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Plastic Injection Molding Technology

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Plastic Injection Molding Technology Powered By Docstoc
					                                         International Training Program
         Plastic Injection Molding Technology
                     2-4 May 2011, Hotel Borobudur, Jakarta, Indonesia

                                                                Program Content
SESSION 1 (Injection Molding Fundamentals)                            - Advantages and Disadvantages of Injection Molding; Applications of Injection
Molding (What is possible with injection molded products); The Injection Molding Cycle (Clamping, Injection, Ejection); Components & functions of an
Injection Molding Machines (Injection Unit - Screw, Barrel, Nozzle, Screw Drive System; Clamping Unit – Mechanical, Hydraulic, Tie Bar Less Clamping
System; Drives – Hydraulic, Electric, Hybrids; Plastic Materials - How they influence machine choice); Injection Molding Machine Types (Standard
Injection Molding Machines, Fast Cycling Machines, Plunger / Shooting Pot Machines, Multi-Component Machines, Micro Injection Molding Machines, Gas
Assisted Molding Machines, Water Assisted Molding machines, Multi-Station Injection Molding Machines, Low-Pressure Injection Molding Machines, In-
Mould Decoration / In-Mould Labelling Machines) ; Injection Control (Profiled / velocity-controlled filling, The feedback loop, Charting and interpretation
of pressure / velocity curves, Pressure limited velocity); Plastics Flow during Injection Molding (How plastic Flows, Laminar flow and fountain flow,
Orientation effects, Effects of temperature, pressure, and molecular weight); Shrinkage and Volume Changes (Pressure-volume-temperature relationship,
Amorphous and semi-crystalline materials, Cavity pressure and mould shrinkage, Flow and temperature effects, Fiber fillers and their effects); Molding
Strategies (Traditional molding, Two-stage molding, Velocity to pressure transfer methods , Process monitoring, Initial mould tryout procedure)

SESSION 2 (Injection Mould Design) - Function of Injection Moulds;                           Mould Types (Single cavity, Multi cavity, 2 plate moulds, 3 plate
moulds, Hot runner moulds); Mould Layout (Mould component parts (Bases), Selection of mould bases, Effects of part design on mould design, Use of inserts
and sub-inserts in construction, Balancing of forces in a mould’s component parts); Tolerances achievable in Mould and Part Design (Tolerances of
mould components and molded articles, Sensitivity of tolerances to molding material and process); Mould Steels (Mould material selection criteria,
Treatments to modify steel properties, Components requiring treatment); Mould Strength (Miscellaneous calculations, Metal fatigue issues, Wear and
undesired hobbing); Ejection (Types of ejection, Actuation and interface to the molding machine, Cosmetic tradeoffs); Cooling (Basic cooling principles &
its importance to product quality, Serial and parallel cooling layouts, Machining cooling lines, Cooling across multiple mould components: (inserts, core pins,
etc.) ,Cooling differences with Amorphous & Crystalline plastics); Gating (Types of gating, Designing the proper gate for the molding material, Balanced
runner layout); Hot Runners (Types of standard systems, Selection and advantages of using a hot runner system, Needle valve gate types: pneumatic,
hydraulic & electric, Needle valve gates & cascade gating); Venting (Importance of venting in injection molding, Designing for proper venting); New
Moulds (Specifying the build, Product take-out: cavity layout implications, Designing for easy maintenance, Measurements and start-up checks, Setting up a
maintenance system, Inspecting the new mould); Older Moulds (What to document before, and when the mould arrives, Establishing cleaning / maintenance
schedule, Spare parts inventory); CAE in Mould Design (Flow analysis for proper gate selection, Cooling analysis for optimal cycle times, Emerging
technologies for mould design)

SESSION 3 (Mould Maintenance and Mould Setting): Mould Maintenance (Problems associated with poor maintenance, Storage,
Corrosion, Cooling Media Conditioning & Filtration, Documentation & logging repair work, Spares itinerary); Mould Setting Considerations (Die height
requirements, Platen usage , Shot capacity, Ejector stroke, Daylight requirements, Projected area and clamp force requirements) ; Set-up of an Injection
Mould (Tool change preparation (Check list), Systematic set-up procedure, Setting Toggle clamp, Setting Hydraulic Clamping system, Attachment methods;
mould to machine, Ejection systems: Types, Tied / coupled ejector/ Ejection Monitoring, Mould protection systems, Services (Coolant /Power / Signals /Air),
Optimising mould movements & actions for safety with speed, Handling systems, Takeout devices)

SESSION 4 (Optimization of Injection Moulding Process) - Establish customer acceptance levels; Mould trial procedures; Process
parameters to measure process stability ; Process Parameter profiles: Why & when to use them (Injection, Holding, Plasticizing, Back pressure) ;
Tolerances for a stable process; Controlling check ring closure & opening; Basic introduction to Design of Experiments / Taguchi® optimization
methods

SESSION 5 (Troubleshooting of Injection Molding)                                   - Troubleshooting Procedures and Logic (How to effectively approach,
analyze, and implement troubleshooting procedures); Exploring Root Causes (Explore the root causes of the various defects from the perspective of the
plastic material as it fills, compresses, and cools within the cavity); Surface Defects (Flow lines and jetting, Splay (moisture or trapped air), Haze, blush, and
poor gloss, Orange peel and surface ripples, Gate blush and gate splay, Stringing witness, Gate vestige); Burning and Contamination Problems (Burn
marks and black specks, Burn streaks, Contamination, Discoloration or poor color match, Burning at the Gate); Physical Problems (Flash and short shots,
Sink marks, Vacuum voids and bubbles, Blisters and delamination) ; Geometry Maintenance Problems (Under- or over-sized dimensions, Poor dimensional
repeatability, Warpage and bowing, post moulding shrinkage) ; Structural Defects (Cracking, crazing, and brittleness, Weld lines, Stuck parts and pin push
marks, Long gates and plugged gates, Drag marks and moulded part damage)

SESSION 6 (Innovative & Tech Trends in Injection Molding) -                             Multi Layer “Sandwich” Molding; Over Molding; Gas
Injection Technology; Water Injection Technology; Injection Compression Molding; Long Fibre Molding; Micro Molding; Introduction to Rapid
Manufacturing Technologies (Fused Deposition Modeling, Selective Laser Sintering, Light curing resins, Uses in mould construction)

Program Language: ENGLISH                                                      Program Agenda: 09.00 am to 05.00 pm (Each Day)

                          Program Instructor : David Jevons, Polybridge Training Limited, UK
                        David Jeavons, proprietor of Polybridge Training Ltd, UK has spent his whole working life in the Injection Moulding Industry. Upon
                        leaving Engineering college in 1969 he served a 4yr indentured apprenticeship with GKN Sankey Ltd. Leaving thereafter to pursue a
                        career in materials technology and then research with RAPRA. After a period with 2 well known trade moulders he worked on behalf
                        of The Ford Motor Company. The late 1980's saw him as part of the PPITB as a technical instructor, moving to become Technical
                        Manager with NETSTAL UK Ltd, eventually leading to the foundation of Polybridge in 1991. Since the mid 1990's he has been closely
                        involved with ENGEL UK Ltd, providing training and technical support on their behalf. Formed in 1991 Polybridge Training Ltd has
built a reputation for customer specific, bespoke training worldwide. Polybridge Training's clients include some of the largest companies in the industry a few
of which are listed as follows: Rapra, Engel, Netstal, Visteon, Sony, Hoover, Mikron, IMI, Metalite, Glazpart, Rexam, FKI, Morgan Materials Technology,
Braun, Gillette, Oral-B, Sims-Portex, Britax, Sumaria Industries (Kenya), AWRE, M.O.D., PERA, Rhone Poulenc, ICI, EMS-Grilon, Ford, Precision Valve
FREE BOOK for All Delegates:
“Injection Molding Process - Troubleshooting & Improvement” published by Plastic Industry Academy. This book has
papers written by injection molding experts on how to improve injection molding process and troubleshooting problems
experienced by injection molders.


Free Software Program “Injection Mold Cost Calculator “for the delegates. This program is developed by
David Jeavons, UK



                        Registration Form – Injection Molding Technology
                                          2-4 May 2011, Hotel Borobudur, Jakarta, Indonesia

Company Name: ………………………………………………………………………………………………………………..
Address …………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………..
Tel……………………………………….. Fax ………………………………….. Email……………………………………..
Contact Person ……………………………………. Mobile…………………………… Email……………………………….


Participant Names
Participant 1 ……………………………………………… Email ……………………………………………………
Participant 2 ……………………………………………… Email ……………………………………………………
Participant 3 ……………………………………………… Email ……………………………………………………

Registration Fee:        950 US$/Person (before 30 March 2011)                 1,050 US$/Person (before 15 April 2011)
                        1,300 US$/Person (after 15 April 2011)


Special Promotion: Register for 2 delegates, 3rd delegate participation is FREE (before 30 March 2011)
                                Register for 3 delegates, 4th delegate participation is FREE (before 15 April 2011)
                                After 15 April 2011, 10% discount for 3 or more than 3 delegates registration from the same company



Remark: Payment is required with registration. The registration fee includes training documentation, lunch and refreshments during the program.

Payment Methods
  Bank Transfer to              Bangkok Bank, Ratchada-Latphrao Road Branch, A/C No: 177-0-70727-9
                                A/C Name: TechnoBiz Communications Co., Ltd., Swift Code: BKKBTHBK
                                (Kindly make payment for all bank charges and fax /email bank slip )

   Credit Card                     Visa       Master Card (5% bank fee for credit card processing will be applied)
                                Card Number ……………………………………………………………………………..
                                Cardholder Name …………………………………………………………………………
                                Last 3 digits on signature panel ……………………Card Expiry Date …………………
                                Signature of Cardholder ………………………………………………Date ……………



Please send completed registration form to

                                                       Plastic Industry Academy@ TechnoBiz, TechnoBiz Communications Co., Ltd.
                                         2521/27, Lardprao Road, Khlongchaokhunsingha, Wangthonglang, Bangkok 10310 Thailand
                                                                        Tel: 66-2-933 0077 Fax: 66-2-955 9971 Cell: 66-81-988 6874
                                          Email: conference@plasticindustry-academy.com Web: www.plasticindustry-academy.com
                                                                        Contact Person: Khun Sirinthip, Program Coordinator     W

				
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