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<FONT style='color:#FFFFFF;font-family:"Times New Roman";font-size:18pt;'><B>BOOK 4, Chapter I </B></FONT></DIV>
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<FONT style='color:#FFFFFF;font-family:"Times New Roman";font-size:22pt;'><B>About Thermal Injection </B></FONT></DIV>
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<B></B><FONT style='color:#000000;'><B> <A class=s17 HREF="http://thelmdfg.com/readme/thermal/index.htm">Thermal Injection</A></B></FONT></DIV>
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<B></B><FONT style='color:#000000;'><B> <A class=s17 HREF="http://thelmdfg.com/readme/urethane/index.htm">Urethane Resins</A></B></FONT></DIV>
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<B></B><FONT style='color:#000000;'><B> <A class=s17 HREF="http://thelmdfg.com/readme/gelcoat/index.htm">Gel Coats</A></B></FONT></DIV>
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<B></B><FONT style='color:#000000;'><B> <A class=s17 HREF="http://thelmdfg.com/readme/pva/index.htm">Polyvinyl Acetate</A></B></FONT></DIV>
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<B> <A class=s17 HREF="http://thelmdfg.com/readme/viscosity/index.htm">Viscosity</A>
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<FONT style='color:#FFFFFF;font-size:8pt;'>8 </FONT></DIV>
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<FONT style='color:#800000;font-size:12pt;'><B>A Typical Thermal Injection Molding System: </B></FONT></DIV>
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<B>Considerable thought, and cost is put into the design of molded parts and their molds, to ensure that the parts will not be trapped in the mold, that the molds can be completely filled before the molten resin solidifies, and to minimize imperfections in the parts, which can occur due to peculiarities of the process, such as shrinking due to extreme temperature change from cooling. </B></DIV>
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<B> </B></DIV>
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<B>Injection Molding is a manufacturing technique for making parts from plastic material. Molten plastic is injected at high pressure into a mold, which is the inverse of the desired shape. The mold is made by a mold maker from metal, usually either steel or aluminum, and precision-machined to form the features of the desired part. Injection molding is very widely used for manufacturing a variety of parts, from the smallest component to entire body panels of cars. </B></DIV>
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<B> </B></DIV>
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<B>Molds separate into at least two halves—called the core and the cavity—to permit the part to be extracted; in general the shape of a part must be such that it will not be locked into the mold. For example, sides of objects typically cannot be parallel with the direction of draw—the direction in which the core and cavity separate from each other. They are angled slightly; examination of most household objects made from plastic will show this aspect of design, known as draft. Parts that are "bucket-like" tend to shrink onto the core while cooling and, after the cavity is pulled away, are typically ejected using pins. More complex parts are formed using more complex molds, which may require moveable sections which are inserted into the mold to form particular features that cannot be formed using only a core and a cavity, but are then withdrawn to allow the part to be released. </B></DIV>
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<B> </B></DIV>
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<B></B><FONT style='color:#800000;font-size:12pt;'><B>Basic Process: </B></FONT></DIV>
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<FONT style='font-size:12pt;'><B> </B></FONT></DIV>
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<B>Heat a thermoplastic material until it melts. Force it into a hollow (cooled) cavity under pressure to fill the mold. When cool remove the finished part. </B></DIV>
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<B> </B></DIV>
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<B></B><FONT style='color:#800000;font-size:12pt;'><B>Typical materials are: </B></FONT></DIV>
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<FONT style='font-size:12pt;'><B> </B></FONT></DIV>
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<B>- nylon </B></DIV>
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<B>- styrene </B></DIV>
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<B>- ethylene </B></DIV>
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<B> </B></DIV>
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<B></B><FONT style='color:#800000;'><B>I</B></FONT><FONT style='color:#800000;font-size:12pt;'><B>njection system: </B></FONT></DIV>
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<FONT style='font-size:12pt;'><B> </B></FONT></DIV>
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<B> - a material hopper acts as an input buffer </B></DIV>
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<B> - a heated chamber melts the material </B></DIV>
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<B> - an injector forces the now viscous fluid into the mold </B></DIV>
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<B> </B></DIV>
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<B>Previous mechanisms used an injection plunger. </B></DIV>
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<B> </B></DIV>
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<B>Current mechanisms use a reciprocating screw. Basically the screw extends from the hopper to the injection chamber. Along the length of the screw chamber, heater bands are used to melt the plastic. </B></DIV>
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<B>As the screw turns, it moves raw solid plastic from the hopper, to the injection chamber. The buildup of pressure in the injection chamber forces the screw back until enough for a shot has accumulated. The screw is forced forward to inject the plastic into the mold. There is a contribution to melting by pressure that allows the temperature of the heating bands to be lower. The purpose of the screw is to generate a homogenous melt with little orientation in flow direction. </B></DIV>
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<B>Typical zones can be identified on the screw. Some feed screws have large cavities to carry more material. The compression portion of the screw thread reduces, leading to elevated pressures, and pressure induced melting. The metering portion of the screw has small and uniform threads to provide controlled quantities. This also serves as a final mixing stage. </B></DIV>
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<B> </B></DIV>
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<B>Screws are often low/medium/high compression ratio as a result of the change of screw volume from the feed to the metering stages - screw selection will vary between materials, but a low compression ration screw will ensure good melting in most cases. </B></DIV>
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<B> </B></DIV>
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<B>Screws are nitride treated to improve tool life. Screws might also be made slightly smaller to compensate for thermal expansion when heated. </B></DIV>
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<B> </B></DIV>
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<B>Screws are often driven by electric or hydraulic motors. </B></DIV>
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<B> </B></DIV>
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<B></B><FONT style='color:#800000;font-size:12pt;'><B>Injection Process: </B></FONT></DIV>
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<FONT style='font-size:12pt;'><B> </B></FONT></DIV>
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<B>Heated plastic is forced under pressure into a mold cavity; it is then clamped together and solidifies into the shape of the mold creating the part. </B></DIV>
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<B> </B></DIV>
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<B>The PC/ABS granules are poured into the Feed hopper, this is pretty much a large open bottom container, which feeds the granules down to the screw. The screw is turned by hydraulic motor that turns the screw feeding the granules up the screw's grooves. The screw travel limit switches set the distance the screw moves. As the PC/ABS granules move up the grooves of the screw, heaters on either side of the screw heat the granules to high temperatures changing their state from solid to liquid plastic. </B></DIV>
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<B> </B></DIV>
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<B>The hydraulic system uses pumps and oil from the oil tank to close up the male and female mold parts that run along the tie bar, then the liquid PC/ABS is injected into the mold. Since the molds are clamp shut by the hydraulics the heated plastic is forced under the pressure to take the shape of the mold. The water-cooling channels then cool the mold and the heated plastic solidifies into the part. </B></DIV>
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<B> </B></DIV>
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<B>Note: PC/ABS stands for amorphous polycarbonate and acrylonitrile-butadiene-styrene terpolymer blend. </B></DIV>
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<B> </B></DIV>
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<B>The heat capacity and melting point temperatures of various materials determine the energy required to melt the plastic and the energy to be removed for solidification (and for ejection). The volume of the injection chamber determines the maximum mold cavity size. The volume provided is often for polystyrene. When using other materials the volume can be corrected using the following formula. For example a 10 oz. shot. The mold is held closed with a certain clamp tonnage. As cycle times decrease, the plastic melt becomes less consistent. Each heating zone uses electrical heating bands with thermocouples, or pyrometers to control the temperature. </B></DIV>
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<B> </B></DIV>
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<B>When injecting, the mold is moved then clamped shut. The mold halves are mounted/clamped/screwed on two platens, one fixed, one moving. The stationary platen has a locating ring to allow positioning on the mold half over the injection nozzle. The moving half has ejector pins to knock out the finished part. Larger plates are found on larger injection molding machines. </B></DIV>
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<B> </B></DIV>
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<B>Injection molding machines pressure is calculated as injection pressure over an area in the mold. Consider the case where a mold with a 10 square inch mold is being filled in a 200 ton machine. The platens are actuated by hydraulic driven mechanisms. These are slow, but can exert great forces. In lighter presses other mechanisms can be used. </B></DIV>
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<B> </B></DIV>
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<B>The resin, or raw material for injection molding, is usually in pellet form, and is electrically melted shortly before being injected into the mold. The channels through which the plastic flows toward the chamber will also solidify, forming an attached frame. This frame is composed of the sprue, which is the main channel from the reservoir of molten resin, parallel with the direction of draw, and runners, which are perpendicular to the direction of draw, and are used to convey molten resin to the gate(s), or point(s) of injection. The sprue and runner system can be cut off and recycled. Some molds are designed such that it is automatically stripped from the part through action of the mold. </B></DIV>
<DIV class=s3>
<B> </B></DIV>
<DIV class=s3>
<B>The quality of the molded part depends on the quality of the mold, the care taken during the molding process, and upon details of the design of the part itself. It is essential that the molten resin be at just the right pressure and temperature, so that it flows easily to all parts of the mold. The parts of the mold must also come together extremely precisely, otherwise small leakages of molten plastic can form, a phenomenon known as flash. When filling a new or unfamiliar mold for the first time, where shot size for that particular mold is unknown, a technician should reduce the nozzle pressure so that the mold fills, but does not flash. Then, using that now-known shot volume, pressure can be raised without fear of damaging the mold. </B></DIV>
<DIV class=s3>
<B> </B></DIV>
<DIV class=s3>
<B>The molds are very expensive to manufacture therefore they are usually only used in mass production where thousands of parts are being produced. The molds are constructed from hardened steel. </B></DIV>
<DIV class=s3>
<B> </B></DIV>
<DIV class=s3>
<B></B><FONT style='color:#800000;font-size:12pt;'><B>This kind of Thermal Plastics Injection</B></FONT><FONT style='color:#800000;'><B> Molding System is the conventional method used to produce a high volume of parts per minute. It uses high temperature, and high tonnage pressure to press thermal plastics into large, multi-cavity, heavy and expensive steel molds. </B></FONT></DIV>
<DIV class=s3>
<FONT style='color:#800000;'><B> </B></FONT></DIV>
<DIV class=s3>
<FONT style='color:#800000;'><B></B><B>These systems cost upwards into the millions of dollars, and are far from the pocket books of homespun lure making enthusiasts. I do not teach the where-with-all’s of using this kind of equipment in the LMDFG. In fact; the LMDFG is all about many other materials and methodologies that make homespun micro factories possible. Having that said; I think knowing about Thermal Plastics Injection will make your background knowledge complete.
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<FONT style='font-size:12pt;'><B>The fundamental workings of a Thermal Plastics Injection System
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