Injection Molding Handbook

Rosato, Dominick V., Rosato, Donald V. (Eds.), 1986. Injection Molding Handbook: The Complete Molding Operation Technology, Performance, Economics. Van Nostrand Reinhold, New York. This book covers the following: Foreword, Kishor S. Mehta - Preface - Section I Overview - 1 The complete injection molding operation, D V Rossato - Introduction - Standard Nomenclature for injection molding machines - Plastic molding materials - Production control of quality - Economic control of equipment - Safety standards / guides - Section II Machine operation - 2 The injection molding machine, W T Flickinger - Machine nomenclature - Standard for using interchangeable molds - Other injection molding machine standards - Basic machine operation - Clamping concepts - Plasticizing units - The machine hydraulics - Hydraulic circuit principles - Barrel temperature control systems - Maintenance and service - 3 The reciprocating screw process, R E Nunn - The reciprocating screw injection unit - Elements of the plasticating process - Overall plasticating process - Specialized screw designs - Vented barrel injection molding - Energy consideration - 4 The injection molding machine operation, J B Dym - Introduction - First stage: running an injection machine - Stage two: Parameter setting and starting a job - Final stage: optimizing molding production - 5 Machine safety, J C Rexford - Responsibility through the development stage - Responsibility of the machine user - Identifying hazards - Safety built into the machine - Current and former installations - Injection molding machine safety check list - Safety rules for molding department - Warning signs - Section III Product and mold design - 6 Designing products with plastics, J B Dym and D V Rosato - Basic in designing - Shape and stiffness - Stress relaxation - Predicting performance - Choosing material and a design - Design considerations - Long-term behavior of plastics: creep - Design features that influence performance - 7 Injection mold design, D V Rosato - Introduction - Types of mold - Flow of cavities - Clamping force - Sprue, Runner, Gate systems - Mold venting - Mold cooling - Removal of parts from the mold - undercuts - Mold shrinkage / tolerance - Mold-steel selection - Polishing - Plating, coating, and heat treating cavities / molds - Deformation of molds - Eyebolt holes - Mold protection - Conclusion: designing for efficiency - 8 Pre-engineered mold bases and components, D V Rosato - Introduction - Standardized mold base assemblies - Mold components - 9 Prototyping, S Galayda - Why prototype? - Advantages of prototype tools vs production tools - The prototype tool - Choosing a prototype tool shop - 10 How to buy a mold, S A Scace - Introduction - Requests for mold quotations - Evaluation of mold quotations - Placing the purchase order - Acceptance of the order - Mold progress report - Mold design - Product design factors that affect mold cost - Other factors that affect mold cost - Mold material comparisons - Section IV Controls - 11 Process control technology, D V Rosato - On-machine monitoring - Temperature control of barrel and melt - PID injection pressure control - Relating process control to product performance - Adaptive ram programmer - Simplified approach to understanding process control - Process control is not a foolproof solution - Process control techniques - Molding diagram techniques - 12 CAD/CAM for plastic part and mold design, J Gosztyla - Introduction - Introduction to CAD/CAM modeling - Additional CAD/CAM features used in plastic part and mold design - Flow of the mold design process, conventional vs CAD/CAM - Use of design data bases - Computer integrated manufacturing - Summary - 13 Process analysis tools for plastics processing, J Gosztyla - Introduction to flow analysis - Flow of plastics into a mold, C Austin - Introduction to mold cooling analysis - mold cool analysis, K R Schauer - 14 Auxiliary equipment overview, D V Rosato - Granulating vs performance - Drying PET is the key to molding productivity - Parts handling equipment (PHE) - Quick mold change - 15 material handling, G A Butzen and G A Adams - Industry needs - basic principles of pneumatic conveying - Air movers - Hoppers - Filters - Bulk storage - Blenders - Dryers - Pneumatic venture conveying - Powder pumps - Piping - Railcar and tank trucks unloading - Material handling systems - 16 Chilling and cooling, G A Butzen - Chilling and cooling needs - General considerations - Calculation of the cooling load - 17 Size reduction / granulating, G A Butzen and G A Adams - Size reduction needs - Granulators - Section VI Plastic molding materials - 18 plastic molding materials overview, D V Rosato - Introduction - Weld line strengths and materials - Guide for identification of plastics materials: D 4000 - 19 ABS molding variable-property response, L W Fritch - Introduction - Molding variables and cause-effect links - Orientation - Cavity melt flow - Molding variable / property responses - Appearance properties - Mechanical properties and molding variables - Molding for electroplating - Property variation with position / mold geometry - 20 Injection mold nylon 66 for optimum performance, W C Filbert - Processing condition influence mold and part design - Welds need not be weak links - Estimating mold shrinkage: a critical factor - Use the nomograph - Mold to close tolerance - 21 Polyphenylene oxide (PPO) and injection molding, G Feth - Introduction - Molding conditions - Effects of molding conditions on shrinkage - Mold release - Hot runner molding - 22 Polycarbonate: processing influences on properties, J M Newcome - Introduction - Premolding preparation - Processing - Conclusion - 23 Polyethylenes, polypropylenes, and copolyester, B V Harris - Low-density polyethylenes - Polypropylenes - Copolyester - 24 Injection molding polyvinyl chloride, D V Rosato - Introduction - Rigid PVC dry blends, R G Hale and K G Mieure - 25 Polymer structure and injection moldability, R D Deanin, P V DeClier and A C Khokhani - Synthesis and structure of polymers - Individual atoms and functional groups - Molecular weight - Molecular flexibility - Crystallinity and orientation - Intermolecular bonding - Additives - 26 The role of rheology in injection molding, J M Dealy - Introduction - Steady shear flow of molten plastics - Role of rheology in mold filling - Measurement of rheological properties relevant to mold filling - Role of melt elasticity in injection molding - Section VII Problem solving - 27 Molding problems and solutions, D V Rosato - Introduction - Troubleshooting - Summary - 28 Testing and quality control, D V Rosato - Introduction - Mechanical properties - Characterizing properties - Types of tests - Thermal properties - Microtoming / optical analysis - Nondestructive testing - Drying hygroscopic plastics - estimating plastics lifetime - QC begins when plastics is received - Economic significance of quality - Industry testing standards - Identification of plastics - Section VIII Different molding techniques - 29 Specialized injection molding machines, D V Rosato - Stretching techniques - Continuous molding of Velcro strips - Continuous rotary injection molding machine - Injection molding metals - Blow molding - Reaction injection molding (RIM) - Liquid injection molding (LIM) - Structural foam - Co-injection - 30 Competitive processes, D V Rosato - Blow molding - casting - Cold forming - Compression molding - Extrusion - Foam molding - Mechanical processing - Reaction injection molding - Reinforced plastics processing - Stampable reinforced thermoplastics - Roational molding - Thermoforming process - Transfer molding - Section IX Summary - Financial management, T R Ozan - The importance of financial management - Cost management - Profit planning and budgeting - Materials management - Conclusion - 32 Summary: Mold with profit, D V Rosato - Interfacing machine performance - Decorating - Computers and statistics - Become involved in CAD / CAM - Productivity: set plant in order - Value analysis - Troubleshooting by remote control: Service and maintain equipment - Profit through technological advances, C E Waters - Analysis if polymers, J L Rolfe - Warehousing - Recycling plastics - Costing - Markets - Analyze failures - Innovate - Education - Conclusion - Index

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