Injection Moulding of Plastic Components: A Guide to Efficiency, Fault Diagnosis and Cure

Bown, J., 1979. Injection Moulding of Plastic Components: A Guide to Efficiency, Fault Diagnosis and Cure. McGraw-Hill Book Company, London. This book covers the following: Preface - 1 Injection moulding - Glossary and definition of terms - Faults in injection moulded components - Incidence and sources of faults - Significance of faults - Dealing with faults - 2 Principles of the process - The moulding cycle - Plunger machine layout - Plunger machine operation - Inherent weaknesses - Reciprocating screw machine - Latest trends and developments in machines - Understanding the process - Developments in control systems - 3 Machines - The power unit - Hydraulic fluid - Hydraulic oil control - Hydraulic pipework - Machine sequencing - Plasticizing unit - Mould unit - Machine specifications - Machine control - Process sequencing - 4 Materials - Thermosetting and thermoplastic materials - Molecular or fine structure of plastics - Chemical structure of plastics - Polymerization and copolymerization - Crystalline and amorphous plastics - Thermal properties of plastics - Effect of pressure on molten plastics - Mouldability of molten plastics - Rheological properties of plastics - 5 Moulds - Mould design - Mould-making methods - Gates for injection moulds - Calculation of gate sizes - Runner systems for injection moulding - 'Family' moulds - Runner dimensions - Three-plate and hot runner moulds - Extended nozzles - Mould cooling systems - Differential shrinkage and cooling effects - Component design - 6 The process and its control - Determination of injection rate - Determination of power requirement - Pressure requirements for injection - Hydraulic pump - Trimming the process - Balancing process variables - Switching systems and process variables - Mechanical systems and process variables - Feed setting - Interdependence of process variables - 7 Injection moulding of thermosetting materials - Problems with thermosetting materials - Machines for thermosetting plastics - Thermosetting moulding materials - Process details - Mould design for thermosetting moulding - Faults in thermosetting moulds - 8 Causes, diagnosis and cure of faults in injection mouldings - Burn marks - Cracking or crazing - Delamination - Distortion - Flash - Flow marks - Poor surface finish - Scuffing - Short mouldings - Sink marks and voids - Splash marks, mica marks, silvering - Splay marking - Staining - Sticking - Warping - Weld lines - Windows - Witness marks - Other faults and problems - 9 Housekeeping as a factor of efficiency - Cleanliness - Contamination and waste - Safety aspects of housekeeping - Maintenance - Plant interior decoration and colour coding - 10 Keeping records - why keep records? - Material balances - Machine operation records - Job records - Mould records - 11 Factory layout, service and ancillary equipment - Power requirements - Power factor correction - Disposition of machines - Service lines - Cooling water supply - Mould temperature controllers and chillers - Granulating and mixing equipment - Hopper driers - General drying equipment - Raw material and finished product stores - Treatment and care of re-work - 12 Financial aspects - Fixed and variable costs - Budgeted machine hourly rates - Estimating and pricing of component production - Cost saving methods - Optimizing time cycle and machine productivity time - Effects of process variables on profitability - Conclusion.

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