould locking unit, injection,
holding and back pressures, start and duration of various operations such as
injection, holding, cooling, ejection, core pulling devices etc. Some machines have
additional temperature controls for the mould and the hot runners too.

Whereas the older generation of machines operated with limit switches for initiating
various operations and ending them, the modern generation uses sensors, which are
faster and more accurate. Operations like injection, holding and dosing, screw speed
etc. can be set in a number of steps with changing values to suit the changing
conditions during filling, compacting and cooling in the mould.

Most machines are of the controlling, or the open loop type; they bring up the set
values of the parameters as accurately as the built-in devices are capable of. The
closed loop machines are equipped to control certain parameters and correct them if
necessary. For example, if the set speed of injection is not being maintained due to
some change, say due to variation in the viscosity of the material caused by a new
charge, the oil input to the injection cylinder is automatically regulated in order to
correct the speed. The parameters controlled and regulated may be the injection
speed, the pressure, the thickness of the melt cushion in front of the screw tip etc.
depending upon the design of the machine. The closed loop machines contain one
or more microprocessor-based computers integrated in the system which receive
signals of various parameters such as screw position, screw speed, holding pressure
and other chosen parameters, process the signals and generate specific output for
altering some functions such as opening or closing valves, changing pressure,
increasing or decreasing temperature. The complete data can be stored and
reactivated as soon as the same mould is loaded again.

The closed loop system contributes to the uniformity of production, narrow

dimensional variation and low rejection by keeping the moulding conditions within
given limits.

2.4 Special Machine configurations.

Injection moulding machine with a horizontal injection unit and a horizontal mould
closing system may be considered as a norm. However, these two main units may
also be placed differently for special applications.

2.4.1 Vertical injection; horizontal locking. The combination of horizontal locking

with vertical injection unit is employed when the injection should take place on the
parting line of the mould. It is often the case with 2-component moulding.

68
2.4.2 Vertical closing; horizontal injection. This configuration is useful for insert
moulding. Insert to be moulded-in can be easily placed in the lower half of the mould
fixed on the lower, immovable machine platen without additional devices to hold the
inserts in place. The upper platen moves up and down to close and open the mould.
The injection takes place on the parting line.

Alternatively, both units may be situated in the vertical position, if injection in the
centre of the mould is more advantageous.

2.4.3 Vertical closing with sliding lower platen; vertical injection. The
combination is especially employed for insert moulding. The mould has one upper
half but two identical lower halves, fixed on the sliding table. When injection is taking
place with one of the lower halves in engagement, inserts can be loaded in the other
half simultaneously. The lower platen slides toward right or left alternatively after the
mould opens. The loaded part of the sliding platen comes to the injection position
and the moulded parts can be ejected from the other station. It can be reloaded with
inserts for the next cycle.
The injection unit can also be mounted in horizontal position for injection on the
parting line.

2.4.4 Vertical closing with revolving lower platen

and vertical injection. The combination is similar to
the foregoing one. The lower platen consists of a
revolving table with 2,3 or 4 stations. Accordingly, the
number of identical lower mould halves corresponds
to the number of stations. The single upper mould
half is common to all. The function is similar to the
configuration with sliding lower platen. However, with
ejection and reloading can be carried out separately
with three stations. In case of an additional station
offers the possibility of carrying out some after-
operation like testing.

Here too, the injection unit may be placed horizontally. Fig. 2.31

Figure 2.31 shows a 2-station revolving table moulding machine with vertical
injection.

69
 Chapter 3

Injection Moulding of Thermoplastic; the Process.

3.1 The process

3.2 The screw preplasticisation
3.3 The mould filling process
3.4 Post operations
3.5 Trouble shooting

3.1 The Process.

The injection moulding process comprises three distinct steps viz. plasticising the
solid plastics raw material, injecting it into a closed mould having the cavity/ cavities
corresponding to the product to be moulded, cooling and solidifying it there before
extracting the mouldings after opening the mould. The set of these sequences is
termed as the moulding cycle.

3.1 .1 The moulding cycle.

The moulding cycle begins when the moving platen gets the command to close the
mould. The closing movement is executed in three steps, viz. slow, fast and again
slow at the end. The locking force is built up.

The second step in the cycle is bringing the injection unit forward till the machine
nozzle comes in contact with the sprue bush of the mould and presses on it.

The next operation is the injection of the melt. It takes place in three stages. The first
stage is the complete filling of the mould through the linear stroke of the screw acting
as a piston. In order to force the melt in the cavity to fill it, pressure is needed to
overcome the resistance to flow in the nozzle and the mould. The second stage
comprising compression of injected melt follows immediately thereafter. Plastics
melts are compressible and the screw pushes in more material but with higher
pressure for compaction. A melt cushion is left in front of the screw tip.

The compression phase is followed by the holding phase, which forms the third
stage. The holding pressure, usually lower than the last one, pushes in melt from the
cushion to make up for the shrinkage taking place during solidification of the melt till
the gates are frozen.

At the termination of the holding period, the cooling period starts. It constitutes the
longest part of a moulding cycle. Its duration is chosen in relation with the thickness
of the moulding. The dosing for the next cycle, decompression and pulling back of
the injection unit is also carried out during this phase. (The injection unit is pulled
back so that the heated machine nozzle does not lose heat to the relatively cold
mould sprue bush).

The mould is opened as soon as the preset cooling time is over and ejection takes
place just before the moving mould half reaches its end position.

70
Summing up, the complete moulding cycle, yielding one shot, consists of following
segments in the given sequence:

1. Closing time
2. Nozzle forward time
3. Injection time
4. Holding time
5. Cooling time
6. Opening and ejection time

3.1.1.1 Closing time. It is the time needed by the moving platen to move forward
and close the mould. The major part of the stroke is covered very fast but the platen
slows down before touching of the two mould halves so that the final closing and
locking takes place gently.

3.1.1.2 Nozzle forward time. The retracted plasticising unit moves forward till it
touches the closed mould. The machine nozzle presses against the sprue bush of
the mould with certain force to prevent leakage during injection. The moulding
operation can begin.

3.1.1.3 Injection time. The time needed by the plunger to force the melt in the
cavity/ cavities of the closed mould is termed as the injection time. It also includes
the time for compression of the melt after filling. Usually, the injection time forms a
small fraction of the total cycle as it is desirable to fill the mould as fast as possible to
have the plastics temperature nearly same in all parts of the cavity and also to
prevent premature freezing of the melt.

3..1.1.4 Holding time. After injection, the melt starts cooling and contracting. In
order to compensate for the space created by contraction, the pressure is kept on by
the plunger on the remaining melt cushion in the front part of the barrel till all melt in
the cavity is frozen (the gate should also freeze at this juncture). This step counters
the formation of sink marks and voids. The holding pressure is usually lower than the
injection pressure but its duration may be much longer. The switch-over from
injection to the holding phase is triggered by a time relay or by a distance switch or
by a hydraulic pressure sensor. It can also be initiated by a pressure sensor built in
the injection mould which effects the switch-over when a preset pressure has been
arrived at in the mould
.
3.1.1.5 Cooling time. The so-called cooling time starts after the holding time is
over. It constitutes the longest part of the total moulding cycle. The moulding is
allowed to dissipate its heat through cooled mould walls till it cools down to a
temperature where it can be ejected without distortion. Main part of the shrinkage
takes place during this phase.

3.1.1.6 Opening and ejection time. At the end of the cooling time, the moving
platen is pulled back in the same manner as during closing, viz. slow, fast, slow and
the mould is opened. Towards the end of the opening stroke, the ejector is activated
and the cooled mouldings are pushed out of the moving half of the mould.

71
The recharging or dosing of the cylinder for the next shot takes place during the
cooling time. Usually, the plasticising unit is retracted after recharging so that the
nozzle of the barrel does not lose heat to the cold mould.

The recharging time, depending upon the shot weight, can be influenced by the
screw speed.

Out of the six time segments forming the cycle time, three segments viz. mould
closing, injection unit forward and opening cum ejection are dependent on the
machine and can be varied only marginally. Injection as well as holding time are
directly linked with the polymer, the size of the moulding and its wall thickness.
These time segments, too,
are quite short as it is aimed
to fill the cavity as fast as
possible. It is the cooling
time which forms the major
segment of the cycle,
coming up to 80% of the
total time for one shot. It can
be influenced favourably
through a good mould
design. The cycle is
generally portrayed as a full
circle. Figure 3.1 portrays Fig.3.1
relationship of the various
segments of a cycle in visual form.

The exact duration of a moulding cycle can be determined only after trials and
optimisation of the process. However, for rough estimation of the cycle time for a
planned product with normal wall thickness, the following thumb rule may be found
helpful.

Cycle time= 2,5x (max. Wall thickness)²

3.2 The screw pre-plastication.

The rotating screw transports the material from the feed zone towards the delivery
end over the compression and the metering zones. In the process, the material is
compacted and made to rub against the inner wall of the barrel which brings it to
melting and sticking to the inner wall of the cylinder. The advancing flank of the
rotating screw scrapes it free and sends it inwards in a curling movement. Its place is
taken by unmolten material. The continuous process of melting, scraping and
replacement results in mixing and homogenising. The metering zone with its
constant depth stabilises the melt before it goes through the non-return valve and
collects in the front part of the barrel vacated by the gradually receding screw. The
amount of the material plasticised and forwarded is directly proportional to the speed
of rotation.

The screw speed influences the time needed for dosing the required amount of melt
for the next shot but also the friction generated. It is usually adjusted to accomplish
the first task within the set cooling time. Too high a speed can lead to overheating

72
and decomposition of the polymer. As a thumb rule, the surface speed should not
exceed 1,5 meters per minute for the thermally less sensitive commodity plastics. It
should be lower for technical polymers. Table 3.1 contains the recommended surface
speed for different thermoplastics.

Table 3.1
Surface speed of the screw

Plastics Surface speed

meters per min..
Polyolefins 1,5
Polystyrene 1,5
SAN, ABS, 0,6
ABS-PC-Blend 0,4
PVC-rigid 0,2
PVC-plasticised 0,6
POM 0,7
PET, PBT 0,7
PMMA 0,6
Polycarbonate 0,6
PPO 0,6
Polyamides 1,0

As the screw recedes continuously during plasticising, its effective length over which
the material travels forward and is subjected to friction, also decreases. This results
in gradual decrease in temperature of the melt. It can be compensated, either by
raising the speed of the screw continuously or by increasing the back pressure while
keeping the speed constant.

The amount of dosing should consist of the melt needed for filling, compacting and
compensating shrinkage as well as an additional amount as cushion to prevent the
screw tip hitting the end of barrel. The melt cushion may vary between 5-10 mm. in
thickness.

3.3 The mould filling mechanism.

When hot melt is injected in the relatively colder
mould, the melt layer coming in contact with its
wall loses heat and comes to a halt. The layer
adjacent to the frozen layer experiences
maximum friction and flows with reduced speed.
The layer next to it has less friction and higher
velocity which in turn reduces the viscosity. The
layer in the centre of the stream has maximum
speed and also maximum temperature. The flow
front advances as parabolically
Fig.3.2

73
Figure 3.2 . The pattern is called fountain flow with all layers having different
temperature, different viscosity and different speed. As the flow proceeds, the melt
from inner layers moves forward as well as upwards, touches the mould walls and
comes to a halt.

The speed with which the melt proceeds in the mould cavity, depends not only on the
pressure exerted on it by the ram but also on the brake applied by the cooling which
again depends upon the mould temperature, the heat conductivity of the tool steel,
the temperature of the melt and its speed and the corresponding viscosity. The shear
caused by the flow generates heat, lowers viscosity and influences the speed of the
melt. This is why, a decrease in pressure results in a disproportional decrease in
velocity of the melt. The decreased speed accelerates the loss of heat and increases
viscosity which means less heat generation through shear and further rise in
viscosity and in loss of speed.

The injection part of the cycle also includes compaction at its conclusion. The
plunger moves at a very slow speed
and compacts the melt. It is followed
by the holding phase which takes
place at comparatively lower
pressure but for a longer period to
compensate the contraction caused
by shrinkage during cooling. It
comes to an end when the gate gets
frozen and no more melt can be
forced into the cavity irrespective of
the pressure. It signals the end of the
mould filling phase. Figure 3.3
illustrates this graphically. Fig.3.3

The complex relationship between pressure, velocity, temperature, heat conduction,

viscosity and heat generation through shear makes it difficult to predict the optimal
moulding parameters in advance. The optimum cycle is always determined through
trials. Softwares like moldflow and many more take these factors into consideration
and calculate the parameters with fair accuracy if the relevant characteristics of the
particular material grade are known.

3.4 The forces

Various forces involved in the process of injection moulding are:

3.4.1 Injection pressure. It is the force with which the screw, acting as a plunger, is
pushed forward to force the melt into the mould. Its magnitude is decided by the
extent of resistance to the flow of the melt in the machine nozzle, in the mould
feeding system and in the mould cavity, which in turn depends upon the wall
thickness of the moulding, the viscosity of the melt, the speed of injection and the
temperature of the mould.

In modern machines, injection speed is the parameter set in the place of pressure.
The aim is to maintain an even flow of melt in the mould. Although it is desirable to fill
the cavity as fast as possible so that the temperature of the melt is almost same in all

74
parts of the cavity, it is recommended to start with a lower speed in the beginning to
avoid turbulence and then increase the speed, cutting it down again at the end to
prevent flashing.

The pressure set on the machine indicates the upper limit which may be reached for
maintaining the speed of injection.

The modern moulding machines have the provision to set the moulding pressure
alternatively the injection speed in a number of variable steps. The aim is to maintain
a uniform speed of the filling front in the mould.

3.4.2 Holding pressure, as described before, has the function to force additional
melt into the mould to compensate for the reduction in volume of the melt through
shrinkage while solidifying. It remains active till the gate freezes.
The holding pressure can be selected in variable steps compatible with the rate of
cooling in modern machines.

3.4.3 The back pressure acts against the free backward movement of the screw
during recharging and helps to subject the melt being charged to greater friction. It is
much lower than the injection or holding pressure.

The closed loop machines employ back pressure to regulate friction which generates
heat for melting of the plastics. As the screw recedes during charging, its length over
which the subsequent material travels (from hopper till screw tip) is reduced. In other
words, the plastics being worked upon at this stage undergoes less amount of
friction and has consequently lower heat input. It can be compensated by increasing
the back pressure in steps.

3.4.4 The locking force of the mould closing unit counters the force created by the
pressurised melt in the mould, which tends to force it open. It is proportional to the
effective injection pressure and the projected area of the moulding. It is a guide to
determination of the size of the moulding machine for a particular mould. The locking
force should exceed the expected force generated by the injection pressure in the
mould by about 20%.

3.4.5 The nozzle lay-on pressure serves to neutralise the backward pressure
exerted by the injected melt upon the plasticising unit through the sprue. It depends
upon the size of the sprue and the extent of the injection pressure. Insufficient nozzle
lay-on pressure would result in leakage of the melt at the junction of the machine
nozzle and the sprue bush of the mould.

3.4.6 The ejection force, variable in modern machines, has to overcome the forces
with which the mouldings stick on the moving side of the mould. These forces are
given rise to by the shrinkage, condition of the mould surface, friction, undercuts etc.

3.5 Post operations on mouldings.

It has been observed in the outset that injection moulded articles are generally ready
for use right after ejection and cooling to the room temperature. The exception to this
rule is formed by parts moulded of hygroscopic thermoplastics. The raw material is

75
dried before moulding and the mouldings are free of moisture. However, they
achieve equilibrium, their normal physical properties and final dimensions only after
absorbing moisture. In most cases, it takes place automatically if the moulded parts
are stored for some time. Polyamides, however, need a very long period and proper
ambient conditions to achieve equilibrium. Under normal atmospheric conditions, a
PA 6 moulding with 2 mm. wall thickness may take as many as ten weeks to absorb
the normal amount of moisture - that is 3% by weight - and have its normal
dimensions and other properties. The dimensional increase after saturation may be
about 0,8%.

3.5.1 Conditioning.
Polyamide mouldings are allowed to cool down for a day, preferably in the moulding
shop. To expedite the process of moisture absorption, the polyamide mouldings are
stored in water for a duration depending upon their wall thickness. The duration can
be shortened significantly by increasing an maintaining the temperature of the
conditioning water bath around 60°C. A 3 mm. thick PA 6 moulding will require 30
hours in a 40°C water bath but only 2 hours if the water temperature is raised to
80°C. As most mouldings have thick and thin sections, the most suitable duration
can be ascertained through trials.

The mouldings should be packed in polyethylene bags and stored for sometime and
then post-conditioned at room temperature in humid surroundings. It may take a few
days to a few months, depending upon the wall thickness. The moulding achieve a
stable state and maintain their properties.

The raw material manufacturers generally recommend the appropriate temperatures

and durations for their products.

3.6 Trouble shooting.

Moulding faults, their causes and remedies.

The process of injection moulding involves temperature, pressure, time and speed.
Most moulding defects are caused by the wrong use of these factors and can be
remedied by the proper application of the same during the moulding process. Some
defects are, however, the outcome of unbalanced article and/ or mould design. The
corrective measures for these faults may be tedious and expensive.

3.6.1 Short shots.

Short shot or an incompletely filled moulding is the result of molten material
solidifying before the cavity is fully filled. The defect appears in areas away from the
gate, near thin sections and in deep recesses.

Causes:
a) Melt temperature too low
b) Mould temperature too low
c) Injection pressure too low
d) Injection speed too low
e) Insufficient injection time
f) Insufficient feed
g) Air trapped in the cavity

76
h) Too small a gate
i) Wrongly located gate
j) Cold slug blocking the flow
k) Switch-over from injection to holding pressure too early

Remedies.
1) Increase the melt temperature
2) Increase the mould temperature
3) Increase the injection pressure
4) Increase the injection speed
5) Increase the injection time
6) Increase the feed
7) Improve venting
8) Increase the gate/ runner size
9) Change the gate location
10)Enlarge the cold slug trap
11) Delay switch-over to holding pressure

3.6.2 Flash
Flash is the undesirable extra material appearing as a thin film at the parting line, in
holes and apertures, around inserts and ejectors, which necessitates additional post
operations for removal.

Causes.
a) Badly matched parting line
b) Too much clearance between apertures and inserts, holes and pins, holes and
ejectors
c) Vents too deep
d) Elastic warpage in mould plates
e) Insufficient clamping force
f) Very high injection pressure
g) Melt temperature too high
h) Switch-over to holding pressure too late
i) Unbalanced runner system (multi-point/ multi-cavity gating/ family mould)

Remedies.
1) Improve mould workmanship
2) Strengthen mould bolster
3) Reduce melt temperature
4) Reduce moulding pressure
5) Switch over to holding pressure earlier
6) Balance the runner system
7) Change over to a higher capacity machine
8) Replace worn out ejectors, core pins and loose inserts

3.6.3 Difficult demoulding

The moulding sticks rigidly to core or cavity and cannot be ejected without distortion
or damage. It may also stick on the side without ejection arrangement.

77
Causes.
a) Bad workmanship, rough mould surface
b) Highly polished surface (in case of some plastics like PP,PVC etc.)
c) Insufficient draft angle
d) Poor venting
e) Overpacking
f) Unbalanced/ unsuitable ejection system
g) Moulding too hot

Remedies.
1) Improve mould surface, remove undercuts
2) Sand blast the mould surface (PP etc.)
3) Increase demoulding taper
4) Improve venting
5) Reduce holding pressure/ time
6) Redesign ejection system
7) Increase cooling time
8) Use differential cooling
9) Use mould release agents

3.6.4 Dimensional variations.

The dimensions of the mouldings are not constant.

Causes.
a) Moulding conditions not constant
b) Mould temperature not constant
c) Non-return valve leaking
d) Cooling time insufficient
e) Oil temperature varying

Remedies.
1) Check thermostats
2) Cool mould through a controlled water temperature gadget
3) Check the thickness of melt cushion and if varying, change valve
4) Increase cooling time
5) Check and clean oil cooling system.

3.6.5 Sink marks, voids (Fig. 3.4)

Sink marks are shallow depressions on the surface of the
moulding and voids are hollow areas inside a moulding.
They are different forms of the same defect. The
contraction in volume during cooling has not been
compensated and makes its appearance as a sink mark. If
the mould is very cold, the upper layer may freeze soon
and become hard, transferring the defect inwards as a
void. Fig.3.4

Causes.
a) Uneven cross section, thick and thin areas, material accumulation

78
b) Unsuitable gate location
c) Insufficient gate/ runner size
d) Mould too cold
e) Insufficient holding pressure/ time
f) Insufficient material cushion in the cylinder
g) Too early switch-over to holding pressure

Remedies.
1) Redesign the article
2) Increase gate/ runner size
3) Place the gate close to the thick section
4) Increase mould temperature
5) Increase holding pressure/ time
6) Increase material cushion
7) Delay switchover

3.6.5 Weld lines.

A weld line is the meeting of two melt streams and appears as a thin hairline if the
streams rejoin properly. Under unfavourable conditions, it may look like a notch. In
most cases, it is only an aesthetic shortcoming. However, in case of filled plastics it
does constitute a weak spot, prone to failure due to orientation of the fibres.

Causes.
a) Parting of melt due to obstruction in the flow path, such as core pins for holes
b) Multiple gating
c) Uneven wall thickness
d) Unequal flow lengths of material streams
e) Trapped air between the flow fronts

Remedies.
1) Change gate location to shift the weld line to a less critical area or closer to the
gate.
2) Increase the size of gate and runners
3) Raise the melt temperature to make the weld stronger.
4) Raise the mould temperature
5) Increase the injection speed to prevent cooling of flow fronts
6) Improve venting
7) Increase the holding pressure/ time

3.6.6 Record effect. (Fig. 3.5)

Fine, concentric lines on the surface of
the moulding are termed as gramophone
record effect.

Causes.
a) High resistance to melt flow in the
cavity ( slip stick effect)
b) Mould too cold
c) Material temperature too low
d) Injection speed too low Fig. 3.5

79
Remedies.
1) Increase mould temperature
2) Increase material temperature
3) Increase injection pressure/ speed

3.6.7 Jetting. (Fig. 3.6)

Jetting has the appearance of a worm, usually
starting from the gate and extending towards the
farthest point of filling.
Fig. 3.6
Causes.
a) Wrong gate location causing free flow. Melt travels unhindered to the distant wall
of the cavity
b) Melt temperature too low
c) Gate size too small

Remedies.
1) Change the gate location to make the melt stream meet a wall/ hindrance
immediately
2) Increase the melt temperature
3) Increase the gate size
4) Increase the mould temperature
5) Reduce injection speed/ change injection profile (slow-fast)

3.6.8 Burn marks.

Burn marks occur when the melt gets charred due to abnormally high temperature
rise. It happens when the air in the mould gets trapped and is compressed either
between two material streams, at the end of the flow path or in blind holes/
depressions such as ribs and bosses. It is also called the "Diesel Effect".

Causes.
a) Wrong gate location
b) Poor venting
c) Uneven wall thickness
d) Very high filling rate
e) Overheating of the melt

Remedies.
1) Relocate gate to eliminate air entrapment
2) Improve venting
3) Change wall thickness
4) Decrease injection speed
5) Decrease material temperature

3.6.9 Burn streaks at gate ( and/or surface )

These are discoloured rays, emanating from the gate or sprue.

Causes.
a) Material temperature too high

80
b) Dwell time in injection unit too long
c) Gate too small
d) Injection speed too high

Remedies.
1) Reduce material temperature
2) Switch over to a smaller machine
3) Increase the gate size
4) Decrease the rate of injection

3.6.10 Silver streaks.

Silver streaks are elongated bubbles pulled in direction of flow and appear like
shining rays emanating from the gate.

Causes.
a). Moisture in granules
b). Water leakage in mould
c). Melt overheated and decomposing
d). Air not expelled from melt
e) Air being sucked in

Remedies.
1) Pre-dry the material
2) Use heaters in the hopper
3) Decrease melt temperature
4) Decrease injection speed
5) increase back pressure
6) reduce retraction speed of screw while decompressing

3.6.11 Fish eyes

It is a defect caused by unmelted or partially melted granules in the melt stream
which appear on the surface of the moulding.

Causes.
1). Low barrel temperature
2). Low screw rpm
3). Low back pressure
4). Contamination in material, mixing with high temperature plastics
5). High proportion of regrind

Remedies.
1). Increase barrel temperature
2). Increase screw rpm
3). Increase back pressure
4). Clean injection unit, charge new material; store materials separately
5). Reduce proportion of reground material

3.6.12 Orange peel

81
This defect manifests itself as an uneven, pit-marked and sometimes, as a dull
surface.

Causes.
a) Material temperature too low
b) Mould temperature too low
c) Injection pressure too low
d) Injection time too low
e) Holding time too low

Remedies.
1. Increase the material temperature
2. Increase the mould temperature
3. Increase the injection pressure
4. Increase the injection time
5. Increase the holding time.

3.6.13 Blushing.
Blushing is the dull surface around the gate.

Causes.
Cold material from the nozzle
Mould too cold

Remedies.
1. Raise the nozzle temperature
2. Prevent drooling, employ suck back
3. Pull back injection unit after dosing
4. Provide/ enlarge cold slug well

3.6.14 Delamination. (Fig. 3.7)

The moulding is formed of layers, which can be pulled apart.

Causes.
a) Mould too cold
b) Material contaminated, mixture with
incompatible material
c) Material too cold
d) Moisture in the material
e) Colorant incompatible
f) Injection speed too low

Remedies.
1) Raise the mould temperature Fig. 3.7
2) Purge the barrel
3) Pre-dry the material
4) Change dye/ pigment
5) Increase the rate of injection

3.6.15 Warpage.

82
Warpage is distortion of the product surface, caving in of the walls, twisting and
waviness.

Causes.
a) Wrong product design, large flat surfaces, unequal wall thickness
b) Non-uniform cooling of the mould
c) Too short a cooling time
d) Holding time too short
e) Unbalanced ejection forces
f) Wrong location of the gate

Remedies.
1) Improve product design
2) Balance mould cooling
3) Increase cooling time
4) Increase holding time
5) Increase demoulding taper, improve surface finish of the side walls.
6) Add ejectors at crucial points
7) Relocate the gate
8) Change to an amorphous material if possible.

3.6.15 Surface gloss not uniform

Shiny product surface with dull patches.

Causes.
a) Mould temperature not uniform
b) Mould polish not uniform
c) Materials of mould components have different heat conductivities
d) Wall thickness differences
e) Sink marks
f) Cold material

Remedies.
1) Improve mould cooling
2) Repolish mould surface
3) Redesign product
4) Heat up mould before production start
4) Increase holding time/ pressure
5) Increase nozzle temperature
6) Pull back injection unit after recharging
7) Enlarge cold slug well

3.6.16 Blistering.
Bubbles, containing air, visible in transparent parts or thin walled mouldings. They
may also appear as projections. (different from voids)

Causes.

a) Entrapped air
b) Drawn-in air

83
c) Gases from decomposed melt

Remedies.
1) Improve venting; relocate vents
2) Decrease melt temperature
3) decrease dwell time; decrease cooling period
4) decrease screw rpm
5) Decrease suck back
6) Enlarge nozzle bore

84
 Chapter 4

Design of Injection Moulds for Thermoplastics

4.1 Design of Injection moulds

4.2 Special injection moulds
4.3 Classification of Injection moulds
4.4 Procedure for designing injection moulds
4.5 Materials for injection moulds
4.6 Manufacturing techniques for injection moulds
4.7 Design of injection moulded articles

4.1 Design of injection moulds.

Injection moulding is one of the major processes for producing articles out of
thermoplastics. The injection moulding machine performs the process with the help
of an injection mould. It is the injection mould which converts the molten plastics
supplied by the machine into the intended article and to be able to do this, it must
have a hollow space corresponding to the article. The “hollow space” or the mould
cavity is formed by two mating components called “cavity” and the “core”. These
constitute the basic mould. The cavity is generally situated in the fixed half of the
mould and the core in the moving half. The mating surface of the two mould halves is
referred to as the “parting line”.

The cavity or the outer contour of the product may be machined directly in the solid
plate forming the fixed mould half or in a separate block, inserted in that plate. It is
then referred to as the “cavity insert”. Depending upon the shape of the product, the
insert may be round, square or rectangular as shown in the introductory design (Fig.
4.1). Similarly, the core forming the inside of the moulding may be shaped out of the
solid plate or inserted into the core plate. In case of multi-cavity moulds, the cores
are invariably inserted.

An injection mould has to perform three main functions:

 Feeding the injected melt into the mould cavity.
 Cooling the injected melt to a rigid article.
 Ejecting the rigid moulding without distortion.

In order to discharge these functions, a mould must contain, besides the core and
cavity, three facilities, viz. feeding, cooling and ejection systems. These systems are
put into practice with the help of a number of components which constitute the
mould.

The mould design shown here (Fig. 4.1) depicts the essential mould components,
their function and their interrelationship. It is intended to employ a standard
nomenclature throughout the book in order to avoid confusion and
misunderstanding.

85
1. Clamping Plate, injection side. Forms the base of the fixed mould half; sits
on the fixed platen of the machine and is clamped onto it either directly with
screws or by means of clamps. Made out of M.S. or EN 8.
2. Cavity Plate. Houses either the outer form of the product directly or an insert
containing that shape. Is fixed with the clamping plate (Pos.1). Made of M.S.,
EN 8, P 20, hardenable alloy steels and in special cases, out of light metal
alloys.
3. Core Plate. Houses the core; Made of M.S., EN 8, P20, hardenable alloy
steels or light metal alloys.
4. Cover Plate. Supports the core from behind. Made of M.S., EN 8, P20.
5. Distance Blocks. Maintain distance between the cover plate and the
clamping plate (Pos. 8) on the ejection side, thus creating room for the
ejection unit and its movement. Made of MS, EN 8.
6. Ejector Holder Plate. Holds the ejectors. Made of MS, En 8.
7. Ejector Cover Plate. Supports the ejectors. Made of MS, EN 8.
8. Clamping plate, ejection side. Forms the base of the moving mould half and
holds components 3,4,5 together; sits on the moving platen of the machine
and is clamped onto it like pos. 1. Made of M.S., EN 8.
9. Register Ring. Centres the mould half on machine platen. Fixed with the
clamping plate. Made of M.S., EN 8.
10. Sprue Bush. Acts as the seat of the machine nozzle and as the first point of
entry of the melt in the mould. Made of hardenable alloy steel, EN 24.
11. Sprue Puller Bush. Pulls out the sprue with the help of reverse taper/
undercut. Made of hardenable alloy steel, EN 24.
12. Cavity Insert. Houses the outer contour of the article. Made of hardenable,
non-shrinking alloy steels.
13. Core Insert. Forms the inside shape of the article. Made of hardenable, non-
shrinking alloy steels.
14. Guide Pillar. Aligns the mould halves accurately through a matching bush.
Made of hardenable steels.

Fig. 4.1
86
 15. Guide bush. Aligns the mould halves accurately through the guide pillar.
Made of hardenable steels.
16. Cylindrical Dowel. Aligns the mould plates upon assembly. Made of
hardenable steels.
17. Ejector Rod. A link between the ejector plates in the mould and the ejection
system of the moulding machine. Made of hardenable steels like EN 24.
18. Guide Bush. Guides the ejector plates. Made of hardenable steel.
19. Return Pin. Pushes the ejector plates back to their initial position. Made of
nitride hardening alloy steels.
20. Ejector Pin. Pushes out the moulding from the core or cavity; made of nitride
hardening alloy steels.
21. Sprue ejector pin. Pushes out sprue and runner. Made of nitride hardening
alloy steel.
22. Transport Strip. Holds both mould halves together during transport, loading
and unloading as well as storage. Also used for lifting the mould with an
eyebolt. Made of M.S., En 8.

Note. The guiding components 14+15, having a H7-g6 fit, are bound to have
some clearance which may
not be acceptable in
exceptional cases of
extremely precise articles. In
such cases, these are
supplemented with an
additional set of guiding
members consisting of a
conical pin and a Fig. 4.2
corresponding bush as
shown in figure 4.2.

a depicts the feeding system comprising sprue, runners and gates.

b shows the cavity or the shape of the article to be moulded.
c represents the cooling network for circulation of cooling medium.
d marks the ejection system and the device to move them.
e denotes the parting line where the two mould halves meet and part.

Understandably, the mould must open at a suitable place to enable extraction of the
article out of the cavity. In other words, it must be made of at least two units, which
are held together during injection but go apart for demoulding. The plane of meeting
is called mould parting line. Depending upon the shape of the product, the cavity
may be housed in one or both mould halves.

The mould, depicted here, is of a so-called 2 plate type, because it consists of two
units or two halves viz. the injection or the fixed half and the ejection or the moving
half. As the name indicates, the fixed half is attached to the fixed platen of the
injection moulding machine and the moving half to the moving platen.

87
Although there are many other types of moulds, which have special components, the
ones shown here occur in almost all variations. However, the common features of all
injection moulds are injection (feeding), core and cavity, parting, cooling and ejection.

Almost all mould components except the core and cavity inserts are available as
standard parts in different sizes and materials.

4.1.1 The Feeding System.

The feeding system in the mould is the path of the melt from the source, that is the
nozzle of the injection moulding machine, to its final destination viz. the mould cavity.
It should perform this function with as little loss in material, temperature and pressure
as possible. It is also required to distribute the melt equally to all cavities of a multi-
cavity mould and fill them simultaneously with same pressure and temperature.
Another condition of equal importance is that the feed paths remain open till the end
of the holding phase but should be adequately solidified to be ejectable when the
article is demoulded.

The feeding network has three distinct sections. They are:

4.1.1.1 The Sprue (Fig.4.3). It is the straight path of the

melt from the machine nozzle to the primary runner or the
melt distribution network. It is round in cross section and
has a taper along the length for easy removal. It is
usually housed in a round standard part called sprue
bush, which has a suitable spherical depression on the
receiving end as seat for the machine nozzle. The
starting diameter of the sprue is about 0,5-1 mm larger
than the bore of the nozzle to accommodate any
misalignment. The sprue is provided a taper of at least
one degree for easy removal. Fig. 4.3
The sprue ends in the main distributing channel or the
primary runner but it may also directly lead to the cavity in
the case of a single cavity mould.

Another variation of this is an inclined sprue (Fig. 4.4). This

design is usually resorted to with single cavity moulds
when the cavity is situated in the centre of the mould but
the sprue is not permitted to be placed
right on the product. The angle of
Fig. 4.4 inclination from the mould axis should not
exceed 30 degrees.

4.1.1.2 The Cold Slug Well. The melt in the tip of the nozzle loses
heat to the cold mould when resting on it. A cold slug well is
provided in the mould at the end of the sprue to receive and retain
the colder melt, preventing it from flowing to the cavities (Fig.4.5).
The cold slug well with reverse taper also serves as a sprue puller.
An ejector is positioned under the well to knock it out.
Fig. 4.5

88
The extent of the taper depends upon the rigidity of the
plastics. Whereas a reverse cone of 5-8° can safely pull out
a sprue of polystyrene, 10-15° may be needed for softer
materials like polyethylene. Too big a taper may pose
problems in ejection. The depth of the well usually equals its
diameter. The depth of the well equals the smaller diameter
of the cone.

An alternative design, combining the two features viz. the

cold slug well and the sprue puller, is shown in figure 4.6. It
is as effective as the foregoing design, is simpler and
cheaper but the sprue may not fall off
automatically after ejection.
Fig. 4.6

4.1.1.3 The Runner. It is the linking channel, which carries the melt from the end of
the sprue to the edge of the cavity. The main or the primary runner may have
secondary runners, smaller in size, which may be needed to lead the material from
the primary runner to the cavities, depending upon the number and arrangement of
the cavities.

A good runner should convey the melt with minimum loss of heat. In other words, the
most effective runner would have maximum cross section with minimum
circumference.
Fig. 4.7 It may be
round, square,
rectangular or semi
circular in cross section
(Fig. 4.7). The most
efficient runner should
have maximum For Fig. 4.7
example:

Circle,10 mm. dia. Cross section =78.54 mm² Circumference=31,4 mm.

Square, 8,86x8,86 Cross section=78,54 mm² Circumference=35,4 mm.
Rectangle, 12,5x6,25 Cross section=78,54 mm² Circumference=37,5 mm.
Semi circle, R=7,07 Cross section=78,54 mm² Circumference=58,56mm.

The round type is the most efficient one as it offers maximum sectional area for flow
with minimum circumference through which the heat is dissipated to the mould. The
same area of cross section in other forms mentioned above will have larger
circumference. The round runner, however, has to be cut in the cavity as well as the
core plates whereas square, rectangular and semi circular runners
can be machined on one side. A modified trapezoidal runner with a
semi circular base, placed in one plate, is the next best solution (Fig.
4.8). A total draft of 10-20 degrees facilitates positive ejection.
Fig. 4.8
The runner or the secondary runner ends about a millimeter before
the cavity.
Fig. 4.8

89
Runner Size. A runner should bring the melt to the cavity with as little loss of
temperature and pressure as possible and should freeze after the gate has closed.
As mentioned earlier, the length of the runner is directly dependent upon the number
of cavities and their layout in the mould. The size of the runner viz. its cross-section
depends upon the particular plastics and its viscosity, the volume of the moulding,
the distance of the cavity from the source of the melt etc. It is very difficult to provide
exact data in the face of so many variables. A general rule, applicable universally, is
that the runner should be at least as thick at the point of gating as the wall of the
article there. In case of multi-cavity moulds, it is generally the secondary runner
which feeds an individual cavity.
Though an oversized runner ensures supply of the melt beyond the point when the
gate freezes, it is accompanied by disadvantages of material wastage and cooling
time prolongation.
The size of the secondary runner should be chosen to maintain a uniform speed of
flow. For example, if the main runner splits into two secondary branches, the total
cross sectional area of the later should equal that of the former.

Though desirable, it is sometimes not practicable to place all cavities equidistant

from the sprue. Sometimes the cavities can only be arranged in a row and have to
be fed one after the other. Simultaneous filling in such cases is achieved by
manipulation of individual gates through trials. The cavities closer to the source of
the melt are provided with smaller gates and those placed farther with bigger ones. It
must, however, be underlined here that the balancing achieved is valid only for that
particular grade of thermoplastics. The filling pattern changes as soon as another
material grade with different flow characteristics is employed. Similar results may
also be obtained by varying the size of the primary runner in different sections or by
increasing the size of the secondary runners as the melt travels away from the
central source. A similar problem of uneven filling is encountered in case of the
family moulds (moulds housing cavities for dissimilar articles). Because of this
reason, fabrication of family moulds should be discouraged.

4.1.1.4 The Gate. It is the ultimate entrance of the melt into the cavity from the end
of the runner. The one shown in the introductory diagram is a side gate, also called
edge gate.

A side gate needs to be trimmed off, leaving a small mark on the product.

The introductory mould design (Fig. 4.1) shows these features viz. the sprue, the
cold slug well and the runner with an edge or side gate. The other common types of
a side gate are the submarine gate, the fan gate, the film gate, the tab gate etc.
which are elaborated below.

4.1.1.4.1 The Edge Gate. In multicavity moulds, runners act as distributors of the
melt and bring it close to each cavity. A thinner channel forms the connection
between the two. It is called an edge gate. The most efficient cross section for a
gate is a circle which can be used if the cavity is placed in both mould halves. It
needs to be machined on both sides. The next best alternative is a trapezoidal gate
like the runner shown in figure 4.8. However, gate with a rectangular cross section,
placed in one mould half, is easy to machine and easy to modify during the try-out. A

90
gate may be as deep as two thirds of the article thickness at the point of entry (for
very thin parts, it may equal the article thickness). The breadth is generally twice the
depth. The length of the gate, also called the land, is 1.0 mm or preferably less. It
remains connected with the moulding and is severed after ejection, leaving a mark.
The edge gate is easy to make and easy to enlarge during trials.

Edge gating has been shown in the introductory mould design (fig. 4.1).

4.1.1.4.2 The submarine gate. It is a conical tunnel, going

from the end of the runner to the wall of the cavity at an
angle through the solid insert. It is round in cross section
and has its smallest diameter where it enters the cavity.
The angle of inclination with the mould parting line should
be at least 45 degrees. In principle, it is a side gate but has
the advantage that it gets sheared off automatically,
leaving an elliptical mark on the wall, when the mould
opens or during ejection. It is practicable with all
thermoplastics (Fig. 4.9).

Another version of the submarine gate is Fig. 4.9

shown in Figure 4.10. The gate is formed like the frustum of a cone,
protruding partly in the cavity. The smaller diameter of the frustum
is 2,5-3,0 mm. It has the advantage of containing a fluid "soul" or
core. It leaves a crescent shaped mark on the product. The angle
of its inclination with the mould axis should be same as in the
previous version.

A gate mark on the visible surface of

Fig. 4.10 some sophisticated product may not
be acceptable. In such cases, the submarine gate may
be placed on an auxiliary detail, such as a thin leg (Fig.
4.11), at an invisible spot. The leg can be removed after
ejection.
Fig. 4.11

4.1.1.4.3 The Banana Gate. It is a further refinement of the submarine gate and has
the form of a semi circular tunnel, starting from the end of the runner and ending on
the underside of the moulding. It is resorted to when a
mark on the visible face of the article is not permitted.
It can be used with almost all materials except the
very brittle ones (Fig. 4.12). As shown, it has to be
housed in a split insert for ease of manufacturing.
However, standardised solid inserts are also available
now with various gate sizes.

Fig. 4.12

91
 4.1.1.4.4 The Film Gate. It is employed for large, flat articles. Spread over the
complete side of the cavity, the film gate ensures an even filling, causing less
warpage and leaving no flow marks, but has to be machined off after ejection (Fig.
4.13).

Fig. 4.13 4.1.1.4.5 The Fan Gate. It serves the same purpose as the
film gate. The difference lies in the configuration,
which gives it the appearance of a fan, emanating from
the end of the runner and encompassing a part of the edge of
the cavity (Fig. 4.14). The length of the gate is computed by
dividing the cross sectional area of the runner Fig. 4.14 by the depth of
the gate.

4.1.1.4.6 The Tab Gate. It is an indirect form of gating as it

connects the runner with a tab on the moulding. It is employed for
some specific materials like Acrylics, Polycarbonate, Acrylonitrile
Styrene (SAN) but also in cases where flow marks are difficult to
eliminate. The material is first introduced into a tab from which it
flows evenly into the cavity. The tab, which may be as deep as one
half or even two thirds of the wall thickness of the moulding, has to
be machined off (Fig. 4.15). The breadth of the tab may be 6 mm.
or more.
Fig. 4.15
4.1.1.4.7 The Ring Gate. It is a film gate for round articles. The
runner is placed like a round ring outside/ inside the article and a thin
film gate connects both all along. It ensures uniform filling and
roundness of the product but necessitates after-operation for
removal. In uncritical cases, where some deviation in roundness is
permitted, three or more gates may be used instead of a continuous
film (Fig. 4.16). The degating is more convenient. It may also be
possible to use self shearing submarine gates.

Fig. 4.16
4.1.1.4.8 The umbrella gate. It is like a conical
ring gate. The runner is connected to the round
article through a film gate all along the rim and fills it uniformly
ensuring roundness. It can also be modified to feed at three or
more places. That facilitates centring of the core (Fig.4.17).

4.1.1.4.9
Fig. The
4.17 sprue as gate.

92
Single cavity moulds have usually the product cavity placed in the centre of the
mould. Here the sprue can take over the function of the runner as well as that of the
gate (Fig.4.18). The sprue is ejected along with the moulding and removed in an
after-operation, leaving a round mark which may not be found disturbing if it is on a
invisible spot, for example, on the back of a bucket or a box.

4.1.1.4.10 The pin point gate. The sprue Fig. gate

4.18 can be
converted into a self severing pin point gate with the help of a
special sprue bush (Fig. 4.19). As the injection unit of the
moulding machine recedes after injection and the holding
period, a part of the sprue bush is pushed back pneumatically,
severing the gate and ejecting the sprue backwards. The gate is
circular in cross section, 1-1,5 mm. in diameter and in length
and tapered backwards so that it breaks at the cavity, leaving a
very small vestige. The included angle of the conical gate may
Fig. 4.19 be around 30°. The opening in the cavity is countersunk to a
depth of 0,5 mm. to provide a defined breaking point.

A pin point gate without a sprue and the moving bush can
also be realised by prolonging the machine nozzle up to the
mould cavity as shown in figure 4.20. The special nozzle can
be standardised so that it fits all such moulds.

The disadvantage is that the face of the nozzle, which is at a

very high temperature, leaves a visible mark with different
surface finish on the moulding. However, it may not be
visible in some cases.
Fig. 4.20
Another alternative is to employ an elongated, self insulating
machine nozzle, reaching almost up to the mould cavity, with
its tip fashioned out of a good heat conducting metal such as
copper or preferably beryllium copper. As shown in figure 4.21 ,
the mould contains a special sprue bush in which the machine
nozzle sits with a gap all around. The melt from the first shot
creates an insulating sheath of plastics around the tip of the
nozzle and prevents loss of heat so that the nozzle remains
hot in a cooled mould and the product surface does not show
Fig. 4.21 any blemishes caused by high temperature. The sheath is
thinner in front (about 0,2-0,3 mm.) but gets thicker gradually around the shaft. The
thin film in front is thick enough to be effective as insulation but not too thick to block
the next injection. The gate length in the sprue bush is about 1,5 mm. The heat loss
through the sprue bush is kept to the minimum by reducing the area of contact
between the mould and the bush.

4.1.1.4.11 Three plate mould.

The side gate in different forms as discussed above, is simple in
mould configuration and economical in cost. The mould is
required to open only at one level to eject runners, gates and the
mouldings. It is called a two plate mould. The side gate, however,
is primarily suitable for shallow articles with uniform wall

93
Fig. 4.22
thickness. It leads to blemishes such as air entrapment, short shots and burn marks
in case of tall parts like boxes, tubes, tumblers etc. The material injected at the edge
of the rim travels around the rim as well as upwards. If the flow path along the rim is
shorter than that across the top, material will fill first around the rim and seal the
escape path of the air contained in the mould before complete injection (Fig. 4.22).
The melt stream, travelling towards the top, goes on compressing the entrapped air
till it gets so overheated that it burns the plastics around it. The problem would not
arise if the product could be injected in the centre. The melt advances like a uniform
front, driving the air before it towards the mould parting line, where it can escape
easily. Such an arrangement is possible in a single cavity mould, where the sprue
can function as a direct gate (see Fig. 4.18). The sprue will have to be removed in
an after-operation and a big mark will be visible. Another alternative is a pin point
gate by means of special sprue bush and nozzles as shown in Fig. 4.19/20/21.

To feed more than one such cavities centrally (or from above) with pin point gate
calls for bifurcation of the runner at a level other than
the parting line (Fig. 4.23). In order to remove the
runners, the mould must be opened at their levels
also. This type of mould would consists of three units
and is named as a “three plate mould”. It will be
discussed in detail in the section 4.1.5 “Special Mould
Designs”.

4.1.1.4.12 The self-Insulating runner The

advantage offered by the three-plate system, viz. the
freedom of location of the gate, is invaluable.
Fig. 4.23 However, the disadvantages of the runner network at
a different level and the complications caused by an additional opening and the
arrangement to eject the runners have encouraged the enterprising designers to find
ways and means to circumvent the drawbacks while retaining the positive points of
the system. The bad heat conductivity (that is, good thermal insulation) of plastics
led to the experiment of making the runner cross-section sufficiently large so that the
frozen outer layer insulated the melt in the centre and kept it fluid till the next shot. It
worked, especially with thermoplastics with a broad melt temperature range. This
was the birth of the runnerless moulding. This system has been named as the self-
insulating runner. The gate is of the pin point type.
As mentioned before, plastics are bad conductors of heat. If the runner were
sufficiently thick, the plastics in the middle of it, insulated by the frozen outer layer,
would remain hot and molten for
a long time (Fig. 4.24).
Successive shots could be
pumped through this insulated
“pipe”, without taking out the
runner. The mould would behave
like its two-plate counterpart and
also have advantages of a three
plate mould.
The system is simple and cheap
and works very well for some

94
Fig. 4.24
thermoplastics if the cycle is short and regular. (see Special Mould Designs, 4.2 for
design details.)

4.1.1.4.13 The hot runner. The foregoing solution of runnerless moulding suffers
from severe limitations. It is not applicable universally. Any disturbance or
interruption in cycle leads to freezing of the runner necessitating its removal and
starting the operation afresh. The hot runner concept aims at keeping the runners
hot at desired temperature with positive means independent from the cycle. It can
be employed for the moulding of almost all thermoplastics.
Hot runner system allows freedom of location of the gate. Standard systems are
available in diverse variations for different materials, products and shot weights.
Some designs have been described in detail in section 4.2 on Special mould
designs.

4.1.1.4.14 The stack mould. A stack mould may be regarded as amalgamation of

the three plate and the hot runner systems. It is basically a three plate construction
but instead of the runner network, another set of cavities is accommodated at that
level. The feeding system is mostly a special hot runner housed between the two
levels, which feeds both sets of cavities.
A stack mould virtually comprises two 2-plate moulds, placed back to back, thus
having twice the number of cavities in aggregate. It can almost double the
production from the same moulding machine. For opening on two level like a three
plate mould, the stack mould also needs special devices. The system is described in
detail in section 4.2.
In principle, a stack mould can have more than two stacks.

4.1.1.4.15 Number of gates.

It may not be possible to fill the cavity with a single gate if the article is very large.
The ratio between the length of flow and the wall thickness for the polymer in
question is a good indicator for deciding the number of gates. Another consideration,
no less important while deciding the number of gates, is that the pressure needed for
filling should not be more than the half of the machine capacity. Overpacking results
in warpage.

More than one gate may also be called for to ensure balanced filling of the cavity.
For example, melt from a centrally placed gate on a rectangular product will cover
the shorter distance first and reach shorter sides of the rectangle later. During this
period, the melt which has already touched the cavity wall will be under pressure
and will get overpacked. It is bound to lead to internal stresses which cause
warpage. Two gates, located to provide equal flow lengths, will eliminate the problem
(Fig. 4.25).

More gates, however, give rise to weld lines and may cause air entrapment in some
cases. The quality of weld lines, i.e. the strength and appearance of the joint,
depends upon the temperature of the meeting streams and their pressure.

95
A gate is also the point of maximum internal stress. More gates also mean more
centres of stress concentration. This results in uneven shrinkage and warpage in
extreme cases.

4.1.1.4.16 Guidelines for location of

the gate.
The function of a gate is to fill the
cavity in a manner that ensures a
sound moulding, free of faults. Its
location has a far reaching influence
on the quality of the product. Following
Fig. 4.25 guidelines deserve due consideration
while determining the gate location.

1. The gate should be so located that the length of flow is same to all end points.
2. The gate location should ensure rapid and uniform filling.
3. It should ensure minimum runner length.
4. It should ensure melt progress as an advancing front.
5. It should facilitate air expulsion and prevent air entrapment.
6. It should direct the melt stream towards a restriction and prevent jetting.
7. It should be close to the thickest section for the holding pressure to be effective
longer.
8. It should banish the unavoidable weld lines to harmless areas.
9. It should not cause deflection in slender mould cores.
10. It should be away from the load bearing section as the gate area has maximum
stresses.
11. It should not make the mould unnecessarily more complicated.
12. The gate location should not interfere with the function and appearance of the
article.

Besides location, the size and the shape, too, play an important role. For a
successful moulding operation, the gate should:

 leave a small vestige

 prevent incomplete filling
 prevent premature freezing
 prevent jetting
 permit unrestricted flow
 provide correct shearing
 hide/disperse cold slug
 prevent drooling and stringing
 prevent blushing
 prevent degradation
 prevent warping

4.1.1.5 Arrangement of cavities.

In a multi-cavity mould, the melt entering the
mould at one central point, viz. the sprue, travels

96
to individual cavities through the runners and gates. If their lengths and sizes are not
identical, the cavities would not fill at the same time. When the holding pressure sets
in, the cavities which filled first would get overpacked and may tend to flashing while
those which filled later would be underpacked and may have sink marks and voids.
The difference in the pressure and its duration leads to difference in dimensions as
well as residual stresses. Such feeding system is termed as unbalanced. The safest
method of a balanced filling is to place the cavities equidistant from the sprue and
have a separate runner to each cavity. This may prove impractical as it necessitates
their placement in a circle which would become bigger with more cavities, making
runners longer. The mass of runners may even overweigh that of the mouldings. The
solution is to divide the cavities in a number of groups and feed the group by a main
runner from which secondary runners lead to individual cavities. Fig. 4.26 shows a
few arrangements of balanced placement of cavities.
In some exceptional cases, it may not be feasible to locate the cavities in the ideal
manner. Sometimes, the linear arrangement is unavoidable. The length of the runner
to each cavity will be different. Here, the balancing is effected by making the gates
different in size so that the filling takes place simultaneously. To start with, all gates
are made equal and then enlarged step by step during the trialFig. on4.26
the machine. It
must, however, be borne in mind that the balancing achieved is valid only for that
particular material. The flow behaviour will be different with a different grade.

4.1,1.6 Number of cavities.

The maximum number of cavities in a mould for a particular machine is directly
dependent upon the locking force of the machine, the projected area of the article
and the effective injection pressure. The last factor is not identical with the set
pressure or the one displayed on the pressure gauge. The melt loses some pressure
till it reaches the end of the cavity. By the time a cavity is completely filled, a part of
the melt has partially frozen and does not exercise full pressure. Effective pressure
may vary between half to two thirds of the pressure displayed. It is influenced by the
melt and mould temperatures, the length of travel and the speed of filling, among
other factors.

The maximum possible number of cavities, however, may not always prove to be the
most economical for a given quantity. Though the production rate increases and the
moulding cost decreases with the increasing number of cavities, the cost of the
mould also goes up.

The profitability of multi-cavity moulds is directly linked with the total quantity to be
moulded. The most economical number of cavities can be computed from the
following data:

Q=Total number of mouldings to be produced

M= Mould manufacturing cost per cavity in Rupees
T= Moulding cycle in seconds
η= Moulding efficiency in decimal
R= Moulding machine rate per hour in Rupees
N= Economical no. of cavities

__________________

97
N= √( QxRxT)/ (Mx 3600xη)

The number of cavities thus calculated may not be an integer. It is advisable to round
it up or down to a whole number depending upon the value of the fraction. It requires
further examination whether some unusual features of the article come in the way of
accommodating the calculated number of cavities in the mould consummate with the
size of the platen and capacity of the machine. These features may be the shape of
the product such as rings and frames with large circumference but relatively small
projected area, or those with less area but large volume, exceeding the shot weight
or products with undercuts requiring sliders on sides etc. Another vital check is the
comparison of the locking force of the machine with that required for the selected
number of cavities.

4.1.1.7 Mould venting.

Before injection, mould cavities contain air which must make place for the plastics.
The advancing melt stream pushes the air farther and farther and in most cases it
can escape at the end of the path through the parting line where the two halves of
the mould meet, unless the mating surfaces are very finely ground. However, the
configuration of the article or the position of entry of the melt may make the melt seal
the parting line before all air could escape as already discussed and illustrated in
figure 4.22. The entrapment of air may also happen in article features like lugs, ribs
and bosses. The advancing melt compresses the air till it also achieves a high
pressure and hinders the flow or it gets so overheated that it singes and chars the
polymer. The phenomenon is rightly termed as the diesel effect.

The normal escape route for the enclosed air is the parting line, which may be
foreseen with additional venting channels on the face, not deeper than 0,04 mm., at
crucial points where the melt reaches last. Ejectors and other moving mould
components like slides and cores and split cores are other effective escape routes
for the entrapped air. The joints of the unmoving cores and inserts also provide a
path for the air but they are likely to get choked with time by the escaping volatile
additives in the plastics and need occasional cleaning.

Additional ejectors at the points of entrapment of air serve as venting aids but in
many cases it may not be possible to position ejectors there. A viable solution is to
incorporate sintered metal inserts at the critical locations, providing holes at their
back for the final escape of air. The sintered metal inserts too require occasional
cleaning. They should be easy to remove and refit.

Air in the feeding channels of the cold runner moulds is driven by the melt into the
cavities. A venting groove, as broad as the runner and about 0,03-0,05 mm. deep at
the end of primary runner, would let the air out.

If the melt is parted in the mould by some design feature like a pin forming a hole,
the streams form a weld line when they meet again. The joint would be weak if some
air is trapped between the two fronts. Venting provision at that juncture can
contribute to the strength of the weld.

98
4.1.2 Mould cooling.
Plastics is injected into the mould in molten condition at an elevated temperature.
For most of the commodity plastics, it is around 200-250 Celsius; for engineering
platics the melt temperature is even higher. The mould gives the melt the intended
shape of the end product but it also does something more than that. It acts as a heat
exchanger. It cools down the hot, injected plastics mass to a temperature where the
moulding becomes rigid and can be ejected out of the mould without distortion. To
facilitate the dissipation of heat of the injected melt, moulds are provided with cooling
channels for circulation of a cooling medium, usually water, but sometimes also oil at
elevated temperatures--in case of some engineering plastics it may exceed 100C. It
is nevertheless referred to as cooling because the melt is cooled, even though the
mould is being heated. While discussing the moulding technology, it was observed
that the cooling time constituted the major part of the moulding cycle. Consequently,
design of the cooling system in a mould deserves proper analysis and careful layout
to achieve the most efficient heat transfer. A longer cooling time means a longer
cycle, which in turn means less production and consequently higher production cost
per unit.

Before designing the cooling layout of a mould, one must consider the following
factors:

(a) The shape of the moulding.

(b) The pattern of cavity filling.
(c) The hot spots.
(d) The thin and thick sections or the zones of less or more heat.
(e) Inaccessible hot areas.

4.1.2.1 Design of the mould cooling.

Cooling would be most effective if it conforms to the shape of the product. In other
words, for rectangular articles, cooling should have a rectangular layout and for
round mouldings, it should be spiral or circular in design. Simultaneously, the cooling
should be more intensive at the hot spots. It can be achieved by providing more
channels near the thicker sections and by arranging the entry of the cooler water
near that spot.

A fact worth taking into account while designing the cooling lay-out is that the mould
core is enclosed by the hot melt and its heat can only be conducted away by the
incorporated cooling. Especially the corners of a core become heat accumulation
zones and the melt cools there last. The cavity block, on the other hand, has more
space to incorporate cooling channels and has all its outer surface exposed to
atmosphere. A good part of its heat is dissipated outwards by convection. This
phenomenon is observed in the moulds for box shaped
articles (Fig. 4.27). The corners of the core constitute hot
spots and cool slower than the walls. The corners shrink
more and pull in the sides which results in caving-in of walls
of the box like article.

Cooling changes the density of the plastics material. The

change is more pronounced in the semi-crystalline polymers
than in the amorphous ones. A non-uniform cooling of a
Fig. 4.27
99
semi-crystalline melt gives rise to different densities at different points, which in turn
leads to warpage. Uniformity of cooling is, therefore, more important than its
intensity.

The importance of uniform cooling is manifested distinctly in the form of warpage

and rejection in products like compact discs and flat screens. In these cases, it is not
only the temperature of the coolant but also its flow and the exactness of distances
of the cooling lines from the cavity in both mould halves that influences the precision.

The side of the article with better cooling will solidify and shrink faster. The hotter
side gets more time to cool and consequently shrinks more. The final product tends
to bend with convexity on the colder side. It is, therefore, imperative that mould
surface temperature be uniform on both sides of the part to prevent warpage. (The
phenomenon may be made use of to counteract bending if one side of the mould
cannot be cooled as efficiently as the other side. The opposite side may be kept
hotter to equalize heat transfer and prevent differential shrinkage).

4.1.2.1.1 Types of Cooling

4.1.2.1.1.1 Cooling holes. It is the cheapest arrangement of cooling. Straight holes

are drilled in the mould plates or inserts and interconnected to form a cooling network.
This method of cooling is employed in case of
rectangular cavities of low height. The rectangular
cores can also be cooled with drilled cooling lines if
the marks of the plugs on the inside of the moulding
are acceptable. It is also resorted to in case of
relatively cheap moulds irrespective of the shape of
the moulding, where the price of the mould and not
its efficiency are the deciding factors, for instance
with experimental moulds and for those for small
quantities. The usual hole diameters range from 6 to
12 mm. For large products, there should be more Fig. 4.28
than one circuits, as otherwise the water may get too hot traversing a long path and
mould temperature may have widely different temperatures at the entry and exit points
of the coolant (Fig. 4.28).

The simple formula of heat transmission highlights the factors which influence the
quality and efficiency of cooling through drilled holes.

Q= λ.Δt.A/ D
where
Q is the amount of heat transmitted
λ is the heat conductivity of the mould material
Δt is the temperature difference between the melt and the coolant
A is the area of the cooling channel
D is the distance between the cavity surface and the cooling channel

Obviously, more heat will be transferred:

100
  if the heat conductivity of the mould material is high (steel has relatively low
heat conductivity)
 the temperature difference is greater (i.e. water is colder)
 the area of cooling channel is larger ( i.e. the diameter of the cooling holes is
bigger) or more channels are provided.
 The distance between the cavity surface and the source of cooling is shorter
(i.e. the channels are placed closer to the cavity)

Steel is practically irreplaceable for mould components subjected to very high

pressure and wear. Be-Cu may be regarded as an alternative. It has excellent heat
conductivity which helps reduce the cooling time considerably but its lower tensile
strength and hardness reduce the mould life.

It is an erroneous supposition that very cold water would expedite the cooling process.
A thin layer of the melt solidifies on the cold walls of the cavity and acts as an
insulating barrier between the hot melt behind and the source of cooling. Too cold a
mould comes in the way of rapid filling and hinders crystallisation in case of semi
crystalline polymers.

Cooling channels placed too close to the

cavity surface result in temperature
variations which will have adverse effect
on the quality of the moulding. It will lead
to different mould temperature at
different points of the cavity (Fig. 4.29),
which manifests itself as non-uniform
shrinkage and
distortion in the
Fig. 4.29 article.

Following guidelines (Fig. 4.30) concerning the size and

distance of the drilled cooling lines ensure uniform and efficient
cooling without impairing the strength of the cooled mould
component.
Fig. 4.30
X= 2,5d
Y= 2,5d

d= 6 mm for t < 1 mm
d= 8 mm for t = 2 mm
d=10 mm for t = 3 mm
d=12 mm for t = 4 mm

Should it not be possible to accommodate adequate number of cooling holes because

of some design features or ejectors in the way, it is better to opt for less holes placed
at a distance larger than that recommended above. Though the cooling would be
slower, it would be more uniform.

101
Long, slender drills are likely to stray from the intended line. Depending upon their
diameter and depth, a clearance of 3-5 mm. must be foreseen between the cooling
hole and any other perforations such as screw holes, ejectors etc. in its path.

The rough surface of drilled cooling holes tends to gather deposits from water which
reduce the cooling efficiency gradually. Water also causes rusting and the sharp
grooves left from drilling form the starting point of cracks. It is therefore advantageous
in the long run to ream the drilled holes and to coat them internally with chemical
nickel.

The cooling efficiency can be enhanced significantly by introducing turbulence in the

water stream. It can be effected by inserting twisted thin strips, preferably made of
stainless steel, in the cooling holes.

4.1.2.1.1.2 Spiral Cooling. Cavities of round products

like shallow boxes, plates or lids can be cooled more
effectively if the cooling channels are cut in the form of
a spiral at the back of the cavity plate and the inlet of
the coolant is placed in the middle, close to the gate
where the temperature is highest. It is cheaper and
equally effective to machine concentric channels and
form a continuous spiral like cooling path by blocking
and joining them as shown in figure 4.31.

4.1.2.1.1.3 Bubbler cooling.

This type of cooling arrangement is usually employed to
cool the cores of long cylindrical Fig. 4.31
products such as tumblers, tubes,
syringes, cones, bobbins and long slender containers (Fig. 4.32).
The core is provided with a hole from the lower end and a pipe is
fixed in the centre of the hole in such a way that there is clearance all
around between the hole and the pipe. The cross sectional area of
the clearance should be preferably less than that of the inlet hole.
Cold water is introduced through the pipe to the hottest area. It
returns around the pipe, cooling the walls of the hole and is led to the
Fig. 4.32 outlet. The bubbler arrangement is a balanced cooling method as the
cold water is first led to the hottest spot, viz. opposite the gate. As the
melt flows down, it gets colder and the cooling water gets warmer while bubbling
down. This system can also be employed in case of deep and narrow articles of all
shapes. Here, a number of bubbler holes are drilled in a row and depending upon
their number, either provided with individual inlets and outlets or interconnected.
Fig. 4.32
In most cases, the holes have to be interconnected as the cooling batteries of the
injection moulding machines have a limited number of water circuits. There are two
ways to interconnect the successive bubblers:

4.1.2.1.1.4 Parallel connection.

A common water inlet channel feeds all
bubblers simultaneously and the used water is
discharged in a common exhaust channel (Fig.

102
Fig. 4.33
 4.33). The main advantage of this arrangement is that all mould cores are treated
alike as far as the temperature of water is concerned. However, even if one or more
bubblers are partially or totally blocked, water flows in and out and it is not possible
to detect the fault. Obviously, the cavities with the blocked water path would not be
cooled as good as the others which fact may lead to variation in quality and even to
rejection.

The system works well if water is soft and free of impurities and the pressure is
adequate.

4.1.2.1.1.5 Series connection.

In this design, fresh water is introduced in one
bubbler and after circulating through it, it enters
the next bubbler. In other words, exit of the first
bubbler is the entrance of the next one (Fig.
4.34). Logically, there is bound to be some
difference in temperatures between the
successive bubblers. However, if any of the
channels is blocked, no water would come out
at the exit and the fault Fig. 4.34
would be detected readily.

The difference of temperatures remains within acceptable limits

if the water pressure is adequate and not too many bubblers are
connected in a row.

4.1.2.1.1.6 Spiral cooling of the core.

For large, round or rectangular articles such as mugs,
buckets, radio and TV-housings, large box shaped articles
etc., insertion of a cooling core inside the mould punch
facilitates incorporation of uniform and effective cooling.
For this purpose, a blind cavity is machined in the mould
punch from the backside and a cooling core, preferably
Fig. 4.35 made of a light metal like aluminium, brass or bronze etc.,
Fig. 4.36
is fitted therein. The cooling core is provided with cooling channels in the form
of spirals, starting at the top where the mould temperature is maximum (Fig.
4.35). Water inlet and outlet are arranged in such a way that the coldest water
enters close to the hottest area and travels downwards through the spiral, cooling
the side walls. This is a balanced system of cooling like the bubbler arrangement.
Fig. 4.35 The principle can be applied in many variations depending upon the shape and size
of the article. The cooling spiral can be broken into more than one independent
segments with separate inlets and outlets for large articles.
The cooling core for a round article can be turned out of a light metal with a spiral
going up to the top. A Hole in the centre serves as water
inlet. A milled channel connects it to the spiral so that water
goes out cooling the core along its length. The inlet and
exhaust may be designed as shown in figure 4.36.
The cooling core for a round article may be foreseen with a
double spiral like a two start thread if the central axis is

103
Fig. 4.37
occupied by an ejector. Now one spiral serves as path for the water to travel up and
the second spiral, which is connected here with the first one, forms the return path.
Round cooling cores with a single or double spiral, machined out of a light metal, are
available as standard components (Fig. 4.37).
4.1.2.1.7 Cooling pipes.
Cooling pipes or heat pipes represent the latest development in the mould cooling
technology. They are employed to cool very slender, long cores (like those of the
mould for an insulin syringe), where it is difficult to use the bubbler system due to
lack of space. The heat pipe is a hollow metal tube sealed at both ends and partially
filled with a liquid which turns into a gas when heated. The heat pipe is
snugly fitted in the mould part to be cooled with its lower end immersed
in flowing cold water. The fluid rises up to the hottest section through a
fabric, gets heated, turns into a gas and then travels down to the lower
end of the pipe that is being cooled constantly by a water circuit. The
gas gives up its heat here and travels up again as a fluid (Fig. 4.38).

Heat pipes are available as thin as 3 mm. in diameter.

Copper wires and copper rods can also be employed in the same way
Fig. 4.38 as the heat pipes to conduct away heat from inaccessible mould
sections though their efficiency would be much less. It
can be improved by increasing length of the free end
being washed by water.

4.1.2.1.1.8 Jacket cooling of the cavity.

For tall, cylindrical products, the cooling of the cavity is
equally important. The cooling layout for the cavity should
also be executed in a balanced manner, with cold water
entering near the hottest zone and proceeding in the
same direction as the melt travels in the cavity. Figure Fig. 4.39
4.39 Illustrates the design of the jacket cooling for a
cylindrical component. A spiral is machined outside on the outer surface of the cavity
insert and the water inlet is placed near the entrance of the melt. The outlet for the
warmed up water is close to the rim of the moulding where the melt is colder.

A spiral may not be feasible for articles of short length. It

is replaced by a single groove (Fig. 4.40)
Fig. 4.39
Sealing rings, suitable for the temperature of the mould,
must be provided to prevent leakage of the cooling
medium.
Fig. 4.40
4.1.2.2 The flow of the coolant. The most common
coolant used is water which is not a good conductor of
heat. If it is allowed to have a laminar flow, the heat from the melt will be conducted
through the mould metal to the outer layer of water flowing through a cooling
channel and then to the next inner layer. The sole mode of heat dissipation is
conduction, which is not very efficient due to poor thermal conductivity of water.
However, if the flow is made turbulent (e.g. by introduction of spirally twisted metal

104
strips in the cooling hole), water will be mixed constantly and heat dissipation will
take place through conduction as well as convection.

4.1.2.3 Mould wall temperature.

The ideal mould temperature is different for different thermoplastics. Formation of
crystallites in case of semi crystalline polymers takes place well above their glass
transition temperatures. The mould wall temperature for these polymers has to be
maintained accordingly. It also facilitates good flow of the melt. The surface finish of
the moulding is influenced by the mould wall temperature. Frozen-in stresses and
warpage can also be minimised by maintaining the right temperature recommended
for the polymer. The post-shrinkage will also be lower as well as more uniform with
correctly cooled/ heated mould. Indirectly, it contributes to the dimensional accuracy.

It is recommendable to cool or heat the mould through a temperature controlled unit

as it makes it possible to re-create the exact moulding conditions when the mould is
put in production again. The temperature of water, straight from a cooling tower,
fluctuates with the ambient conditions.

Table 4.1 gives the most suitable mould wall temperature for various thermoplastics.

Table 4.1
Mould wall temperatures

Polymer Temperature °C
CA 20-50
LDPE/ HDPE 20-70
PP 20-80
PS 20-60
HIP 50-70
SAN 40-70
ABS 40-70
PVC 40-60
PMMA 50-80
POM 70-120
PC 80-110
PA 6 50-80
PA 66 60-90
PETP 70-110
PBTP 70-140
PPO 70-150
PPS 80-180
PES 120-190
PSU 140-190
PEI 135-165
PEEK 160-200
Polyblend PC+ABS 50-100
LCP 40-150

105
4.1.3 Ejection.
When the injected melt cools in the mould, it shrinks in volume and hence becomes
smaller in all dimensions. Consequently it becomes free from the cavity but holds
onto the core, pins forming holes, ribs, bosses and other such details. After the
mould opens, the product, sticking onto the core, has to be ejected by force. This
force is applied onto the moulding by means of specific mould elements forming the
ejection system. The guidelines governing the design of the ejection system and the
choice of ejection elements are:
 The moulding should be ejected without deformation and damage
 The ejector marks should not be visible disturbingly.
 The ejection elements should not interfere with other functional
components and features such as cooling or feeding

4.1.3.1 Ejection elements. There are several standard ejection elements which are
incorporated in the mould and serve to push out the solidified moulding. Their shape
and design varies with the configuration of the moulded article. Although it is
possible to compute the force holding the moulding, it suffices to choose surface
area of the ejecting elements as one tenth of the area of holding, viz. that of the
vertical walls, core pins, bosses etc. The usual ejection devices are:
4.1.3.1.1 Ejector pin (Fig.4.41). It is the most commonly used ejection element.
Round ejector pins are available in standard diameters, ranging from 0.5 mm to 20
mm or more in various lengths in hardened state. Their incorporation in the mould is
very simple; a drilled and reamed H7 hole in the core or sometimes the cavity,
enlarged after a certain guiding length, is practically all that is needed. Their lower
end culminates in a flat head of bigger diameter, which
serves to hold them in the ejector plates as shown in the
introductory mould design Fig. 4.1. They are basically
Fig. 4.41
suitable for ejection of shallow mouldings made of
rigid/semi-rigid materials. They leave a mark on the surface of the article. Round
pins are also employed to eject the cold slug and the runners.

4.1.3.1.2 Blade ejector (4.42). This is a variation of the round ejector pin and
resembles one with certain length in front machined
down flat. It is employed to eject mouldings with thin
walls and deep ribs. The aperture for a blade ejector
in the cavity is made by EDM, wire cutting or by
parting the cavity insert and milling a rectangular slot Fig. 4.42
for the ejector at the joint.

4.1.3.1.3 Sleeve ejector (4.43). It resembles a

round ejector pin with a round bore in the centre
Fig. 4.43 along the longitudinal axis. Sleeve ejectors are
employed for ejection of round articles and for
those having bosses with holes formed by round
core pins. They exert a uniform, alround
ejection force for distortion free demoulding
and do not leave a visible mark when used
under a round boss.. Because of the accuracy

106
 required both on outside as well as inside diameter, a sleeve ejector is expensive.
Sleeve ejectors are available ready made in some standard sizes.
Fig. 4.44
Figure 4.44 shows various modes of the application of above ejectors.

4.1.3.1.4 Mushroom ejector. Tall products, especially those

out of softer plastics, cannot be demoulded with the help of
ejector pins without distortion and damage. The disposable thin
walled tumblers are one such example. Here a specially
designed mushroom ejector ensures safe ejection as it
distributes the applied force over a large area. It constitutes a
part of the core and must be foreseen with cooling. In
appearance, it resembles a
poppet valve (Fig. 4.45).

Fig. 4.45 Mushroom ejector is usually

anchored in the ejector plates

and moved by them.

4.1.3.1.5 Stripper ring/ Stripper plate. For

articles having a regular, geometrical contour and relatively deep walls such as
tumblers, round or rectangular containers, tubular products, bowls and even
technical components, where the main holding is along the walls, stripper ejection is
the most suitable method for safe demoulding. A closely fitting ring around the core,
which sits under the moulding and is connected to the ejector plates, strips the
cooled moulding off the core after the mould has opened (Fig. 4.46). It is equally
suitable for soft as well as rigid plastics and does not leave a mark on the surface.
Its action is the same as that of a sleeve ejector. In case of moulds for large articles
or those with a number of cavities, a stripper plate instead of stripper rings may
Fig. 4.46
perform the demoulding action. Hardened rings may be fitted in an unhardened
mould plate, which is activated by the ejector plates.
Fig. 4.47 The stripper plate, as mentioned before, is generally connected with the ejector
plates of the mould and pushed by them during the ejection operation. Alternatively,
the stripper plate can be pulled by bolts attached to the fixed mould half, which come
into action after the mould has opened by a predetermined distance (Fig. 4.47). The
method is economical as it obviates the need of ejector plates. It is also independent
of the stroke of the machine ejector.

107
 The method is also applicable to a stripper plate situated on the
injection side.

4.1.3.1.6 Stripper bar (Fig. 4.48). It is a variation of the stripper

ring and is employed to demould articles with a partially geometrical
contour. Stripper bars are located under the straight edges of the
moulding and moved through connecting bolts joining them with
ejector plates.

Stripper bars may be employed in conjunction with other ejection

devices such as ejector pins, ejector sleeves etc.

4.1.3.1.7 Air ejector. Articles with geometrical contours such as

buckets, bins and big containers, usually Fig. 4.48
moulded out of semi-rigid plastics such as
polyethylene, and polypropylene, could be demoulded by
stripping. Their size, however, would call for huge stripper
rings and extremely long ejection strokes. Air ejectors (Fig.
4.49) are round air valves placed under the bottom of the
product. Compressed air pushes them up by distorting the
moulded bottom in the elastic range and fills up the gap
under the entire bottom.

The force of compressed air working upon whole area is

Fig. 4.49 sufficient to release the moulding from the core. It may also
happen that the moulding sticks in the cavity due to the vacuum. The force of suction
may be greater than that of shrinkage. To break the vacuum, air ejectors may also be
placed on the cavity side. Moulds for buckets usually have this provision. However,
the working principle remains the same as discussed above.

Another configuration of air ejector, for use in

cases were the ejector mark may not be
desirable, is shown in Fig. (4.50).

4.1.3.2 Choice and location of ejection

elements.
Mouldings, sticking onto the core by dint of
shrinkage of the plastics, are ejected with the
help of demoulding elements described above.
The placement as well as the size of ejectors
plays a vital role in safe, distortion free Fig. 4.50
demoulding.

The vertical walls of the core are the main site of the holding force. Ejectors should
be placed as close to these sections as possible. Ejector pins can be used with rigid
plastics but with flexible or semi-rigid materials like LDPE, plasticised PVC, EVA etc.
the ejector pins, if unavoidable, should be situated almost in line with the vertical

108
walls. As a rule, other elements of ejection such as stripper rings and bars, sleeve
ejectors and mushroom ejectors should be given preference for the semi-rigid
plastics mouldings.

Ribs. bosses and hole forming pins also hold the moulding and should be foreseen
with suitable ejectors.

The vertical walls of the core should be free of machining marks and should be
polished in direction of ejection. It may be remarked that some plastics tend to
adhere to polished surfaces. In such cases, the surface is roughened through fine
sand blasting after polishing as recommended. Taper facilitates ejection.

4.1.3.3 Undercuts.
The means of ejection considered so far apply to mouldings, which hold onto the
core or cavity by virtue of shrinkage or vacuum. Some articles, however, may have
design features, which cause holding through interference in the path of ejection.
These details, preventing direct ejection, are known as undercuts and may be on the
inner or the outer side of the article. Side holes across the axis of ejection,
continuous or interrupted grooves and beads around the circumference, internal and
external threads, raised or depressed lettering, logos and designs on the side walls
are some of these features. Obviously, if the moulding is pushed forward in the
conventional manner before removing the obstacles, it is bound to get damaged. In
some cases, the mould may suffer too. One must, therefore, make arrangement to
remove these hindrances before the ejection
process can be actuated.
Fig. 4.51 shows an example where aperture at an
angle to the line of ejection has been neutralised by
splitting the obstruction and dividing it between the
core and the cavity. Here too, a section of the
parting line has been shifted so that all points of the
moulding are in the line of draw.
Fig. 4.51
Mouldings with external undercuts like threads,
grooves and projections (Fig. 4.52) can be forced out
of the cavity safely, provided these features are well
rounded and dimensionally within a certain limit,
depending upon the rigidity of the plastics in question
(Table 4.2). It is, however, essential that the
mouldings are in a position to collapse inwards
elastically. In order to facilitate that, the internal core
must be pulled out before the ejection process sets
in. In other words, the ejection process has to be
performed in two steps, viz. pulling out the core and
then pushing out the moulding. It is referred to as two
stage ejection

4.1.3.3.1 Two
Stage Ejection.
As described above,
demoulding may

Fig. 4.52
109
Fig. 4.53(a)
have to be carried out in two steps in certain cases depending upon the design of
the article. It may be necessary to move one or more mould plates before the final
ejection.

The classical device of moving a mould plate for a predetermined distance and then
releasing it is illustrated by figures 4.53 a, b and c. It consists of a hinged claw and a
cam plate with an adjustable hump. The claw is fixed onto the moving mould half
and holds the loose plate. The cam plate is fixed
onto the stationary mould half. As the machine
opens, the moving mould half moves away and
takes along the loose plate held by the claw till the
hump of the cam forces open the claw and sets
the plate P free. It does not move further with the
ejection mould half.

It may be noted that in some cases, it may be 4.53(b)

found necessary to reverse the position of the
two components of the device. The claw may be
fixed on the stationary side and the cam plate
onto the moving half. The working principle,
however, remains unchanged. The device is
employed in pairs to apply force on both sides of
the plate.

There are numerous solutions to the central idea

of two stepped movement. Several devices to
execute the movement, including the one shown
above, are available as standard mould
components.
4.53(c)
Such devices are also employed in three plate moulds to move
the cavity plate and create gap for the runners to fall.

4.1.3.4 External Undercuts. Side holes, external threads, grooves, beads,

projections and depressions on the outside of an article are usually cleared by
making the mould component forming the undercut move outwards across the axis
of ejection before the ejection device is set in operation. The cross movement of the
sliding mould component can be achieved either through mechanical devices or with
the help of pneumatic or hydraulic
cylinders.

4.1.3.4.1 The slider with slanting pin.

The most common mechanical mode of
converting the available opening stroke of
the machine into a movement across is
shown in figure 4.54. A cylindrical pin,
fixed in one half of the mould at an angle,
passes through the moving mould
component, which is retained by guides
fixed on the other half of the mould. As the

110
Fig. 4.54
mould halves move apart, the slanting pin imparts a cross movement to the slide.
The extent of the stroke is decided by the angle and the length of the slanting pin.
The angle of inclination with the mould axis should not exceed 30 degrees as
otherwise the component of the force acting across it may bend and damage the pin.

The force exerted by the melt on the slide is countered by the angular heel formation
in the plate housing the pin. It backs up the slider during injection. It may also be
shaped as a separate hardened insert, fixed in the plate. The angle at the end of the
moving block and consequently on the face of the heel should be at least as much
as the inclination of the pin to eliminate fouling. In practice, it is kept about 2-3 
larger to be on the safer side.

The cross movement is repeated in reverse direction when the mould closes. Again
the movement is imparted by the pin only; the heel comes in contact with the slide at
the fag end. Hence there is no friction and wear which could lead to clearance and to
flash.

It is absolutely necessary that the slide stays at the position where it was left by the
pin so that the later can re-enter the bore when the mould closes. A spring-loaded
ball catcher, as shown in the diagram, arrests the slide at the end of its travel. The
device works satisfactorily if the slide moves horizontally. A slide moving up or down
viz. vertical to the machine axis may drop down or change its position due to its own
weight which may exceed the force exerted by the catcher spring. Unless
unavoidable, the mould layout should foresee a horizontal movement of the slides.
The vertically moving slides should be retained in the end position with more positive
arrangements like end stops and springs.

Depending upon the shape of the product, the outer contour may be partially or
wholly formed by slides. The later case is referred to
as a split cavity.

4.1.3.4.2 The slider with dog leg is an improved

version of the slanting-pin mechanical device to
achieve movement at an angle to that of the machine.
It has the advantage that the starting point of the slide
movement can be delayed as much as required (Fig.
4.55). Obviously, it is more expensive in execution.

Fig. 4.55

4.1.3.4.3 The slider with cam

plate (Fig. 4.56). The cross
movement in this version of the
sliders is generated by a cam plate
which guides a pin fixed with the
slider block. The slider pair covers
the whole length of the core plate.
It is generally employed when the

Fig. 4.56

111
outer shape of the product has to be formed by means of splits. The cavities are
placed in a row.

The design enables use of the whole length of the slider. One or more cooling lines
can be easily incorporated in the block.

4.1.3.4.5 Pneumatic/ hydraulic cylinders. Mechanical devices for cross

movement are subject to limitations posed by the machine stroke. Pneumatic or
hydraulic cylinders can deliver the required travel independent of the machine
movement. They can be operated at any juncture during the opening stroke of the
machine. The sliders fulfil the same function as described before and do not differ in
design, except that they are directly connected to the cylinder providing the motive
force. The cylinders are fixed to the mould half housing the slider. Self locking
cylinders do not need additional mechanical backing for countering the injection
force.

4.1.3.5 Internal undercuts. Internal threads, grooves, beads, and blind pockets are
some of the undercuts, which come in the way of ejection. Such obstructions, if not
very deep and sharp, can be overcome by sheer ejection force, provided the outside
of the product is free before ejection to expand within the elastic limits and skip over
the core forming the obstruction, analogous to clearing of external undercuts
illustrated in figure 4.52. The main criteria is the yield stress at the ejection
temperature. The undercuts must be well rounded to facilitate slipping over the
projection. Flexibility of the plastics used is also an important factor. The bigger the
article and the more flexible the plastic, the deeper can be the undercut.

The position of the undercut is crucial as an undercut near the open end of a
container will release more easily than the one close to the bottom for the later case,
half the permissible depth will be safer.

The table given below lists the amount of expansion for safe ejection for various
plastics.

Table No. 4.2

Permissible Elastic Expansion.

Material Max. Elastic Expansion (%)

PS 0.5
SAN 1.0
ABS 1.5
PC 1.0
PA 2.0
POM 2.0
LDPE 5.0
HDPE 3.0
PP 2.0
PVC rigid 1,0
PVC plasticised 10.0

112
Figure 4.57 illustrates an unusual
application of this attribute to form
grooves for flexible seals in moulded
sanitary fittings. The internal mould
core A, forming the groove, is
extracted after the outer cavity
inserts C, restricting expansion of the
pipe end, have been pulled away.
The end of the fitting can expand
within elastic limits and regain its
moulded shape. Fig. 4.57
4.1,3.5.1 Tapered slides. Partial internal undercuts,
interrupted protrusions like partial internal threads etc.
are cleared by making the relevant mould insert or the
tongue forming the undercut move forward at an angle
during the ejection stroke (Fig. 4.58) Depending upon the
angle, the undercut is made free after a particular
distance. The product can now be ejected in the usual
way.

Large screw-on closures are

often provided with interrupted
Fig. 4.58 internal threads so that they
form two segments. The method to release the undercut is
to make the mould component containing the threads as
tapered slides (A) and the unthreaded middle section (B) as
a central core with corresponding slope. The three
components together form the mould core when the mould
is in closed position. The cores with threads are housed in
the stripper plate whereas the central core is fixed in the
plate below. Figure 4.59 depicts the arrangement.

As the mould opens, the stripper plate is moved forward,

leaving the central core (B) behind and creating a gap for the Fig.
threaded
4.59 cores (A) to
move inwards. After some distance the moulded threads are free of the cores. The
mouldings can be ejected.

4.1.3.5.2 Collapsible Core.

Another device, well suited for clearing continuous internal undercuts like threads,
grooves, projections etc. is the collapsible core. Figure 4.60 depicts its working
principle. The device consists of two main components; the stationary internal core
and two sets of sliding segments,
arranged around the stationary
core. The segments, made of spring
steel, form a complete circle in
cross section when the tapered

Fig. 4.60

113
inner core is in the forward position. They collapse inwards to their original position
when the core is withdrawn.

The sketches a, and b illustrate the working principle of the collapsible core. The
central core is stationary whereas the segments slide forward with the plate housing
the core. The segments move inwards i.e. “collapse” as space is created through
withdrawal of the tapered core. Thus the undercut gets cleared.

Another version of the collapsible core attaches the segments to the tapered central
core by means of dovetails which are cut at different inclinations. The inward
movement of the segments is now dictated by the dovetails and not by the natural
resilience of the spring steel segments.

As the angles of inclination for both sets of segments are different, they do not clash
and hinder each others’ movement.

4.1.3.5.3 Unscrewing of Internal Threads.

The most common internal undercut in mouldings is the internal thread. Screw caps
and closures with internal threads for bottles and containers are produced in large
quantities. Closures with round threads can be stripped off but other forms of
threads call for some safer device to clear the undercut. In other words, the
moulding must be unscrewed. The methods of unscrewing commonly resorted to
involve:

 Holding the moulded article to prevent rotation

 Rotation of the threaded mould core
 Receding of the core during rotation or
 Lifting up the threaded moulding during rotation of the (non-receding) core.
 Ejection.

The most common method is to rotate the threaded cores in

the mould, The rotation can be effected manually,
mechanically, hydraulically or electrically. The mouldings like
screw caps are provided with notches on the periphery
around the threads to prevent their simultaneous rotation
along with the cores (Fig.4.61).

Numerous methods of unscrewing have been developed. A

few typical designs will be reviewed here.

4.1.3.5.3.1 Manual Method.

Adopted for very small quantities and mostly with single
cavity hand moulds, the method consists of inserting a loose
core with the threads in the mould and ejecting it with the moulded closure. For the
next shot, another identical core is laid in the mould. The ejected moulding is
unscrewed from the first core manually. Fig. 4.61

114
 4.1.3.5.3.2 Semi-automatic unscrewing. It is
a mechanical method used with small moulds,
especially when the quantity required is not
very large. As obvious from figure 4.62, the
rotary movement executed by the operator in
horizontal plane is transferred to the threaded
core of the mould through the bevel gears. The
mould core does not recede but the ribs on
cap’s circumference prevent it from rotation and
make it lift up and come out of the cavity.

Fig. 4.62 With appropriate modification, the method can

be converted into an automatic one.

4.1.3.5.3.3 Fully automatic unscrewing. The operation of unscrewing can be

made automatic if the threaded mould cores are rotated automatically. The rotational
movement can be generated by:
 Converting the linear movement of platen into rotation during the opening
stroke of the moulding machine.
 Hydraulic cylinders
 Hydraulic or electrical motors
Section 4.2 on Special mould designs describes and depicts examples of automatic
unscrewing employing the above mentioned methods.

4.1.3.6 The ejection force.

By dint of shrinkage, the mouldings tend to become smaller but are hindered by the
mould core. Consequently they hold onto the core with a force which is proportional
to the amount of shrinkage and the elastic modulus of the plastics, as discussed
before. The ejection force has to overcome the frictional force between the moulding
and the core. Understandably, the frictional force exists on the vertical sections,
where the moulding has to move in the direction of ejection. It is a product of the
holding force caused by the shrinkage and the coefficient of friction between the
particular plastics and the metal of the mould core (Table 4.3). The ejection force is
applied on the moulding through the ejection elements described above.

The coefficient of friction can be reduced by improving the surface of the mould core
through grinding, polishing , plating, coating etc.

Table 4.3
Coefficient of friction; plastics on steel

Thermoplastic Coefficient of
s friction
LDPE 0,40
HDPE 0,25
PP 0,33
PS 0,40
SB 0,50
SAN 0,50

115
 ABS 0,50
PVC 0,55
PMMA 0,40
POM 0,25
PA 6 0,40
PC 0,55

It becomes a complicated task to calculate the force of ejection in case of irregular,

ungeometrical shapes. A thumb rule, which has been found to be quite close to the
mark, is to provide ejectors with total surface area equalling one tenth of the area of
vertical walls of the core.

4.1.3.7 The unscrewing force.

As discussed before, mouldings hold onto the core with certain force. It is
proportional to the area, the amount of shrinkage, modulus of elasticity of the
particular plastics and the coefficient of friction between the plastics moulding and
the metal core. In order to unscrew a moulded core, a torque has to be applied to
overcome the holding force. It can be computed as explained below.

Assuming for the illustrated screw cap (Fig. 4.61)

Shrinkage s (0,02mm/mm)
Elasticity modulus of the plastics T (1000 N/mm²)
Coefficient of friction f (0,33)

Total shrinkage S = Dxs=27x0,02=0,54

Area of shrinkage A = Mxπxhx2 mm²(accounting for the area of flanks)
= 24x3.1416x15x2=2261.95
Shrinkage force Fs =AxSxT =0,54x2261,95x1000=1221453
Total frictional force Fr = Fsxf =1221453x0,33=403079,49
Torque Tr = Frx M/2= 403079,49x12
=4836953,9 Nmm.

It may be remarked that the friction is reduced significantly if the threads are well
machined and subsequently ground and polished.

4.1.4 Mould shrinkage.

Plastics expand in volume when melted and contract when cooled. During injection,
they are in the molten and expanded state and occupy more space. Hence a
shrinkage allowance has to be incorporated while deciding the mould dimensions.

Mould shrinkage is defined as the ratio of dimensional difference between the

moulding and the mould, measured 24 hours after moulding, at room temperature.
Dimensions of the mould for a proposed article have to be chosen larger by the
amount of expected shrinkage. In mathematical form, the mould shrinkage may be
expressed as:

Mould dimension – Article dimension

Mould shrinkage (in %) = -------------------------------------------------- x 100

116
 Article dimension

Mould shrinkage is not an absolute factor which could be applied to all dimensions
uniformly. It is always stated as a range for individual plastics. The amount of
shrinkage depends upon the following factors:
 Amorphous polymers expand less in volume (~15%) than the semi-crystalline
ones (>30%) upon melting. Consequently, the former shrink less than the later
while solidifying.
 Semi-crystalline thermoplastics have greater shrinkage in direction of flow
than perpendicular to it. The amorphous ones exhibit a more uniform
shrinkage.
 Higher injection and holding pressures decrease the mould shrinkage.
 Higher melt temperature leads to higher shrinkage.
 Higher mould temperature increases the shrinkage.
 Restricted dimensions, such as the diameter around a core or the distance
between two hole-forming core pins, do not shrink till the moulding is ejected.
Their final shrinkage outside the mould is less than that of the free
dimensions.
 Thicker sections shrink more than the thinner ones.
 Filled thermoplastics shrink less than the unfilled ones. The difference in
shrinkage also depends upon the degree of orientation of the fibres.
 Some plastics undergo post-shrinkage over a long period. Again, some
hygroscopic polymers like polyamides, on the other hand, expand after
ejection after they have absorbed moisture.
 The expansion of mould dimensions, when the mould is heated, must also be
accounted for when computing the shrinkage allowance.

The mould designer must take into account these conditions while dimensioning the
core and the cavity of a mould in design. The gate position, especially with the semi-
crystalline plastics, also influences the extent of shrinkage as it decides the direction
of flow and where the material freezes last. Sections which remain longer under
holding pressure shrink less.

Table 4.4 lists the mould shrinkage of various thermoplastics processed by injection
moulding.

Table 4.4
Mould shrinkage

Acronym Polymer Shrinkage %

CA Cellulose Acetate 0,4-0,7
PS Polystyrene 0,4-0,6
SB (HIP) High Impact Polystyrene 0,4-0,7
SAN Acrylonitrile Styrene 0,4-0,7
ABS Acrylonitrile Butadien styrene 0,4-0,7
PVC-R Polyvinyl Chloride Rigid 0,4-0,5
PVC-S Polyvinyl Chloride Soft 1,5-2,5
PMMA Polymethyl Methacrylate 0,4-0,8

117
 PC Polycarbonate 0,6-0,8
PPO Polyphenylene Oxide 0,4-0,7
PSU Polysulfone 0,7-0,8
PETP Polyethyleterephthalate 0,2-0,4
(amorphous.)
PETP (linear) Polyethyleterephthalate 1,2-2,0
PBTP Polybutyleneteraphthalate 0,7-2,2
LDPE Low Density Polyethylene 1,5-3,0
HDPE High Density Polyethylene 1,5-4,0
PP Polypropylene 1,0-2,5
PA 6 Polyamide 6 0,8-2,1
PA 6 6 Polyamide 6 6 2,5-3,1
PA 6 10 Polyamide 6 10 1,2-1,6
PA 11 Polyamide 11 0,8-1,2
PA 12 Polyamide 12 0,7-1,1
POM Polyoxymethylene 1,9-2,3
PEEK Polyether Etherketone 0,7-1,2
LCP Liquid Crystal Polymer 0,3-0,6

The shrinkage figures, as listed above, are average values. These may be different
for the same polymer from different manufacturers. It is advisable to go by the data
provided by the particular supplier.

4.1.5 Tolerances.
Tolerance is the total permissible variation of size, form or location. The aim is to
ensure that the fit, function and performance of the moulded component are not
effected in spite of the variation.

Tolerances or the extent of dimensional fluctuations of thermoplastics mouldings are

dependent upon the following factors:
 The polymer and its shrinkage range
 The moulding parameters
 The melt and mould temperature
 The pressure and its duration
 The constancy of machine settings
 The constancy of polymer characteristics, size of granulate, viscosity
 Constancy of the ambient conditions

Shrinkage of certain polymers varies within a broad band. Tolerances or the variation
of dimensions for products moulded out of these plastics would naturally be more
than those for polymers with less shrinkage.

Moulding parameters, especially the pressure, temperature and time, influence the
shrinkage and consequently control the dimensional variation of the final product.

Material and mould temperatures directly influence the flowability, the filling time, the
injection pressure, the effective period of holding and the cooling time. Any variation
in these temperatures effects shrinkage and consequently the tolerance.

118
The degree of constancy and accuracy of machine settings, viz. the temperature,
pressure, time of different operations and size of the melt cushion, influences the
dimensions of the mouldings directly. Dimensions of mouldings from a closed loop
machine will be in a narrower range of variation than of those moulded on a
conventional machine.

The melt flow index of a polymer may vary from batch to batch. A conventional
moulding machine cannot adjust itself accordingly. The consequent change in
pressure and speed of injection also leads to a change in dimensions of the product.

The ambient conditions such as the temperature, humidity and air circulation at the
place of moulding influence temperature of the barrel, the mould, and the hydraulic
oil which effects pressure, injection speed, rate of cooling etc. Unless kept constant,
they can lead to wide variations in final dimensions.

It will be seen in the light of above facts that a uniform standard of tolerance cannot
be applied to all materials and all cases. It is advisable to limit the narrow tolerances
to as few dimensions as possible. Tool makers tolerance should also be taken into
account.

Table 4.5 gives the practicable tolerances for open dimensions with unspecified
tolerances of moulded articles.

Table 4.5
Dimensional tolerances

Dimension in mm. Tolerance in mm.

1-6 ±0,1
6-10 ±0,2
10-18 ±0,3
18-30 ±0,4
30-50 ±0,6
50-80 ±0,8
80-120 ±1,0
120-180 ±1,3
180-250 ±1,6
250-315 ±2,0
315-500 ±2,6

4.1.6 The parting line. The mating face of the cavity

and core is known as the mould parting line. The
mould opens at the parting line to enable extraction of

119
 Fig. 4.65

the cooled moulding. The shape of the product is one of the major considerations
governing the course of the parting line. The main criteria for the choice is the safe
ejection of the moulding.

The parting line for most articles with geometrical

Fig. 4.63
configuration is usually a straight line in one plane. In
other words, the mating surface of two mould halves is
flat. In many such moulds, the cavity for the product is
situated on one side only (Fig. 4.63). The plane parting
line, however, may have to divide the cavity in two parts
to enable extraction (Fig.4.64). Such a parting line calls
for utmost accuracy in matching of the two halves.
Fig. 4.64
Depending upon the outer contour of the product, the
parting line may follow a straight, a slanting, a
stepped or a curve path. It may even be a
Fig. 4.65
combination of
these (Fig. 4.65,
4.66, 4.67). As a
rule, the parting
line passes
through the highest points on the periphery of the
moulding to circumvent undercuts. Industrial
components, products with free curves, toys etc.
necessitate choice of such parting lines. Parting
surface for animal or human figures may even be
three dimensional.
Fig. 4.66 Apart from the product configuration, the other
factors having a say in the choice of the parting line are:

 The polymer. The flexibility of some

plastics permits ejection of undercuts
like grooves, beads, threads etc. without
having to part the cavity. The course of
the parting line may be different with rigid
or brittle plastics.
 The number of cavities. The mode of
placement of the product and the
course of the parting line in a multi-
Fig. 4.66 cavity mould may have to be chosen other than that in
Fig. 4.67
a single cavity mould in order to use common splits,
slides, cores or other mould features.
 Aesthetic considerations. A comparatively less
convenient parting may have to be chosen instead of
a more favourable one in order to avoid marks on an
aesthetically important surface of the moulding.
 Machine constraints.
Fig. 4.68 The product may have to
be placed and parted differently than the obvious

120
 course in order to suit the machine dimensions. For example , a long cone
placed conventionally in the mould calls for an opening stroke of at least twice
its height (Fig. 4.68). Parted differently, it may be moulded on a machine with
smaller stroke ( Fig. 4.69).
 Venting. The parting line should facilitate free escape of the air contained in
the cavity.
Fig. 4.69
4.2 Special Mould Designs.

4.2.1 The three plate mould.

In the so-called three plate mould, The mould cavities and the runner network are at
two different levels so that the mould has to open at two planes unlike a two plate
mould. The mould has three distinct units; the fixed half, the floating cavity plate and
the moving mould half. The runner network is situated between the fixed mould half
and the cavity plate, at the back of the later. The sequence of operations is as
follows:
1. As the machine opens after cooling of the moulding, the floating cavity plate
remains attached with the moving mould half and moves away from the fixed
half, thus creating enough space for the runners to fall. The runner is held
onto the fixed mould half.
2. The mould opens further. The floating cavity plate moves on and the runner is
stripped off from its holders. The cavity plate stops. The machine keeps on
opening. The moulding sticks onto the core in the moving mould half.
3. The machine opens to its end position and the ejection system for the
moulding is activated.
It implies that the mould requires additional
devices to pull along the cavity plate by a
predetermined distance. It also needs
arrangement to hold the runner during the above
operation and to strip it off at some juncture.
The arrangement adopted here makes use of the
standard mould component called puller (see
Fig. 4.53) discussed in the section “Ejection”.
The claws hold the cavity plate on the moving
side during the opening stroke till cams
disengage the plate by pushing back the claws.
As shown in the mould design (Fig. 4.70), the runner is held onFig.to 4.70
the fixed mould
half by means of pins having undercuts. These runner-holding pins pass through a
stripper plate. After the cavity plate has travelled a predetermined distance, it pulls
the stripper plate by means of the distance bolts and the runner network slips over
the holder pins. It can fall down by dint of its weight.
The additional plates and other paraphernalia for effecting the second opening to
eject the runners make a three plate mould costlier and slower. The runner network,
especially when the number of cavities is large, is quite unwieldy. It may tilt while
falling and get entangled between the plates, endangering automatic operation of the
process. However, it has some advantages too. It enables positioning of the gate at

121
the most suitable point and its automatic severing. For large products, any number of
gates can be placed at desired locations.

4.2.2 The self-insulating runner mould. Plastics are bad conductors of heat. If the
runner were sufficiently thick, the plastics in the middle of it, insulated by the frozen
outer layer, would remain hot and molten for a long time. Successive shots could be
pumped through this insulated “pipe”, without taking out the runner every time. The
mould would have characteristics of a three plate mould without its drawbacks.

The system is simple and cheap and works very well if the cycle is short and regular.
Figure 4.71 shows a self-insulating runner design.
The system is successfully employed with thermoplastics having a broad melting
range such as polyethylene, polypropylene, polystyrene
etc. In case of an interruption in the cycle, a shut off and
restart, the frozen runner must be taken out and the cycle
restarted. The system, though uncomplicated and
economical, may pose problems if the power supply is
erratic.
The key point of the mould is the runner,
its shape, thickness and length. The
runner should be as short as the
placement of cavities allows. A circular
cross section offers advantages over
other forms. A minimum runner diameter
Fig. 4.71 of about 20 mm. has been found
necessary for moulding of polyolefines.
One should keep some margin in the design for enlargement of
runners after the try-out. The sprue should be short, well tapered
and equal to the runner in size at the junction. The secondary Fig. 4.72
runners too must be short, round and as big as the runner. The plates enclosing the
runner should house the network for circulation of hot water/ oil. The mould should
be maintained at the highest temperature level permitted for the particular plastics. It
may even be heated above 100°C to start with and, after a number of successful
cycles, brought down gradually to the recommended temperature. The runner
achieves an equilibrium if the molten core is renewed with each shot.
As the runner may cool down and may have to be removed after interruptions, an
arrangement to open the mould quickly at that level, right on the machine, is a must.
The arrangement employed in the depicted design (Fig. 4.72) consists of removing
the bolt attaching the side clamp to the fixed half, swinging the latch and attaching it
to the clamp bolt. Now tha cavity plate becomes a part of the moving half. As the
mould opens now, the cavity plate travels with the ejection side and the runner
becomes accessible for removal.
The mould plates on the injection side should not be very thick so
that the sprue remains short. These should be manufactured out of
prehardened materials like P20. It must be noted that a thick runner
exercises a large force which may deform plates made of ordinary
materials.

122
 The most critical point in the feeding system is the end of the secondary runner
where the gate starts. Here, the frozen layer may become too thick to be pierced
open with the injection pressure.
Incorporation of short torpedoes,
Fig. 4.73 heated internally with slender cartridge
heaters, can help keep the gates open
(Fig. 4.73).

Fig. 4.74
4.2.3 The hot runner mould. Another way
of keeping runners in the molten
condition is to provide a heating
arrangement for them in the mould. It is analogous to extending the machine nozzle
right up to the mould cavity. As the mould must be cooled to dissipate the heat
contained in the moulding, one must segregate the runners from the mould body in
order to preserve their heat. To effect this, the feeding system is constructed as a
separate unit, consisting of a sprue bush, a manifold containing runners and the
nozzles attached to the manifold bringing the melt to the individual cavities (Fig.
4.74). The unit is maintained at a temperature suitable for the flow of the melt.
Though the unit is housed in the injection half of the mould, it is segregated from it as
much as possible.

4.2.3.1 The Manifold. The primary runner and its branches are housed in a block
called the manifold. It is usually a solid hot die steel block with drilled holes for
runners and sub runners. The ends of the drilled holes are blocked with plugs which
divert the melt to sub runners. The diverting pins also eliminate dead ends where the
melt could stagnate and degenerate. The drilled holes for the melt forming the
runners must be as smooth as possible to cause very little pressure loss through
friction. Rough surface can also arrest polymer particles which could get released
later and lead to rejection when plastics of another colour is moulded.

The size of the runners is chosen to restrict the dwell time of the melt in the runner
system to one or two shots. However, too small a runner may result in considerable
loss in pressure and overheating of the melt. Runner diameters less than 5 mm. are
generally avoided. Too large a diameter, on the other hand, takes too long to melt
when the cold mould is restarted.

The manifold block is heated by means of electrical heaters. The factors for
determining the required heating capacity is the weight of the block and the heat
conductivity of its material. As per a thumb rule, 200-300 watts are needed per
Kilogramme of steel. The source of heat may be cartridge heaters, inserted in drilled
holes parallel to the runner channels. The holes must be accurate and well reamed
so that the heaters sit snugly and transfer their heat efficiently. Air gaps may lead to
accumulation of heat in the cartridge at untouching spots and to its burning out. The
holes for the heaters should be through going to facilitate easy removal for
replacement.

The cartridge heaters are built out of cylindrical metal tubes and contain heating
spirals insulated by heat conductive magnesium oxide. They are cheap, easy to
replace and are available in various sizes and surface watt densities. As they can be
placed only in straight lines, they cannot heat all secondary runners equally and

123
uniformly in case of multi-cavity moulds. Thermocouples for controlling and
regulating the temperature may also be integrated in the heaters. It has, however,
been found more convenient to place separate thermocouples in the manifold close
to the injection points.

A point worth remembering while designing with heating cartridges is that these do
not have heating spirals close to both ends for a length of about 10-15 mm.

The manifold is supported at crucial points by hardened discs, about 5 mm. in

thickness, made of stainless steel which has much poorer heat conductivity than
most tool steels. Titanium can also be set it to this end. The area of contact is further
reduced by provided grooves on the discs. The discs also provide an insulating air
gap all around the manifold. The heat losses due to convection are considerably
reduced by sealing the gap to prevent air circulation. The amount of heat lost
through radiation is insignificant.

4.2.3.2 The sprue bush is a separate unit and is mostly screwed onto the manifold
block. In simple moulds for commodity plastics, it need not be heated separately as it
gets heat from the machine nozzle on one end and from the heated manifold on the
other end.

The sprue bush is a round component, turned out of hot die steel and hardened. It
has a straight hole along the axis for conveying the melt from the machine nozzle to
the primary runner in the manifold. It has a spherical depression matching with the
radius of the machine nozzle.

The sprue bush can also be provided with a sleeve like or a coil type heater with a
thermocouple.

4.2.3.3 The nozzles. The melt is conveyed from the manifold to

individual cavities by the nozzles. There are two basic versions
of nozzles, viz. the indirectly heated and the directly heated
ones.

The indirectly heated nozzles are fabricated out of heat

conducting metals like beryllium copper for self–fabricated hot
runner units. These nozzles without own heaters get their heat
from the manifold. Their exact temperature cannot be measured Fig. 4.75
and regulated directly. An indirectly heated nozzle, as per BASF design, as depicted
in the figure 4.75, heats the melt from outside. Another version of an indirectly
heated nozzle or torpedo from Hoechst of Germany(Fig. 4.76)
heats plastics from inside. The indirectly heated Be-Cu nozzle is
surrounded by a hardened steel bush provided foreseen with an
air jacket. In order to reduce the heat
losses, the contact surface between the
hot and cold components is reduced to
the minimum. The manifold is sealed in
the housing to prevent heat losses by
convection through air circulation. The
system is simple, economical, space

124
 saving and feasible with easily available materials and components. It must,
however, be pointed out that in this system, it is not possible to control and regulate
the temperature of individual nozzles.
Fig. 4.76
Indirectly heated nozzles work fairly satisfactorily with commodity plastics, which have
a broad temperature range.

A directly heated torpedo like nozzle, which can be fabricated by the users, is shown
in figure 4.77. It is heated by means of a cartridge heater inserted in a bore along the
longitudinal axis. A thermocouple is built in the cartridge. The front part of the torpedo
is foreseen with a tapering tip which keeps the gate open. The heated Fig. 4.77torpedo
passes through the manifold and sits against the mould back plate. The melt from the
manifold flows around the torpedo to the mould cavity. A major disadvantage of the
commercial cartridge heaters is the absence of heating coil in the front part where
the torpedo requires more heat to keep the melt fluid and the gate open. The
drawback can be compensated to some extent by making the body of the torpedo
out of beryllium copper and the back part, which is held by the manifold and sits
against the cold mould plate, out of hardenable stainless steel as shown here. It is
worth remembering that the temperature measured and displayed by the
thermocouple is that of the outer mantle of the cartridge heater.

Figure 4.78 illustrates a patented cartridge heater which

is free of the shortcomings mentioned above. The
heating is effective all over the length and the
thermocouple, which extends into the tip of the nozzle, Fig. 4.78
measures the actual temperature.

Another recent development comprises a hard pipe equipped with a jacket enclosing
heating coils together with a thermocouple (Fig.4.79). The front part of the pipe,
jutting out of the heater, can be shaped as per requirement—e.g. a hard tip can be
screwed in to form a hot runner nozzle. The head too
can be machined to suit the self fabricated hot runner
manifold for special cases.

The fixed mould half, housing the hot runner system,

is bound to get heated because of the heat
transferred. It needs very efficient cooling otherwise
the linear expansion may make the mould closing
difficult. Such moulds are generally foreseen with a
Fig. 4.79 special set of guiding devices, which align the mould
halves without interfering
with expansion, The
device depicted here (Fig. 4.80)
consists of a u-shaped female part
and a flat finger fitting in it, is
mounted outside on horizontal and

Fig. 4.80 125

vertical axes of the mould plates. The guide pillars are given more clearance to
eliminate fouling due to expansion.

4.2.4 Standard hot runner systems.

Self fabricated hot runners have been replaced, to a great extent, by standardised
systems with direct heating. Most standardised systems are based on two distinct
heating principles, viz. external heating and internal heating. The source of heat
energy is invariably the electricity.

4.2.4.1 Externally heated hot runner system.

It may be regarded as a refined version of the self fabricated systems discussed so
far. The essential components viz. the manifold, the sprue bush and individual

Fig. 4.81

nozzles (also called drops or torpedoes) of the foregoing system play here
too the same role. The difference lies in improvement of heating and
standardisation. Figure 4.81 shows a typical externally heated system with
usual components viz. the sprue bush, the manifold and the nozzles.

1. Register ring 2. Sprue bush 3. Support ring

4. Hot runner manifold 5. Multipole connector 6. Thermocouple
7. Nozzle cover 8. Heating coil 9. Nozzle body
10. Bush 11. Plastics melt 12. Hot runner nozzle
13. Cooling lines 14. Moulding

4.2.4.1.1 The sprue bush, a hardened round component is either

screwed onto the manifold or joined to it in some other way. It is generally
fitted with a sleeve heater with individual thermocouple. It has a spherical
depression on the face for seating the machine nozzle.

126
 4.2.4.1.2 The manifold, like its predecessor, is generally a one-piece melt
distribution block, equipped with controllable heating arrangement. Cartridge heaters
have been replaced by tubular heaters for heating of the manifold. The tubular
heaters can be bent and housed in channels machined on both sides of the manifold
block to heat the runners uniformly. To intensify the heat transfer, channels are filled
with a high temperature cement containing powdered copper.

The shape of the manifold is decided by the number of nozzles being fed by it.
Standard manifold shapes are rectangle, H , X , circle or double X joined together
Fig. 4.82 (Fig. 4.82). However unusual shapes for special cases, as shown in figure 4.83, can
also be fabricated and heated uniformly.

The inlaid heaters with conductive cement offer some significant advantages over the
cartridge heaters:
 Larger area of heat transfer
 More uniform temperature distribution
 Freedom in location and number of cavities as
highlighted in figure 4.83
Fig. 4.82
A serious drawback of the method is the difficult replaceability of the profiled heater
as it is fixed by means of a cement. It is more expensive and requires precise milling
on both faces of the manifold. The bending operation of the tube requires special
fixtures.

A solution to the problem of replaceability, as practiced

by one manufacturer of hot runners, is to add plates on
both faces of the manifold and mill the channel for the
profiled tubular heater partly on the manifold and partly
in the covering plate. Insulating plates are added onto
the covering plates and bolted to the manifold. Although
the assembled manifold is more expensive, the easy
replaceability of the heaters and considerable saving in
Fig. 4.83 heat energy make it economical in the long run. As the
mould does not have to dissipate the heat convected
and radiated to it from the manifold faces, the cooling
time too is shorter.

A flexible version of the tubular heater with rectangular/ square cross section can be
placed in the milled channel manually without pre-bending.

An inevitable disadvantage of the drilled feeding network in solid manifolds is the

sharp junctions of the runners and sub-runners
which invariably results in loss of pressure. The
latest method of diffusion welding has made it
possible to divide the block into two half plates
and machine the runners with rounded bends in
both halves (Fig. 4.84). The surface finish of the
channels can be optimised to facilitate easy flow
and eliminate pit marks where material particles

Fig. 4.84
127
could stagnate. A perfect matching of contours in both halves is, of course,
imperative. The two halves form a single solid plate after welding.

The manifold must sit snugly in the injection half of the mould to prevent leakage of
the melt but contact with the relatively colder mould plates will result in undesirable
transfer of heat to the mould. Here too, hardened discs made of a material with
adequate toughness and poor heat conductivity such as stainless steel, titanium or
even special ceramics are employed to support and fix the manifold between the
clamping plate and the cavity plate. The supporting discs also create an insulating air
gap between the manifold and the mould plates. The discs are located opposite the
sprue bush and behind the nozzles leading the melt to the cavities to counter the
bending forces on the manifold exerted by the machine nozzle on one hand and the
injection pressure reaction on the other. Any deflection of the manifold caused by
these forces will result in leakage of the melt, incomplete filling of cavities, filling of
the insulating gap around the manifold, melting of the wiring of heating elements and
finally to short circuits, destruction of heaters and total failure of the system.

Heat losses through radiation are much less as compared to those through
conduction and convection and usually no special measures are undertaken to
eliminate or reduce them. It is, however, possible to minimise the losses by covering
the faces of the manifold block with thin reflector sheets made of aluminium alloy.

4.2.4.1.3 The nozzle. It represents the final, vital link

between the melt feeding system and the cavity being
filled. Its design should ensure supply of the melt with
as little loss of pressure and heat as possible. The
temperature too must be adjustable and controllable
within very narrow limits.

In its basic form, an externally heated nozzle (Fig. 4.85)

is a round, cylindrical bush with a slender body and a
bigger head which butts against the manifold. Along its
axis, it has a bore, the diameter of which equals that of
the manifold at the junction but narrows down to form a Fig. 4.85
gate at the exit end.

The open tip of the nozzle, as shown in the diagram, conveys the melt in a straight
path. This configuration leaves a small vestige of the gate on the moulding. An
alternative design (4.85b) ending in a pointed tip extending into the gate, closes the
melt channel and makes the melt flow around the tip to the gate. The hot tip keeps
the gate open and the vestige is very small.

The nozzle is equipped with a coil heater around the

body. It may be a sleeve (Fig. 4.86) or a heater coil as
shown. The later has the
advantage that the windings
can be spaced closer or wider
apart locally according to the
amount of heat needed. For
example, windings are closer

Fig. 4.86
128
Fig. 4.87
 near the exit point of the melt. A thermocouple is housed in a narrow slot on the
nozzle body to measure the temperature near the end. A protective steel bush
encloses the heated nozzle. The gate to the mould cavity is located in the bush
which also forms a part of the cavity,

As obvious, the nozzle with heaters and protective

bushes add to the size of the system. It proves
disadvantageous in case of small articles, which
cannot be located as close as their size would enable,
resulting in less cavities in the mould. Multi-gating hot
runner nozzles provide the solution. The cavities can
be gated from the top (Fig. 4.87/4.88) or from the side
Fig. 4.88 (Fig. 4.89). The temperature control is common for all
cavities.

The nozzles described so far may be summed up as open

type nozzles. A small gate vestige is inevitable. Secondly,
these cannot prevent drooling of easy flowing polymers which
require positive shut-off nozzles for trouble free moulding. It
involves opening of the gate before injection and shutting it off
at conclusion of the holding period. It is also termed as valve
gating.

One of the valve gating nozzles (Fig. 4.90) works on the

same principle as the spring loaded shut-off machine nozzle.
A needle with conical tip, placed in the nozzle in line with the
gate and loaded with springs at the back, is pushed back with
injection pressure, thus opening the gate. The compressed Fig. 4.89
spring regains its initial height and pushes the valve needle
forward to close the gate after the holding pressure is switched off. The device works
satisfactorily if the holding pressure is not too low.

A more positive arrangement replaces springs with small

pneumatic/hydraulic cylinders, built in the back plate of the mould
(Fig.4.91). The injection
moulding machine must have
controls for air/a core pulling
arrangement for their operation.
One common cylinder can
operate a number of needle
valves in case of multi-gating
Fig. 4.90 nozzles.

Externally heated systems are distinguished by

following advantages:
 Changing over to materials with different
colour or altogether to a different material is
unproblematic. Runners become free of the
previous material after a few shots.

129
  The melt temperature can be measured and controlled accurately.
 Incorporation of valve gating is possible.
Fig. 4.91
The system has also some disadvantages:
 Some heat is invariably lost to the mould housing. Effective thermal insulation
between the mould clamping plate and the machine platen is indispensable to
prevent conduction of heat.
 The manifold block undergoes linear expansion which changes centre
distances of nozzles. The overall expansion may also cause melt leakage.
 Energy is consumed, not only to heat the plastics but also theFig. 4.91
manifold.

4.2.4.2 Internally heated

hot runner system.

As the name implies, the

material is heated from
inside In this system. The
heaters are situated right in
the stream of the melt. Fig.
4.92 shows an arrangement
with internally placed rods
made of special alloys,
which get heated when low
voltage, high ampere current is passed through Fig. 4.92 them.

The heaters situated in the middle of the runner in the manifold melt plastics around
them. Here again, the poor heat conductivity of plastics prevents melting of the entire
shell surrounding the heater. A cross section of the runner would show plastics layers
at various temperatures. The layer adjacent to the outer wall of the bore remains
unmolten, whereas that in contact with the heater is fluid and at the desired
temperature. There is a temperature gradient from centre to the periphery.

As the manifold remains cold, it need not be segregated from the mould body. There
is no linear expansion either. The leakage too is eliminated by the frozen layer on all
junctions. The heater in the nozzle keeps the gate open.

The advantages of the internal heating system are:

 The plastics material is heated directly. The energy consumption is very low.
 The heaters heat only the core of the melt which flows.
 The outer layer of the melt in contact with the cold mould walls acts as a
thermal insulator. The heat loss from the melt to the mould is very low.
Insulating plates are not required.
 The manifold remains cold and does not undergo a linear expansion. No
correction is required to be made for the change in position of the nozzles.
 The frozen outer layer prevents leakage of the melt.

130
  Runners and heaters may be incorporated right in the cavity plate. The mould
becomes simpler and smaller.
 Because of the low voltage, the system is electrically harmless. It does not
require special electrical insulation.

Some drawbacks of the system are:

 The heaters are a source of additional friction to the melt flow. More pressure is
needed for injection.
 Between the frozen outer layer and the fluid core of the melt, there are semi-
frozen layers from which cold particles may be dragged along by the melt into
the cavity.
 It is difficult to measure the temperature of the melt.
 It is not possible to incorporate valve gating through the heaters.
 Change of material or colour is difficult. Some particles from the previous
material, frozen along the surface of the bore may occasionally get into the
melt stream and cause rejection.
 The low voltage requires step down transformers.

Some hybrid systems combine both types of heating to make the best of both
principles.

4.2.4.3 Hot runner with cascade injection.

Large articles may need more than one injection points for complete filling. This may
be accompanied by weld lines and even air entrapment at the junction of different
melt streams. Cascade injection, viz. sequential opening of the nozzles can eliminate
the defect. The injection starts at one end and the next gate is opened when the melt
from the foregoing gate has reached it. Likewise, consecutive gates are opened in
sequence. The nozzles are, of course, equipped with valve gating and are regulated
through a special controlling system, synchronised with machine controls.

4.2.4.4 The stack mould.

Injection moulds for articles with large projected area but comparatively less weight
such as shallow plates, lids, covers, trays, audio and video cassette bodies etc.
utilise only a fraction of the plasticising capacity of a given moulding machine
because a limited number of
impressions can be
accommodated in the mould,
both from the angle of the
locking force as well as due to
large space requirement. A 2-
stack mould design enables
accommodation of twice as
many cavities in the mould as
a normal mould and can be
operated on the same
machine without calling for
additional locking force.

A stack mould may be seen

as a combination of two
Fig. 4.93

131
identical conventional moulds, placed back to back with a common melt distribution
system housed between them (Fig. 4.93). The feed system is usually of the hot
runner type although theoretically a cold runner can also be employed. Apart from
the feed system, the two moulds possess the usual components and design
features. An additional device, characteristic of stack moulds, is the mechanism to
open the mould at two levels in an equidistant way. The system illustrated in the
present example employs a central pinion and two racks fixed to the two ejection
mould halves. The same results can also be achieved with toggle levers, pivoted on
the central plate and attached to the “fixed” mould halves.

The hot runner feed system may be self-fabricated as shown here. The manifold is
made of hot working steels like 1.2344 and provided with cartridge heaters to make
up for the heat lost by conduction, convection and radiation. The conduction losses
can be kept to the minimum by reducing the area of contact between the hot
manifold and the colder mould plates and the convection can be minimised by
enclosing the heated manifold from all sides. A thermocouple helps keep the
temperature within the pre-set limits. The nozzles, which convey the melt from the
manifold to the runners, are foreseen with their individual heater coils and controlled
through thermocouples. The exceptional feature of the system is a long, heated
sprue bush, going through the right hand mould and projecting out of it.

Standard hot runner units, with special manifolds for stack moulds, can also be
employed instead of the one described.

The ejection plates on the left are moved in conventional manner through the
ejection mechanism of the machine but those in the right-hand mould need an
additional device. These may be pullers as employed in the present case or toggle
levers which move the ejector plates when the mould opens. Hydraulic cylinders too
can be incorporated in the mould to perform this function.

A stack mould, obviously takes up more daylight in the machine. However, the
shallow articles, generally moulded with stack moulds, do not call for large openings.
Mostly, the normal injection moulding machines can be employed for stack moulds.
Only in rare cases, it may be found necessary to set in machines with enlarged
mould height capacity. However, the locking force remains unaffected as the
injection pressures acting on two levels neutralise each other inwardly so that the net
locking force remains the same as for a single mould.

A stack mould with two layers of cavities increases the production almost two-folds.
It is also possible to have more than two stacks, with corresponding changes in
feeding and ejection systems.

4.2.4.5 The temperature regulation of hot runner systems.

Efficiency of a hot runner system is coupled with the precision and constancy of
temperatures of its various components. Special controllers have been developed to
this end. Most controllers consist of individual modules for each circuit and work
according to the PID controlling characteristics. The sophisticated ones are generally
equipped with microprocessors.

They perform following functions:

132
  Control the set temperatures and maintain them in close limits.
 Automatic soft start; heating up with lower power
 Automatic switch over to calculated average power supply in case of
thermocouple damage
 Have a leakage current control
 Protection against overheating of the mould
 Have a memory function
 Possibility of remote monitoring
 Fault diagnosis, display and protocol functions
 Give visual and/ or audio alarm in case of failure.
 Report deviations and faults.
 Possibility of coupling with the moulding machine controls
 Automatic temperature reduction during production interruption /disturbance
 Have interface for printer

One regulating module can control an individual circuit or a number of circuits joined
together in case of large multi-cavity moulds. In the later case, all circuits governed
by one module will be treated as identical. For example, 16 modules could regulate
the temperature of 64 nozzles of a mould which are wired in groups of four.

The latest version of temperature controllers consists of versatile modules which are
capable of regulating a number of circuits individually in all respects.

4.2.4.6 Conclusions
The advantages of a hot runner system are:
 No runners have to be cooled, ejected, reground and remixed.
 The mould is simpler as it does not have to open (and close) at two levels.
 The temperature of the melt to all cavities can be maintained at the required
level.
 The balancing of filling can be manipulated through variation of temperatures
of the nozzles.
 The product can be gated at the most suitable points.
 The melt reaches the cavity at the predetermined temperature.
 The machine needs less energy as it has to melt and inject only the material
for the cavities and not for the runners.
 The production cycle is shorter as no runners have to be injected, cooled and
ejected.
 The machine can be smaller and hence cheaper.

Disadvantages of hot runner systems are:

 High initial investment in the mould.
 Need for additional regulating equipment
 More chances of disturbance due to failure of heaters and thermocouples
 Possibilities of leakage at junctions of nozzles and the manifold
 Delay at restart

133
The cumulative effect of above points is a possibility of automation, uniformity in
quality, decrease in rejection and reduction in the cycle time.

When using glass reinforced resins with hot runner moulds, it is advisable to make
the first shot with unfilled material. The resident material forming the insulating cap
around the nozzle tip is less conducting than the filled material, which makes it
easier while restarting after a pause.

4.2.5 Unscrewing moulds

4.2.5.1 Unscrewing
with Archimedean
screw.
It is a method to derive a
rotary movement from
the linear movement of
the mould. It employs a
long pitch screw, fixed on
the injection side of the
mould, which rotates a
nut housed in the moving
half when the mould
opens. The periphery of
the nut is either formed like a gear or else a gear is fixed onto it. This acts as a sun
Fig. 4.94
gear and transfers the rotary motion to the planet gears fixed on the threaded cores
of the mould cavities (Fig. 4.94)
The number of revolutions achieved by the central gear is decided by the pitch of the
Archimedean screw and the opening stroke of the machine. These revolutions have
to be converted into the number of revolutions a threaded core has to make to be
free of the moulded threads in the product. In other words, The size of the sun and
planet gears and consequently the distance of the cavities from the centre and the
size of the mould, is dependent upon the opening stroke of the machine, the pitch of
the screw and the number of threads to be unscrewed.

The pitch of the multi-start Archimedean screw is selected in relationship with its
diameter. The aim is to keep the helix angle between 30 and 40 degrees so that the
major part of the force acting between the screw and the nut (here the inside of the
sun gear) goes towards rotation.

All rotating tool components must be provided with bearings. The bronze bushes are
employed in moulds destined to produce small quantities. Ball bearings reduce friction
and prolong the mould life. The bearings for the sun gear have to be of the combined
type as these are required to guide axially and take up thrust too.

It may be added that an unscrewing mould with Archimedean screw can be designed
in a number of variations. The screw may also be incorporated in the moving half of
the mould and the nut may be fixed on the third platen behind the moving platen or

134
else it may be pushed with the help of the ejection device. The principle of converting
linear motion into a rotary one with the help of an Archimedean screw remains the
same.

4.2.5.2 Unscrewing with rack and pinion.

The linear movement of the machine platen can also be employed to obtain rotary
motion needed for unscrewing, with the help of a rack (A) and a pinion (B) as
illustrated in figure 4.95. Rack A, fixed to the stationary mould half, rotates the pinion B
mounted on the moving mould half, which in turn operates another rack (C). The aim
is to derive linear movement at right angles to the movement of the machine platen.
Now the rack C can rotate a number of pinions attached to the threaded mould cores,
housed in the moving half.

The method, although also mechanical, differs from the foregoing one in that no
intermediate sun gear is involved and the
rack transfers the movement directly to
the mould cores. These are provided with
extensions having male threads of the
same pitch as the product, reaching into
threaded bushes as also in the previous
example. Upon rotation, the cores are
made to recede by the same amount as
they disengage from the moulding so that
the latter is free to fall down after
complete unscrewing. The cores return to
their initial position as the mould closes.
Here too, the opening stroke of the
machine imposes a limit to the number of
revolutions achievable. Fig. 4.95

As obvious from the sketch, the rack A has to extend over and beyond the moving
platen. The height of the main pinion B has to be chosen accordingly.

4.2.5.3 Unscrewing with hydraulic cylinder

The process of unscrewing can be made
independent of the machine stroke if a
hydraulic cylinder is employed as the
primary source of linear movement of the
rack C of the foregoing example,
responsible for rotating the mould cores
(Fig. 4.96). Obviously, rack A and pinion B
are not needed in this variation.

Here too, the cavities are arranged in rows

and straight racks, engaged with the gears
on the threaded cores, rotate them, when
they are imparted linear movement by a
hydraulic cylinder attached at the end. The
cylinder/cylinders can be placed above or
below as convenient.
Fig. 4.96

135
The process has an additional advantage that it can be carried out at any stage of the
moulding cycle, also when the mould is still closed. The cores come to their initial
position when the mould is closed for injection, as in the foregoing case.

A module between 1-2 mm. for the rack and the gears is found to be adequate in most
cases. The larger number of teeth facilitates finer adjustment of threaded cores.
(1.Flat bearing 2.rack 3. threaded core 4. bearing)

4.2.5.4 Unscrewing with a hydraulic/ electric motor.

The rotary movement required for unscrewing can also be obtained from a hydraulic
or an electric motor. These can be mounted on the mould and coupled to the sun gear
with intermediate gears, chains or belts. These devices are in no way dependent on
the stroke of the machine and can provide unlimited number of revolutions. However,
they rotate in one direction only and cannot be limited exactly to the revolutions
corresponding to the number of threads in the moulding. The fact becomes significant
if the start of the thread in the moulding has always to be in a particular position. This
method cannot always guarantee the same position. Instead of making the core
recede during unscrewing and advance to the original position before moulding as it

Fig. 4.96

Fig. 4.97

136
happens with a rack and pinion arrangement, the cores rotate in place and the stripper
plate is made to move forwards with the help of springs (Fig. 4.97). The mouldings are
retained on the stripper plate by means of the notches provided on their periphery till
the unscrewing is almost complete. The stripper plate is arrested at this stage and by
further unscrewing, the moulding moves further, becomes free from the holding
notches and falls off.

The alternative method of rotating the cores without moving them linearly offers an
additional advantage. It is possible to cool these components if they are not very
slender, whereas cooling the cores performing both rotary and linear movements is
very difficult.

To operate a hydraulic motor, one needs additional machine accessory called the
core-pulling device, regulating delivery and exhaust of oil under pressure, in the
moulding machine. In absence of that, hydraulic connections and controls from the
ejector can be employed to operate the motor.

The method needs less number of components in the mould, as there is no

conversion of a linear motion into a rotary one.

4.3 Classification of injection moulds.

In order to describe the type, construction, complicacy etc. through the
nomenclature, injection moulds are classified according to various design features
such as the number of cavities, number of parting lines, the feeding system, the
ejection system, special features etc. The broad categories are:
1. Standard mould. It is the simplest type of injection mould, consisting of two basic
units; the cavity side (fixed half) and the core side (moving half). It is also referred to
as a two-plate mould. The feeding is through cold runners and ejection through
ejector pins and/ or sleeves. Fig. 4.1 depicts a standard, two plate mould.
2. Semi-automatic/ fully automatic mould. Depending upon the purpose of
production or the quantity needed, a mould may be very simple with a partial manual
operation, say for putting in a core or an insert before injection. Most production
moulds operate fully automatic.
3. Single cavity/ multi-cavity mould. This indicates the number of impressions in a
mould. The consideration for the choice may be the shape of the product, the size of
the machine, or the quantity required. The cost varies accordingly.
4. Cold runner mould. A mould with conventional feeding system which is cooled
and ejected out along with the product is termed as a cold runner mould. The mould
shown in Fig 4.1 is an example of a cold runner mould.
5. Three plate mould. As described before, the runner of a three plate mould is not
on the same level as the moulding and necessitates another floating plate unit for
ejection of the former. It has been illustrated in figure 4.59.
6. Semi hot runner/ full hot runner mould. Semi hot runner mould has a part of its
feed lines in a heated block. The last channels leading to the cavities are in
conventional form and are cooled and ejected.
A full hot runner mould has no runners to be ejected.

137
7. Stripper plate mould. This classification is on the basis of the ejection system.
Here a plate strips off the moulding or mouldings from the core/s.
8. Split cavity mould. The mould is named so when the outer contour of the article
is formed by movable splits,
9. Slider mould. When some details in the article like side depressions ( such as
holes) or projections (such as plugs) prevent ejection and have to be cleared with
the help of an external cross slide before the moulding can be ejected.
10 Unscrewing mould. Mould for an article with internal threads, incorporating a
device to clear the threads before ejection.
Most moulds contain more than one of the above features and hence it is not
possible to restrict their classification to one particular category. The descriptive
nomenclature emphasizes the salient features, such as “Four cavity hot runner
unscrewing mould” or a “Split cavity stripper plate mould”.

4.4 Procedure for designing an injection mould.

1. Collect full information regarding:

a) The product- mode of use; visually, functionally and dimensionally important
features; matching and mating parts if any; after-operations; weight, colour
and surface finish; quantity.
b) The plastics- filled or unfilled; flow properties; moulding and mould
temperature, shrinkage and its pattern; rigidity.
c) Injection moulding machine- locking force and shot weight; platen drawing,
opening stroke, height of the mould; nozzle type and its position, nozzle
radius and bore diameter; ejection mechanism and the stroke; position of air
and cooling water sources; ancillary equipment etc.
d) The tool materials- steels specified and available; possibilities of hardening
and polishing.
e) Standard mould components- specified; available in stores and market.
f) The Quotation- terms concerning the tool.

2. Study the design of the product.

Check the dimensions. Are they correct? Are all relevant dimensions given? Are
tolerances specified? Are they feasible?
Examine the design for special features like undercuts, threads, holes, metal
Inserts etc.
Will these make the mould design more complicated? Will a modification simplify
the mould without jeopardising the function?
Is the product design compatible with the specified plastics?
Any unusual standards to be followed?

3. Decide the number of cavities.

Are these specified? Are they limited by the machine capacity? Should these be
decided on the basis of profitability?

1. Decide the mode of operation of the mould.

Manual, semi-automatic or fully automatic. Is it specified?

138
2. Select the mould parting line.

3. Choose the position and type and number of the gates if not specified (It also
influences the type of the mould viz. 2-plate, 3-plate, hot runner). Check the melt
flow, weld lines, air entrapment, sink marks etc.

7. Select the most suitable arrangement of cavities if not specified.

8. Ascertain the taper required and permitted.

In absence of a specifically mentioned taper, split the tolerances to create taper.
Check whether reverse taper is called for to retain the moulding on the ejection side.

7. Calculate the mould dimensions (product dimensions+ shrinkage allowance).

8. Decide the mode of placing and securing inserts to be moulded-in, if any.

9. Decide the mode, elements and location of ejection keeping in mind the visible
areas.

10. Lay out the sectional elevation and the plan of the mould simultaneously. Build up
the mould around the article. Draw the mould in the way, as it would be fitted on
the machine.

11. Draw ejectors in the plan and then lay out the cooling, keeping in mind the hot
spots. Make sure that the ejector pins, return pins and pullers etc. do not come in
the way of free fall of mouldings and runners. The water inlet and outlets should
be away from the hot runner connections and should not foul with clamping
position of the mould on machine.

12. The length of the guide pillars should ensure that the two mould halves are in
engagement before a mould core enters the cavity.

13. The assembly drawing should depict the function of the mould, the
interrelationship of the mould components and their mode of assembly and
matching.

14. Review, which components are more prone to damage or excessive wear and
tear. Design them as easily replaceable inserts.

15. As far as possible, draw the individual components in detail as the machinist will
see them and dimension them accordingly. Keep the mating parts close to one
another to facilitate quick cross-checking.

16. Specify material and the treatment for all components. Indicate the surface finish
and tolerances/ fits wherever applicable. Put short but clear remarks wherever
the function, matching, fit, or accuracy cannot be expressed in figures.

17. Specify the cavity identification, its size and location.

139
Select the simplest one among various possible design solutions!

4.8 Design of injection moulded articles.

The function of an article decides its shape and size as well as the most suitable
material for it. In order to select the right material for a new component, one has to
analyse all conditions--mechanical, electrical, chemical, thermal, optical and
commercial-- which the new article will be subjected to. The following list facilitates
the selection.

1) The function
2) Environmental conditions; sunlight, UV rays, direct and radiated heat, humidity,
sand and dust, fluids, fumes and gases, snow and ice etc.
3) Temperature range; short term/ long term
4) Forces; tensile, compressive, shear, bending, impact
5) Electrical requirements
6) Resistance to chemicals
7) Permeability to gases
8) Resistance to wear, scratch resistance
9) Fireproofness, inflammability
10)Conformance to food laws
11) Conformance to safety standards
12)Surface finish
13)Clarity, transparency
14)Colour assortment
15)Dimensional accuracy, tolerances
16)Matching components, type of matching
17)Method of assembly such as riveting, bolting, pasting, welding etc.
18)After-operations; machining, printing, embossing, painting, metallising
19)Special features; integral hinge, snap fitting, multi component moulding etc.
20)The present material, process of forming and design
21)Price range

Irrespective of the thermoplastics chosen, certain guidelines which ensure, not only
a sound component but also an efficient, sturdy and economical mould and a trouble
free moulding, must be followed while designing the article. These are:

4.8.1 Uniform wall thickness.

This must be regarded as a universal rule, applicable
under all conditions. It ensures uniform mould filling,
uniform cooling, uniform shrinkage and therefore less
stresses and less warpage. Thicker sections (Fig.
4.98 a) are bound to cave in upon moulding as shown
through dotted lines. The article can be modified as
depicted in figure 4.92 b to fulfil the same function
without being prone to the said defect. Wall thickness
is primarily decided upon from the strength angle.
Another factor governing the wall thickness, no less
important, is the possible distance the selected
material can flow with the given wall thickness before
freezing. It is expressed as L/T ratio.
Fig. 4.98

140
4.8.2 Strengthening ribs.
Large surfaces can be strengthened by providing ribs instead of increasing the wall
thickness. Thick sections cool slowly, prolong the cycle and may get sink marks.
Ribs reduce material, decrease cooling time, add stiffness and strength and reduce
warpage.

Thick ribs, too, can give rise to sink marks at their

junction. Their breadth should not exceed two thirds of
the thickness of the wall they join. For ribs which are
joined to the article wall on one side only, the height is
limited to thrice their breadth. A small fillet radius at the
joint reduces the notch effect.

Cross ribs on a large area generate another source of

moulding defects. There is unavoidable material
accumulation where two ribs cross each other. One
measure to reduce the material at the junction is to place Fig. 4.99
a blind hole there (Fig. 4.99). It may, however, necessitate additional ejectors. The
alternative remedy is to stagger the ribs as shown in
figure 4.100.

Depending upon their direction, ribs may act as additional

runners and give rise to separate melt streams leading to
air entrapment.

Hexagonally arranged ribs lend greater rigidity than those

in square array, without increasing weight. .

4.8.3 Gradual variation of wall thickness.

Thin sections cool down and shrink while the thicker ones are still in the process of
coolingFig.
and4.100
shrinking. It leads to stresses and warpage. The changes in thickness, if
unavoidable, should be gradual.

4.8.4 Relaxing walls.

Straight walls of box like articles tend to cave in, especially when moulded in semi-
crystalline thermoplastics. A light convexity in design can counter this tendency. The
walls tend to become straight after cooling and shrinkage.

4.8.5 Rim reinforcement.

Hollow containers like buckets, boxes and bins become
stiffer if provided with reinforcement on rims. However a
solid beading or extra thickening leads to sink marks,
distortion and long cycles. A hollow beading, semi
circular or rectangular in section lends additional
strength without any of these defects (Fig. 4.101).

Fig. 4.101

141
4.8.6 Base design. Large symmetrical containers like boxes, lids, buckets, basins,
tubs etc., injected in the centre of the base, tend to develop cracks there because of
concentration of moulding stresses around the gate and
due to differential shrinkage
(different along the flow and
across it) in semi-crystalline
plastics. A lens shaped base
(Fig. 4.102), especially in the
Fig. 4.102 case of round articles, helps
Fig. 4.103
release the stresses. Same
effect can be achieved by resorting to a pyramid shaped
base for rectangular articles (Fig. 4.103). Internal stresses flatten the dome or the
pyramid and thus get released without causing damage to the moulding. A base,
slightly thicker in the middle and tapering down to the normal wall thickness towards
the side walls offers the added advantage of aiding the melt flow with less pressure
and providing strength at the point of maximum stresses.

4.8.7 Rounded edges and corners. Sharp corners lead to accumulation of material.
Their cooling is much slower because of heat accumulation and because corners of
mould cores cannot be cooled as efficiently as the outside surface of a moulding
through the cavity plate/ insert. The result is non-uniform shrinkage and
concentration of stresses causing distortion and cracks.

4.8.8 Taper in direction of ejection for distortion free demoulding. A minimum draft
angle of 1 degree is recommendable.

4.8.9 Sharp notches facilitate cracks. Sharp edges and corners, if unavoidable,
must be rounded off. Provide fillet radii at the junctions of pins, bosses, ribs etc.

4.8.10 Lettering.
Raised lettering on a moulding,
though easiest to make in the mould,
is liable to damage and wear in use.
Sunken letters are safe but difficult/
more expensive to make. The
combination viz. raised letters on a
depressed surface offer the best of
both (Fig. 4.104).
Fig. 4.104

4.8.11 Assembly aid in industrial components should be

situated away from edges and corners. The holes for
location of punches or cores in the mould forming the
desired holes, when drilled too close to the edge of the
mould cavity or core, weaken it considerably. Figure
4.105 illustrates the point and also the alternative.
Fig. 4.105

142
4.8.12 Attachment lugs for assembly of the component
should be strong. Avoid sharp- edged changes in section as
well as holes at the change of sections . Place attachment
points outside, rather than inside (Fig. 4.106). Lugs located
inside constitute undercuts and necessitate special devices
like tapered slides in the mould, which increase its
complexity and cost.

4.8.13 The bosses (Fig. 4.107) should be preferably hollow.

Their wall thickness, taper and Fig. 4.106 radii should follow the rules
applicable to the ribs.

The boses should not be too close to or joined to the

walls. For support, one or more ribs may be used as
shown in figure 4.108.

Bosses with moulded holes

for self tapping screws should
be well tapered outside and
should have fillet radii where
Fig. 4.107
they join the article. The hole
for the screw should have a diameter ranging between 0,7
to 0,95 times the screw diameter. The smaller core hole
diameter is applicable to softer plastics and the larger hole
to hard ones. The hole should be foreseen with a
countersinking equalling the diameter of the screw in
diameter and depth.
Fig. 4.108

4.8.13 Threaded holes, a recurring feature of industrial

components, can be formed during moulding if start of the
thread is placed well below the surface to avoid damage.
Likewise, the thread should stop a few turns before the end
(Fig. 109).

4.8.14 Assembly aids; snap fit joints for temporary or

permanent attachment of moulded components facilitate
assembly without additional fasteners. Their design depends
upon certain properties of the plastics employed. Figure 4.110 Fig. 4.109
depicts an example of a permanent snap-fit joint.. The hole, which is smaller than the
shaft, is shaped to guide the entry of the
later. The hole expands within the elastics
limit to permit entry of the bigger part of the
shaft and resuming its original size
thereafter, holds it permanently in its
narrower portion or neck. In assembled
state, neither of the two parts is under
stress.
Fig. 4.110

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4.8.15 Integral hinge. Integral hinge in polypropylene makes it possible to produce
a container and its lid as one moulding. A properly designed and properly moulded
hinge has virtually an unlimited life.
Figure 4.111 illustrates the main
features and dimensions.
Polypropylene acquires a high
orientation by being flexed which
increases its tensile yield strength
enormously.

The pp-hinge is basically a light duty

feature, limited to applications where Fig. 4.111
Fig. 4.111 bending force is the main load .

Integral hinge can also be moulded in

polyacetal.

4.8.16 Apertures and side holes. These

features require moving components in a
mould, limit the number of cavities which can
be accommodated and add to the cost. A
modification in their design as shown in
Figure 4.112 can make it possible to form
them without the moving aids in the mould. Fig. 4.112

Fig. 4.113 shows yet another example of redesigned

side opening.

Additional holes, apertures and cut outs, if located

judiciously, can help reduce the weight of the article. It
must, however, be examined whether they give rise to
unacceptable weld lines or weak spots. In certain type
of products, the cut outs may even add to the aesthetic
appeal Fig. 4.113
of the product.

4.8.17 Insert moulding (Fig. 114).

Metallic inserts, such as reinforcing
metal plates, electrical contact pins,
internally threaded metal sleeves etc.,
should not be too large as compared to
the moulding. The thin plastics material
around a big insert, when prevented
from shrinking, may develop cracks.
They should not be positioned near the Fig. 4.114
surface or the edges. Provide flats,
knurling, and grooves on the outer surface of round inserts to prevent turning and
withdrawal. These undercuts should not have sharp edges.

144
4.8.18 Tolerances. It is very difficult to predict shrinkage precisely, especially for
materials with a wide shrinkage range and for the articles with varying wall thickness.
Very narrow tolerances add to the cost of the mould and cause more rejection in
production because any variation in material, ambient conditions and moulding
parameters influences the shrinkage.

Tolerances can be narrower for thermoplastics with less shrinkage. They should be
larger on the free dimensions of the product. More tolerance should be allowed if the
mould has to be a multi-cavity one.

Containers for household as well as for industrial use were the first articles where
thermoplastics proved their worth. Soon after, housings for household gadgets,
radios, gramophones etc. were moulded in thermoplastics. It would be noted that
many of the above guidelines relate to such products and are the outcome of an
experience extending over a century. Now, plastics are finding application in all major
technical fields. The new applications have given rise to additional design rules.
However, the principle that a good design involves the use of minimum of material so
distributed as to ensure sufficient strength at all points, remains unchanged.

Before finalising design of a product in plastics, it should also be reviewed from the
tooling angle. Is there a feature which makes the tool very complicated? Will the
mould design necessitate very delicate mould components prone to frequent
damage, repair and replacement? Can the design be modified to make the mould
simpler without influencing its function adversely?

Chapter 5

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 Mould Making

5.1 Mould manufacturing

5.1.1 Special mould making processes
5.2 Mould materials
5.2.1 Ferrous materials
5.2.2 Non-Ferrous materials
5.3 Post treatments

5.1 Mould manufacturing.

Although there has been a lot of progress in the field of mould making, certain basic
realities have not changed. A mould may be said to consist of two main parts, viz. the
bolster and the core and cavity. Conventional machining methods have retained their
position as the most economical way of making the bolster and even the core and
cavity for regular geometrical shapes. Turning, drilling, milling, surface and cylindrical
grinding, jig grinding and polishing operations are even today as irreplaceable as in
the early days of mould making. The corresponding machine tools have become
more sophisticated, efficient and accurate. CNC technique has brought speed,
economy and reliability but the basic concept of material removal has remained
unchanged. The conventional machine tools still form an important and sizeable part
of a mould making tool room and they still do the bulk of material removal.
It cannot be overlooked that the process of EDM has revolutionised the basic
concepts of core and cavity fabrication. Almost all constraints to the shape and form
of the article to be moulded have been removed with the advent of spark erosion and
its allied process, viz. the wire cutting. Since their introduction, plastics have been
able to enter all fields of industry.

It is not intended to dwell upon the conventional processes well established in this
field. In fact, these metal removal processes and machine tools are not peculiar to
the field of mould making only. It is intended to confine the dissertation to certain
specialised techniques, which are not found in every tool room but are still useful in
out-of-the-way cases.

5.1.1 Special mould making

processes.

5.1.1.1 Ceramic casting. (Fig. 5.1)

The manufacture of core and cavity in

steel by the conventional process of
sand casting is unsuitable due to poor
surface finish, porosity and inaccuracy.
However, the ceramic casting process is
not plagued by these drawbacks and is
often employed for making cores and Fig. 5.1
cavities of large moulds.

146
The first step is the fabrication of a pattern of the mould core with final dimensions
including the shrinkage allowance for plastics as well as steel. The pattern is
positioned in a casting box and slurry consisting of fine refractory particles
suspended in a bonding agent like ethyl silicate is poured over it (Fig. 5.1 a) The
slurry block, after solidification, is removed from the casting frame, ignited and then
placed in a furnace at 900 0 C to remove water and alcohol (Fig. 5.1 b).The negative
ceramic mould is now ready to receive molten steel at 1600 0C (fig. 5.1 c) . After
solidification, the mould component (core) is ready for further finishing operations.
The achievable dimensional accuracy is about 0,5%, which may be found adequate
in many non-critical cases.
The cavity block can also be manufactured in the same way. The pattern can be
made of any material which yields a smooth, non-porous surface and does not react
with the ceramic slurry.

5.1.1.2 Epoxy resin casting (Fig. 5.2)

Moulds meant for a limited
production can be readily cast out
of special epoxy resins,
impregnated with up to 80%
aluminium powder, which lends
them strength, polishability and
heat conductivity. The model for
casting can be made out of
metal, wood, plaster, leather,
silicone plastics resin etc. The Fig. 5.2
model is positioned in a casting
frame; metal inserts, if any, can be fixed onto it and even the cooling pipes can be
placed before the preheated and degassed mixture of resin and hardener is poured
over the model. Both halves of the mould are cast in this fashion separately, left to
cure for a day, taken out of the casting frames, assembled and heat cured. The
mould inserts, cast in this fashion, can be fitted in a steel frame. The ejector holes
and the runner system can be machined in the conventional way.

The resin reproduces all details of the model faithfully. It can also be highly polished.
The resin has negligible shrinkage (0,02%), having practically no effect on the
product dimensions. The cast resins have adequate surface hardness but low tensile
strength. Such moulds may yield over 1000 shots, depending upon the intricacy of
the product and the plastics material being moulded.

5.1.1.3 Electroforming.
It is an electro-chemical process of material deposition on a given pattern, which has
the reverse form of the required cavity/core. Because of the ease of fabrication of a
pattern or model in male form, the method is generally adopted for production of
cavity inserts.
The model can be made out of any easily machineable material such as brass,
acrylics or epoxy resin. However, the non-conducting materials have to be provided
with a conducting outer layer, mostly a very thin coating of silver.

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The pattern acts as a cathode in an
electrolytic bath and nickel-cobalt is
deposited on it till a shell of about 4
mm. thickness is formed. The Ni-Co
shell is backed up by electrically
deposited hard copper till the block
achieves a size out of which an insert
can be machined (Fig. 5.3).
Although it is a relatively slow process,
it has the advantage of yielding inserts
with adequate hardness (~45-55 Rc.). Fig. 5.3
The surface finish too is as good as
that of the pattern. It reproduces the accuracy of the pattern, which though not
hardened, can be used again and again.
Electroformed inserts are used for deep, narrow cavities such as those for textile
garn cones, medical disposables etc. which would be difficult to polish if made by
other processes.

5.1.1.4 Cold Hobbing (Fig. 5.4).

Cold hobbing is a technique of producing cavities by metal displacement instead of
metal removal. A hardened and polished punch called hob, which has the external
contour of the intended cavity, is slowly forced into a block of soft annealed low
carbon steel, positioned in a conical holder, at room temperature. The depression
achieved has the shape and surface quality of the hob.
Whereas the hob has the exact dimensions of the required cavity, the steel block is
considerably bigger than the final size of the cavity insert. Its diameter and thickness
is not less than twice the diameter and the depth of the impression to be sunk. After
hobbing, it is machined down to the final size of the insert and heat treated.
The process is particularly economical for multi-cavity moulds with cavity forms
which may be difficult/ expensive to machine and polish but can be conveniently
produced as a punch. One hob can produce
any number of cavities, identical in shape,
finish and dimensions. The finish of the hob is
reproduced faithfully in the sunken impression
and little polish is needed after case hardening
of the insert. The structure of the material also
becomes more compact due to compression.
Another advantage is the creation of raised
lettering on the horizontal or nearly horizontal
surfaces of the hobbed cavity. Fig. 5.4

5.1.1.5 Metal Spraying (Fig. 5.5)

A very fast method of producing a cavity/ core is the spraying of low melting
temperature alloys of bismuth and tin with the help of compressed air onto a pattern
possessing the reverse shape of the cavity/ core. The pattern can be made of metal,

148
ceramics, wood, epoxy resin or even thermoplastics. In other words, even a sample
can be used as pattern.
The pattern is treated with a releasing agent and the alloy is sprayed on it till a shell
of about 4-5 mm. thickness is formed. Though the metal may have a temperature of
200-4000C, it cools down to 40-50 degrees when it hits the pattern and settles down
on it in the form of a non-porous layer. The shell is backed up by epoxy resin
impregnated with aluminium powder to form an insert, which can be fitted in a steel
bolster. It is also possible to incorporate cooling by placing bent copper pipes in
position before pouring the backing material.
The bismuth alloys are comparatively
soft. The life of an injection mould is
limited to about 1000 shots. However,
the speed of mould making enables
quick production of prototypes or small
pilot series.
The expensive bismuth alloys can be
salvaged and reused.
Fig. 5.5

5.1.1.6 Chemoforming.
It is a process of selective metal removal with the help of acids. Its working is similar
to that of EDM or spark erosion without the use of electric current for removing the
metal. As in the EDM process, here too a movable horizontal table with a tank is
required to house and position the job or the insert. The surrounding fluid is an acid.
The pre-machined job is coated with a protective material. The "electrode", held in
the upper plunger of the machine, is the negative replica of the desired shape. It can
be made of plastics or any other material as it is not subjected to any wear or tear. Its
function is to touch the work-piece and remove the protective coating. The work of
metal removal is accomplished by the acid. Through repeated strokes, more and
more surface is bared, more and more metal removed and gradually the job gets a
contour which is an exact reverse reproduction of the "electrode" in dimensions and
design details and surface finish. If the "electrode" is well polished, the job also does
not require any further touch up.
The process is faster than EDM. Its significant advantage is that it does not effect the
structure of the metal. Also the "electrode' does not undergo any wear and tear and
can be used any number of times. Furthermore, the workpiece may be hardened or
unhardened and may be made of non-ferrous metals like copper, brass, bronze and
aluminium. The surface finish is finer than that achievable by spark erosion.
The process proves highly economical in conjunction with other material removal
processes like machining and EDM.

5.1.1.7 Direct metal laser sintering.

This is the latest process of forming an article or a mould insert with the help of a
laser beam, which is directed and moved by 3-D data on fine metal powder. A thin
layer of the metal powder melts under the heat of the moving laser beam and sticks
together in the shape generated by the beam. Layer by layer, the desired article or a
mould insert is created out of the metal powder. Its physical properties such as
tensile strength, hardness etc. depend upon the composition of the metal powder.

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Out of a variety of metal powders available for the process, those most suitable for
injection mould inserts are either a bronze-based mixture or a tool steel one. The
former mixture is faster in manufacturing but is comparatively softer (115 HV) and is
generally employed for moulds for trial series. It is, however, possible to mould up to
a few hundred thousand components depending upon the thermoplastics to be
processed. The maximum operating temperature is 400°C.

Inserts, laser-sintered out of the bronze mixture, display a minimum rest porosity of
8%. The surface is generally sealed by micro shot-peening before use. The
redeeming feature is its good heat conductivity, which results in faster heat
dissipation and shorter moulding cycles.

A tool steel material comprising Marging 300 (DIN 1.2709

- X3NiCoMoTi) is suitable for inserts for production
moulds. In as-sintered state, the inserts possess a
hardness of 35-37 Rc but can be easily hardened up to
50-54 Rc. In hardened state, their service life is
comparable with those manufactured in traditional
fashion. They can withstand temperatures as high as
1100°C. They are almost fully dense (porosity lower than
0,5%) and do not require a surface sealing treatment.
Fig. 5.6
The surface lends to a good finish through polishing.

Laser sintered inserts are generally incorporated in mould bolsters but up to a

certain size, they can replace mould plates and form a mould
directly. Figure 5.6 shows a laser sintered mould insert along
with the moulding.

A unique advantage of the process is the speed of

manufacture without any model or pattern and the facility of
incorporating integral cooling network, matched to the
contours of the product as well as ejector holes and even
undercuts during laser-sintering. The integrated 3-D cooling
network leads to faster production, more uniform shrinkage,
less stresses and consequently lower rejection rate (Fig. 5.7).

The Direct Metal Laser Sintering process is in the process of

Fig. 5.7 further development to enable manufacturing of moulds out of
different alloys with longer production life.

5.2 Materials for injection moulds

Injection moulds are subjected to severe conditions such as fast fluctuating
temperatures, very high pressures with cyclic changes, wear, corroding fumes and
rust. They are required to maintain high dimensional accuracy and reliable function
ability under extreme working condition. This is why, the production moulds are
fabricated out of alloyed steels, alloying elements like Chromium, Vanadium, Nickel
etc. adding the desired property. Depending upon the function of the component, the
required finish and the working life, following steels has proved their suitability for
moulds.

150
In order to select the right material for fabrication of mould components, one must
consider conditions of operation, methods of their fabrication, demands on quality
and accuracy, the working life and economics.
A mould is, as a rule, a one-time job, a prototype so to say. The most economical
method of its fabrication is machining. In other words, the cost of fabrication is
directly linked with the time required for machining. Easy machinability will, therefore,
be a positive feature of the material.

The mould bolster is subjected to compression from the clamping force of the
machine and to deflection by the injection pressure. The guiding elements and the
moving components undergo friction and are likely to wear out, causing inaccuracy
and moulding defects unless made of a hardened material. Depending upon the
climatic conditions and the plastics being processed, the mould parts may be
attacked by rust and corrosion. Cooling water can give rise to rusting from inside the
mould inserts, which may result in creation and propagation of cracks.

The components shaping the moulding are required to serve for a long time under
stringent conditions of quickly fluctuating pressure and temperature. Plastics melt,
flowing at a very high speed, subjects the material to wear and tear and dimensional
variations. In case of filled plastics, this effect is very prominent. The surface finish of
the product is a direct replica of the mould surface and in most cases high gloss is
demanded. Last not least is the property of heat conductivity which directly
influences the cooling time and consequently the productivity.

In the light of above considerations, it may be summarised that the mould materials
should possess the following attributes:
a) Easy machinability
b) Toughness
c) Fatigue resistance
d) Resistance to wear
e) Strength at elevated temperatures
f) Hardenability without distortion
g) Good polishability
h) Corrosion resistance
i) Good heat conductivity

5.2.1 Ferrous materials.

5.2.1.1 Unalloyed steels e.g. EN-8

It is the most common steel employed for mould bolsters and many other
components not coming in contact with the melt and not subjected to friction.
Generally, it is used in unhardened state and has a tensile strength of about 60
kp/sq. mm. It is easily machineable but not rust proof. In exceptional cases, it may
also be hardened.

EN-8 is not recommended for the mould components forming the product. However,
for cheap moulds with a short life, it may be used with a proper surface treatment like
chemical nickel plating, hard chrome plating, nitriding etc.

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5.2.1.2 Prehardened steels like 1.2311, 1.2312 (P20, P20+S)
The prehardened steels are used for making bolster for high production moulds and
also for core and cavity inserts of moulds with medium range of life and accuracy.
Their main advantage lies in their initial toughness (tensile strength 110 to 140 kp/sq.
mm), obviating the need of hardening operations, which may lead to distortion. In
rare cases, the surface hardness is enhanced by nickel/ chrome plating and nitriding
etc.
Due to initial toughness, the prehardened steels are more difficult to machine. The
machinability can, however, be improved by incorporation of sulphur in the structure.
It has, however, adverse effect on the surface finish, especially if any surface
structuring is to be carried out.
Their polishability is adequate for industrial and less demanding articles.
5.2.1.3 Case hardening steels DIN 1.2162 (AISI P2), DIN 1.2764 (AISI P21)
These steels are used for mould bolsters of high production tools and also for mould
inserts such as cores and cavity inserts for relatively less complicated large
products. The machining is easy but hardening operation is unavoidable. Therefore,
some after-operations like grinding and repolishing must be carried out. These
materials are economical in price, have good polishability and long service life.
Through nickel or chromium plating, the resistance to corrosion can be improved.
Case hardening steels, when properly annealed, can also be employed for cold
hobbing - an economical process to produce identical mould inserts for multi cavity
moulds.
Because of their hard surface and tough core, case hardening steels are also used
for fabrication of mould components subject to wear and bending.

5.2.1.4 Through hardening steels DIN 1.2767 (AISI GF7)

The advantage of through hardening steels lies in the uniformity in their structures
through and through. Thus they have less in-built stresses, negligible distortion and
long service life. The steel cited here has excellent dimensional stability and
polishability. It is the most widely employed material for inserts of the high production
moulds. This steel also lacks the corrosion resistance and must be surface treated in
critical cases.

5.2.1.5 Hot die steels DIN 1.2443 / H 11

Hot die steels possess a tough core and retain their strength and hardness also at
raised temperatures. They can also withstand temperature fluctuations. They are
highly suitable for making hot runner manifolds and components of moulds for
plastics such as speciality polymers needing high mould temperatures. They can be
machined, spark eroded, hardened and polished. Nitriding is the preferred hardening
process for hot die steels as it gives them a hard, wear resistant surface and does
not reduce the core toughness. They are not corrosion resistant but can be plated.

5.2.1.6 Nitriding steels (EN-31)

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Nitriding is a process of surface hardening at comparatively lower temperatures, by
incorporating nitrogen into the steel. It forms hard nitrides with some elements like Al,
Mo, Va, and Cr. The main advantage lies in the absence of distortion due to
hardening. No after-operations are, therefore, required for correction. Usually the
steels are prehardened before nitriding to combine a tough core with a hard surface.
Nitrided surface also forms a rust resistant layer. Sometimes all plates of the bolster
of an expensive mould are nitrided solely as protection against rusting in tropical
climate.
5.2.1.7 Stainless steels DIN 1.2083 (AISI 420)
Some plastics release aggressive gases like chlorine, formaldehyde etc. on
overheating, which attack the metals and corrode them. PVC and POM (Polyacetal)
are the prominent examples of such thermoplastics. Chromium plating of moulds /
inserts solves the problems to some extent, but the chromium layer tends to peel off
after a little damage. Secondly, the thickness of the deposited layer is never uniform
which may be found unacceptable in case of very tight tolerances.
Corrosion is also caused by some additives in certain plastics. High moisture in the
air may condense on the cold mould surface leading to corrosion. The cooling water
is another potential source of rust. The sharp furrows in the drilled cooling channels
develop into internal cracks under the effect of rust.
Stainless steels for moulds inserts offer a good solution to these problems. The
chromium content in the alloy steel has to be 12% or above. It forms a protective
layer of chromium oxide on the steel, which prevents corrosion once for all. These
steels are hardenable to about 52-56 Rc.
It may be added that the steels containing chromium are inferior in conduction of
heat.

5.2.2 Non-ferrous materials.

5.2.2.1 Copper–beryllium alloys.
Cu-Be alloys, especially those with a beryllium content of more than 1.7%, combine
excellent heat conductivity with adequate hardness (35-38 Rc) and toughness. They
represent an ideal material for the mould components like slender cores and thin
inserts, which cannot be cooled directly. Be-Cu can be finely polished and is
corrosion resistant which property can be further enhanced through chemical nickel
plating. Their gliding characteristics are also better than those of tool steels so that
trouble free ejection can be achieved with less taper.

Cu-Be is also used for manufacturing heat conducting nozzles of hot runner moulds.

5.2.2.2 Aluminium alloys.

Certain aluminium alloys can be used for short-run moulds. The Al Zn Mg Cu 1.5
(DIN 3.4363) alloy, which is employed in aircrafts, has very good heat conductivity
and a modulus of elasticity equalling a third of that of steel. Apart from a good
cooling effect, these alloys have the advantage of easy and fast machinability—also
through spark erosion-- and adequate polishability. Due to their lightness, the mould
parts can be transported in the tool room without the help of cranes. However, their
use remains confined to trial injection moulds or those for pilot series.

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5.2.2.3 Tin-bismuth alloys.
These are low melting temperature alloys (melting point about 200 0C) which can be
sprayed. Mould inserts can be formed within a matter of hours, by spraying the
molten metal on a model. The reproduction of details is very good. The inserts can
be mounted in standard bolsters made of steel to make experimental moulds within
24 hours. It must, however, be underlined that the mechanical strength of bismuth
alloys is very low. Hence the moulds primarily serve as a fast help to get prototypes
for trials.
Bismuth alloys are quite expensive but they can be remelted and reused any number
of times.
Bismuth alloys are also employed to make cores for the “fusible core” moulding
technology (Chapter 8)

5.3 Post-treatments.

4.7.1 Heat Treatment.

As a rule, the product-forming components of a production mould, viz. the core and
cavity, are hardened to prolong their service life. It is also not seldom that the plates
housing these mould components are also hardened and ground out of the same
consideration. Guiding members, and other moving components like ejectors, slides,
strippers, pullers, etc. which are subjected to wear, are invariably hardened. All
conventional heat treatment processes such as case hardening, through hardening,
nitriding, vacuum hardening etc. are also employed for injection moulds and their
components. In fact, most standard components come in hardened state, ready for
use.

4.7.2 Polishing. The mould components, shaping the moulding, leave their imprint
on the surface of the product. Thus the marks left by the machining operations on
core and cavity of the mould are transferred onto the product. In most cases, these
are not acceptable. The uneven surface may also come in the way of easy
demoulding. This is why, the relevant surfaces of all such components are worked
upon or “polished” to eliminate the machining marks before hardening. The degree of
polish depends upon the end use of the moulded product. Polishing of moulds for
technical components is usually confined to removing all traces of machining.
However, for the products in which the surface finish has an aesthetic value, the
polishing may call for a smoothness of 0,001-0,01 μm. The mould cores and cavities
for consumer products are required to have a mirror like surface finish. The relevant
surface are polished again after hardening to remove deposits left by the hardening
process.

The process of polishing is essentially manual and is carried out, with or without the
help of electrical hand tools, in a number of steps. The first step consists of removing
machining marks with corundum polishing stones of different fineness in sequence
and then going over to lapping with emery pastes. Here too, one starts with relatively
coarser grit size, coming to very fine sizes in 2 or three steps. Mostly pastes with fine
diamond particles are used in final stages. For technical plastics, pastes used are P
240-320. However, for shining surfaces of opaque articles, the range will be P 240-

154
400 and for transparent mouldings, final polish with P 500 is imperative. In most
cases, polishing is done or “drawn” in the direction of ejection for easy demoulding.

A precondition for obtaining a mirror like polish is corresponding steel quality. It must
be free from inclusions and have fine grain structure.

The process of electro-polishing is based on removing the top layers micronwise

from the surface to be polished electrochemically. The surface must, however, be
absolutely free of machine marks and unevenness which would otherwise get
accentuated. The process can deliver mirror like finish on prepared surfaces. The
steel too must be of a suitable quality.

Most common mechanical tool for polishing is the flexible shaft grinder. Polishing
can be carried out with the help of special machines in some cases where the
surface is large and regular. The operation is purely manual for very small cavities
with sharp corners. Fine polishing without the help of mechanical devices may take
about half to one hour per square centimetre.

The ultimate quality of the polish is also dependent upon the homogeneity of the
steel structure, the extent of impurities, the grain size and the heat treatment.

Some products are designed with matt surface finish in parts or completely. Here
too, the mould components are first polished to remove the machining marks and
then finished to the required degree of polish. Ultimately, the designated portions
are roughened through sand or glass bead blasting, spark erosion etc, after masking
the rest area. The process of spark erosion is capable of delivering surface of
desired roughness. Silken surface produced by spark erosion is found to be the most
suitable for polymers containing glass fibres as it camouflages surface defects like
dull spots.

4.7.3 Plating. The mould surface can be made more durable and more resistant to
aggressive materials through plating with chromium or nickel. Hard chromium plating
is a galvanic process, carried out in a bath containing chromium solution. The
component to be plated acts as a cathode. The chromium layer lends additional
hardness to the mould surface. Moulds for polymers like PVC or polyacetal, which
may release aggressive chemicals upon overheating, are provided with a protective
layer of chromium. However, it does not undergo a bond with the parent metal of the
mould and may peel off if damaged. Nickel layer is deposited chemically without the
use of electric current and forms a bond with the mould.

4.7.4 Structuring. Quite often, the consumer products are provided with granular
surface to look like leather, wood, fabric etc. The surface of corresponding mould
components is formed accordingly. The process resorted to is called photo etching.
The polished mould surface is coated with light-sensitive chemicals and an image of
the intended surface design is exposed on it. It is processed like an exposed
negative and then treated with etching chemicals which act on the surface
according to the intensity of light and shade of the exposure. A negative structure
with varying depth is created by the corrosive chemical.

155
Photo etching is a corrosive material removal process. This is why, Stainless steels
with high percentage of chromium are difficult to etch.

Tool steels can be hardened before photo etching but the thickness of the hardened
layer must exceed the depth of etching. Again, steels with sulphur are not
recommended for photo etching treatment as sulphur may get washed out and leave
pits on the surface.

Non-ferrous metals like aluminium, copper and zinc can also be etched and
chromium plated.

The structured vertical surfaces act as deterrent to ejection. Such moulds need
larger draft angles for safe demoulding. As a rule, a taper of 1° must be provided per
0,1 mm. depth of etching.

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 Chapter 6

Intrusion Injection Moulding

6.1 The process

6.2 The equipment
6.3 The mould
6.4 Advantages
6.5 Applications

6.1 The process.

Intrusion injection moulding may rightly be regarded as an extension of the
conventional injection moulding process as it can be carried out with the same
machine without hardware alterations and without additional equipment. The
process is a combination of extrusion and injection moulding as the filling of the
mould is achieved partly by extrusion and partly by injection. In other words, it is
a combination of low pressure and high pressure injection moulding steps. The
process is carried out in four steps:
 The mould is closed and the nozzle of the plasticising unit is brought in
touch with the sprue bush of the mould. The screw is in the forward
position, close to the nozzle, i.e. the barrel is empty.

 The charging or dosing operation is started with back pressure. The melt
fills the mould gradually, the back pressure acting as the injection
pressure. Here the rotating screw is basically acting as a conveyor of the
melt as in an extruder, filling the mould with low pressure. As the mould
gets filled, the back pressure forces the rotating screw to recede to a pre-
set point and stop dosing.

 The screw takes over the function of a plunger, makes a forward stroke
and compacts the filled material. A holding phase follows.

 After cooling, the moulding is ejected out in the normal manner.

Figure 6.1 illustrates the process in three

steps.

An alternative to the above procedure is as

follows:
 Charging during the cooling time till
the screw has arrived at the pre-set
end position.

 Filling the mould through extrusion, i.e,

through rotation of the screw in the
end position after the mould has
closed again after opening and
ejection.

Fig. 6.1
157
  Ultimate injection through forward stroke of the screw as plunger.

 Holding and cooling as in conventional injection moulding process.

Apart from the two variations described above, a number of alternative

combinations are possible.

6.2 The equipment.

The moulding machine for intrusion moulding process differs from the
conventional one only in a few controls which permit extrusion for the set time
and subsequent injection and holding. Modification in controls to effect pulsating
holding pressure help eliminate surface defects.

A normal injection moulding machine can be manipulated to perform the process

in manual mode without any alteration. The method is resorted to only for trials or
for production of a very small lot.

6.3 The mould.

The mould for the intrusion moulding process is identical to the one for the
conventional injection moulding. The difference lies in the dimensions of the feed
paths which, understandably, have to be larger than those for normal, high
pressure moulding to permit passage of melt at lower pressure. It is also
advantageous to maintain the maximum permissible mould temperature for the
polymer in question.

6.4 Advantages and disadvantages.

The advantage of the process lies in overstepping the limitations of maximum
shot volume. Depending upon the wall thickness of the article, products with ten
times the nominal shot weight of the machine can be injection moulded by
intrusion injection. The safe wall thickness to length of flow ratio is 1:50.

The low pressure may give rise to sink marks or blow holes in case of thick
walled mouldings. Machines with arrangement for pulsating holding pressure
help overcome the problem.

It is possible to mould elastomers as well as thermosets by this process.

The process has a limited application because it can essentially mould thick
walled articles. The machine controls, too, must be altered. The production is
slow.

6.5 Applications.
Trial and operation of moulds of thick walled articles on smaller machines.
Moulding of thick walled articles like boxes, flower pots, furniture components.

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 Chapter 7
Injection Compression Moulding

7.1 The process

7.2 The Equipment
7.3 The mould
7.4 Advantages
7.5 Application

7.1 The process.

As the name suggests, the process is a combination of injection and compression
moulding. The aim is two folds. It exploits the efficiency of the injection moulding
process but employs compression to even out the differences in dimensions brought
about by differential shrinkage unavoidable in injection moulding. A typical example
of products of the process are optical lenses moulded out of thermoplastics.

Another advantage of the combined process is the possibility of moulding large

articles with high L:T (length of travel of the melt/ wall thickness) ratios. Under
normal circumstances, it may not be possible to fill the cavity on the particular
machine. The very high pressure needed to fill the cavity may force open the mould,
but if the injection takes place with partially open mould which amounts to an
increased wall thickness, injection of the amount of melt required for the final product
can be accomplished with less pressure. The machine can close now and compress
the melt to its final thickness, pushing it simultaneously to the unfilled outer areas.
The cooling takes place under a pressure acting all over the surface.

Basically, it is an injection moulding process followed or accompanied by

compression. There are four variations of the process depending upon when the
second step, that is the compression, is brought into action.

7.1.1 Sequential injection compression moulding.

As the name suggests, the two operations of injecting and
compressing take place one after the other. The mould is closed
incompletely, leaving a gap of twice the final wall thickness; a
measured amount of material is injected and then the mould is
closed to its final position, thereby compressing the melt all over
uniformly (Fig. 7.1).
Because of the increased wall thickness, injection takes place
with less pressure. Consequently, the locking force needed to
counter the pressure is also low. The moulding can take place on
a smaller machine as compared to the standard injection
moulding. As the mould closes and the compression sets in, the
melt is pushed to the unfilled extremities. In between, there is a
phase of “hesitation” when the melt was stationary. The restart of
melt movement bestows flow lines on the surface of the product,
which may not be acceptable in some cases. Fig. 7.1
The injection pressure remains below 75% of that needed for normal filling and the
clamping force does not exceed 30%.

159
7.1.2 Simultaneous injection compression moulding.
In this variation too, injection starts with the partially open mould but the closing of
the mould commences almost simultaneously, with a maximum lag of 2-3 seconds.
The result is that the melt front remains constantly in motion and has no “hesitation”
pause. Consequently, there are no surface marks.

Both variations suffer from a common drawback. In case of large mouldings, the
melt tends to flow downwards under the force of gravity, causing the lower side of
the mould to fill first. This may introduce problems of uneven distribution during
compression.

The injection pressure and the locking forces are low like in the foregoing case.

7.1.3 Breathing injection compression moulding.

The injection starts with the mould closed to the final position but it keeps on
opening continuously, either under the injection pressure or through pre-
programmed controls. The melt remains always under pressure. This eliminates the
possibility of uneven filling encountered in the previous two variations of the ICM
process. At the juncture, when nearly complete volume has been injected, the
clamping force is activated and the melt is compressed to the final wall thickness.

7.1.4 Passive injection compression moulding.

It may be rightly regarded as a variation of the breathing injection compression
moulding applicable in special cases and practicable with machines having fully
hydraulic locking.

The process makes use of controlled breathing of the mould during injection by
setting the locking force lower than the internal mould pressure arrived at after
complete filling. It is effected by first filling the mould under normal locking force of
the machine and then reducing it gradually till the moving half recedes by an amount
permitted for venting in case of the particular plastics. As the mould opening force
generated by injection decreases because of partial cooling of the injected melt, the
machine closes fully under its set locking force.

The process does not require any modifications in the machine hardware. The
mould is equipped with sensitive dial gauges to display the gap between its two
halves for accurate adjustment of the locking force. The fully hydraulic machines are
most suitable for the process as hydraulic oil is compressible.

An essential condition of the process is that the injected volume of the melt must
remain constant irrespective of the mould breathing. It can be achieved by adjusting
the charging to the amount needed for the article. The screw must inject the full
amount of the dosed melt and touch the end of the cylinder. It must be held in this
position with sufficient force so that the melt being compressed through the closing
action of the moving platen cannot force its way back into the injection unit.

The process is suitable for large round products with central gating as the side
gating may cause partial flashing during breathing.

7.1.5. Selective injection compression moulding.

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By selective ICM, the mould is completely closed before injection and a separate
core in the mould is moved up locally, during or after injection (Fig. 7.2). This results
in localised compression, compaction and thinning in a relatively large section. In
some cases, the compression pressure exerted by the core can replace the holding
pressure albeit with the difference that the compensation for shrinkage takes place
not by pushing more melt in the cavity but by displacing a part of the available
material. If necessary, the holding pressure can be active along with the
compression process. Fig. 7.2

The selective ICM can be carried out on a conventional moulding machine with a
core pulling device. In absence of this option, a separate hydraulic facility can
activate the core. The connections to the hydraulic ejector, with alteration in machine
controls, can also be employed to operate a hydraulic device for movement of the
core/cores after injection in the still closed mould as shown in figure 7.2.

Injection compression moulds for lenses work according to this method with the
difference that not a part of the core, but the whole core forming one side of the
moulding, is pushed up with the mechanism built in the mould and operated with
core pulling device of the moulding machine.

Selective ICM can also be gainfully employed to eliminate sink marks in areas away
from the gate, where the holding force may cease to be effective before solidification
due to freezing of the gate.

7.2. The equipment.

The Moulding machine. The injection moulding machine performing injection
compression process differs from a conventional moulding machine only in a few
controls governing the mould closing and the injection operations. The mould closing
unit of the machine should stop at a predestined point and have the set closing force
to counterbalance the injection pressure. In the second step, it should close fully
after the preset duration and develop full locking force. It should be possible to
regulate the speed of closing. This is called the sequential compression stroke. As
an alternative, the second movement can also take place at the time of injection.
This variation is termed as the simultaneous compression control. Likewise, it should

161
be possible to have the moving platen open with controlled speed during injection
with the third variation of injection compression moulding.

In principle, it is possible to use any standard injection moulding machine to this end
with these alterations in controls. Most machine manufacturers offer these additional
controls as an option on standard moulding machines. In most cases, the older
machines, too, can be retrofitted with the relevant controls.

The injection moulding machines with electro-mechanical drives show an edge over
the hydraulic machines in consistency as oil is compressible and changes its
characteristics with temperature variations.

During the compression phase, the melt can be forced back to the plasticising
cylinder. It is therefore essential that the gate should have frozen before
commencement of compression. The machine nozzle too should be of the positive
shut-off type.

7.3. The mould.

The injection mould, as described above and shown in figure 7.1, closes in two
steps. Even in the partially open state during injection, it must not let the melt go out
of it. It implies that it has to be of a positive type like the compression moulds for
thermosets. This adds to the complicacy of the tool in case of articles with irregular
contours.

Instead of one part of the mould

dipping in the other, a spring-loaded
frame incorporated in one half of the
mould (Fig. 7.3) can act as the
outermost border. The mould becomes
simpler as the two mould halves can
have a plain parting face. The force
acting on the frame cannot be
adjusted unless the springs are
changed. The frame can also be
moved hydraulically through the core
pulling controls in the machine. It
enables easy adjustment of the pre-
tension but makes the mould more Fig. 7.3
expensive.

It is also possible to integrate hydraulic cylinders in the mould itself for the secondary
movement as illustrated in Fig. 7.2. The lower cores of the mould may be fixed on a
common ejector plate. A hydraulic cylinder, operated by the core pulling device of
the machine, pushes up the cores in the partially filled, closed mould and
compresses a section of mouldings to their final thickness. This makes the mould a
self contained unit which can run on any standard moulding machines having a core
pulling device. The hydraulic cylinder is required to provide the compression force for
all cavities. The pressure required depends upon the material and its viscosity. In
case of PMMA, which is often used to mould lenses, the compression pressure may
come to 700 Kp. per square centimeter.

162
The major application of the process and consequently the moulds is in the field of
lenses, glasses, prisms and other accurate articles like gears as well as for moulding
thin walled products such as compact discs, housings for mobile telephones,
calculators, laptops and other articles combining light weight with accuracy. An
added advantage is the surface finish which is a faithful reproduction of the cavity
surface details. Any cores forming through holes and apertures have to dip into the
opposite side of the mould.

Moulds for injection compression moulding need accurate matching of the two
halves or of the sliding components as the case may be. The dipping parts or
components are subjected to very high wear and tear. It calls for wear resistant
steels for the mould inserts which must also resist bending. The mould components
must be sturdy as any bending can aggravate the problem of wear and lead to
inaccuracies in the wall thickness of the moulding. It may be pointed out that the
stationary half of the mould is not supported by the other mould half during injection
(except in the selective injection compression moulding). It also has to withstand the
lay on pressure of the machine nozzle. This calls for adequate stiffness of the
stationary mould half as well as that of the clamping arrangement. Uneven cooling
can also contribute to variation in dimensions of the matching components and to
distortion and higher wear. It reflects adversely in the quality of the moulding.

Another prerequisite of the form-shaping mould components is a very fine and

accurate finish which gets transferred in the minutest details on the moulding. Alloy
steels with maximum purity, hardened to 54-58 Rc, fill the bill. Hard chromium plating
is not recommendable as it may peel off due to constant friction. Some stainless
steels too have proved suitable.

The location of sprue or gate should ensure even filling of the mould cavity. The
mould filling programmes can prove helpful in choosing gate location and predicting
pressures.

It is not possible to incorporate slides and other such conventional components to

form undercuts. As the melt has to be forced to remote regions through
compression, the process works well with relatively flat articles. General product
design guidelines such as those for ribs, bosses, projections etc. are applicable here
too.

7.4. Advantages of injection compression moulding.

The process enables thin wall moulding with low pressure and low clamping force.
Larger articles can be produced on relatively smaller machines.

The lower moulding pressure results in lower stresses. The shrinkage is lower as
well as more uniform because of the uniform compression pressure and
consequently the warpage is minimal.

The higher density achieved in mouldings out of semi crystalline thermoplastics

improves toughness and wear resistance.

The cavity surface details are reproduced faithfully.

163
The optical components like lenses can be produced more accurately and
economically without post-operations. Concave lenses, thin in the middle, which are
problematic to produce by conventional injection moulding, can be manufactured
accurately by compression injection.

The orientation of fibres in filled plastics is significantly lower, which fact ensures
more uniform strength in the article.

A major drawback of the process is its inability to compensate the volumetric

contraction in ribs, bosses and other such functional details upon cooling. Sink
marks may be unavoidable at these locations.

7.5 Fields of application.

Accurate optical components like lenses and prisms, large thin-walled mouldings
such as membranes for loud speakers, car panes, housings of light weight
appliances, mobile phones, pocket radios and portable CD-players, laptops, Digital
Versatile Discs (DVD) etc.

The injection compression process is also employed for moulding of thermosets and
elastomers. Another field of application is the moulding of inlay foils and textiles

164
 Chapter 8

Multi Component Injection Moulding

8.1 The process

8.2 The equipment
8.3 The mould
8.4 The product design
8.5 Alternative processes
8.6 Advantages
8.7 Applications

8.1 The process.

Multi-component moulding, also called overmoulding, is the process of injection
moulding a component successively in more than one steps, using different material
each time, till it has achieved its final shape. The plastics injected in successive
steps may be the same but different in colour as in the case of typewriter keys, radio
knobs and countless such components or it may be entirely different in its chemical
composition and properties such as a hard plug with a soft seal. Irrespective of the
number of materials or colours, the basic feature of the process is that each material
has its separate path to the mould cavity. This differentiates it from other multi-
component processes involving more than one plastics for a product.

The process can be readily visualised by considering the case of a two-colour

typewriter key as an example. The letter on the key is required to be in a differently
coloured material, say black, than the rest of the component which may be white. It
means that the product is made up of two components. The basic component or the
substrate may have the letter and a part of the inner structure and be in black
material and the shell surrounding the letter and forming the body may consist of the
material having white colour of the key. Now if the substrate is moulded separately
and transferred along with the mould core to another mould having a cavity with the
outer shape of the shell, the final moulding will be a key with a black letter
surrounded by a white shell.

The process can be carried out automatically in one mould with two sets of cavities.
One group corresponds to the external shape of the substrate and the other group
with an equal number has the shape of the outer shell. The two sets of cavities are
placed equidistant on either side of the mould centre line. The cores for both sets are
identical. The injection moulding machine has two injection units. The additional unit
may be placed at right angles to the horizontal axis of the machine, either vertically
from above or horizontally from the back so that it can inject at the parting line of the
mould.
As the mould opens after the first injection viz. that of the substrates, the moving half
of the mould is rotated by 180 degrees, thereby bringing the cores with moulded
substrates opposite the cavities of the shell and the empty ones in line with the
cavities of the substrate. By the next moulding shot, the first injection unit moulds a
fresh set of substrates and the second unit injects a shell over the substrates
moulded in the previous cycle and transferred to the second station. As the mould

165
opens again, The moulding from
the second station is ejected
and the core plate is turned
again. Thus every cycle delivers
a group of finished keys
moulded in two materials.
Figures 8.1 a & b illustrate two
steps of the process for a single
cavity mould.

An article can be moulded in any a b

number of materials with corresponding
Fig. 8.1 number of
injection units in the machine and as many groups of cavities in the mould. So far,
articles in six materials have been moulded. The plastics may be different but must
be compatible. They should have natural adhesion with one another. In some cases,
it may be possible to provide mechanical anchorage through undercuts but generally,
it is difficult if not impossible. In any case, the mould becomes very complicated in
construction and big in size.

It is also possible to mould thermoplastics with Elastomers and thermosets.

8.2 The Equipment.

The basic moulding machine is a conventional one. It

has to have additional injection units corresponding to
the number and type of materials to be moulded. For
example, the injection unit for a thermosetting material
will obviously be different from that for thermoplastics.
Their parameters can be set independently.

The special machines have a built in turning

mechanism on the moving side for indexing the
moving half of the mould (Fig. 8.2). The turn table also
houses the cooling, pneumatic and hydraulic lines for
the mould. The turning of the mould platen is carried
out by a built-in hydraulic motor.
Fig.8.2
8.3 The mould.
The injection mould will have as many sets of different cavities as the number of
materials to be moulded. The number of cores corresponds to the total number of
cavities. All cores, however, are identical in design.
With each moulding cycle, a set of finished articles is produced. The mould must be
equipped with a selective ejection arrangements which demould only the finished
group and not the substrates. It may be actuated by means of a small hydraulic
cylinder built in the mould.

Although it is possible to use conventional cold runners, the preferred system of

feeding is through hot runners. The cooling of the revolving half of the mould is
carried out through connection with the water circulation system built in the
revolving machine platen.

166
If the moulding machine does not possess an indexing mechanism, it has to be
incorporated in the mould. In that case, not the whole mould half but only the core
carrying plate is indexed. The rotation may be imparted mechanically, hydraulically
or electrically. It adds to the complicacy of the mould. A crucial feature of the tooling
is the extreme accuracy in matching of cores and cavities in shape as well as in
alignment. The smallest deviation may result in flash and blurring of meeting lines of
different colours.

8.3.1 Mechanical indexing system.

Fig. 8.3 depicts the moving half of a 2-component injection mould with built-in
mechanical indexing mechanism. The central spindle, attached with the core holding
cum ejector plate assembly, bears two longitudinal grooves placed opposite to each
other. Two spring-loaded pins, housed in the back plate of the mould, grip the spindle
in the grooves and control its rotation when it is moved forward. The spindle
performs the following functions:
Fig. 8.3

a) It pushes the set of stripper plates forward and ejects the finished mouldings.
b) It imparts 180 degree rotation to the core plate assembly as well as the
stripper plates.
c) It moves back straight without turning when the mould closes.

The path of the grooves (view z), which is primarily straight but partly in the form of
a helix covering half the circumference of the spindle and opening into the opposite
groove, governs the axial and the rotational movement of the spindle. Seen from
right to left, the groove runs straight for certain length (stripping stroke) at the end of
which a helical section starts and makes half a turn. Simultaneously, the groove

167
continues straight along the axis. Its depth varies in different sections. The first
straight section, the helical section and the last straight path have different depths.
The depth of the middle straight section changes gradually as can be seen in the
sectional view.

As the mould opens and the machine ejector system is actuated, it pushes the
spindle which moves straight for certain distance.

The subsequent part of the ejection stroke is converted by the helical groove into a
180 degree rotation of the spindle and also of the core plate assembly fixed with it.
The core with the substrate moulding (A) gets positioned opposite the outer shell
cavity and the empty core faces cavity for the substrate. The spring-loaded pins are
now in the last and the deepest section of the grooves.

When the mould closes, the stripper plates etc. are pushed back along with the
spindle. The spring-loaded pins cannot get back into helical section of the groove
because of the difference in its depth. There is no rotation and the pins travel
(relatively speaking) in straight line over the middle part of the groove, to the front
section.

The mechanical system has the advantage that it forms an integral part of the mould
and does not necessitate any additional arrangement or accessory in the moulding
machine. However, it has to be designed and manufactured afresh for every article.

8.3.2 The hydraulic system.

The basic principle, viz. moulding the article in two steps remains unchanged in this
version also. The task of turning the core carrying plate is, however, accomplished
hydraulically. The central spindle is provided with pinion and a rack, powered by a
double acting hydraulic cylinder, turns the spindle. The rack is pushed forward and
pulled backwards in successive shots unlike with unscrewing moulds.

The turning movement can also be generated with the help of worm and gear
actuated by an electric motor.

8.4 The product Design.

A plastics article made of more than one material has to be conceived from the point
of view of the moulding sequence as well as from the basic angle of its function. The
flnal product consists of a number of layers or segments of different materials. Each
substrate has to provide the possibility of flow and of firm anchorage to the next one.
The degree of adhesion between the bonding surfaces is dependent upon:
 The material combination
 The part geometry
 The process control

Mechanical anchorage alone may often be found inadequate. It is imperative that

there should also be chemical interaction, viz. the free molecular movement between
the two mating surfaces. The important parameters for this are the temperatures of
the contact surfaces and the crystallisation temperature or the glass transition
temperatures of the material pair. Additives and fillers, too, influence the strength of
the bond. Some specific additives called compatibilizers can improve the adhesion in

168
 certain cases. The mould shrinkage values of the material pair should not be too far
apart.

In case of pairing different materials for subsequent layers, compatibility must be

given due consideration. Table 8.1 shows the suitability of combination of various
materials.

Table 8.1
Adhesive bonding of polymers.

PC-PETP

PC-ABS
PE-HD

PVC-S
PMMA
PE-LD

PBTP

PETP
POM

SAN

PSU
PA 6

TPU
EVA
ABS

PC
CA

PP

PS

SB
ABS + + + + + - - + - - o o + + + + + + + +
CA + + o x X - - x - - - - + + + + x x x X
EVA + o - x X + + x x + + + x x - + x x x X
PA 6 + x x + + O o x - o - - + + x + x x + +
PC + x x + + - - x - - - - + + x + + + + +
PE-HD - - - o - + + o o - - - - - - - - - - -
PE-LD - - - o - + + o o + o - - - - - - - - -
PMMA + x x x X O o + x o - - - x + + - x + +
POM - - x - - O o x + - - - - x x - - x - -
PP - - - o - - + o - + - - - - - - x - - -
PS o - - - - - o - - - + + - - - - - - - -
SB o - - - - - - - -. - + + - - - - - - - -
PBTP + + x + + - - - - - - - + + + + + + + +
TPU + + x + + - - x x - - - + + + + + + + +
PVC-S + + - x X - - - x - - - + + + + x x + +
SAN + + + + + - - + - - - - + + + + x x + +
PETP + x x x + - - - - x - - + x x x + + + +
PSU + x x X + - - x x - - - + x x x + + + +
PC-PETP + x x + + - - - - - - - + + + + + + + +
PC-ABS + x x + + - - - - - - - + + + + + + + +

+ Good bond
- Poor bond
0 No bond
x No test results

 PA 6 & PA 66 are identical in behaviour except with PC. PA 6 bonds with PC

but PA 66 does not.
 PPO is not compatible with any of the plastics listed in the table.

It is also possible to mould thermosets as well as elastomers with thermoplastics in

multi-component moulding process The most crucial point in these combinations is
that the thermoplastics should be able to withstand the mould temperatures required
for processing of the thermosetting polymers. The few thermoplastics, which come in
question, are polyamides, polyacetal, polycarbonate, polyphenylene sulphide,
polyesters etc. The liquid silicone rubbers have to be modified to bond with these

169
thermoplastics. The basic conditions for moulding thermoplastics with thermosetting
elastomers are:

a) In case of a combination of hard material (thermoplastics) and a

thermosetting/ vulcanising elastomer, the hard material must retain its shape
and rigidity at the curing/ vulcanising temperature of the elastomer till ejection.

b) The mould must have a very effective thermal separation between the heated
cavity for elastomer and the relatively colder cavity of the hard thermoplastics
and also between the hot runner system for thermoplastics and the cold
runner system for the elastomer.

c) The cycle time is usually decided by the curing/ vulcanising time of the
elastomer.

As mentioned before, the different materials used for subsequent layers must be
compatible und should form a bond with each other besides the mechanical joint.
Mechanical anchorage may have to be employed for overmoulding mutually
incompatible materials. The process of incorporating undercuts in the moulding for
holding the subsequent layer, however, adds to the complexity and the cost of the
mould.

A positive use of the incompatibility of two materials is made in moulding multi-

component products with moveable parts, such as hinges and toy figures with
movable limbs.

Of course, the other guidelines for design of the moulded products concerning wall
thickness, material accumulation, radii, ribs and shrinkage etc. apply here also.

8.5 Alternative processes for multi-component moulding.

8.5.1 Substrate transfer by handling device.

A variation of the process consists of employing a handling device or a robot to
transfer the moulded substrates from one set of cavities to the other before the next
shot. It obviates the indexing mechanism and makes the mould less complicated.

Yet another variation of the method of transferring the substrates with the help of a
handling device is to employ a stack mould. The cavities for substrates and final
products are placed on separate levels and the robot transfers the moulded
substrates from one level to the other where these are overmoulded through the
second injection unit.

The advantages of a stack mould are manifold. The whole mould plate area can be
utilised for one type of moulding. The pressure distribution is even and the cooling
arrangement is more uniform. The separation of two injection systems, especially in
case of different types of plastics is unproblematic. The mould cost is, of course,
higher but is well compensated by higher productivity.

170
8.5.2 Sliding split system.
Another method of multi-component injection moulding, applicable in special cases,
is to block the second material sections of the mould cavity with slides, mould it in
one material and then remove the barriers without opening the mould. Now the
second component is injected. It is possible to inject further materials successively
after removing the blockage. The system, introduced by Battenfeld of Germany, is
also called the combiform process.

The injection of different materials takes place in sequence and not simultaneously
as in the rotating mould technique described above. Though the method is slow, it
may prove economical for smaller production batches. As there is no need to
transfer parts or rotate mould plates, the tool cost is much lower than in the previous
method. Also the more compact mould construction allows the use of a smaller
moulding machine. The method, however, is not universally applicable. It is limited to
special product configurations which permit blocking of sections of the moulding
which will be moulded in another material subsequently.

8.5.3 Swivel plate system.

A special machine for two component moulding, developed by Engel of Austria,
employs the moving platen side for the second injection. An injection unit is situated
behind it and travels with it to and fro. The fixed platen carries the mould half with
cavities for the substrate in the first material whereas the moving platen has the
mould half with equal number of cavities for the shell in second material. The
positions of cavities are, of course, identical. The special feature of the machine is a
swivelling plate, positioned between the two platen on the same axis. It can revolve
around its own vertical axis by 180 degrees and can slide horizontally on linear
guides on the axis of the moulding machine. The swivelling plate carries two identical
mould halves for cores on two opposite faces. It also houses the ejection
mechanism. In closed position of the machine, there is a complete mould for the
substrates on the fixed platen side and another complete mould for the shell on the
moving platen side.

After the substrate is moulded, the machine opens, the swivel plate slides to the
middle and revolves by 180
degrees to bring the moulded
substrates opposite the
cavities for the shell in the
mould half on moving platen.
The machine closes and both
injection units inject. Now on
the moving platen side, the
shell has been moulded over
the substrate and a set of
substrates has been moulded
on the fixed platen side. Each
shot yields a set of finished
article. Figure 8.4 shows the
machine in open condition
with the substrate and the Fig. 8.4
finished article.

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Whereas in the first system of core plate rotation, the mould contained two sets of
cavities differing in size and subject to different pressures, the pressure here is
distributed evenly as the mould cavities are placed symmetrically all over the mould
plate. There is more space for cooling hoses in a swivel plate mould which results in
faster cycles and higher output. The moulds are simpler and therefore cheaper as
they do not have any moving or rotating components.

The system is particularly advantageous for large products. The injection in the
middle obviates the need for complicated hot runner systems.

In another variation of the swivel plate method, the second injection unit is placed
vertically at right angles to the machine axis (i.e. not behind the moving platen), so
that the second injection is either on the parting line or through a hot runner system
housed in the core plate of the mould-half on moving side, which will also house the
ejection system.

8.5.4 Swivel Cube System (Fig. 8.5).

The swivel cube system may be regarded as a further development of the swivel
plate technology. A cube, capable of revolving by 90 degrees about its own vertical
axis takes the place of the swivel plate. Here too, the fixed platen carries the mould
cavity half for the substrate and the moving platen the mould cavity half for the shell.
The swivel block is equipped with four identical mould halves for the cores, one on
each face. The first injection is carried out in conventional manner through the fixed

Fig. 8.5

platen and the second one by means of an additional injection unit placed in L
configuration to inject at the parting line. The cube contains lines for water and air
and also houses the ejection mechanism.

The first 90 degree revolution of the cube after moulding brings the substrates to a
free station where it can be loaded with inserts etc. The second revolution after the
moulding shot brings the same core mould opposite the shell cavities of the moving
platen and the third revolution again to a free station where the doubly moulded

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finished article can be ejected. The cycle is a continuous one and every revolution
yields a set of finished mouldings.

8.6 Advantages of multi-component moulding.

 Properties of various plastics can be combined.
 Moulding of individual parts, their assembly and other after-operations are
eliminated.
 Intermediate storage and inspection of individual components is obviated.
 Only one moulding machine is needed.

8.7 Fields of application.

 Keys for type writers , computers, telephones etc.
 Buttons and knobs for electronic, industrial and household gadgets,
automobiles etc.
 Components with integrated scripts and symbols
 Covers with transparent windows
 Multi-coloured covers for automobile lights
 Decorative publicity articles
 Machine components with integral gaskets
 Closures with seals
 Toys with moveable parts
 Technical components like hinges, air ducts

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 Chapter 9

Sandwich Injection Moulding

9.1 The process

9.2 The equipment
9.3 The mould
9.4 The product design
9.5 Faults and remedies
9.6 Alternative processes
9.7 Advantages and disadvantages
9.8 Applications

9.1 The process.

Sandwich moulding, also called co-injection moulding, is the method of moulding a
component out of two (or more) materials whereby one of the materials forms the
outer skin or the sheath and the other material constitutes the core. The aim is to
combine properties of two or more materials, such as high quality visual appearance
with a core out of recycled or filled material. It may also be a combination of
transparent outer layer and a coloured core or a soft external sheath with rigid core.
In fact, the process offers possibilities of unlimited combinations for specific
applications. The prime condition for a successful moulding is the good bonding of
materials. Table 8.1 (chapter 8) shows various material combinations and their
compatibility.

The difference between the two-component moulding and the sandwich moulding is
that in the former process, the second material is either moulded over the first or
besides it whereas the second component in sandwich moulding is injected into the
first one to be entirely enclosed by it.

Sandwich moulding is carried out with an injection moulding machine having as

many injection units as the number of plastics to be moulded. It may be remarked
that it is mostly practised with two materials or the same material in two forms such
as virgin material for the skin and reground material for the core or transparent (or
uncoloured) material for outer layer and coloured one for the core. Consequently, in
most cases it is a standard moulding machine with an additional injection unit
placed vertically or from the back in horizontal position. A special co-injection nozzle
with separate paths
for melts from the two
injection units
mounted on the
standard machine
permits injection of
melts in turns (Fig.
9.1).

The melt forming the

sheath (coming from
the outer channel) is Fig. 9.1

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injected first, filling the mould partially while the channel for core material is blocked.
Now the bush X is advanced by means of a lever operated by a small hydraulic
cylinder (not shown). It blocks the melt channel for the sheath material and opens
the path for the core material. Now the second melt is injected through the common
sprue in the still plastic interior of the first material, the outer layer of which has
solidified along the mould cavity wall. The in-coming melt pushes the still fluid core of
the first material further and outwards to the cavity wall in the manner of a fountain
flow, thus filling the cavity completely.

The central channel is closed by pulling back the bush X . It opens the path for the
sheath plastics which is injected once again. The purpose is to create a seal in the
sprue area to obliterate the mark left by the second melt. The sheath gets again an
uninterrupted appearance and the nozzle contains again the right material for the
next cycle.

It may be remarked that between the switchover of channels, there is a short phase.
when both materials flow simultaneously. This is necessary to avoid a break in the
pressure and any marks caused by the halt of the sheath material.

The core material constitutes 40-75 % of the total volume. It may also contain
foaming agents.

Sandwich moulding is based on the characteristic of “fountain flow” of visco-elastic

melts. During injection, the outer layer of the melt touches the mould wall, cools
down and becomes stationary. On further injection, the plastic melt in the core
moves forward, swells and touches the walls and stays put. Now, if the second
material is injected after the first material has filled the mould only partially, it would
push the still fluid core of the first material forward and outwards. In this way, a
sheath would be formed out of the first material gradually till the end and the second
material would occupy the place of the first in the core.

The thickness of sheath depends upon:

 Volume of the first material

 Melt and mould temperature
 Viscosity of the polymers
 Injection and holding pressure
 Injection speed
 Cooling design of mould
 Product design

The filling pattern can be studied by injecting the first material in transparent version
(possible with amorphous polymers) and then its coloured version or by moulding
natural polypropylene first and its coloured version after that.

As a general rule, the viscosity of the sheath material should be lower than that of
the core plastics. This step facilitates more uniform distribution.

9.2 The equipment. The main part of the equipment is a standard injection
moulding machine, fitted with a special nozzle. A second injection unit is also docked

175
with the same nozzle. The second injection unit with its own controls may be
mounted vertically or horizontally at right angle to the first one. Controls of both
injection units are entirely independent although these are interconnected to
coordinate the start and termination of injection. The specially designed nozzle
houses two separate melt channels, independent of each other. An inbuilt
mechanism moves the needle valve and opens one channel blocking the other one
so that at one time, melt from only one unit can be injected. It is, however, also
possible to let both materials flow simultaneously. This is done towards the fag end
of injection of the first material so that there is no break in the flow. The mechanism
to switch over the channels is operated hydraulically. Figure 9.1 (based on Engel-
nozzle design) depicts the working principle.

The closing side of the machine does not differ from that of a standard injection
moulding machine.

9.3 The mould.

The mould is essentially a cold runner type. In all other respects, it corresponds to a
standard injection mould.

9.4 The product design.

The article is required to have certain minimum wall thickness so that the core of the
first material remains plastic till the second melt is injected. 4 mm. may be taken as
the absolute minimum for most material combinations.

Parts of the cavity, which are likely to get filled first and form blind alleys, such as thin
lugs or side arms and which cannot be flowed through, will not have the second
material in the core. Very thin or narrow side details may be filled only partially by the
first melt and form a skin on the front. The second material may break the skin and
fill the rest of the side cavity. As a rule, details forming dead ends should be avoided
as far as possible.

The thickness of the sheath depends, among other factors, upon the product design.
Uniform wall thickness also guarantees a uniformly thick sheath. The core material
tends to follow the thicker sections if the article combines sections of varying wall
thickness. It is also termed as finger effect.

Add flow aids for the core material to reach far corners after the first trial.

All other rules governing the injection moulded articles are applicable here too.

9.5 Faults and remedies.

The most common fault encountered in sandwich mouldings is a blemish on the
surface at the spot where the sheath material had come to a halt and had partly
frozen before the core material was injected. The core of the first material, still in
plastic state, is pushed by the second melt and forms the rest of the outer surface.
The joint may be found visually disturbing.

The fault may be eliminated by starting injection of the second material before the
end of the first injection. In absence of that facility, the blemish can be camouflaged
with a structured mould surface or with decorative foils.

176
The switchover from the first to the second material, howsoever fast, causes slowing
of the flow front. It may appear as a shadow or as a minute notch in extreme cases.
It can be remedied to a great extent by optimising the process of switchover.

Gas bubbles may appear on the surface of the moulding as silver streaks,
particularly towards the end of the flow path. There are two causes giving rise to this
blemish. If the melt has too long a dwell time in the plasticising unit, some additive
chemicals get overheated and release gases. It is advisable to delay re-charging
towards the end of the cooling time so that the melt does not have a long waiting
time before injection. Slow injection also gives time to bubbles to appear on the
surface and get elongated through friction. A fast injection remedies the defect to a
great extent.

Distortion in the moulding is the result of non-uniform distribution of the core

material. It is caused by improper product design and unfavourable viscosity
combination of the two plastics. Too low a viscosity of the core material brings
instability in its flow pattern caused by differences in resistance to the flow. The core
melt flows more in sections offering less resistance, neglecting thereby less
favourable paths. Consequently, the core thickness will not be uniform. Some
sections may not have any core at all. As mentioned earlier, it is termed as the finger
effect. Unbalanced mould cooling layout may also give rise to similar defect. Sink
marks are also to be attributed to the same cause.

The sandwich moulding process is offered by various moulding machine

manufacturers. Their main difference lies in the design of the multi-channel nozzle.

9.6 Alternative methods of sandwich moulding.

9.6.1 Mono-sandwich moulding. Ferromatic of Germany has developed and

patented a so-called mono-sandwich process which differs from the foregoing one in
principle and equipment.

Fig. 9.2

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Here too, two separate plasticising units deliver the two melts. The horizontally
placed injection unit of a standard injection moulding machine plasticises the
material forming the core. A vertical extruder, coupled to the main injection unit at the
head before the nozzle via a connecting block, forces the molten skin plastics into
the main injection unit, pushing back the plasticised core material. Now the barrel of
the main unit has both melts in a row. The connecting block also acts as the machine
nozzle. As the horizontal injection unit starts injection, the channel connecting the
two units is blocked and the path to the mould opened. The material in front viz. the
sheath plastics delivered by the vertical extruder, forms the forerunner, followed
immediately by the core melt which forces the first material as a thin, uniform layer
against the mould walls. Fig. 9.2 illustrates the successive stages of the process.

As obvious, the gate would leave a mark showing the core material. It is, however, of
no consequence if the feeding point is located at an invisible spot.

The main advantage of the process is the comparative simplicity of the equipment.
As the injection takes place without a break, there are no blemishes on the surface
due to hesitation.

The mould does not differ in any way from that for the first version.

9.6.2 Sandwich moulding with a single injection unit.

As shown in the mono-sandwich process, two melts placed one after the other in the
barrel, do not mix during injection. The same perception has been made use of by
plasticising two polymers in sequence in the same plasticing unit and achieving the
same effect.

The equipment consists of a conventional injection moulding machine in all features.

It is equipped with two hoppers which contain two different plastics raw materials
(Fig. 9.3). The feeding to the barrel takes place in turns and is directed electronically.
The sheath polymer (S) is fed first in exactly measured quantity, followed by the core
material (C) in similar manner. The sheath material for sealing the sprue is fed again.
The plasticised melt collects in the front part of the barrel in the sequence S-C-S.
The injection of the melt brings forth a sandwich moulding as that with the equipment
discussed in the outset.

Fig. 9.3
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9.7 Advantages of sandwich moulding.

 Cost reduction by using cheaper material/ reground material for the core
 Weight reduction through foaming of the core
 Cycle time reduction through weight reduction
 Elimination of sink marks with foamed core
 Combination of properties of two materials
 Enhanced aesthetic appeal through transparent sheath and coloured core

9.8 Applications.

 Furniture parts
 Outdoor furniture with UV-shield
 Household goods
 Sanitary ware like toilet seat, water cistern
 Housings for electronic goods with EMI shield
 Housings for office equipment.
 Automobile components like dash board parts, bumpers, fenders, spoilers
 Massive grips and handles

Chapter 10

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 Fusible Core Injection Moulding

10.1 The process

10.2 The equipment
10.3 The materials
10.4 The mould
10.5 Advantages and disadvantages
10.6 Applications

Injection moulding with fusible core or lost core is identical with the moulding process
where a core to form an internal detail such as a hole, internal threads or a channel
in the moulding is laid in the injection mould before closing it, injecting the melt and
then ejecting the moulding after cooling along with the core, which is extracted out of
it outside.

The difference in case of the fusible core is that it is used for forming complex
internal details which defy extraction of the core without damage to the mould and
the product. The only way to remove the core is by destroying it. The classical case
is the air-intake manifold of an automobile engine. It had been previously fabricated
out of two sheet metal halves and then joined together. It may be claimed that the
lost core moulding process has been specifically developed for this component after
it was found that it could be moulded out of certain plastics resisting high
temperatures. Glass filled polyamides 6 as well as 66 and polyester are the materials
being used now.

10.1 The moulding process consists of placing a preheated core, made of a low
melting temperature alloy corresponding to the shape of the ducts it is intended to
form, in the mould and then performing the standard injection moulding operation.

The fusible core is made of a Bi-Sn alloy with a melting temperature of 138°C. The
core is generally in one piece but for very complex shapes, it may be assembled out
of more than one components. The alloy has a high specific heat and very good
thermal conductivity. Though the melt coming in contact with it may have a
temperature above 260°C, the core does not melt because of its excellent thermal
conductivity and high specific heat. The poor thermal conductivity of the frozen
plastics layer over it provides it a protective sheath against the still molten material
behind it. The alloy has very low tensile strength and the core may bend or break
under the direct pressure of injected material. It is, therefore, essential that the
feeding system is designed in such a way that the incoming melt flows along it and
not impinge on it directly. It may call for multiple gating. For complex articles, the
gating is determined with the help of mould flow programmes.

The core is ejected along with the product and fused out in a bath, hot enough to
melt the alloy but not the polymer. The molten alloy can be collected and, after
cleaning, reused.

The last step in the production cycle is washing and drying of the product.

180
The process is finding application also in other fields besides the automobile sector.
Some plastics require cores out of alloys with higher melting points.

The continuous process consists of the following steps:

1. Cast the fusible core

2. Assemble the core if it consists of more parts
3. Place the core in the injection mould and overmould with plastics
4. Eject the moulding along with the core
5. Melt out the core in the melting bath
6. Remove the moulding from the bath, clean and dry it
7. Recover the alloy from the bath and return it to the stores

10.2 The materials.

The thermoplastics commonly employed are the ones which can withstand high
temperatures. Apart from glass filled polyamides 6 and 66, PBT is also being used
for specific applications. In view of the low tensile strength of the core alloy, the
flowability of plastics may be enhanced by means of certain additives in order to
inject them at lower pressures.

The low melting temperature alloy for casting of fusible core consists of bismuth
(58%) and tin (42%). Its melting temperature is 138°C. The melting temperature can
be manipulated by changing proportion of the ingredients.

The medium to melt out the core is modified polyglycol ether which can be safely
heated up to 160-170°C.

Water with some detergent is used for cleaning the mouldings after the core has
been melted out.

10.3 The equipment:

10.3.1 The injection moulding machine.

The moulding machine for the process is in no way different than the conventional
one. It is equipped with a shut-off nozzle if polyamide is being processed. As the
plastics moulded is usually of the glass filled variety, the machine should preferably
have bi-metal screw and barrel for a long life. The operations of taking out a moulded
part and laying in a fresh core is usually performed by a robot in mass production. It
may need greater opening of the mould closing unit than the normal one.

Fusible cores may weigh around 80 Kilogramme or more in some cases. It may not
be convenient to place and secure them in the mould on a horizontal injection
moulding machine. Especially for large production batches, a sliding table or a
revolving table vertical machine is found more suitable. The hot cores are liable to
bend under their own weight. The handling devices for transferring them to the
mould must support them at all points.

After the moulding process, the moulding containing the core is taken immediately to
a hot bath for removing the core by melting. The heat contained in the core helps
reduce the melting time.

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10.3.2 The melting bath
It consists of a rectangular tank with heating arrangement to melt out the core. The
fluid employed for transferring heat to the core is a modified polyglycol ether which is
quite stable till about 160-170°C. It does not react with the Bi-Sn alloy but undergoes
a reaction with iron (some assembled cores may have iron parts). Consequently, the
tank is fabricated out of stainless steel sheet. The time needed to melt the core
depends upon its weight. It is a slow process. The tank is chosen big enough to
accommodate a large number of mouldings so that with every cycle, when a new
moulding is put in, at least one in the tank has become free of the core and can be
taken out. The salvaged core material can be reused.

Another method of melting out the core is the high frequency induction heating. It is
fast but more expensive as the heater has to match the shape of the product.
Induction heating is not suitable if the moulding contains metallic inserts.

10.3.3 The washing equipment. After the last operation of core removal, the
mouldings contain traces of the melting medium which have to be removed before
the moulding is put to its end use. It is done with water and suitable detergents in
simple washing machines. Water can be recovered by methods such as vacuum
distillation.

With glycol ether as the metal core melting medium, no additional cleaning chemical
are required with water. Cleaning of the mouldings is achieved by dipping in
successive water baths.

The cores may be procured from vendors but for mass production, it is economical to
cast them in own shop parallel to the moulding section. An advantage of this
arrangement is that the freshly cast core need not be reheated to 80°C before
loading in the mould. The casting machine forms part of the manufacturing
equipment for production of the lost core mouldings.

10.3.4 The equipment for core casting.

The flowability of the molten Bi-Sn alloy is a million times higher than that of the
average polymer. It needs very little pressure for filling the mould. The process
resembles injection moulding with the difference that the alloy is melted outside in a
separate tank and conveyed, through a gear pump, to the mould held in the mould
closing unit of a moulding machine, by means of metal pipes which are heated and
insulated. However, unlike in injection moulding, the filling of the mould is not central
as in conventional single cavity injection moulds for plastics but from below to avoid
formation of bubbles on the surface of the casting. The solidified casting is
transferred from the mould to the injection moulding station by a robot as mentioned
before.

10.4 The moulds.

10.4.1 The injection mould.

The mould for overmoulding of the fusible core has no special features other than
the conventional ones for glass-filled polymers. The multiple gating may necessitate
a hot runner feeding system with shut-off nozzles to prevent drooling. The flow of the

182
melt should be along the core, so that the core is supported by the sheath formed by
the advancing plastics. A mould flow analysis prior to the design is recommendable.
The mould temperature should be maintained as recommended for the particular
plastics.

10.4.2 The mould for the fusible Core.

The mould consists of two halves with ejection mechanism like an injection mould for
thermoplastics. The injection, however, takes place from below under low pressure.
The alloy has very low contraction which obviates a holding pressure but the filling
pressure has to be kept up till the gate is frozen.

The mould is maintained at 70-80°C by circulation of hot medium in a network of

holes or channels in the core and cavity plates or through electrical heaters. The tool
is not subjected to high pressures and can, therefore, be safely fabricated out of
non-ferrous alloys which do not react with the alloy of bismuth and tin. Eluxidated
aluminium has proved suitable for the application with the added advantage of better
heat conductivity resulting in shorter moulding cycles.

The ejection arrangement should ensure a balanced demoulding without distortion

as the bismuth alloy has a very low tensile strength.

Note. In principle, it is possible to combine the two manufacturing steps, viz. core
casting and overmoulding in one mould like in the two component moulding. Special
custom made equipment, combining the two processes, may prove profitable for
very large quantities.

10.5 Advantages and disadvantages.

10.5.1 Advantages. The fusible core moulding process has the following
advantages:
 Freedom of product design. No compromises need be made to extract the
core.
 Compact moulding without a joint
 Elimination of the joining operation of two component halves
 Accuracy of external and internal dimensions
 Good surface finish both outside as well as inside
 Injection mould uncomplicated
 The Bi-Sn alloy can be used again and again

10.5.2 Disadvantage:
 Very high investment in equipment

10.6 Applications.
Automobile components, housings for pumps, water distribution heads, oil channels
etc.

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 Chapter 11

Injection Moulding of Structural Foams

11.1 The process

11.1.1 Foaming with chemicals
11.1.2 The equipment
11.1.3 The mould
11.1.4 Advantages and disadvantages
11.2.1 Foaming with fluids
11.2.2 The equipment
11.2.3 Alternative equipment for foaming with fluids
11.2.4 The mould
11.2.4 Advantages and disadvantages
11.3. Product design for structural foam moulding
11.4 Applications of structural foam mouldings

11.1 The process.

Injection moulding of structural foams is a process to mould articles in thermoplastics
with a compact outer layer and a foamed interior, resembling a honey comb. In
principle, the process is applicable to all thermoplastics. However, plastics most
commonly used are PS, ABS, PC, PP and PVC.

There are two variations of the process which differ in execution, equipment and
ingredients but deliver similar results.

11.1.1 Foaming with chemicals.

Chemical foaming agents are azo-compounds, sodium bicarbonate and mixtures of
organic acids and their derivatives such as the citric acid. They decompose at a
certain temperature releasing gases like nitrogen, carbon dioxide, ammonia and
steam and some solids. The gases produce a cellular structure in the melt.

Chemical foaming agents are added to the polymer before injection moulding, either
in powder form whereby an adhesive agent like glycerine acid is used as a wetting
medium or in the form of master batches with an appropriate polymer as carrier with
different concentrations so that a desired cellular structure can be achieved. Those
with very low concentrations are used primarily to eliminate sink marks in thick
walled mouldings. The amount of foaming chemicals may vary between 2 to 5 per
cent by weight. They can be added to the polymer pallets like other master batches.
The screw of the moulding machine acts also as a mixer. The foaming agent lowers
the viscosity of the resultant melt.

The melt, impregnated with the foaming chemical, is injected into the mould, filling it
partially, usually up to about 80%. The pressure required is obviously low. It should
be less than the pressure developed by gases when the foaming agents evaporate.
The outer layer of the melt in contact with the relatively colder mould cavity walls
solidifies whereas the gases released due to decompression of the melt in the mould
lead to the foaming of the interior thereby increasing its volume and filling up the

184
mould cavity completely. The gas develops pressure of about 15 bar and acts as the
source of the holding pressure. No holding pressure need be applied by the
moulding machine.

The temperature of different zones of the barrel of the injection unit is set in such a
way that the decomposing temperature of foaming chemicals is arrived at after the
start of compression zone. This prevents the released gases from escaping through
the hopper. In any case, the chemicals must be fully degraded before injection as
any undecomposed residue may appear as a blemish on the surface of the product.

The moulding cycles for the foam injection moulding are considerably shorter than
for compact injection moulding because less material has to be cooled and the
holding time is eliminated. The gases keep the plastics in contact with the cold mould
surface till the end. Injection moulds made of light metal alloys dissipate the heat
faster and contribute to further reduction in cycle time.

The different phases of the moulding process are:

1. Injection of the plasticised melt into the mould with partial filling.
2. Release of gases, foaming of the melt resulting in complete filling of the
cavity.
3. Cooling of the melt with simultaneous holding by gases.
4. Recharging and plasticising for the next shot.
5. Ejection.

The moulded product may be compared to a bone in its structure. The outer surface
is smooth whereas the interior is porous. The product possesses higher mechanical
strength with less weight as compared to a compact moulding. The final density
achieved may be around 60% of the compact polymer. The density is, however, not
uniform in the structure of the moulding. Porosity is maximum in the core and
decreases gradually towards the outer surface. In other words, the density is
maximum on the surface and minimum in the core.

11.1.2 The injection moulding machine.

Any conventional moulding machine with a three zone screw would perform the
operation satisfactorily. As the injection pressure required to fill the mould cavity of a
thick walled article partially is not very high, the locking force of the machine can also
be low. In other words, an injection unit with the biggest screw will not only be
adequate but would also increase the output. Alternatively, the moulding machine for
foam injection can have bigger platen for the same locking force.

As the foaming agents decrease the viscosity of the melt, injection can take place
with less pressure. Alternatively, the temperature of the melt can be lowered but this
measure has an adverse effect on absorption of the foaming agent in the polymer.

Desirable additional features for a moulding machine, specifically meant for

structural foam moulding with chemicals, are static mixers and screws with barriers.
These measure enhance the homogeneity of the melt and consequently the
uniformity of the cellular structure of the moulding.

185
A shut-off nozzle is mandatory with the injection moulding machine as otherwise the
melt may be forced out of the barrel by the gases under pressure.

Gravimetric or volumetric dosing systems for the master batch make the mixture
more homogenous, which fact is reflected positively in the product.

11.1.3 The injection mould.

The moulds for structural foam moulding are essentially identical in design to those
for compact injection moulding. As the pressures involved are much lower than in the
later case, non-ferrous metals like aluminium and alloys may be used for mould
construction. It offers manifold advantages. The higher heat conductivity of
aluminium helps reduce the cooling period. The machining time for aluminium is also
much less than that for steel and the mould too is much lighter, facilitating easy
handling. The cooling can be laid out quite close to the cavity surface to make it
more effecient as the mould is not subjected to very high compressive forces.

Though the moulds for foam moulding have ejection and feeding systems like those
for conventional injection moulds, the hot runner nozzles must be equipped with
positive type needle valves to eliminate leakage of the melt under gas pressure
when the mould is in the opened state. Also the sprue bush of the hot runner system
needs an effective closure.

The runners and gates are required to be larger than those with compact moulding
because the pressure driving the melt is quite low. The moulds must be foreseen
with very efficient venting also out of the same consideration. Entrapped air can
hinder complete filling of the mould and good reproduction of surface details. Hence
adequate escape paths for the enclosed air must be provided at the points where the
air would be driven to by the expanding melt.

The surface of a moulding with foam is not as smooth as that of a compact one. A
structured surface design can camouflage this visual flaw. The moulds for this
process are never polished. If not structured, the cavity surface of the mould is kept
rough.

11.1.4 Advantages of moulding with chemical foaming agents.

 Weight reduction due to lower density

 Cycle time reduction
 Elimination of sink marks
 Higher stiffness and bending strength
 No local stresses near gate
 Uniform shrinkage, less than that with compact moulding
 Lower heat conductivity, better thermal insulation
 Bubbles arrest the propagation of cracks
 Less chances of degradation due to lower melt temperature
 Less stresses hence less distortion
 Possible to mould thicker walls (5-15 mm.) than by compact moulding.
 More dimensional accuracy, narrower tolerances.
 Lower mould cost

186
  Lower machine cost

Disadvantages.

 Lower noise absorption

 Unattractive surface finish, silvery streaks due to ruptured air bubbles
 Solid residue from decomposition of the foaming agent can cause surface
blemishes.

11.2.1 Foaming with fluids.

Though economical in equipment investment, foaming with chemical has some
drawbacks. On decomposition, the chemicals release not only gases but also some
solids which can deposit on the surface of the moulding and produce blemishes. The
level of foaming is also limited. The alternative process of foaming with fluids does
not suffer from these limitations.

In the process employing fluids, a pressurised gas, nitrogen or carbon dioxide, is

injected into the melt in the metering zone of the plasticising unit of a modified
injection moulding machine. The high pressure in the barrel leads to the complete
dissolution and uniform dispersion of the gas in the melt. The rotating screw
homogenises the melt-gas mixture.

The melt is injected into the mould, filling it partly. The finely distributed gas
nucleates and creates microcellular structure. The outer layer of the polymer in
contact with mould walls remains compact and smooth. Viscosity of the foamed melt
is lower than that of the pure melt with the result that the expanding melt flows
further and fills up the mould completely.

As the gas pressure in this process is much higher (150-200 bar) than that
generated by the decomposing chemicals in the chemical foam moulding process,
articles with wall thickness lower than 5 mm can also be moulded satisfactorily. The
higher pressure also leads to higher dimensional stability. The wall thickness, the
size of bubbles and the density of the product can be regulated through moulding
parameters to some extent.

11.2.2 The equipment.

The injection moulding machine for moulding with pressurised gases differs from the
conventional moulding machine primarily in respect of the plasticising unit. The
screw is longer, with an L:D ratio of about 24:1 to 28:1. A mixing section forms the
end of the screw. The barrel is equipped with one or more gas injection nozzles in
the metering zone. The last section of the barrel is equipped with cooling blowers
along with the heaters so that the temperature of the melt-gas mixture, which has
lower viscosity, can be adjusted down. The nozzle is invariably of positive shut-off
type to prevent leakage of the melt under the gas pressure.

As obvious, the moulding machine is a specific one and cannot be employed for
conventional processing.

The gas generation unit does not form a part of the machine though the controls
for the gas may be integrated in the machine control panel.

187
The above description relates to the machinery being manufactured by Engel of
Austria. It must, however, be added that many other variations of the equipment
have been developed by other machine manufacturers. They all adhere to the basic
principle of injecting the fluid into the melt before its entry in the mould.

11.2.3 Alternative equipment for fluid foaming.

A way to circumvent the drawback
of investment in a special machine
is to devise an independent fluid
injection module which can be
coupled with a conventional
injection moulding machine. It has
to fullfill the following functions and
criteria for successful operation:

1. Load the fluid into the melt at the

end of the plasticising phase.
2. Prevent the melt under pressure Fig. 11.1
from getting into the gas injectors
and pipelines.
3. Provide adequate surface area for diffusion of the fluid within a short length.
4. Ease of coupling and maintenance.

One of the more successful designs in use has been developed by the Institute of
Plastics Processing Aachen (IKV) of Germany. The device (Fig. 11.1) consists of a
sintered sleeve housed in a torpedo which forms an intermediate connector between
the barrel of the plasticising unit and the machine nozzle. The system forms the path
of the melt through the porous sleeve, which is injected with the foaming fluid from
outside as well as from inside.
The sleeve distributes the
fluid all along its area, thus
loading the melt with fluid, not
at one point as in the previous
case, but all along its internal
and external surface. A static
mixer incorporated in the
nozzle homogenises the
mixture which remains in
single phase till it enters the
mould. The fall of pressure in
the empty mould creates a
thermodynamic instability
which in turn leads to a two
phase mixing. The gas
nucleates, builds cells and
creates a foamed structure. It
also takes over the function of the holding Fig. 11.2

188
pressure. Figure 11.1 represents the complete unit and figure 11.2 illustrates details
of the special attachment.

The system is being marketed by Sulzer of Switzerland.

11.2.4 The mould.

The injection mould for fluid foaming is essentially the same as for the method of
chemical foaming. Here too, the pressures involved are much lower than those with
the compact moulding process. Light metal alloys with higher heat conductivity than
that of the steel for mould plates serve the purpose adequately and also decrease
the cycle time, which is further shortened by the absence of a separate holding time.
The cooling network can be placed closer to the mould cavity walls.

11.2.5 Advantages of foam moulding with fluids.

Basically, the moulding process with fluids offers the same advantages as that with
chemicals. However, as only gases are injected in the melt, there is no solid residue
left which could give rise to surface blemishes. The proportion of gas and its
pressure can be regulated to adjust the final composition of the melt and through
that, the inner structure of the moulding.

The main disadvantage is the cost of the special equipment which can only be
used for foam moulding. The special screw does not permit the use of the machine
for conventional moulding. However, with the special attachments like Optifoam, a
conventional moulding machine can be employed.

11.3 The product design for Structural Foaming. Apart from the general rules
valid for moulded articles, following guidelines apply to those produced by structural
moulding:

 Minimum wall thickness 4 mm. as the skin is 1-1,25 mm. thick; for chemical
foaming agents at least 5 mm.
 Thick and thin sections can co-exist without leading to sink marks.
 All bends and corners well rounded.

11.4 Fields of Application for foamed Mouldings.

Packaging and furniture industry, medical appliances, housings of electrical and
electronic gadgets, large containers for material handling, pallets and thick walled
large articles for diverse fields where the surface finish is of secondary importance,
sports goods, toys etc.

189
 Chapter 12

Gas-assisted Injection Moulding

Water-assisted Injection Moulding

12.1 The process

12.2 The materials
12.3 The equipment
12.4 The mould
12.5 The product Design
12.6 Advantages and disadvantages
12.7 Fields of application
12.8 Trouble shooting
12.8 External gas moulding
12.9 Water injection technique

12.1 The process.

The compact injection moulding viz. the traditional process, has some limitations; it
cannot produce thick walled mouldings without sink marks and voids. Furthermore,
there is a size limit to the moulding of thin walled large components. These
shortcomings can be overcome by the process termed as Gas Injection Technique
(GIT). The thick walled component is rendered hollow by injection of gas in the
interior, creating a hollow core so that the product retains its outside dimensions
without having accumulation of material which would lead to sink marks and voids.

The process is practiced in a few variations as described below.

12.1.1 The short shot

method.
In its basic version, the GIT
resembles the sandwich
moulding (Chapter 8). The
mould cavity is filled partially
(50-95%) with the plasticised
polymer (Fig. 12.1) and then the
second component--in this
case, a neutral gas--is injected
in the fluid core of the melt, either through the F.ig 12.1 second channel
of a special machine nozzle as shown in figure 12.2 or through
a separate injection device, which drives it further, pushing
it outwards to the cavity walls and filling the mould as it happens with sandwich
moulding. The gas pressure, which acts as a constant holding pressure, is
maintained till the moulding has
cooled to a rigid, undeformable
article. The gas is evacuated
before opening of the mould,

Fig. 12.2 190

either to the atmosphere or back to the storage. The various stages of the process
are:

1. Partial filling of the cavity with melt

2. Injection of compressed gas after the pressure in the mould has reduced
below the gas pressure
3. Holding phase with the gas
4. Evacuation of the gas
5. Ejection of the moulding

To ensure exact (partial) filling, the screw moves till the end of the cylinder, leaving
no material cushion.

The pause between injection of melt and the introduction of gas leaves a mark on
the surface of the moulding. However, injection of the melt and the gas cannot be
undertaken simultaneously as it causes turbulence.

The gas pressure may be in the range of 25 to 300 bar.

The process in the described form is also termed as the Standard GIT.

As obvious, the sprue gate after removal would leave a hole on the moulding. It can,
however, be covered by a second injection of the melt as practiced in sandwich
moulding (see also 8.1).

12.1.2 Gas injection technique with

plastics expulsion.
As pointed out before, the gas injection
technique of partial filling may cause
surface blemishes, the so-called
hesitation marks or splays, which are
generated because of the time gap Fig. 12.3
between the end of melt injection and the
start of gas injection when the melt is
pushed up from the core to the surface. A
variation of the basic process to eliminate
this defect comprises filling the cavity
completely with the melt (Fig.12.3) and
then injecting the gas into the melt core.
The melt, displaced by the gas, is led to
an auxiliary cavity, also called an overspill
cavity, the inlet path to which is opened
before gas injection (Fig. 12.4). The two Fig. 12.4
diagrams portray this version of GIT in successive steps.

The main advantage of the process is elimination of the surface defects. Moreover,
as the cavity is filled completely, holding pressure can be applied and thin sections
brought to solidification before injection of the gas. With this, the undesireable finger
effect can also be hindered.

191
The process is accompanied by some drawbacks and disadvantages. The moulding
machine has to plasticise and inject as much material as with conventional injection
moulding. The expelled material may be counted as a loss. The walls of the final
product are generally thicker than with the partial moulding GIT process.
Consequently, the cooling time is also longer. The mould, too, is more complicated
with additional cavities and the shut-off arrangement.

In order to salvage the expelled material, the overspill cavities may be in the form of
some article of use either with the main product or elsewhere. However, very little
control is possible over its quality as all parameters have to be set for the main
cavity.

12.1.3 Gas injection technique with melt push back.

This method offers an alternative to
transferring the melt to overspill cavities,
thus saving material besides delivering a
surface finish free of blemishes. The
process is similar to the forgoing one
with the difference that the injected gas
pushes the melt back into the plasticising
unit while creating a hollow path (Fig.
12.5). There are, however, some
stringent limitations to the process and
the product which prevent its universal Fig. 12.5
application.

 The gas has to be injected at the last point of the melt path.
 The product cannot have side branches.
 It is practicable only with single cavity moulds. There can be only one injection
point.
 The return path to the plasticing unit, viz. the sprue and runners, must remain
molten.
 The gas may penetrate into the plasticising unit.
 The cooling time is longer.
 The material is susceptible to thermal damage.

12.1.4. Gas injection technique with retractable core.

Yet another variation of the basic GIT process
consists of filling the mould cavity having a
retractable core, with the plastics melt
completely when the core is in the front
position. In other words, the volume of the
cavity is reduced at the time of filling. The
core is retracted simultaneously as the gas is
injected. The space vacated by the core is
filled by the melt being pushed out by the gas.
Because of complete filling without
interruption, the surface finish of the article is
Fig. 12.6

192
uniform and there are no marks of the melt coming out on surface after injection of
the gas.

This variation of GIT has limited application. All articles do not offer possibility of
incorporation of cores. The retracting cores leave their mark on the surface of the
article. The mould too is more expensive. Diagram 12.6, with the core in pulled-back
position, illustrates and explains the process.

The setting of machine parameters, especially the start of the gas injection, its
pressure profile, the pressure, temperature and viscosity of the melt at the time of
gas injection as well as the mould temperature exercise a decisive effect on the
surface quality, length of the channel hollowed by the gas, wall thickness of the
moulding and its uniformity. Fillers influence rheology of the melt and consequently
the wall thickness. They raise the thermal conductivity of the melt and accelerate the
heat dissipation. The faster cooling results in thicker frozen layer. The geometry of
the article too influences the resultant wall thickness.

In view of the myriad variables, the optimal parameter setting is still a matter of trial
and error.

12.1.5 Process variations.

There are several variations to the basic process, developed and patented by
different companies and bearing different names. Some of them are:
 GIT Gas Injection Technology
 GAIM Gas Assisted Injection Moulding
 GAM Gas Assisted Moulding
 GAIN Gas Assisted INjection moulding
 GID Gas Innen Druck (English: Gas Internal Pressure)
 GIP Gas Injection Process
 CINPRES Controlled Internal Pressure moulding
 EGM External Gas Moulding
 WIT Water Injection Technique

All processes named above, except the last two, are based on the same principle,
viz. creating hollows inside the moulding by injection of a gas. Developed by different
manufacturers, they differ in details, equipment and conditions of licensing.

12.2 Materials.

12.2.1 Plastics.
It is possible to mould practically all thermoplastics and also some thermosets ( they
must have a fountain flow) with the gas injection technique. Thermally sensitive
materials like PVC are prone to degradation, especially with blow-out and push–back
versions of the process. Filled and unfilled thermoplastics, amorphous as well as
semi-crystalline, have been successfully moulded. Grades with lower melt flow indici
are better suited for the process as the melt has more strength and the risk of the
gas blowing through is lower.

The most common materials processed commercially with GIT are PP, HIPS, ABS-
PC blends, PA 6 and PA 66.

193
12.2.2 The gas.
Compressed air, though the cheapest alternative, has proved hazardous because of
the oxygen component. It reacts with certain plastics and leads to complications.

Nitrogen, although more expensive, is absolutely neutral, inert and safe as it does
not react with any of the plastics. It is in abundant supply, forming major part of the
air. It can be extracted with suitable equipment in house or purchased in cylinders or
tanks. Its disposal poses no problems as it can either be let out directly in the
atmosphere or re-routed to storage for reuse.

A major drawback of nitrogen is its very low specific heat or the cooling capacity.
Nitrogen can also be chilled before injection to expedite cooling. It needs special
cooling equipment and additional relief valve for venting of excessive pressure
generated when the liquid gas turns into vapour.

12.3 The equipment.

12.3.1 The injection moulding machine.

In GIT too, a normal injection moulding machine forms the key unit. The accuracy of
the product is directly dependent on the accuracy of the shot volume, particularly in
the basic process. A closed loop machine yields more consistent results. As the
injection takes place without a material cushion and the tip of the screw touches the
end of the barrel bore, it is vital that the non-return valve functions impeccably. Any
leakage will have an adverse effect on consistency of production.

Injection of the melt and subsequently that of the compressed gas can be carried out
in various manners. The method, which does not call for a modification in the basic
moulding machine, involves injection of the melt through a shut-off nozzle, whereby
the filling taking place through a runner and a side gate. The nozzle is closed and the
gas is injected by means of a separate, independent gas injection nozzle placed at
a convenient point in the cavity or in the runner. The disadvantage in the former case
is that the hole left by the gas injector cannot be overmoulded. The location for gas
injection is chosen so that it is either invisible in normal position of the component in
use or it does not influence the function adversely.

12.3.2 The special nozzle.

Gas injection moulding can also be carried out by equipping the moulding machine
with a special nozzle having separate flow paths for
the melt and the gas (Fig. 12.7). As described in
section 12.1, the injection takes place through a
sprue gate. After injection of the predetermined
volume of the melt in the mould cavity, the path of
plastics in the nozzle is blocked and that for the gas
is opened when the pressure prevalent in the cavity
has come down below that of the gas. The
pressurised gas pushes the fluid material from the
core forward and upwards, filling the cavity
Fig. 12.7
completely. Thereafter, the gas acts as the medium

194
for the holding pressure till the moulding is rigid enough to be ejected without
distortion.

The machine controls have to be modified for operation of the nozzle and injection of
the gas.

12.3.3 Gas injection equipment.

Nitrogen can be obtained in cylinders or tanks. It has to be compressed to the
required level, usually to 300 bar and in rare cases up to 400 bar. It needs pressure
regulation during injection and holding phases. In other words, a gas injection unit
consists of:

a) compressor
b) pressure regulator
c) timers and controls

The controls of the gas equipment must be synchronised with those of the injection
moulding machine. Special machines have an interface for that but it is possible to
incorporate it in the normal moulding machines also. Machines, especially built for
GIT, have all relevant controls for the gas integrated in their control systems. The
switch-over from melt injection to gas injection can take place either time bound or
distance related. It can also be connected with the machine hydraulic pressure or the
melt pressure in the mould cavity over a pressure transducer built therein.

GIT specialised injection moulding machines have also the provision for storage of
data of a number of mould settings.

In case of regular consumption on a large scale, it is more economical to generate

nitrogen in house with the help of special equipment, which would extract the gas out
of air, compress it and regulate it. Depending upon the size, the equipment can act
as central supplier to a number of machines. The regulation takes place individually
through a pressure regulation module with electrical controls, which can also be
mounted on the mould.

12.3.4 Gas injectors.

Unless the gas is injected into the melt through the special machine nozzle as
illustrated in figure 12.1, provision must be made in the mould to introduce it either in
the runner or directly in the mould cavity. It is executed by incorporating an injector in
the mould. Its simplest version is a slender hollow tube with a core pin which leaves
an annular gap of 0,02-0,04, which is wide enough for the gas to pass but too narrow
for the melt to get in. The core pin moves up and down with flow of the gas and
performs a cleaning operation with each stroke.

The narrow-gap injector may get chocked if used with “melt expulsion GIT” because
of the high melt pressure involved for filling the cavity completely.

The injector is housed in the cavity plate in direction of ejection.

A variation of the above design is a hollow tube closed with a sintered plug. The
porosity of the plug enables passage of the gas. The plugs get clogged after some

195
time and must be changed or cleaned. The design of the porous injector facilitates a
ready exchange of the plug.

A more sophisticated version of injector consists of a hollow

outer tube with a movable central mushroom shaped valve,
which is kept closed during injection of the melt by a spring
(Fig. 12.8). When pressurised gas is injected through it, the
valve opens and the gas drives the melt from the core in the
unfilled parts of the mould cavity, creating thereby a hollow in
the moulding. The injector also serves as a conduit for gas
evacuation. To this end, the lower end of the valve is shaped
like a piston of a pneumatic cylinder. Pressurised gas,
introduced through a channel below the piston pushes up the
valve, forming an exit path for the gas from the moulding.
Fig. 12.8
A dual purpose injector nozzle, developed by Cinpres, has
a spring loaded mushroom valve which keeps the injector
tube closed till it is pushed open by the incoming gas. For
evacuation of the gas, the injector nozzle assembly,
consisting of the valve, tube and its holder at the base, is
pulled back by a small hydraulic cylinder fitted at the back
of the nozzle, thereby exposing the exhaust path covered
by the nozzle base in the front position. Figure 12.9
illustrates the mode of operation in principle.

The configuration of the product may not permit location of

Fig. 12.9 the injector in direction of the mould opening. Injectors
placed at an angle to the axis of opening must be retracted
before ejection stroke can begin. The retraction can be effected mechanically,
pneumatically, hydraulically or electrically.

Injectors offer several advantages over special dual purpose machine nozzles such
as:

 Small size
 Flexibility in choice of optimal location for gas injection
 Ease of assembly and replacement
 Incorporation of more than one injector if dictated by product configuration
 Possibility of gas injection in multi cavity moulds
 Saving in cost compared to special nozzles

The tubular injectors leave a small hole in the product.

12.4. The mould design

Gas assisted injection moulding can be rightly regarded as an extension of the
standard injection moulding process. Consequently the moulds for GIT are
essentially similar to those for the parent process with suitable modifications.

The mould for the process variation with partial filling, carried out with dual purpose
machine nozzle, is a single cavity one. It is identical to a standard injection mould in

196
all respects. The core and cavity plates can, however, be fabricated out of non-
ferrous alloys as the pressures involved are low. The higher heat conductivity of
these alloys contributes also to the cooling efficiency.

Partial injection GIT moulds with separate gas injection can be of multicavity type.
The feeding may be through conventional runner network or also by means of a hot
runner system with shut off nozzles. The crucial requirement is the accuracy and
uniformity of the shot in all cavities. It is extremely important to fill the cavity
homogeneously so that the gas bubble can be guided as designed in order to
achieve uniform wall thickness. Fill the cavity from bottom to top against the force of
gravity to achieve a swell flow. The machine nozzle should be of positive closing
type.

As far as possible, the gas injector should be positioned in direction of ejection. It is

generally housed in the cavity plate on the moving half of the mould. Most standard
injectors have a threaded base for assembly. Their size permits their accommodation
between cooling lines. The rule for their location is that the gas should drive the melt
towards the unfilled extremities of the cavity. The injector should be placed in the
vicinity of injection so that the gas bubble follows the melt flow and expands in one
direction only. More than one injectors should be employed sparingly and only in
situations when the gas channels remain independent.

If the configuration of the article makes it unavoidable to place the injector across the
axis of ejection, arrangement has to be made to pull it back before the mould opens
or before ejection starts. It may be achieved mechanically, pneumatically or
hydraulically as the case may be.

The timings of start of the gas injection, its pressure, volume, duration and exhaust
are set on and regulated by the gas control unit.

Injection moulds for GIT are cooled in the conventional manner. Any thin sections of
the article, which should not be blown, should have more intensive cooling so that it
is solidified before the gas is injected. The measure helps prevent the finger effect.

The relatively low pressure of the gas, which is used to fill the cavity completely,
makes it imperative to provide efficient venting in the mould so that filling can
proceed evenly and cavity details are reproduced faithfully. Entrapment of air can
lead to usual defects.

Injection moulds for Melt pushback technique are essentially the single cavity type
as driving back the melt from more cavities into a single source will cause mutual
hindrance and blockage. The location of the gas injectors must drive the melt in the
direction of the sprue. In all other respects, the mould is similar to a cold runner
mould for standard injection moulding.

Injection moulds for the Melt expulsion process are of two types, viz. with overspill
cavities of fixed size and alternatively of variable size. They are linked to the main
cavity through a gate-like small channel which may be an open or shut-off type. Its
size and shape influence filling as well as gas propagation.

197
 From aesthetic angle, it is desirable to have the “gate” as small as possible so that
the unavoidable mark on the main product does not mar the appearance. Too small
a channel may, however, give rise to jetting. It may also retard the flow of gas and
thus give rise to thicker walls. Too large a gate tends to let the melt out in the
overspill cavity before injection of the gas and freeze and close prematurely.

It is recommended to keep the length of the gate as short as possible, say about 1
mm. The depth and breadth may be 2-3 mm. The edges should be rounded off.

The shut-off gate employs a sluice operated by a pneumatic or hydraulic cylinder

controlled by the machine. Its operation is linked with the injection of the gas.

The overspill cavity with fixed volume does not add to the complexity of the mould
but its size must be pre-calculated accurately. The variable volume overspill cavity,
on the other hand, provides freedom in setting of parameters to achieve the desired
wall thickness but necessitates moving devices such as a hydraulic cylinder to
operate the slide varying the volume of the cavity. The cylinder has to be operated
and controlled in relation with gas injection. It bestows a measure of flexibility but
also adds to the cost of the mould as well as to the complicacy in setting.

Demoulding takes place predominantly with ejector pins of adequate size. These
also serve as self cleaning venting devices. Ejectors are also placed under the
auxiliary cavities, which should be provided with adequate draft for safe ejection.

12.5 The product design.

The gas injection technique is primarily suitable for two
types of moulded articles.

 Thick walled, long

and slim uni-
directional articles
like hollow rods,
closed tubes, Fig.12.10
handle bars, table
legs, pedals etc.
(Fig. 12.10).
 Thin articles with large area, foreseen with thick walled gas channels (Fig.
Fig. 12.11 12.11)

12.5.1 Longitudinal articles.

The guiding principle for design of articles to be moulded by GID is the shape
favourable to the fluid flow. The most natural path that a fluid under pressure, be it a
gas or a liquid, would carve out for itself in a plastics melt is round. A fluid can push
out the melt which comes in its path in a directed manner but side branches cannot
be controlled effectively. Some guidelines for an effective product design are given
below.

198
  As the gas forms preferably a circular channel, the outer
contour of the product should also be as close to a
circle as possible so that the wall thickness is nearly
uniform all over. Material accumulation leads to same
defects with GIT as with standard injection moulding
(Fig.12.12).
 If a circular cross section is not
feasible, the outer corners
Fig. 12.12should be
rounded off generously to reduce material accumulation
(12.13).
 If the product profile consists of multiple sections, the
meeting points of the sections or the transition zones should
Fig. 12.13
be foreseen with as large radii as possible. Sharp corners
yield thin walls (Fig. 12.14).
 Bends represent critical areas. Sharp bends result in
uneven wall thickness whereby the wall on the inner side
may become too thin and that on the outer side too thick.
Select the greatest possible bend radius
(Fig. 12.15).
 Maximum width of a moulding can be 3-5
times its height. The Fig. 12.14 length should not
exceed five times the height.
 The ratio of the article wall thickness and the gas channel
breadth should be 1:2 to 1:3
Fig. 12.15

12.5.2 Large flat articles.

Thin walled articles with large areas, when injection moulded in standard manner,
call for very high injection pressure and large machines with high clamping force.
The resultant mouldings contain stresses which cause distortion. Multiple gating,
which is often unavoidable for filling, brings weld lines and weak spots. Such
products, suitably modified, can be easily moulded in GIT, without the defects cited
above.

The redesign of the articles involves incorporation of ribs which discharge a dual
function. They stiffen and strengthen the flat area and serve also as channels for
conveying the gas. The pressurised gas pushes the melt out and thus fills the initially
incompletely moulded article.

The advantages are obvious. As the thin-walled article need not be moulded
completely, the injection takes place at lower pressures. Consequently, a smaller
machine with lower clamping tonnage may be employed. Simultaneously, lower
injection pressure results in lower stresses and less distortion. The gas pressure,
which remains same at all points unlike the holding pressure, ensures an overall
uniform shrinkage. Following are some guidelines and rules for design of GID
compatible large, flat articles:

199
  Avoid material accumulations; provide for uniform wall thickness for the entire
moulded part.
 Thick-walled large areas are unfavourable as the penetration of gas
progresses uncontrolled and undefined. Finger effect, that is, breaking away
of gas in several small channels from the main stream, is quite likely.
 Reduce wall thickness of a large article and provide ribs which strengthen and
transport gas. The article wall thickness should be uniform and not exceed 3
mm. as far as possible. The root of the rib is designed as a structure which
acts as gas channel. Likewise Fig. the 12.16
corner, where two walls meet, can be
fashioned as a gas channel. Figure 12.16 illustrates some examples.


The thickness and height of the ribs are correlated to the thickness of the article.
a) The thickness of the rib (t) should lie between 0.5 to one times the
thickness of the wall (T) it stands upon. Adequate taper for ejection must be
foreseen.
b) The height of the rib (h) above the gas channel may vary from 5 to 10
times its thickness.
 The gas channel at the root of the rib may be 2 to 3 times as high (H) as the
wall thickness (H=2-3xt). The width (W) of the channel should equal its height.
The outer corners should be well rounded.
 The junction of the channel and the product wall should be provided with
small radii to eliminate the notch effect. A big radius increases the wall
thickness and with that, the risk of
the gas penetrating sideways in the
product wall.
 The ribs should be so placed that
gas and the melt are driven
towards unfilled extremities of the
cavity (Fig. 12.17).
 Channels closer to the gate would Fig. 12.17
take the melt farther than those
away from it, resulting in uneven filling. The flow can be equalised by varying
the size of the channels.
 Labyrinthine ribs and those laid out in zigzag or grid pattern should be
avoided as far as possible. Gas bubbles proceeding from two directions may
cause choking, air traps, burn marks and sink marks at locations where gas
could not reach.

12.5.3 Functional elements. Theoretically, it is possible to integrate functional

details like fastening lugs, brackets, hinges, pins and holes, snap fit elements etc. in
the articles for GIT moulding but these are likely to cause problems during cooling
and shrinkage. These form zones of material accumulation but unlike in standard

200
injection moulding, these cannot be taken care of with compensating holding
pressure. Sink marks, deformations and dimensional inaccuracies become
unavoidable without additional measures such as individual gas injection.

Holes across the flow of the gas can be made as in conventional moulding by means
of sliders but the cross pins divide the gas bubble unpredictably. It may lead to
critical and unacceptable wall thickness variations.

In conclusion, it may be underlined that many of the processing faults encountered in

GIT are the outcome of inadequate product design. It is often very difficult to remove
or subdue the defects by changing processing parameters.

12.6 Advantages of the gas assisted injection moulding.

 Elimination of sink marks and voids in thick mouldings

 Reduction of weight, material saving in the range of 20-30%. More rigidity with
less weight due to hollow structure
 Large components can be moulded with fewer gates and fewer weld lines.
 Cheaper hot runner aggregate because of fewer nozzles.
 Faster moulding cycle because of less material to cool.
 Greater stiffness with less material by dint of hollow ribs.
 The gas is a million time less viscous than the melt and does not lose
pressure through flow, hence uniform holding pressure through the gas at all
points, which is lower and remains effective till the end independent of gate
closure, consequently uniform shrinkage, lower stresses and less distortion.
 90 % of the gas can be retrieved and reused.
 Closer tolerances because of uniform holding pressure and uniform
shrinkage.
 Lower clamping force, smaller injection moulding machine with less energy
consumption.
 Cheaper moulds made of non-ferrous alloys because of lower forces.
 Less material to plasticise hence lower energy consumption
 Less cooling time because of less material and better heat conducting
moulds.
 Long flow paths possible.
 More flexibility of product design; possibility of combining thick and thin
sections. Elimination of assembly of separately moulded solid and hollow
components.
 Possibility of including slim inserts as the pressure is low.
 Possibility of creating parts with hollow channels for fluids etc. (A shower head
is moulded in this way)

Disadvantages.
 Additional cost for the gas unit and the gas.
 Changes in the controls of the moulding machine.
 Not suitable for very complex products with features mouldable at high
pressures.
 Hole at the point of gas injection.
 Wall thickness is not uniform.

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  Splays on surface in partial filling variation.
 Possibility of difference in surface finish over the gas channel.
 Surface blush over the gas channels.
 Loss of material in the melt expulsion process.
 Higher mould cost in blow-out and retraceable core processes.

12.7 Applications:
 Automotive: bumpers, grilles, door panels, spoiler, gas pedal,
mirror housing, instrument panels, glove box, motorcycle shield etc.
 Aerospace: interior and structural panels.
 Consumer electronics: TV cabinets, back covers, computer housing.
 Appliance cabinets, refrigerator and washing machine panels, top covers.
 Garden furniture.
 Housings for electrical components.
 Office equipment panels and housings.
 Sanitary equipment like shower head, toilet seat, bath handles.

12.8 Faults and remedies.

12.8.1 Switch-over marks.

There are lines on the surface of the moulding at extreme ends
of the melt charge. These constitute a visual but not a structural fault.

In GIT with partial filling, there is always a time lag between the end of the melt
injection and the start of gas introduction. The surface of the melt in contact with the
mould walls and at the ends of charge get cooled and forms a rigid layer. As the gas
pushes out the molten material out of the core to the surface, the frozen ends of the
the melt front are pushed up against the mould wall but cannot assume the surface
texture. This causes marks at the joint of the stationary charge and the pushed up
material. It is more or less a hallmark of the process.

The time lag, the root cause of the fault, is unavoidable as the gas can be injected
only when the melt pressure has come down to a level lower than the gas pressure.
The marks may be reduced, shifted to some less conspicuous part of the article or
hidden by:

 changing the shot volume

 increasing the melt temperature and reducing the injection pressure
 increasing the mould temperature
 increasing the gas pressure
 enlarging the runners and gates
 changing over to a better flowing material
 choosing material with lighter colour
 removing or covering the marks in after-operations.

12.8.2 Finger effect.

The fault occurs predominantly with large, thin walled articles foreseen with gas
channels. The gas leaves the predetermined path and carves out irregular side
channels. The surface finish over the fingers is distinctly different.

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The gas follows the path of least resistance. If it encounters resistance while blowing
the partly filled cavity, it will make ingress into areas which offer less resistance. The
product design may have built-in pitfalls which facilitate incursions of the gas in
undesired regions.

The finger effect can be avoided by:

 dimensioning the gas channels as recommended in the product design guide

 not exceeding the prescribed wall thickness limitations for the thinner section
 providing very small radii at the joints of ribs with the flat surface
 extending the time gap between melt injection and gas injection
 decreasing the gas pressure or setting it in a decreasing profile
 reducing the gas holding time
 using a thermoplastics with lower shrinkage (Amorphous thermoplastics are
less prone to finger effect)

12.8.3 The slip-stick effect.

The defect manifests itself as a scaly surface of the product.

As the process of melt displacement by the pressurised gas proceeds and the
amount of melt being pushed decreases, the speed of the gas can achieve such
proportions that the frozen material already sticking to the mould wall is pulled loose,
dragged along and deposited further.

The remedy lies in:

 reducing the gas pressure
 creating a pressure profile during the holding phase
 increasing the melt charge
 raising the mould temperature

12.8.4 The diesel effect.

Burn marks indicating charred material.

The defect and its cause are the same as in conventional injection moulding. The
entrapped air is compressed by the advancing melt front and gets overheated
resulting in burning of the material in contact. The phenomenon may occur with
standard GIT with partial filling.

The defect can be eliminated by:

 adequate venting through shallow slots at the location of entrapment
 strategically placed ejectors or sintered metal inserts
 decreasing the gas pressure and thus slowing the speed of the front, so that
air gets time to escape
 selecting alternative location of injection to prevent formation of two flow fronts
which are coming in the way of air escape

12.8.5 Glass fibre streaks.

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White streaks showing glass fibres on the outer surface. The defect is more
prominent in materials of dark colours.

 It can be circumvented by using higher gas pressure.

 It can be rendered less conspicuous by using a lighter colour.

12.8.6 Sink marks.

Sink marks are unforeseen depressions on the surface of the moulding.

The cause of sink marks is same as with conventional injection moulding. Material
accumulations cause sink marks during cooling if the material deficit created by
shrinkage is not compensated through input of additional material.

A major cause of material accumulation is the faulty product design. Some solid
functional details like assembly elements, fixtures, hubs and studs may need wall
thickness which produces sink marks unless compensated. The gas pressure is
generally too low to perform this task. Material accumulation may also take place at
the extreme end of the gas channels, at the bends and besides cores in the path of
the gas. The fault can be countered by:

 reducing the shot volume

 providing separate gas injection for thick details
 decreasing the gas pressure
 increasing the gas holding time
 designing the bends with larger radii and a larger angle
 increasing the size of the overspill cavity to reduce rest material at the end
 increasing the cooling period
 cooling the sink mark prone areas intensively to transfer the void inwards.

12.8.7 Distension of the moulding.

The article blows up after ejection.

As a rule, the gas is evacuated and the product has the normal atmospheric
pressure also inside before the mould is opened but the gas is a poor cooling
medium and the poor heat conductivity of plastics retards heat dissipation to the
cooled mould walls so that the interior walls may still be in semi-molten state. The
escaping gas tears along minute material particles which choke the narrow annular
gap of the injector. Runners and gates too may no more be open when gas is
evacuated. The trapped gas causes the article to blow out or even burst.

Following measures help eliminate the problem:

 longer cooling period

 colder mould
 larger runners and gates
 lower gas pressure
 retarded exhaust rate
 frequent cleaning of injectors or gas channel of the machine nozzle

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12.8.8 Gas channel imprint.
The difference in surface finish over the path of the gas in the article.

The channel cored out by gas does not have a uniform wall thickness. The difference
in thickness is accompanied by different shrinkage and also difference in reflection of
light by the surface of the moulding. It is particularly distracting when the gas does
not follow the intended path, e.g. wanders out in flat sections.

The most effective remedy is revision of the article design. Some improvement can,
however, be achieved by:

 varying the gas pressure to reduce wall thickness difference

 reducing the shot volume to decrease material accumulation
 Increasing the gas holding period

12.9 External gas moulding.

Unlike other gas assisted processes, the EGM does not use gas to create hollows in
the moulding. The process is more like injection compression moulding whereby the
gas, injected below the article, forms a micro-thin layer and compresses the melt
against one face of the mould to counter emergence of sink marks on that side.

Large thin articles with ribs can be moulded successfully with standard GIT but the
marks left by the gas channels on the opposite surface, usually against the ribs,
may not be acceptable in many cases. EGM provides a solution here by pressing the
entire surface of the moulding against the mould face forming the visible side of the
product till the end of solidification. Unlike the normal holding pressure which is
higher near the gate and diminishes with the distance and time, the external gas
pressure is uniform and constant. The process eliminates the sink marks and surface
finish differences on the intended face entirely or to a great extent depending upon
the product design and the plastics.

It must be understood that sink

marks are not eliminated; they are
transferred to the less critical face
such as the inner side of a housing
or a cover.

The process of external gas

moulding takes place in four
distinct steps (Fig. 12.18). After
complete filling of the cavity (1),
compressed gas is introduced in
the mould, from the opposite side
of the visible face (2) and forms a
micro thin layer under a high
pressure which may range
between 50 and 300 bar. The Fig 12.18
injection mould has to be designed
to permit access of the gas over

205
the entire face and hold it in place till expulsion. The parting face of the mould must
be provided with a seal. The gas takes over the role of holding pressure with the
difference that it acts uniformly over the complete area till the end (3). The gas
equipment is the same as for other GIT processes. The gas is evacuated before the
mould is opened (4).

Apart from eliminating sink marks on the surface, the process manifests other
improvements like reduced moulded-in stresses, more uniform shrinkage, narrower
tolerances, less distortion and better flatness—an attribute highly important in case
of mating components. The process also proves highly effective for moulding large
flat articles like flat panels for office equipment, tops for domestic appliances,
furniture components like table tops, outdoor furniture parts, wash tubs and
automobile panels etc. There may be a reduction in the cycle time and also in the
weight as no additional material is pushed in during the holding phase.

EGM offers more freedom in product design as thicker functional details can be
integrated without the risk of visual defects.

12.10 The water injection technology.

12.10.1 The process.

The basic difference between the GIT and WIT is that the later employs water
instead of a gas as the medium to core out the moulding. The process was
developed by IKV, the Institute for Plastics Processing, University of Aachen,
Germany and taken over by Battenfeld, the moulding machine manufacturer in the
same country. BASF, the plastics raw material producer, has tested various materials
for their suitability for WIT and has developed some special grades of materials for
processing with this technology.

The process is almost identical to the gas aided injection moulding. Pressurised
water is introduced through injectors situated in the mould cavity, filled partially or
fully with plastics melt. All variations of GIT except the one with dual purpose
machine nozzle are valid for WIT also. The pressure of water is about 300 bar.
Before opening the mould for ejection, water is evacuated either through gravity or
expelled by blowing air or gas through another nozzle built in the cavity for this
purpose.

For evacuation of water by gravity, it is imperative that water injection takes place
from the lowest point in the mould. It necessitates placement of the article in the
mould accordingly. The melt should also flow against the gravity in the mould cavity
to ensure good surface finish.

WIT has proved especially advantageous for

two types of articles. These are:

 Pipelines for fluids (Fig. 12.19)

 Structural components stiffened by
means of hollow channels
Fig..12.19

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12.10.2 Materials.
WIT has been almost exclusively employed for production of technical components.
Consequently, engineering thermoplastics have been tested, modified and employed
commercially for mass production. Predominant polymers are PA 6 as well as PA 66,
with or without glass fibres. PBT too has found application in some cases.

12.10.3 Advantages and disadvantages.

12.10.3.1 Advantages.
Water as the agent to core out the moulding offers several advantages over the gas.

 Water is cheaper than the gas.

 Its heat conductivity is forty times higher than that of nitrogen so that it
exercises a faster, direct cooling from inside. The cycle time is considerably
shorter, almost a quarter of the GIT process.
 It has higher viscosity, almost equalling that of the polymer melt with the result
that the wall thickness distribution is more uniform. It yields thinner walls as
compared to gas.
 Water injection yields a much smoother internal surface than the gas. The
fibres are not cored out.
 Water facilitates moulding of combination of thick and thin sections.
 Water is incompressible. It can core out very long sections as its front acts as
a solid ram against the fluid melt, pushing it farther and also cooling it in the
process.
 The cooling time can be shortened, especially in case of thick-walled
mouldings, by maintaining an inflow of fresh water in the product by means of
two separate water nozzles.
 Water injection moulding eliminates the danger of foaming.
 The water injection moulding offers a viable alternative for blow moulding in
certain cases, especially for fluid-carrying components.

12.10.3.2 Disadvantages.
 Unlike gas, water cannot be injected through a common machine nozzle. It
needs a separate water injection nozzle.
 Water must be injected rapidly to achieve an
even wall thickness distribution and to yield a
smooth surface inside. It necessitates large
channels for its flow. Consequently, the water
nozzles are much larger than their
counterparts for gas injection and need more
space in the mould. Fig. 12.20
 Water nozzles must have a shut off
arrangement. The function is executed hydraulically, which contributes to their
complexity, size and cost (Fig.11.20)..The moulding machine, too, must
possess the additional hydraulic circuits with relevant controls.
 Water leakage causes greater nuisance than the gas leakage.
 Water must be removed from the moulding before ejection. It may necessitate
additional arrangement to inject compressed air in the article to expel water.
That calls for an additional injection opening.

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  The Water injection technology requires a process specific water compression
unit with all relevant controls to bring up a pressure of 300 bar.
 WIT has proved economical mostly in case of thick walled long components.

12.10.4 Applications
 Seats, back and arm rests for cars and buses
 Car mirror holder
 Car roof railing
 Wiper arm
 Pipe fittings, ducts
 Furniture components like chair legs
 Sports goods, tennis rackets
 Conveyor rollers
 Handles
 Machine components like chain saw handles

12.10.5 Faults and remedies.

Some faults which are typical to the WIT process are:

12.10.5.1 Surface waviness and whirls close to the water injection point.

The defect is caused by too high a water pressure and can be eliminated by starting
with a lower pressure and increasing it to the required level quickly.

12.10.5.2 Partial coring by steam.

Water is turned into steam by the heat of the melt which cores out partly the article. It
occurs when the quantity of water is too small. It can be remedied by increasing the
volume of water.

12.10.5.3 Pores.
These are tiny depressions on the inner surface and below it. If the water pressure
builds up very slowly, a very thin layer gets frozen which gets punctured susequently
by the high pressure.

The fault can be eliminated by adjusting the rate of pressure build up.

12.10.5.4 Voids.
Voids are the hollows or cavities in the wall of the article, invisible from both sides.

These are caused by the cold walls of the mould and cold water under lower
pressure. Thick layers get frozen both inside and outside. As the water pressure
cannot compensate the shrinking material between the frozen layers, voids are
formed in the walls.

The solution of the problem lies in increasing the shot volume and maintaining high
water pressure during the cooling phase.

12.10.6 Conclusion.

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The process is undergoing continuous development. A combination of gas injection
with that of pressurised water has extended the palette of plastics which can be
processed by WIT. In this variation, a bubble of gas is introduced before injection of
water in the melt. This acts as a cushion between the hot melt and cold water,
preventing sudden freezing and yielding much smoother surface besides reducing
turbulence in water flow where the article section changes.

Chapter 13
Powder Injection Moulding

209
13.1 The process
13.2 The materials
13.3 The equipment
13.4 The mould
13.5 The product design
13.6 Advantages
13.7 Applications

13.1 The process.

Injection moulding of powders, although a form of the conventional moulding of the
thermoplastics, differs from the normal process in some vital details. The term
“Powder Injection Moulding” stands for moulding of articles out of powdered solid
materials rendered mouldable with the help of a thermoplastics carrier. If the powder
is that of a metal, the process is termed as MIM. Likewise, in case of ceramic
powders, it is called CIM. In its entirety, the process encompasses:

 Preparation of the feedstock

 Injection moulding of “green compacts”
 Debinding to “brown compacts”
 Sintering

13.1.1 Preparation of the feedstock.

Fine ceramic or metal powder is mixed with a binder, which is invariably an organic
compound, mostly a thermoplastics. The function of the binder is, as its name
suggests, binding the powder particles together. The primary condition that a binder
must fulfil is that it should wet the powder particles, encompass them completely and
act as a holder without reacting with them. It must also be completely removable
without effecting the shape of the article formed out of the powder. Other desirable
characteristics are good mould removal properties, dimensional stability and
adequate green strength after moulding. It should be thermally stable but must
decompose easily.

The proportion of the binder is kept to a minimum possible, generally between 30

and 40 per cent in volume, depending upon the type of filler and the binder. The aim
is to keep shrinkage, resulting from the binder removal, as low as possible. This
ensures closer dimensional tolerances in the finished product. Waxes, lubricants and
wetting agents as well as pigments in the form of powdered metallic oxides may also
be added. The mixture is homogenised and palletised on an extruder. The resultant
granulate forms the feedstock for injection moulding.

All metals and ceramics, which can be powdered and sintered, are suitable for
powder injection moulding. The powder grains should preferably be spherical in form
and as small and uniform in size as possible. Coarse grains cause higher friction in
the injection unit and reduce its service life.

Ready-made feedstocks with different metals and ceramics are now available
commercially.

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13.1.2 Injection moulding.
The process of injection moulding of powder feedstock is essentially the same as for
the thermoplastics granulate. The peculiarity of the raw material, viz. the very high
contents of non-melting abrasive fillers and very low amount of the melting
thermoplastics binder has influence, not only on the moulding parameters but also
on the design, material and construction of the moulding equipment and the mould.
The process of plasticising, viz. feeding, compression, melting and metering is
exactly the same as in case of thermoplastics. The low contents of thermoplastics in
the feedstock, however, cause less expansion of the melt and permit very little
compression. The screw speed is also kept low as the low amount of the plastics
needs less shear. The circumferential velocity should not exceed 15 meters per
minute. It should be lower for ceramic powder moulding.

The feed stocks with powders have a significantly higher viscosity than the binder
thermoplastics. Consequently, the injection and holding pressures would also be on
the higher side. The fillers make the melt highly heat conductive. It is therefore
necessary to fill the cavity as fast as possible.
Jetting must be avoided, preferably through
proper gate positioning and if that is not possible,
through lower filling rate in the beginning . The
temperature profile set on the barrel corresponds
to that suitable for the binder plastics. The nozzle
temperature should, however, reduce the melt
viscosity The holding pressure is kept up till the
gate freezes. The melt cools comparatively fast.
A thumb rule for the cooling time of metal filled
moulding is that it is as many seconds as the
square of the thickest section of the article in Fig.13.1
millimeters.

The mouldings are referred to as “green compact” (Fig. 13.1) and are prone to
distortion during ejection. They should be handled with robots and stacked in
suitable trays providing adequate support and protection against deformation. The
trays must be suitable for use in the subsequent operations of debinding and
sintering.

13.1.3 Debinding.
Debinding is the operation of removing the thermoplastics which has acted as the
carrier and the binder of the powder that was to be given a foreseen shape by
injection moulding. It has fulfilled its function and now it must be eliminated in such a
way that the moulding retains its form and can be subjected to the final operation of
sintering.

Different binders are employed for different powders. The method of removal
depends upon the type of the thermoplastics used in the particular case. The binders
are extracted by way of catalysis, dissolution or thermal decomposition. Binders
consisting of polyolefin-wax mixtures are removed by melting. The process has to
be carried out at a very low rate to prevent distortion caused by expansion in volume
of the binder on melting. Some binders can be removed by disolving them in organic

211
solvents. Polyalcohols and polyvinylalcohols, which are soluble in water, are most
suitable for this method.

Polyacetal, the most common binder, is eliminated by thermal decomposition,

supported by gaseous nitric acid. The process is carried out in a debinding oven.
The green compacts to be debinded are put on oven grids in the trays these were
placed in after demoulding. Nitrogen creates an
inert atmosphere in the oven, which is heated and
maintained at 110°C. Nitric acid is introduced after
the green compacts have been warmed up. The
decomposed binder releases formaldehyde in
gaseous form which is extracted and burnt out.

The debinding rate at 110°C varies between 1-2

mm of the article thickness per hour. The process
can be carried out in a long, tunnel type oven at
appropriate speed so that the articles emerging at
the other end of the tunnel (now they are called Fig. 13.2
brown compacts in case of metals and white compacts with ceramics), are ready for
the next operation. A brown compact is illustrated in figure 13.2.

About 80-90% of the binder is eliminated by debinding. The rest is required to keep
the filler grains together for safe transport to the sintering oven.

13.1.4 Sintering
In order to firmly bind the particles of the brown
compact and to turn it into a pore-free component,
it is sintered by application of heat. The process is
the same as that for the press-sintered articles as
far as the furnace atmosphere and the
temperature-time curve are concerned. The
temperature may range from 1300°C to 2000°C
depending upon the material being sintered but it is
raised gradually in the beginning to drive away the
rest of the binder. The cooling, too, is effected in
small steps of 5-10°C per minute.
Fig.13.3
Injection moulded sintered parts can approach the
theoretical material density up to 99,9%. They would have all properties of the parent
metal when properly debinded and sintered. A sintered article in its final shape is
shown in figure 13.3.
The three steps of production from moulding to sintering are usually carried out in a
row as a continuous process as shown in the schematic diagram 13.4.

The production process may be regarded as well-balanced when the final product
has a uniform structure and appearance, is free of pores, has a smooth surface and
possesses all properties of the parent material.

212
 Fig. 13.4

The Shrinkage. The moulded components shrink in two steps:

The mouldings shrink after ejection and cooling. The shrinkage occurs in the binder
thermoplastics but not to the extent as when it were unfilled. A fact worth taking into
account is the expansion of the heated mould. At 130°C, the mould dimensions are
larger by 0,2%. Consequently, the moulding too is bigger by that amount. The net
moulding shrinkage is therefore less.

The operation of sintering leads to further contraction as the filler particles come
closer and fill up the gaps left by the extracted binder. With suitable binder, the
brown compacts shrink isotropically, i.e. evenly in all directions during sintering. The
shrinkage after sintering may be 20% or even higher. This has a significant effect on
achievable tolerances.

Other factors which influence shrinkage are:

 The binder contents

 Powder characteristics

213
  Mixing process and quality of mixing
 Moulding parameters
 Distortion due to gravity
 Sliding properties on the sintering underlay
 Uniformity of the sintering process

Dimensional accuracy.
Typical tolerances for powder injection mouldings are:

Nominal limit in mm. Tolerance ± mm.

<3 0,05
3.6 0,06
6.15 0,075
15.30 0,15
30.60 0,25
>60 ± 0,5% of nominal value

13.2 The materials.

Among metals, copper, hard metals, stainless steel, strontium ferrite and platinum
are some of the materials processed successfully by the powder moulding
technology. The achievable particle size depends upon the hardness of the material.
It may vary between 1 and 20 μm. A spherical form of the particles causes less
friction and wear of the processing equipment.

The palette of ceramics processed by CIM includes aluminium oxide, porcelain,

zirconium oxide, silicon carbide as well as silicone nitride. The particle size varies
between 15 and 45 µm.

Polyolefins and polyacetals are the most commonly used binders.

Additives are waxes, lubricants and wetting agents as well as pigments in the form of
powdered metallic oxides.

The material is recyclable. A 50:50 blend of reground and virgin material can be
safely used for the same moulding.

13.3 The equipment.

13.3.1 The injection moulding machine for PIM differs from its conventional
counterpart primarily in geometry of the screw of the plasticising unit. The low
contents of the thermoplastics in the feedstock permit very little compression of the
melt. Consequently, the screw can have only a small compression ratio. It is usually
in the range of 1:1,16 to 1:1,2.

The metal as well as ceramic powders are highly abrasive. Unless suitably
hardened, the components of the plasticing unit will wear out very soon. It is
particularly true for the non-return valve. Any back leakage caused by a worn out
valve would result in inconsistent shot volume and loss of pressure during the

214
holding phase, which may prove detrimental to the dimensional accuracy of the
moulding. The valve components should preferably be made of sintered carbide.
A closed loop machine would yield more uniform quality.

A robot for taking out the ejected mouldings and positioning them for the subsequent
operation of debinding invariably forms a part of the moulding unit.

13.4 The mould.

The injection moulds for powder injection moulding are subject to the same
guidelines of design as their counterparts for thermoplastics. However, the altered
nature of the melt, such as its increased viscosity and the high proportion of the
fillers and their abrasiveness make certain modifications unavoidable. The feeding
system has to be more generously dimensioned because of the sluggishness of the
melt. A good polish facilitates the flow and demoulding. All parts coming in contact
with the abrasive fluid must be through-hardened. If possible, the gate section, which
is likely to get worn out fast, should be easily replaceable. Sintered carbide inserts
for gating have a longer service life. In case of polyacetal based feedstock, it is safer
to employ hardenable stainless steel for crucial mould components.

The very high content of the filler leads to a reduction in shrinkage, necessitating
generous taper for a trouble free demoulding. A minimum taper of 1 degree is a must
though a larger one up to 3 degrees would be preferable. It must be borne in mind
that the mouldings do not possess much rigidity because of the low amount of the
binder and are liable to distort during ejection. It is not only the generous draft angle
but also adequate area of ejectors which helps avoid distortion and damage during
demoulding.

The feeding system merits special attention because the very high content of fillers
raises the viscosity considerably. Following measures keep the pressure drop within
reasonable limits:

 Runners as short as necessary.

 Runner cross section as large as possible.
 Runner cross section preferably circular.
 No sharp bends in feeders. All junctions generously rounded.
 Gate at the thickest section but no free flow of the melt stream.
 Gate size bigger than that for the unfilled resin.

All known gate types, including the submarine gate, can be employed. Hot runner
systems, too, can be used. In fact, it is easier to insulate the hot runner unit against
heat losses here as the entire mould is maintained at a high temperature. However,
provision must be made for abrasive nature of the melt. Complex needle valve
nozzles are unnecessary since the melt does not tend to drool or string during
demoulding. The gate tears off cleanly.

The flow pattern of the melt in the mould is identical to that of unfilled thermoplastics.
A bad mould design and wrong moulding parameters can give rise to moulding faults
like weld lines, warpage and imperfect reproduction of the surface and the finish.
These defects cannot be remedied in the subsequent operation of sintering. They
must be eliminated at the stage of moulding only.

215
The moulds are maintained at an elevated temperature during the moulding process
by circulating a hot fluid through a network of holes or a labyrinth, incorporated in the
mould for this purpose. The layout of the network must ensure uniform temperature
at all points. The maximum deviation should not exceed ± 2°C. A larger variation
manifests itself as differences in surface finish, strength and dimensions. The high
mould surface temperature is necessary as the filled melt loses heat rapidly due to
the high heat conductivity of the fillers. The mould temperature may have to be set
as high as 140°C for feedstocks with polyacetal as binder. The seals should
withstand the temperature.

The injection moulds for the powder injection moulding can have all usual features
such as three plate feeding system, moving, sliding, revolving or collapsible cores as
well as unscrewing devices and other mechanisms, common in moulds for
thermoplastics.

A vital feature of the mould is the venting arrangement. Entrapped air acts as a
brake to the even flow of the melt. Apart from the well known diesel effect with burnt
material, the trapped air may lead to inadequate reproduction of the surface details.

The resistance offered to the advancing front by the enclosed air being progressively
compressed may slow it down and result in incomplete filling due to fast cooling of
the melt. In most cases, venting slots on the parting face, 0,01-0,02 mm. deep at the
end of the flow path, prove effective. However, depending upon the geometry of the
article, air may get trapped at points away from the parting line. In such cases,
auxiliary ejectors, positioned at the crucial spots, offer escape route to the air.

Though seemingly a minor point, the prevention of loss of heat from the mould is no
less important for maintaining a constant temperature in the mould. Insulation sheets
between the mould clamping plates and the machine platen help save heat energy
and reduce temperature fluctuations.

13.5 The product design.

Although the final product would consist of metal or ceramics only, the process of its
formation viz. injection moulding, subjects its design to the rules valid for moulded
plastics articles. Some applicable guidelines are:

 To counter distortion, the walls of the product should have a uniform

thickness.
 Avoid abrupt wall thickness changes.
 Employ ribs instead of thickening the walls.
 Core out thick sections. Maximum wall thickness < 20 mm
 Avoid sharp corners. Minimum corner radius - 0,3mm.
 Provide a generous draft angle for safe demoulding.
 As far as possible, one face of the product should be designed flat to seat the
green moulding.

The powder injection moulding process can also be employed for moulding products
in more than one material as well as in conjunction with gas injection. The prime
condition is similarity of shrinkage and sintering temperatures.

216
The MIM products can be subjected to usual post operations like sand blasting,
grinding, polishing, galvanising, plating, soldering, welding, machining and
hardening.

13.6 Advantages.
The process offers following advantages:

 Production of ready to use components. Post operations in rare cases.

 Possibility of surface treatment and decoration after sintering by physical,
chemical and mechanical methods.
 No restrictions on design intricacies.
 High surface quality.
 Dimensional stability and repeatability.
 Possibility of full automation.
 Recyclability of material. No wastage.

13.7 Applications.

13.7.1 Metals.
Watch bodies, small gears, components for hand and machine tools, weapons,
medical and dental tools, computers and printers etc.

13.7.2 Ceramics.
Thread guides, sealing washers, components for pumps, valves, motors, turbine
wheels, heater cores, bearing sleeves, spray jet nozzles etc.

217
 Chapter 14

Injection Moulding of Thermosetting Plastics

14.1 The materials

14.2 The process
14.3 The equipment
14.4 The mould design
14.5 The product design
14.6 Trouble shooting
14.7 Advantages and disadvantages

14.1 The materials. Thermosets were the first fully synthetic plastics. Baekland
brought out Phenol Formeldehyde under the name of Bakelite way back in 1909.
Since then, they have been processed by compression moulding and transfer
moulding processes which are essentially semi-automatic, labour intensive and
consequently expensive. Despite their outstanding properties, thermosets have
been losing ground to the more rationally processible thermoplastics.
Development of the injection moulding process for thermosets in 1965 has given
a new lease of life to them. It has enabled the duroplasts a spectacular
comeback. Their inherent properties have secured them a firm position in certain
branches of industrial applications. The thermosets have:

 high static and dynamic strength

 high electrical and thermal insulation
 high thermal and chemical resistance
 no softening after curing
 no halogens, sulphur and heavy metals
 very high wear resistance
 the capability of replacing non-ferrous metals

14.1.1 The form of the moulding compound.

Injection moulding depends upon gravity feeding of the machine with material.
The compound should, therefore, be free flowing. In other words, it cannot have
rough type of fillers. The suitable fillers are wood flour or refined sawdust, cotton
flock, short glass fibres not longer than 0,5 mm., crystalline calcium silicate etc.
These fillers reduce the material cost, lend heat resistance, improve electrical
properties and enhance strength. It also has certain additives, which retard cross-
linking at lower temperatures to prevent hardening during the dwell time in the
injection unit but accelerate curing at higher temperatures.

The material should also have as little dust or powder as possible. It may hamper
free flow and cause irregularities in the charge.

Injection moulding machines for moulding of dough and bulk compounds are
equipped with arrangements for forced feeding.

Summing up, the thermosetting compound for injection moulding should have the
following attributes:

218
  Uniform granular form of a size between 0,5-1 mm.; free of dust and powder
 No coarse fillers
 Easy gliding in the hopper for uniform charging
 Should glide easily through the barrel and over the screw
 Slow hardening around 100°C, the temperature of flow in the barrel
 Fast curing at temperatures above 150°C.

14.1.2 Storage of thermosetting raw materials.

As the heat favours curing or crosslinking, the packed and sealed bags of duroplasts
must be stored in cool rooms, less prone to temperature and humidity fluctuations.
Out of this consideration, there should be no heating or water pipes passing through
the stores. The bags should not be in touch with the cold floor either as the moisture
is likely to shift towards the colder part of the packaging. The ideal conditions for
storage are:

 The ambient temperature about 20°C and the relative humidity around 50-
60%.
 The shelf life of duroplasts is always limited. It is advisable to store only the
quantity needed for a short time and keep on replenishing it.
 Before processing, the material from the stores should be conditioned by
keeping it in the production rooms for sufficiently long time, at least a day or
more.

14.2 The process.

Injection moulding process for thermosets is similar to that for thermoplastics in many
ways. In a plasticising unit consisting of a barrel and a revolving and reciprocating
screw, with controlled heating, the material is brought to a state where it can flow
under pressure without undergoing any appreciable curing, that is, crosslinking. It is
injected by the screw acting as a plunger into a mould which has one or more
cavities of the shape of the required product. After complete filling, the pressure is
reduced but kept on till the gate solidifies. The screw of the plasticising unit can start
the charging for the next shot at this stage by rotating and receding. The moulding
can be ejected when it has cured to an extent that it would not distort during
demoulding. The internal chemical reaction process continues outside the mould till
completion. The individual phases of the process are described below.

The material in the form of granules is fed into a hopper at one end of the plasticising
unit consisting of a hollow steel barrel and a closely fitting screw. The screw
transports it further towards the opposite end. The material passes through an
intermediate stage of sintering mainly from the heat of friction and from the heating
jackets around the barrel of the plasticising unit, if the former does not suffice, till it
assumes the form of a viscous fluid. Should the heat generated by the rotating screw
be in excess of that required, the heating jackets perform the function of coolers. The
increasing pressure exerted by the plasticised material expels the air and gases
towards the hopper.

As the fluid material is injected into the mould through a linear stroke of the screw,
the pressure needed is that to overcome the resistance offered to the flow by the
feeding path and the mould walls (the thicker the article, the lower the resistance)

219
and the viscosity of the material. It is to be noted that the fillers have a far reaching
influence on the flow properties. As the melt proceeds further, it receives heat from
friction against the mould walls, from the heated mould and from the exothermic
reaction it is undergoing. The reaction gets faster as more and more heat is
generated. It results in reduction of viscosity and that of the injection pressure. The
pressure rises again when the mould is filled up and the compaction starts. Another
factor responsible for increase in pressure is the decreasing viscosity as a result of
the progressive curing. The material at peak temperature expands and may generate
flash if the locking force of the machine is inadequate. Trapped air and gases
liberated at high temperature, if not evacuated through efficient venting, may further
push up the internal pressure and contribute flash.

As the curing progresses, the material undergoes contraction. The pressure at this
stage, viz. the holding pressure, can be reduced. It is generally about 60% of the
injection pressure. The viscosity of the material also declines with curing and at one
stage, the holding pressure becomes ineffective.

The total time needed for hardening is governed by the maximum wall thickness.

14.2.1 The machine setting.

Following is a typical setting of parameters for most thermosets.

Barrel temperatures:
Feeding zone 60°C, middle zone 60-70°C, Nozzle 90°C
Screw speed 70-100 r.p.m.
Injection pressure 1400 bar
Holding pressure 600-1000 bar
Back pressure 150-200 bar

14.2.2 The moulding cycle.

The time taken for injection is relatively short. The friction during injection enhances
the flowability. The holding phase too is not much longer. The major part of the cycle
is formed by the curing time. It may be as much as 60-80% of the total cycle time. It
can be reduced if the compound can be subjected to higher temperatures in the
barrel as well as in the mould without reducing its flowability or expediting curing.

The sequences of a moulding cycle are:

Mould closes
Injection unit advances
Injection phase
Holding phase
Curing
Mould opens
Ejection
(Charging takes place after
the holding phase during
curing.)

Fig. 14.1
220
Figure 14.1 illustrates various steps of a moulding cycle in relation with one another.

14.2.3 The heating.

Various sources of heat to plasticise and cure the material are:

 Heating jackets around the barrel

 Work done by the screw
 Frictional heat through flow in the runner
 Exothermic condensation reaction
 Heaters in the mould

The phase in the cylinder may be regarded as “preheating”. It is a sensitive

operation
as the material at too low a temperature resists injection and too high a material
temperature may initiate the chemical reaction right in the barrel, leading to
hardening and blockage. The right temperature of the melt for injection is the one
when the fluid has almost the lowest viscosity.

The vital difference from the moulding process for thermoplastics is that the barrel of
the plasticising unit for thermosets is heated only to a level where the material is
plasticised without undergoing a crosslinking reaction. Secondly, the quantity of the
material plasticised corresponds to one shot only. The screw acts mainly as a
transporter and mixer. The mould is heated to a much higher level which initiates and
facilitates the crosslinking action which in turn hardens the moulding. This, too, is a
significant difference from the moulding of thermoplastics. These are made flowable
by input of heat and hardened by its extraction. Thermosetting plastics are also
heated to make them flowable but it is the chemical reaction and not the cooling
which brings them to solidification.

14.3 The equipment:

The injection moulding machine for thermosets is similar to, and in many respects
identical with, that for the thermoplastics. It also has a plasticising unit, a mould
closing unit and an ejection unit, performing functions suggested by the
nomenclature. The difference, if any, lies in details.

14.3.1 The plasticising unit (Fig.14.2) consists of a hollow steel barrel placed
horizontally and provided with 2-3 water/ oil heating jackets, and in rare cases with
electrical band
heaters and
cooling fans,
around its
circumference.
The heating
jacket closer to
the feeding
zone has lower
temperature
than the next

Fig. 14.2
221
one. There is usually a separate jacket for the last section adjoining the nozzle as it
is here that the friction caused by injection may raise the temperature significantly.
The hot mould too transfers heat to the nozzle, particularly during the dosing
operation. The circulating fluid extracts the surplus heat.

On the barrel end forming the start, a material hopper sits on an opening cut in the
barrel. It is a conical container made of stainless steel plate. As the filled
thermosetting granules do not glide down very easily, the slope of the cone is not
more than 40 degrees. The inside of the hopper, too, is well polished to facilitate
gliding. The hopper is foreseen with a transparent window to display the level of
contents. The other end of the barrel forming the exit is fitted with an open nozzle
having the exit hole much smaller than the bore of the barrel. The barrel contains a
screw, closely fitting in it and capable of rotation, retraction and forward movement.
When it rotates, the raw material falling on it from the hopper is transported forward
towards the nozzle. The depth of the flutes and the pitch of the screw are generally
constant all along the length and the material experiences no compression during its
transport from the feed end to the exit. In some cases, the depth may decrease a
little after some distance from the feeding point causing a slight compression of the
raw material to expel air. In other words, the screw may have a compression ratio
varying between 1:1 and 1:1,1 for different materials. The minimal variation in depth
also facilitates removal of solidified material for cleaning. A screw with compression
will have three sections, viz. feed, compression and metering zones as with screws
for moulding of thermoplastics. The material should not have a long dwell time in the
barrel. The screw, therefore, is much shorter than that in plasticising unit for
thermoplastics. The screw length varies between 10 to 15 times its diameter. The
depth of the flutes is generally one tenth of the diameter. The surface of the screw is
highly polished whereas the bore of the barrel is kept rough. This measure helps
transport of the material. The difference in temperatures of the barrel and the screw
also serve the same purpose. Screws of larger diameters are provided with an
internal heating arrangement.

As most thermosetting compounds contain highly abrasive fillers like glass fibres,
minerals, wood flour, wood fibres, clay, carbon black, fabrics etc., the screw and the
barrel are subjected to considerable wear and tear. The steels for these machine
parts and particularly their heat treatment should take this into account.

It may be underlined that the main function of the

plasticising unit is to convey the material to the
mould with as little curing as possible. This is
why, the length of the unit is less, the
compression is very low and the heating is with
water as the temperature of the compound in the
barrel is kept below 90°C. Out of same
considerations, non-return valves which may
give rise to friction and overheating, are seldom
employed in the moulding machines for
thermosets. The backflow of the resin is checked
partly by the special design of the screw/barrel
head (Fig. 14.3) and by blocking the reverse
Fig. 14.3

222
rotation of the screw. An open type nozzle, screwed onto the end of the barrel, forms
the end of the plasticising unit.

Short interruptions in production cycle lead to hardening of the material close to the
nozzle in the barrel and longer interruptions to the hardening of the whole charge in
the barrel. The nozzle and the screw should, therefore, be easily dismantleable.

The size of the charge is slightly more than the shot weight. The additional material
serves as cushion needed for transmitting the holding pressure. However, with some
thermosets like epoxides, which harden readily, no cushion is permitted so that the
screw tip, which is formed like a cone as shown, almost touches the corresponding
conical cavity of the nozzle at the end of the injection stroke.

14.3.2 The mould-closing unit of a thermoset injection moulding machine is, in

principle, a replica of its counterpart in an injection moulding machine for
thermoplastics. It consists of a stationary platen, placed vertically in line with and
close to the plasticising unit. It bears an accurately formed circular opening in the
middle to provide exact location to the mould and access to the nozzle of the
injection unit. The platen, which is fixed on the machine bed, has a number of tapped
holes for clamping of the mould. A parallel platen placed on the same axis and
capable of a linear movement towards and away from the fixed platen, forms the
other part of the mould clamping unit. A set of tie bars, usually four in number, joins
the platen and guides the moving platen. The moving platen too, has a number of
tapped holes for mould clamping and also an accurate round hole in the middle for
centring the other mould half. This opening also enables the machine ejector to
move the ejector plates of the mould. A third platen behind the moving one, fixed to
the bed, supports the tie bars and also serves to hold one end of the toggle lever or
the hydraulic system for powering the moving platen. The whole assembly is
mounted on a bed which houses oil tank, the motor, the pump, valves and other
controls.

With the moulding machines for thermosets, hydraulic cylinders are preferred to the
toggle lever mechanisms for imparting movement to the platen and locking it. The
hydraulic devices exert force in the middle of the moving platen (Fig. 14.4) and are
not effected by the increase in the mould height due to heating. As a result, any
deflection in the mould due to the closing force and the injection pressure is in the
same direction. This is not the
case with toggle levers, which
depend upon the extension of the
tie bars for locking and press on
the moving platen away from the
central axis. Consequently, the
heated mould halves may bend in
opposite directions, giving rise to Fig. 14.4
flash.

14.3.3 Ejection. The ejection device is identical with that in injection moulding
machines.

223
14.3.4 Special features and ejection. Most modern thermoset moulding machines
possess a “breathing” device for the mould closing unit, a pneumatic powered
brushing fixture and air blowers for cleaning of the mould. The breathing device
provides venting by opening the mould locking unit by 0,01-0,03 mm. right after
filling of the mould. The brushes and the air blowers remove the thin fragments of
the cured material left by the mouldings after ejection.

14.4 Injection moulds for thermosets.

14.4.1 The mould heating.

The moulds for thermosets are not much different from those for the thermoplastics.
In fact, they are much simpler as they do not require cooling at all. Instead, they are
heated. The heating arrangement for moulds for thermosets usually consists of
electrical heating cartridges incorporated in the retaining plates. They should sit
snugly to ensure efficient heat transfer. Their main function is to heat up the mould in
a short time before the operations can start. Their capacity is estimated on the basis
of the weight of steel they have to heat. As a thumb rule, 200-300 watts are provided
per kilogramme of the weight. Round moulds can also be heated with band heaters.
During the moulding process, a major part of the heat required for cross-linking
comes from the friction generated during
injection of the material at a high velocity
through the runner system. A sophisticated
device aiming at maintaining a uniform
temperature in all sections of the mould
cavity is shown in figure 14.5. Strategically
placed heat pipes convey heat from the
retainer plates, heated by cartridge heaters
to the inaccessible parts of the core and
cavity. The thermal consistency results in
uniform curing, shorter cycle time and less Fig. 14.5
warpage.

14.4.2 The feeding system.

Apart from the fact that the sprue and runners cannot be
reground and reused, the feeding system in injection moulds
for thermosets is no different than that employed in injection
moulds. The shape of the sprue may be identical to that for
thermoplastics. The diameter is usually bigger. In order to
reduce the wastage, either a special machine nozzle going
deep in the mould may be used or better still, the sprue bush
may be provided with cooling from outside and/or from inside
(Fig. 14.6. The cooled sprue remains practically uncured and
need not be taken out. The runners, too, may be shaped like
those for moulding of thermoplastics. A circular cross section
is ideal but the runners may also be trapezoidal or
Fig. 14.6
rectangular. The three-plate system can also be employed if required. The main
difference in concept is that here there is no solidified insulating layer protecting the
fluid "core". The runners should be smooth and well polished. In general, the runners
should not be thinner than the thickest section of the moulding. They should be as

224
short as possible to avoid premature hardening. If a mould does not fill well under
normal conditions with an injection pressure of 5 tonnes, then the feed system is too
restricted, the feed path too long and/or its cross section too small.

The secondary runners should be smaller than the main one in order to maintain the
material under pressure, the proportion being very much a matter of experience as
the material does not behave like a true hydraulic fluid. The longer the flow path, the
more viscous it becomes.

The entrance to secondary runners must have generous radii to assist the flow to
change direction.

14.4.2.1 The cold runner system.

Analogous to the hot runner system of injection moulds for thermoplastics, a cold
runner system has been developed for thermosets to keep the runner temperature
low and thus reduce or totally eliminate the wastage of the material forming runners.
The whole network of runners is accommodated in a separate block, housed in the
mould but having very little physical contact with it (Fig. 14.7). The block is efficiently
cooled to keep the level of cross-linking as low as possible. The part of the mould
Fig.with
housing the core and cavity is provided 14.7heating.

Like the hot runner standard units for thermoplastics moulds, ready-made cold
runner composite systems for thermosets are also available in various sizes, with
open or shut off nozzles.

Figure 14.8 shows one such system from a German manufacturer of hot runner
devices. It can have open nozzles as shown on the left or the valve gated ones as

225
shown on the right side. The system is water cooled. The needle valves are actuated

Fig. 14.8
pneumatically.

Like the hot runner standard units for thermoplastics moulds, ready-made cold
runner composite systems for thermosets are also available in various sizes, with
open or shut off nozzles.

Figure 14.8 shows one such system from a German manufacturer of hot runner
devices. It can have open nozzles as shown on the left or the valve gated ones as
shown on the right side. The system is water cooled. The needle valves are actuated
pneumatically.

The gate.
For single cavity moulds, a sprue gate is quite suitable if the gate mark is not found
disturbing. It causes very little pressure loss and fills the cavity very fast with less
injection pressure. The sprue gate is, however, not suitable for aminoplasts as it may
give rise to internal stresses around the gate area.

The best cross section for a gate is a circle followed by a square. All types of
conventional gates, including the submarine gate, can be used for thermosets. Most
common are the film gate and the edge gate. The film gate is thin, is easy to remove
and leaves a very small mark on the moulding. It causes very little
orientation and does not damage the fibres. The edge gate is easy
to make and modify but requires some post operational work for
neat removal.

A modified version of the film gate (Fig. 14.9), which consists of a

number of edge gates from the main runner in place of a

Fig. 14.9226
continuous film, provides the possibility of straightening the flow front by selectively
altering the size of individual gates. It proves particularly advantageous with
relatively flat rectangular articles as the melt can be made to reach the other end
simultaneously at all points. In order to keep the flow path as short as possible, the
film gate should be situated on the longer side of the moulding.

The submarine gate obviates post operations but calls for meticulous adherence to
rules concerning its shape, size, inclination and the placement of ejectors for safe
demoulding. These factors are governed by the nature and composition of the
compound. It can, however, damage the fibres if the gate is too small.

The side gating of a cylindrical moulding may bring forth a poor weld line as the flow
fronts may be in advanced state of cure as they meet. A diaphragm gate may be
more suitable here.

The gate for materials with fine fillers should have a depth of 0,5 mm. or more and
that for coarse ones between 0,75 and 1 mm to start with. Too small a gate can also
result in abnormal increase in temperature, bringing the outer skin to an advanced
stage of cure. It would not bond with the following melt.

The filled thermosets, passing through narrow gates at very high speeds, cause
rapid wear in the gate area. The gate sections should, therefore, be designed as
replaceable inserts made of hard metals such as carbides.

The gate location should take into account the usual problems of weld lines, product
appearance, venting, cost of gate removal etc.
The ideal location for the gate is the thickest section of the moulding. The free flow
of the melt in case of thermosets does not cause problems like those encountered
with thermoplastics.

The arrangement of cavities in a multi-cavity mould should ensure equal flow

paths for the material from the central source if it does not result in extra ordinary
increase in length of the runner. Experience has, however, shown that the balanced
runner system is not always necessary to produce good mouldings if the product is
relatively small. Here, the runner system, being small, fills first and the built up
pressure causes the melt to enter all cavities simultaneously. However, in case of
large articles, the cavities closer to the main sprue will start filling earlier than the
remote ones. A balance can be achieved by varying the gate size.

14.4.3 The ejection system.

In principle, the ejection devices in injection moulds for thermosets are no different
than those for thermoplastics. However, the resin extruding down the ejector pin
holes poses additional problems in moulds for the former. It leads to seizure of the
ejection assembly. The situation gets worse with progressive wear. To counter the
hazard, the ejector pins over 5 mm diameter are provided with flats (Fig. 14.10). A
triangular cross section after a smooth length equalling one diameter in the front
offers maximum of alignment with minimum of friction and wear. The flats should
extend well enough along the length of the pin so that the escaped resin and other
foreign matter may fall away freely. The flats must terminate at the moulding end of
the pin with a face at right angles to the surface of the flat. This helps to break up

227
and fragment any resin that extrudes down the pin, to fall away instead of forming a
tube around the pin. The flats should leave 1,5 mm broad guiding surface along the
shank. For pins smaller than 5 mm in diameter, the breadth of flats may be less but
their number should be at least three. It is, however, advisable not to use ejectors
less than 6 mm in diameter.

Almost all devices of clearing

undercuts, employed in
injection moulds, are applicable
here too. Internal undercuts,
Fig. 14.10
however, cannot be
circumvented by forced
ejection. The air jets should ensure that no chips or material fragment remain sticking
in the guides for slides.

14.4.4 The mould venting. The moulds being filled in closed condition need venting
on the parting line and in deep crevices to allow the hot air or the volatiles, released
by the compound while entering the mould, to escape.

The usual technique for venting is to grind "flats", about 0.07 mm deep and 6-10 mm
broad on the face or land of the cavity in locations where the melt would reach last. It
is, however, not always possible to predict the flow pattern. In such cases, the vents
are ground in the mould after the first trial. Lack of proper venting may lead to
surface porosity, incomplete filling, burn marks and staining of the mould in areas
where the volatiles have not been able to escape. The venting slots should be highly
polished to reduce the risk of flash sticking onto the mould.

The air trapped in deep sections such as bosses, ribs etc cannot be vented by the
slots on the parting line. Ejectors and inserts placed at the strategic points can be a
good solution in such cases.

The technical components moulded out of thermosets may not require very high
surface finish but a rough mould surface acts against smooth ejection. The vertical
walls of the mould cavity should, therefore, be well polished in direction of ejection.

14.4.5 The mould material.

As the injection moulds for thermosets operate at elevated temperatures, it is
advisable to fabricate mould plates and core and cavity inserts out of hot die steels
like DIN 1.2344 which retain their strength at those temperatures. Standard mould
components like ejector pins are available in heat resistant steels. The steels should
be polishable.

The gate insert is subjected to considerable friction and wear. It must be made of a
through hardening steel and for filled materials out of carbides.

14.4.6 The mould shrinkage.

Thermosets also undergo shrinkage. The shrinkage is measured 24-168 days after
moulding and compared with the tool dimensions at 20 ± 2°C. The shrinkage is
usually specified by the raw material manufacturer and it is added to the product

228
dimensions proportionately while determining the mould dimensions. The factors
contributing to shrinkage are:
 Volume contraction due to curing
 Escape of moisture from the resin
 Escape of volatile components
 Difference of thermal expansion between the mould and the moulding
compound.
 Elastic relaxation of the material after release of pressure.
 The shrinkage increases with increasing mould temperature. It may be
attributed to the differential thermal expansion between the tool and the
moulding material. Secondly, the material loses more volatile matter at
higher temperatures.
 The shrinkage decreases with increasing injection and holding pressures.
An increase in holding time results in significant decrease in shrinkage.
The effect is reverse in case of the injection speed.
 Shrinkage of materials impregnated with fibrous matter is not uniform in all
directions. It is greater in the radial direction than in the tangential one, due
to orientation of fibres. The ratio may be as high as 2:1. Pure resins exhibit
negligible difference in shrinkage in different directions.

The post-shrinkage.
The moulded articles undergo further contraction upon conditioning after cooling.
It is carried out for 168 hours in an oven at 110°C. The cause may be
reorientation of molecules as well as further loss of volatile constituents. It follows
the pattern of the main shrinkage viz. more in the radial direction than in the
tangential one.

14.5 The product design.

The rules for design of articles produced by casting of molten plastics under
pressure are almost universal. Guidelines valid for the design of moulded
thermoplastics products also apply to those out of thermosets. There are,
however, variations in some cases due to peculiarities of materials and their
processes. The following points merit special attention:

Undercuts. External undercuts usually require devices like slides for clearance.
Moving mould components function well if their guides are kept free from the dirt,
loose material chips, powder and flash particles. The moving devices are costly in
any case. If possible, the undercuts should be avoided or formed in a way that
permits ejection without slides.

Parts with internal undercuts like continuous grooves and beads etc., unless very
shallow and well rounded, cannot be ejected by '"jumping over" the obstruction
after injection moulding because of the rigidity of the material. It is also advisable
to avoid all internal undercuts requiring parting of the core as far as possible.

Although it is possible to incorporate slides and other undercut clearing devices

in case of injection moulding, it must be borne in mind that the fillers will part
around the obstruction and form a weld behind it, which may prove to be a weak
point.

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Wall thickness. Regardless of the compound employed, the wall thickness
should be kept uniform and to a minimum, consistent with the functional
requirement. It determines the curing time, which in turn controls the overall cycle
time, productivity and the cost. Unequal wall thickness results in variations in
curing time of different sections and leads to non-uniform density. Very thin
sections may hinder the flow of fillers and the filler-less compound may cure there
much faster. All these factors effect the ultimate mechanical, electrical and
chemical properties of the end product. The table 14.1 gives minimum and
maximum recommended wall thickness for various materials.

Table 14.1
Recommended wall thickness

Wall Thickness mm.

Material
Minimum Maximum
Phenolics, General purpose 1,25 25
Phenolics, flock filled 1,25 25
Phenolics, glass filled 0,8 19
Phenolics, fabric filled 1,6 9,5
Phenolics, mineral filled 6,5 25
Urea, cellulose filled 0,9 4,5
Melamine, cellulose filled 0,9 4,5
Epoxy 0,8 25
Polyester 1,0 25

Ribs. Large flat surfaces tend

to distort. Ribs lend stiffness,
help in saving material and
shortening curing time and
also work against warpage.
Their wall thickness should be
preferably less than that of the
article; in no case should it
exceed the later. A taper of at
least 1 on each side, or more
if feasible, helps in safe
ejection. Their height too
should not be more than three
times their thickness.
Fig. 14.11

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Generous fillet radii ensure strength, easy filling and ejection. Flow lines may
appear on the back of ribs in injection moulding. These can be eliminated or
camouflaged by introducing shallow flutes or decorative features (Fig. 14.11).

Bosses. The wall thickness of a boss should not

exceed that of the wall on which it stands. Its joint with
the adjacent side walls should not result in material
accumulation. It may be joined to the side wall by a rib
(Fig. 14.12).

Corner radii. Sharp inner corners retard the flow of

material. During curing and shrinking, the inner corners
Fig. 14.12 may generate stresses. Sharp corner may give rise to
cracks.

As a rule, an inner radius of 0,75 times the wall thickness proves adequate. It has
been found that the larger radii do not influence the stress situation significantly.
They, however, ease the flow.

Draft. The injection moulded parts are generally demoulded with the help of
ejector pins, which are placed close to, but not directly in line with, the forces of
retention. Unless the sidewalls, on which the article shrinks, are foreseen with
adequate taper, the moulding may get damaged or distorted during ejection. A
Fig. 14.12
minimum taper of 0,5 is a must, though a larger angle would be safer.

Threads. It is possible to form male or female threads in injection moulded parts,

usually in a semi-automatic mode by placing threaded cores in the mould,
ejecting them along with the moulding and unscrewing them outside. Threads
with v-profile are most suitable. The pitch, however, should not be less than 0,8
mm, especially for
compounds with coarse fillers.
Both the start and the end of
the threads should be about 1
mm below the surface as
shown in figure 14.13.
Threads can also be cut after
moulding. The moulded core
hole should be conical to
avoid excessive friction while
tapping. If drilled, the core
hole should be bigger by 0,5
mm than Fig. 14.13
that for metals.

Screws. Parts moulded in thermosets can be fastened together

by means of screw fasteners. A cylindrical head screw is
preferable to one with a countersunk head as wedge action of
the later may lead to cracks and fracture (Fig. 14.14).

231
Fig. 14.14 Inserts. Metal inserts, placed in the mould before moulding, can save certain
post–operations like drilling and tapping. The inserts are foreseen with anchoring
aids like diamond knurling on the outer surface. They should not have sharp
edges, which could cause cracks. Also electrical contacts and assembly lugs etc.
can be moulded as inserts. Inserts with special configurations can also be
pressed in right after ejection when the moulding is still hot.

14.6 Trouble shooting (Moulding defects, their causes and remedies).

A number of factors influence the quality of a moulding. A flaw or incongruence
there results in a defective product. Recognition of the cause is the first step
towards finding the remedy. The influencing factors are:

1. The properties of the material

2. The product design
3. The screw geometry
4. The screw speed
5. The mould temperature
6. The injection pressure
7. The holding pressure
8. The curing time

14.6.1 The flash.

A thin material film at the parting line, joined with the moulding.

Causes.
The machine locking force insufficient.
Too high an injection pressure.
Too late switchover from injection to holding pressure
Mould temperature too high; the curing is too fast
Mould parting not parallel or damaged

Remedies.
Shift to a bigger machine
Reduce injection pressure/ speed
Switch over to holding pressure earlier
Reduce mould temperature
Grind/repair the parting surface,

14.6.2 Demoulding problems.

The part sticks in the mould and distorts during ejection.

Causes:
Draft too small
Mould surface too rough.
Ejectors insufficient, too small in area, unbalanced positioning.
Holding pressure too high and/or too long.
Mould temperature too high
Part not fully cured.

232
Remedies.
Increase taper if possible
Check and improve mould surface
Replace ejectors, increase size, add more ejectors
Reduce pressure/ pressure duration
Reduce mould temperature
Increase pre-heating time

14.6.3 Dull areas.

Dull zones on the surface.

Causes.
Sediments on mould walls, release agent.
Local hot spots in the mould causing colour variation.
Porosity, caused by volatiles, incomplete filling, air entrapment.
Impurities in the moulding compound.
Low mould pressure.

Remedies.
Clean the mould.
Equalise mould heating.
Preheat the compound.
Improve venting
Increase holding pressure/time.

14.6.4 Blistering.
Hollow high spots on the surface of the moulding.

Causes.
Gases, trapped under the hardened skin, lifting up the layer.
Mould temperature not uniform.
Inefficient venting.
Product not fully cured.

Remedies.
Increase preheating to drive away the volatiles.
Equalise mould temperature.
Improve venting.
Introduce breathing.
Increase curing time.

14.6.5 Orange peel.

Pit marks, elevations and depressions on the surface.

Causes.
Coarse/ hard grain compound. Skin hardens but coarse grain below cures later
and unequally.
Flow of material too slow, grains not melted.
Mould temperature too low.

233
Remedies.
Change material, use refined/ softer grain.
Decrease preheating time.
Increase mould temperature.
Increase pressure.
Increase curing time.

14.6.6 Sink marks.

Shallow depressions on the surface, visible through gloss difference.

Causes.
Material accumulation.
Unfavourable rib-to-wall thickness ratio.
Fillet radii too big.
Vent channels too deep.
Curing time too short.
Moulding pressure too low.

Remedies.
Change product design, reduce material accumulation.
Correct venting channels.
Increase the material dosage.
Increase pressure.
Increase curing time.

14.6.7 White areas.

Some areas on the surface appear light-coloured (applicable to UF,MF).

Causes.
Thermal degradation of pigments.
Barrel temperature and/ dwell time too high.
Mould temperature too high at some spots.
Material not flowing easily.

Remedies.
Decrease barrel temperature.
Increase injection speed.
Decrease overall cycle time.

14.6.8 Silver streaks.

Elongated bubbles, silvery in appearance, on the surface.

Causes.
Moisture in the compound forming steam.
Venting ineffective/ clogged.
Mould closing too tight.

Remedies.
Change the compound.
Facilitate escape of moisture by injecting slowly.

234
 Clean/ improve the vents.

14.6.9 Warpage.
The part deforming after ejection.

Causes.
Incomplete curing due to low mould temperature.
Insufficient curing time.

Remedies.
Increase mould temperature.
Increase curing time.

14.6.10 Diesel effect.

Burn marks on the product.

Causes.
Too much lubricant in the compound.
Entrapped gases, poor venting.
Choked vent holes
Mould temperature too high

Remedies.
Change compound.
Reduce preheating
Reduce mould temperature.
Improve venting.
Change gate position.
Clean vent slots, ejectors.

14.6.11 Cracks.
Through-going crevices especially near sharp corners, cut-outs, change of
section, inserts.

Causes.
Internal stresses caused by obstructed shrinkage near sharp corners.
Plastics layer around inserts too thin.
External stresses during ejection.

Remedies.
Round off sharp corners.
Preheat metal inserts.
Redesign product with more material around inserts.
Decrease mould temperature.
Increase curing time.
Increase demoulding draft.
Place ejectors at crucial points

14.7 Advantages and disadvantages of injection moulding.

235
14.7.1 Advantages:
 Homogeneity due to mixing action of the screw.
 Greater accuracy
 More freedom in product design as wall thickness may vary.
 Less post-operations
 More uniform temperature of the melt in the mould, consequently more
uniform curing and more uniform shrinkage. Closer tolerances.
 Shorter cycles
 Automation

14.7.2 Disadvantages:
 Higher investment
 Greater orientation of fibres
 Special material formulations

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 Chapter 15

Injection Moulding of Liquid Silicone Rubber

15.1 The material

15.2 The moulding process
15.3 The moulding equipment
15.4 The mould
15.5 Two component moulding
15.6 Trouble shooting
15.7 Applications

15.1 The material.

Liquid silicon rubbers are high purity platinum cured silicones. They belong to the
family of thermoset elastomers that have a backbone of alternating silicone and
oxygen atoms and methyl or vinyl groups and vulcanise by the process of
polyaddition. The reaction starts when two components of the material are mixed
together. The speed of the vulcanisation is proportional to the ambient temperature.
The reaction is very slow at room temperature but proceeds very fast at
temperatures above 150°C. This characteristics of the liquid silicon rubbers forms
the basis of their processing by injection moulding, which may be considered similar
to that for the thermosetting polymers (Chapter 14). In both cases, the material is
injected in fluid, uncured state into the mould, where the temperature initiates
chemical reaction resulting in hardening of the melt.

Liquid silicone rubbers possess following characteristics:

 High transparency
 Low compression set
 Flexibility between -50°C and 200°C
 Light resistance (including UV and X-rays)
 Resistance to steam
 Very good ageing resistance
 Very good long term mechanical endurance
 Constant mechanical properties over a wide temperature range
 Excellent electrical insulation
 Excellent environmental compatibility
 No toxic products on burning
 Adhesion to metals and plastics possible with additives
 Repulsion to water

15.2 The moulding process (Fig. 15.1).

The liquid silicon rubber for injection moulding is supplied, ready for use, as two
separate fluids, usually referred to as component A and component B. One of the
component contains the platinum-based catalyst. These are stored separately and
pumped under pressure in equal proportion to a static mixer. It is also possible to
include a pigment conveyor in parallel connection to the mixer. These devices are

237
maintained at a
controlled
temperature of 18-
20°C. The cold
mixture is conveyed
at a pressure of 30-70
bar to the injection
unit of the injection
moulding machine,
which is similar to that
of an injection Fig. 15.1
moulding machine for
thermosets. The
barrel differs from its counterpart in conventional moulding in two aspects; it has no
hopper and no heaters. The moulding material in the form of a liquid mixture comes
to its feeding section through a flexible pipe from the static mixer and it is provided
with a cooling jacket for circulation of a cooling fluid, usually water. The screw in the
barrel has two functions; it acts as a conveyor of the fluid mixture from the feeding
point to the machine nozzle at the end of the barrel and as a piston to inject the fluid
into the mould. The material transport takes place under a back pressure of 5-30 bar.
The screw does not have to compress and plasticise the mixture which is already in
a fluid state. It is also not necessary to make the fluid travel a certain distance from
feeding point to the nozzle for plasticising. Therefore, the feeding zone in converted
moulding machines is usually advanced in position. The cooling arrangement of the
injection unit is tailored to maintain a uniform temperature between 18-20°C.

15.2.1 Melt injection.

The operation of injection is similar to that for thermosets. The melt is forced into the
mould, which is maintained at an elevated temperature, by the screw acting as a
piston moving linearly. The uncured liquid silicon rubbers are very thin flowing and
hence do not need high injection pressures. Most varieties can be moulded with an
injection pressure close to 100 bar. The material cushion is kept to a bare minimum,
almost zero, in order to avoid flashing. The silicon rubbers expand in volume on
curing, thereby increasing the cavity pressure manifold, in some cases upto 300 bar.
To take care of the expansion, the cavity is filled to about 95-98 % by injection and
gets filled completely through increase in volume of the crosslinking silicon rubber.

Testing of a new mould invariably starts with intentional short shots. The optimum
filling limit is explored through a number of progressive shots to avoid overloading
and flashing. The speed and feed is chosen to fill the mould as fast as possible to
forestall curing. The injection speed is throttled towards the end of injection stroke to
enable effective venting. The vulcanising or the curing time, which takes the place of
the “cooling time”, depends upon the wall thickness of the moulding and ranges
between 3-5 seconds per mm. Vulcanisation my be considered to be over when the
article can be ejected without damage or permanent distortion.

Unlike thermosetting polymers, silicon rubber does not undergo any contraction
during curing in the mould; it expands on the other hand and tends to ooze out of the
gate after termination of injection. Holding pressure, unlike with thermoplastics
moulding, has the sole function of preventing the reverse flow till the gate section

238
has cured and closed. It may take about 1-4 seconds, depending upon the size and
location of the gate. The holding time can be considerably shorter with shut-off
nozzles. The holding pressure may range between 50-100 bar.

A measure specific to the moulding of LSR is the so-called “bumping”, which is

carried out to dislodge entrapped air bubbles. It is sudden release of moulding
pressure followed by its build-up to full extent. It is repeated several times in rapid
succession during injection before the curing process sets in.

15.2 Ejection.
Although the moulding machine is equipped with the usual ejection device and the
mould also has ejectors and strippers, the flexibility of the cured moulding makes the
use of additional external aids unavoidable. These may be rollers, pickers, robots etc
as discussed later.

15.2.3 Interrupting or terminating the moulding process.

The polymer starts crosslinking right from the moment of mixing of the two
components. Its speed of reaction, however, is very low at 18-20°C at which the
mixer, the flow lines and the injection unit of the moulding machine are maintained.
Short breaks, lasting a few hours, do not cause much damage but an interruption
involving more than three days calls for special measures. It becomes necessary to
either purge the injection unit with the component A or store it at -20°C. The same
treatment must be meted out to the cold runner assembly of the mould.

If the production is required to be stopped for a longer period, all machine and mould
parts containing the mixture must be flushed out with the component A of the
polymer. Storage of the above parts at -20°C obviates purging.

In locations with high or fluctuating temperatures, air conditioning is necessary for

trouble free production.

15.2.4 Post-operations.
LSR mouldings are generally ready for use after cooling but post curing is carried out
in special cases like those where foodstuff or medicines are involved. It is also
resorted to for obtaining a low compression set. The process involves baking the
mouldings in a forced circulation oven at an elevated temperature (~200°C) for a
certain period (4 hours for 2 mm. thick plane parallel components) to drive out
volatile constituents, which are primarily combustible siloxanes. Clean fresh air is
passed through constantly to avoid deflagration. Good ventilation of the site is
imperative.

15.3 The moulding machine.

The injection moulding machine for processing liquid silicone rubbers differs from its
counterpart for thermosets only in a few design features of the plasticising unit. In
the first instance, it cannot be truly designated as a plasticising unit as it receives the
raw material in a fluid state which is not altered in the barrel in any way till the point
of injection. The unit does have a barrel, a screw , a non-return valve and a nozzle.
The screw does not have to compress and plasticise the material. Its function is
limited to that of a conveyor and a piston. The conventional design of the non-return
valve is inadequate for the extremely thin flowing liquid silicon rubber. Special valve

239
with spring support has been devised for this polymer. The machine nozzle too must
be of the shut-off type, preferably a hydraulically operated one. The barrel does not
have a hopper and heaters. It is provided with a cooling jacket to keep its
temperature within a narrow range of 18-20°C. The machine nozzle is also water
cooled. As the material is not required to traverse a certain distance for its
plastication, the feeding zone is shifted further towards the exit end.

The mould closing and ejection units do not differ from those of the conventional
injection moulding machines in any way. It is, therefore, possible to employ a
conventional machine for processing of LSR by changing only the injection unit. The
very low viscosity of the mixed fluid, however, makes very fine control of the injection
stroke and the injection speed imperative. It is, in the end, economical to employ a
closed loop machines with precise controls for pressures and speeds.

A prime requirement of the closing unit is the parallelism of the highest order
between the mould platen to prevent flashing of the thin fluid. The injection pressure
needed for processing of LSR is much lower than that for thermoplastics. It enables
moulding of articles with large surface areas on machines with lower locking force.

Ejection of flexible LSR mouldings only with conventional devices like ejector pins,
sleeves and strippers is not always successful. Additional supportive arrangements
like roller sweeps, brushes and pickers add a measure of certainty to the operation
of demoulding. Robots are a useful accessory to a moulding unit for LSR.

Controls for the mould heating may be separate in case of converted machines but
machines devoted specifically to LSR moulding have them integrated in their
systems. Same holds good for the vacuum devices for mould venting. In order to
facilitate evacuation of air from the mould, these machine have the arrangement to
close the mould with a low pressure, inject the material and then apply the final
locking force. Another arrangement to enable creation of vacuum in moulds with a
seal on their parting face is to stop the moving platen 0,5-2,0 mm. before the mould
halves touch each other, suck out the air and then lock the mould before injecting the
mixture.

A moulding machine for a particular product is selected on the basis of the locking
force needed to counterbalance the cavity pressure generated by the expanding
polymer injected in the mould. To be on the safer side, a cavity pressure of 400 bar
per square centimeter is assumed. The locking force of the machine should be
slightly higher than the total cavity pressure. Another feature, no less important, is
the shot weight. The screw must make a stroke equalling 1-5 times its diameter to
inject the shot otherwise its revolutions for dosing the next charge would be
insufficient for an adequate mixing. The injection unit should not be oversized.

15.4 The mould.

15.4.1 The mould design and construction. In principle, an injection mould for
LSR is almost identical to its counterpart for injection moulding of thermoplastics. It is
required to perform the same basic functions and has the same or similar design
features, viz. a feeding path for the “melt” from the entry point to the cavity, the
cooling (here the heating) system for solidification of the injected fluid and an
arrangement to eject the mouldings without damage and distortion.

240
The extra ordinary high fluidity of LSR puts extreme demands on the leakproofness
of the mould. Any deviation in parallelism of plates may prove disastrous. Smallest
distortion and gaps to the tune of 0,01-0,02 mm. result in flash. The best way to
eliminate distortion caused by machining stresses is to anneal the mould plates after
every machining operation.

The feeding system can be similar to that of thermoplastics but the cross section of
the runners, which should preferably be circular, may be much smaller. The runner
system must be a balanced one to fill all cavities evenly.

Conventional gates such as edge gate, film gate, pin point and submarine gate are
also applicable for moulding of silicone rubbers though their size can be much
smaller. For instance, a submarine gate with a diameter of 0,2-0,5 mm. proves
adequate in most cases.

Conventional feeding systems with primary and secondary runners result in

considerable wastage as the runners cannot be recycled. To circumvent this
drawback, a cold runner system, similar to the one for moulds for thermosets
(chapter 14), has also been developed for moulding of LSR. The aim is to bring the
polymer mixture from the machine nozzle up to the mould cavity in uncured state i.e.
without any appreciable rise in temperature. The cold runner system is housed in a
separate block, integrated in the mould but insulated from it. An efficient cooling
network is essential to prevent a rise in its temperature through conduction,
convection and radiation from the hot mould surrounding it. The nozzles of the cold
runner system, bringing the polymer into the cavity, are equipped with shut-off
needles, operated hydraulically or pneumatically, to prevent drooling of the mixture
when the mould opens.

Multi-point gating is, in the rule, not necessary even for large articles due to excellent
flowability of the “melt”. More than one gate may introduce another problem too.
Even minute differences in the gate size may cause unbalanced filling.

The necessity for rapid injection to forestall premature curing before complete filling
is accompanied by difficulties in efficient expulsion of air out of the closed mould.
Venting is usually provided on the mould parting line in the form of shallow slots. Air
vents deeper than 0,004-0,005 mm. will give rise to undesired flash. The slots are
usually 1-3 mm. wide and are located at the point of last filling. When compressed
highly, the trapped air gets overheated and causes whitening of edges due to
degradation of the compound.

To evacuate enclosed air from a critical place, the parting line may be made to pass
through it.

In critical cases, when conventional venting proves inadequate, it becomes

necessary to evacuate air from the mould before injection of material. To this end,
the mould is provided with a flexible, heat resistant seal around the cavity on the
parting face. The mould is closed incompletely, leaving a gap of 0,5-2 mm. between
the mould halves. The enclosed air is sucked out with the help of a vacuum pump
and the mould is closed fully before the injection takes place.

241
Moulds for LSR, particularly the plates housing the cavities and cores, must have a
uniform temperature. Depending upon the polymer, these mould components are
maintained at a temperature between 170-220°C, usually through incorporation of
cartridge heaters. A thumb rule for determining the heating capacity is allocating 50
watts for every kilogramme of steel to be heated. Oil heating is preferred for large
moulds. In order to preclude any distortion, the holes for cartridges or for oil
circulation should not be too close to the parting line of the mould. If only core and
cavity plates are being heated, these must be insulated from the rest of the mould
bolster through insulating plates.

15.4.2 The ejection system.

Liquid solid rubbers do not shrink in the mould, they expand upon crosslinking. The
moulding may not remain on the core side when the mould opens. The sticking
tendency of the LSR moulding may make it adhere to the mould side with greater
surface area. In ambiguous cases, it is more practical to determine this in a trial
mould before going in for a production tool. One way of keeping the mouldings on
the desired side is to choose parting line forming an undercut. The flexibility of the
material enables demoulding without special arrangements of clearing undercuts.

Among the ejection devices, the cylindrical ejector pins are the least effective. They
tend to pierce the flexible moulding sticking to the mould surface. They may be
employed selectively in conjunction with other internal and external ejection devices
such as :

 Strippers
 Sleeve ejectors
 Mushroom ejectors
 Air ejectors
 Roller sweep
 External brushes and pickers
 Robots

15.4.3 The mould shrinkage.

As mentioned before, liquid silicone rubbers expand during curing instead of
shrinking. Shrinkage takes place while cooling after ejection and varies between 2,5-
3 %. The extent of shrinkage depends upon:

 mould temperature and demoulding temperature

 pressure in the cavity
 gate location; shrinkage is more along the flow and less across it.
 wall thickness; thicker sections shrink less
 post curing; additional shrinkage of 0,5-0,7%

15.4.4 Mould materials.

Steels used for the mould components must retain their hardness, strength, wear
resistance, parallelism and polish at temperatures above 200°C. The mould bolster
may be fabricated out of an unalloyed steel like EN8 but the mould plates must be
made of a tougher material such as P20. The heated plates and mould inserts must

242
be formed out of hot die steels. AISI H11 is highly suited for this application. The
filled varieties of LSR cause a considerable wear in the mould. Ti-Ni treatment of the
mould surface prolongs the mould life considerably.
The mould surface should not be polished too much as SLR tends to stick on shining
surfaces. If permissible, the surface should be roughened either through spark
erosion, etching or by wet sandblasting. The recommended surface roughness is
0,5-3,2 μm. Only in case of transparent mouldings, there is no alternative to
polishing the mould. The sticking tendency of the material can be countered by a
PTFE-Ni treatment of the mould surface.

The mould must be provided with insulating plates on both sides to prevent loss of
heat to the machine platen.

15.5 Two component injection moulding with LSR.

It is possible to mould liquid silicone rubbers over one another as well as over
thermoplastics and metals. As a rule, these rubbers do not bond with thermoplastics
and metals. The bond has to be achieved through mechanical means like undercuts
or by application of primers over thermoplastics and metal substrates. However, it is
also possible to compound the bonding agent with the LSR so that the process of
overmoulding can be carried out without interruption. The adhesion improves with
ageing and reaches the optimal level in about two weeks after moulding. The
process can be accelerated by heat treatment to 100°C for 1 hour.

There are two ways to perform the two component moulding:

15.5.1 Tandem Moulding.

The method employs two injection moulding machines, running side by side. One of
the machines produces thermoplastics substrates which are transferred to the
second machine devoted to the moulding of LSR. A robot positions the mouldings
from the first machine in the mould on the second one. After overmoulding, a
composite article is ejected out.

The process needs two standard injection moulding units as well as a handling
device. Investment in capital and space is, of course, high. The cycles, too, have to
be synchronised.

The advantage lies in the simplicity of moulds and independence of the choice of
working parameters from each other, which can be optimised according to the need
of the process and the material in each case.

15.5.2 Composite Moulding.

The process requires a special injection moulding machine with two injection units.
The unit for the thermoplastics moulding is heated whereas the one for LSR is
maintained at temperatures around 20°C. The mould houses equal number of
cavities for the thermoplastics substrate and for the final moulding. As the mould
opens after moulding of the thermoplastics substrates, the core plate of the mould is
rotated by 180 degrees to position the substrate mouldings opposite the
overmoulding cavities. Simultaneously, the other set of empty cores gets positioned
opposite the corresponding cavities for injection with thermoplastics. The mechanism

243
for rotation of the core plate is housed either in the mould itself or the machine has a
built-in device to rotate the moving mould half after each shot. The mould may also
contain a hot runner system for thermoplastics and a cold runner system for the
liquid silicone rubber. A compromise has to be made about the mould temperature,
which as a rule, should be much higher for the LSR than for the thermoplastics. As a
way out, usually those thermoplastics are used for substrate which permit higher
demoulding temperatures. These are: polyamides, polyacetals, polycarbonate,
polyester, polyphenylene sulphide etc. The liquid silicone rubbers too are of the type
which vulcanise at lower temperatures. The mould is heated to about 110-130°C.

As obvious, the single machine alternative is economical in capital cost and space
requirement. The compromise between conflicting processing requirements of the
two different materials usually results in slower production. The mould, too, becomes
highly complicated.

Two component mouldings may also be made out of two different types of LSR for
having two different colours or for making one side or one part of the product
electrically conductive.

15.6 Trouble Shooting

Moulding defects, their causes and remedies.

15.6.1 Short moulding.

The moulding is not filled completely/ has less weight/ has wavy surface.

Causes.
Injection speed/ pressure too low
Material flowing back
Dosage insufficient
Inadequate venting
Premature curing
Back leakage in the barrel
Runners/ gate too small
Runner system unbalanced

Remedies.
Increase injection speed/ pressure
Delay switch-over to holding pressure
Increase shot volume
Increase holding time
Improve venting
Reduce mould temperature/ barrel temperature
Check non-return valve
Increase runner/ gate size
Balance runner system

15.6.2 Burn marks.

White edges, streaks, blisters

Causes.

244
Overheating of the mixture
Inadequate venting
Very high injection speed
Very high mould temperature

Remedies.
Decrease mould temperature
Decrease injection speed
Improve mould venting

15.6.3 Orange peel.

Pit marks, depressions and raised spots on surface.

Causes.
Injection speed too low
Mould temperature too high

Remedies.
Raise injection speed/ pressure
Decrease mould temperature and cold runner temperature

15.6.4 Included air

Bubbles in the moulding.

Causes.
Mould temperature too high
Cold runner temperature too high
Injection speed too low
Inadequate venting (if bubbles are away from the gate)

Remedies.
Reduce mould temperature
Reduce cold runner temperature
Increase injection speed (gradually)
Improve venting (if bubbles are away from the gate)

15.6.5 Demoulding problems.

Article sticks in the cavity, damage during ejection

Causes.
Mould too hot
Holding pressure too high/ too long
Curing time too long
Mould surface too glossy

Remedies.
Decrease mould temperature
Reduce curing time
Roughen up mould surface/ coat with PTFE

245
15.6.6 Flash.
Silicone film at parting line.

Causes.
Shot too large
Injection speed too high
Switch-over to holding phase too late
Clamping force too low
Mould plates not plane/ damaged
Venting slots too deep

Remedies.
Reduce shot volume
Reduce injection speed
Set switch-over point earlier
Increase clamping force
Change over to bigger machine
Check mould plates and rework
Reduce depth of vents.

15.6.7 Article size incorrect.

Dimensions are out of range.

Causes.
Insufficient curing.
Different shrinkage
Deformation on ejection

Remedies.
Increase curing time
Check mould temperature and increase if necessary
Check for uniform mould temperature
Improve ejection, roughen cavity surface

15.6.8 Tacky surface.

Greasy areas on surface.

Causes.
Incomplete curing
Mould temperature too low
Components’ proportion unequal
Inhibitors in vicinity

Remedies.
Increase curing period
Increase mould temperature
Check heaters and thermocouples
Check mixer for pressure fluctuations
Clean mixer and supply lines

246
Check for sulphur compounds, rubbers, urethane and epoxy resins etc. in
neighbourhood and remove

15.7 Fields of Application.

 High temperature gaskets and seals for automobiles, household gadgets,
food processing machinery, electrical and electronic equipment, connectors
 Pump membranes and components, bellows
 Medical appliances, inhalation masks
 Kitchen goods, baking pans, spatulas
 Diving masks
 Nipples for baby feeding bottles

247
 Chapter 16

Reaction Injection Mouldings

16.1 The process

16.2 The materials
16.3 The equipment
16.4 The mould
16.5 Advantages
16.6 Applications

16.1 The process.

RIM is a process for rapid production of plastics articles directly from low viscosity
monomers. Two or more liquids are combined by impingement mixing at high
pressure and then fed into a mould at very low pressure. Solid polymers are formed
by cross-linking of the monomers in the mould. RIM is, therefore, a chemical as well
as a moulding process and quite different from conventional thermoplastics injection
moulding because it uses polymerisation, rather than cooling, to form a solid
polymer which has properties different from those of the materials being fed into the
mould. Although moulding processes like monomer casting or thermoset injection
moulding also use polymerisation to set the part shape, they employ hot mould walls
to activate the reaction. In RIM, monomer and mould temperatures are not so
different and the reaction is initiated by the impingement mixing.

Reaction injection moulding process differs from the classical injection moulding in
many of its features. The plasticising does not take place in a barrel through heat
and mixing and injection is not achieved by means of a screw. The “melt” does not
need high pressure for injection into the mould. The filling into the cavity is more like
casting than injection. Again, the solidification of the “melt” into the moulding takes
place neither by extraction of heat viz. cooling, nor by addition of heat as with the
moulding of thermosets. The polymerisation of the injected mixture of monomers
leads to solidification. The mould plays the role of a container for polymerisation.

In case of polyurethane, two or more low viscosity (0,1-1,0 Pa.s) liquid reactants (di-
or trialcohols and di- or tri-isocynate), which are held in separate temperature
controlled tanks equipped with agitators, are fed through supply lines to metering
units. From there, they flow at high pressure – 100 to 200 bar – into a mixing
chamber. The flow rate ratio between the different streams must be precisely
metered. In the mixer head, the streams impinge at high velocity, mix and begin to
polymerise as they flow out in the mould cavity. Because the mixture is initially at
low viscosity, low pressures – 2 to 10 bar – suffice to fill the mould. The mixing
chambers, the metering heads, the mixhead and the pumps take over the role
performed by the plasticising unit in conventional injection moulding.

The reaction in the injected mixture generates some heat and also an increase in
volume initially but as the polymerisation progresses and solidification sets in,
contraction takes place. Some holding pressure may be needed to compensate the

248
contraction but it can be bypassed by adding a small amount of a foaming agent,
usually monofluor trichloromethane or triflouro trichloroethane, at the time of creating
the mixture.

The moulds are maintained at a temperature between 40-65°C depending upon the
composition of the polymer.

The manufacturing process takes place in the following sequence:

a) High pressure metering of reactants to the mixer head
b) Filling the mould (at high speed)
c) Curing by chemical reaction (polycondensation)
d) Demoulding
e) Finishing – flash trimming, post curing, cleaning, painting etc.

16.2 The moulding materials.

The RIM process has evolved from the PU rigid foam technology for manufacturing
large articles which were difficult to mould in conventional process. Although the
range of materials which can be processed by RIM has been extended,
polyurethane in various forms such as flexible, semi-rigid, solid, foamed, reinforced
and gas assisted constitutes over 90% of consumption. Other materials found
suitable for the process are: nylon block copolymers, acrylics, polyureas, polyesters,
epoxies, dicyclopentadiene (DCPD) and hybrid urethane systems.

Glass fibres are commonly used for reinforcement. They increase flextural strength
and reduce shrinkage. Scrap plastics and wood flour too have been added for
particular applications.

16.3 The equipment.

The equipment for the RIM process
consists of:

a) Conditioning system to prepare the

ingredients for use
b) Metered pumping system to transfer
intermediates for mixing
c) Mixing heads, where the liquid
ingredients are combined through
impingement
d) Mould carrier to hold, open, close
and swivel the mould
Fig. 16.1
Figure 16.1 depicts the first three
steps of the process and figure 16.2 shows the mould carriers schematically.

16.4 Moulds for RIM

The three characteristics viz. the low
viscosity. low pressure and low
temperatures enable use of a wide

Fig. 16.2
249
range of mould construction materials, depending upon the quality, quantity and the
cost of the products.

Silicone rubber moulds prove economical in cost and time when a few pieces are
required for trials and prototypes. The quality of the surface is low.

Moulds, cast out of epoxy resins, render the surface details much better. They can
be used to produce fairly large numbers of articles in foamed systems. The
production rate is quite low.

Moulds made by spraying of low melting temperature tin-bismuth alloys can be

produced very fast. The reproduction of the details of the model, too, is very good.
The heat dissipation is also better than with resin moulds. The alloys have, however,
a very low tensile strength and are bound to give rise to flash. The alloys are very
expensive but can be used again and again.

Moulds for RIM can also be cast out of special zinc alloys like kirksite and aluminium
alloys. Although more expensive, these offer higher dimensional accuracy, better
reproduction of surface details, faster production and longer service life.

The optimum results are obtained by employing hardenable alloy steels or

prehardened steels as mould materials. These can be polished to a very high degree
which counters the tendency of urethanes to stick to metals and makes ejection
easier. Nickel plating adds to the ease of demoulding. The surface details are
reproduced exactly. An efficient cooling system can be incorporated. Because of
higher strength and hardness, the mould service life is long and the flashing remains
minimum.

Electroformed nickel shells, suitably backed and fortified, also offer a good
alternative for fabricating efficient RIM moulds. The quality of the surface is optimum.

The moulds have to be maintained at a constant temperature (40-65°C, depending

upon the composition being used) within a range of ± 2°C. Hence the RIM mould
requires balanced cooling lines like the ones for injection moulding. The mould
orientation should be such as to allow filling from the bottom of the mould cavity,
allowing escape of air through a controlled vent on the top.

The feeding system of RIM moulds is similar to that in conventional moulding. The
sprue, runner and gate act also as a transition zone and transform the turbulent flow
from the mixing head into a laminar one.

The ejection of the soft PU-mouldings is carried out by stripping. Because of the
very low injection pressure, the RIM equipment does not require high clamping
forces, which may be as low as 2-5% of those needed for the same article if moulded
in conventional injection moulding process. Moulds for small articles need not be
clamped in a press; they can be locked by latches hinged with the mould halves.

16.5 Applications.

250
The RIM process has evolved from the PU rigid foam technology. The major
application has been the facia of car bumpers in USA. Later, automobile fenders and
body panels were made of glass filled urethanes. Though it is primarily being used
for exterior automobile parts, there has also been significant application for interior
car parts, appliances and recreational equipment. Over 90% of RIM production is
polyurethane, as flexible, semi-rigid or micro cellular components. The advantage of
RIM over conventional injection moulding includes the moulding of parts larger than
5 kg, those with very thin walls as the viscosity of the resin is very low and also those
with very thick walls because curing is uniform throughout the moulding.
Some typical products made by RIM are:

 Large automotive parts like bumpers, spoilers, side panels

 Housings for electronic equipment, computers, copiers, type writers
 Housings, covers, large components for domestic appliances,
 Office furniture
 Outdoor furniture for beaches
 Bathroom articles like shower cabinets, tubs, cupboards
 Toilet seats, urinal partitions,
 Sports goods, snow-mobile parts
 Submersible sewage pump components
 Medical and laboratory equipment, dentists chair and wheel chair parts etc.
 Lighting fixtures

16.6 Advantages.

 Low cost tooling

 Design freedom; combination of thick and thin sections unproblematic
 Large L:T ratios possible due to low viscosity of components
 Excellent reproduction of surface details
 Flexibility in physical properties of mouldings through variation in material
composition
 Higher strength with less weight by foaming

251
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