_E-book Mini Vertical Injection Plastic Molding Machine Operation Student GuideStandard

MINI VERTICAL
INJECTION MOULDING MACHINE

OPERATION

Student Guide

Ts. JOHNNY YAKIN SINIT

MINI VERTICAL

INJECTION MOULDING MACHINE

FIRST EDITION

Diterbitkan oleh:
POLITEKNIK KOTA KINABALU
No.4, Jalan Politeknik, KKIP Barat
Kota Kinabalu Industrial Park
88460 Kota Kinabalu, Sabah

Tel : 088-401800
Faks : 088-499960
Website : https://polikk.mypolycc.edu.my

© Politeknik Kota Kinabalu
Edisi Pertama, 2022

Hakcipta terpelihara. Tidak dibenar mengeluar ulang mana-mana bahagian artikel,
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MINI VERTICAL INJECTION MOULDING MACHINE

ISBN

PREFACE



E-book with the title of a Student Guide Mini Vertical Injection Moulding Machine
published mainly to help student as a reference for DJF41032 Manufacturing Workshop
Practice 3 course when handling plastic workshop practical. The content of this e-book is
made in accordance with the level of students understanding and based on the syllabus.

This e-book development resources using real pictures of plastic injection moulds that
exist in plastic workshop, reference books and additional references from internet as
appropriate.

The content of this e-book is updated from time to time and any feedback or suggestion
for improvement is really appreciated.

Hopefully this e-book can benefit students.




Ts. Johnny Yakin Sinit
MME (System Design)
B. Tech and Edu (Mechanical Engineering)

TABLE OF
CONTENTS Page

1 Plastic Processing Process 1

2 The Procedure for Plastic 18

Processing Works

3 Mini Injection Moulding 28

Machine

4 Run Step by Step 32

5 Maintenance of Machine 54

6 Moulding Defects 61

7 References 70

1

PLASTIC PROCESSING
PROCESSES

On completion of this course, students should be able to:
i. Explain plastic processing process.

1

1

PLASTIC PROCESSING
PROCESSES

Plastic processing can be defined as converting the plastics' raw
ingredients into (semi-) finished products. These bulk plastics
come in resin, granules, pellets, powders, sheets, preforms, or
fluids and are converted into formed shapes or parts.

Plastic can be processed with the following methods:
i. Injection Moulding
ii.Blow Moulding
iii.Extrusion Moulding
iv.Compression Moulding
v.Thermoforming Moulding
vi.Blown Film Moulding
vii.Transfer Moulding

2

1

INJECTION MOULDING

The injection molding is a process to form the plastic resin into the desired
shape. Injection molding machine press the melted plastic into the mold,
and cool down by cooling system into solid designed shape. Almost all
thermoplastics using this method. This plastic processing has advantage of
accuracy and productivity. It has higher requirement for equipment and
mold cost, so it is mainly for High volume production.

Process Stage
1.Filing - Filing the melt flow into mould
cavities is the first step in the process

2. Packing-The holding pressure is
continuously applied in packing stage, the
melt compacted to increase the density of

the plastic (densification)
3.Cooling-need to cooled and solidified to
avoid deformation or damage. The cooling

time takes about 70% to 80% of the
injection cycle.

4.Releasing-releasing the parts form mold
cavities, it's also called de-molding

Figure 1: Injection Moulding Machine Your pa3

1

SAMPLES
PRODUCT
THROUGH
INJECTION
MOULDING

Figure 2: Sample Products using Injection Moulding Machine 4

1

BLOW MOULDING

Blow moulding is a moulding process used in the manufacturing industry to
create hollow objects made of plastic. It involves the use of heated, liquid
material that's forced into a mold cavity under pressure.

Process Stage



1.Melting the resin which are done in
extruder.

2.Form a molten risen into a cylinder or
tube , also called Parison.

3.The parison placed inside a mold, and
inflated so that the plastic is pushed
outward against the cazvity wall.

4. The part is cooled in the mould and is
then ejected.

5.The part is trimmed

Figure 3: Blow Moulding Machine 5

1

SAMPLES
PRODUCT
THROUGH BLOW
MOULDING

Figure 4: Sample Products using Blow Moulding Machine 6

1

EXTRUSION MOULDING

In plastic extrusion, resin beads are melted down, filtered for uniform
consistency, pushed through a die cut for the final product shape, and then
cooled. “Plastic extrusion is used to produce a wide range of products on
the market, from building materials to consumer products to industrial
parts. Pipes, window frames, electrical covers, fence, edging, and weather
stripping are just a few of the common items made by plastic extrusion,
along with thousands of custom profiles.

Process Stage



1.The material melted, and pushed
through an extrusion moulding machine,

forming a long, tube-like shape or rod
2. Product is cooled and cut the required

length
3. Often, extrusion moulding plastic
products created in this way are used for

wiring or insulating applications.

Figure 5: Extrusion Blow Moulding Machine 7

1

SAMPLES
PRODUCT
THROUGH
EXTRUSION
MOULDING

Figure 6: Extrusion Blow Moulding Machine 8

1

COMPRESSION MOULDING

Compression molding is a process of molding in which a feeding material is
placed into an open, heated mold cavity. The mold is then closed with a top
plug and compressed with large hydraulic presses in order to have the
material contact all areas of the mold.

Process Stage



1. The material is placed into the mould.
2. The product is heated until somewhat

soft and pliable.
3. A hydraulic tool presses the material

against the mould.
4. Once the material is hardened and has

taken shape of the mould it is ejected.





Figure 7: Compression Moulding Machine 9

1

SAMPLES
PRODUCT
THROUGH
COMPRESSION
MOULDING

Figure 8: Sample Products using Compression Moulding Machine

10

1

THERMOFORMING
MOULDING

Plastic Thermoforming is a plastic manufacturing process that applies a

force (vacuum or pressure) to stretch a sheet of heated thermoplastic

material (thermos) over an engineered mold to create a 3-dimensional

shape or part (forming). After forming, the shaped part can then be

trimmed and finished to specification to meet an end-user's requirements.

The process and thermoplastic materials are extremely versatile and can be

utilized to manufacture parts for a very wide range of applications.

Process Stage



1. The process of heating thin plastic
sheets to its forming temperature and
stretching it over a mould which takes
it shape.

2. After cooling and setting of the
moulded plastic sheet, each part will
be separated from its batch to form a
single unit or product.

3. Thermoforming is a considered a
secondary moulding , the primary

process being that which produces the
sheet or film with a uniform cross-
section

4. 4.The forming phase happens in a
mould cavity when the plastic is drawn
by air and/or vacuum pressure





Figure 9: Thermoforming Moulding Machine 11

1

SAMPLES
PRODUCT
THROUGH
THERMOFORMING
MOULDING

Figure 10: Sample Products using Thermoforming Moulding Machine

12

1

BLOWN FILM MOULDING

Blown film is another extrusion processes used to fabricate film products.
In this case the extrusion die is shaped as a circle and air pressure is used
to further expand the film. After it is expanded to the desired dimensions it
is cooled to solidify the polymer. Typical applications include industry
packaging, consumer packaging, laminating film, films for the packaging of
medical products and agriculture film.

Process Stage



1.Plastic melt is extruded through an
annular slit die, usually vertically to form a

thin walled tube.
2.Air introduced via a hole in the Centre of
the die to blow up the tube like a balloon.

3.Mounted on the top of the die, a high
speed air ring blows onto the hot film to
cool it. The tube of film then continues
upwards, continually cooling, until it passes

through nip rolls where the tube is
flattened.

4.This lay flat or collapsed tube is then
taken back down extrusion tower via more

rollers.
5.Blown film can be used either in a tube

form.







Figure 11: Blown Film Moulding Machine 13

1

SAMPLES
PRODUCT
THROUGH BLOWN
FILM MOULDING

Figure 12: Sample Products using Blown Film Moulding Machine 14

1

TRANSFER MOULDING

Transfer Moulding involves using a piston and cylinder device to force
rubber through small holes into the mold cavity. A piece of uncured
compound is put into a part of the mold called the pot, and a plunger then
pushes the stock into the closed mold through a sprue. The mold is kept
closed while the rubber cures. The plunger is then raised, and the transfer
pad material is removed and discarded. The mold is opened for removal of
the part; then the flash and sprue material is trimmed off and discarded.

Process Stage



The preform plastic material is provided as
a liquid or semi liquid state inside a pot or

sprue/gating system.
2. When the charge is supplied inside the
pot or gating system, a plunger or piston

system pushes the material inside the
cavity of the mold.

3.Inside the cavity, curing of thermosetting
material takes place.

4.The cure part inside the mold cavity is
detached from the mould with ejectors

pins.



Figure 13: Transfer Moulding Machine 15

1

SAMPLES
PRODUCT
THROUGH
TRANSFER
MOULDING

Figure 14: Sample Products using Transfer Moulding Machine 16

1

i. Lists seven of plastic processes methods.
ii. Explain how plastic processing processes of Injection

Moulding are done.
ii. What type of plastic processes methods if want to produce car

tyres.
Student can check answer by peer review

17

2

THE PROCEDURES PLASTIC
PROCESSING WORKS

On completion of this course, students should be able to:
i. Explain the procedures plastic processing works.

18

THE PROCEDURES PLASTIC
PROCESSING WORKS

The processing of plastics involve operations similar to those
used to form and shape metals, Plastics can be moulded, cast,
and formed, as well as machined and joined, into many shapes
with relative ease and with little or no additional operation
required Table 1. Plastics melt or cure at relatively low
temperature Table 2. Plastic usually shipped manufacturing
plants as pellets or powders and are melted just before the
shaping process. Plastics are also available as sheet, plate, rod,
and tubing, which may be formed into a variety of products.
Liquid plastic are used especially in making reinforced plastics
part. (S. Kalpakjian, 1997)

19

2

Table 1: Glass-transition and Melting Temperatures of some Polymers

Material Tg oC Tm oC
Nylon 6,6 57 265
Polycarbonate 150 265
Polyester 73 265
Polyethylene High Density -90 137
Polyethylene High Density -110 115
Polymethylmethacrylates 105
Polypropylene (PP) -14 -
Polytetrafluorethylene -90 176
Polystyrene 100 327
Polyvinyl chloride 87 239
Rubber -73 212

-

Glass transition temperature Tgis an important parameter used for identification of plastics. The
Tg value is the temperature at which amorphous polymers change from hard to soft. The

concentration of crystalline regions in amorphous (semicrystalline) polymers affects the rigidity of

the polymer. The crystalline melting temperature Tmcan be used for quality control and for
identification of polymers. (J. Virt , 2005)

20

2

Table 2 :Charateristics of processing plastics and Reinforced plastics
Process Extrusion
Long, uniform solid or hollow complex cross-sections; high production
rates; low tooling costs; wide tolerances.
Process Injection Moulding

Complex shapes of various sizes, eliminating assembly; high production
rates; costly tooling; good dimensional accuracy.
Process Blow Moulding
Complex shapes of various sizes, eliminating assembly; high production
rates; costly tooling; good dimensional accuracy.
Process Thermoforming
Shallow or relatively deep cavities; low tooling costs; medium production
rates.
Process Compression Moulding
Parts similar to impression-die forging; relatively inexpensive tooling;
medium production rates
Process Transfer Moulding
More complex parts than compression moulding and higher production
rates; some scrap loss; medium tooling post

21

2

Process Procedures of plastics

Process procedures of plastic involved Startup, Steady state, and
Shutdown. (S. A. Brent, 2006)

1 4

Start up Safety

2 3

Steady-state Shutdown

22

2

Process Procedures Injection Moulding

1 4

Start up Safety

23

Steady-state Shutdown

Start up

Heat barrel and mould sufficiently before starting screw.
Heat system from outlet to inlet.
Open hopper slide gate slowly or fill hopper slowly to avoid bridging.
Allow proper drying/preheating temperature and time for material supply.
Purge old material from barrel.
Run a few manual cycles before engaging semi/automatic controls.
Start mould cooling system.
Ensure proper barrel/sprue bushing seal and alignment.
Inspect electrical wires and connectors.
Inspect water and hydraulic hoses, connections.
Performed necessary mould release. application
Inspect mould for damage.
Ensure proper mold clamping pressure, sealing

Steady-state

Maintain recommended lubrication/release of mould and moving parts. Adjust
temperature as needed.
Keep hopper full, or ensure unblocked supply hose for the pellets.

Shutdown 23

Retract injection unit
Close slide gate on hopper or run hopper empty of pellets.
Purge barrel of molten material.
Run barrel and mould cooling until fully cooled.

Safety

Always set safety interlock before reaching into mold area.
Be cautions of hot resin ejected during purge or flowchecks.
Do not look nozzle opening.

2

Process Procedures Blow Moulding

1 4

Start up Safety

23

Steady-state Shutdown

Start up

Two major types of blow moulding, extrusion and injection; follow appropriate

startup procedure as previously given for injection.

Initiate parison forming process.

If using premade parisons, preheat parison oven.

Inspect mould for damage.

Install correct mold pieces (labelers, volume adjusting blocks, etc)

Set mould clamping pressure.

Initiate mould cooling system.

Turn on air supply, inspect for moisture or other contamination.

Verify proper parison size, weight, formation.

Initiate blow moulder operation.

Make needed adjustments to parison speed, blow/cooling time, clamping

pressure.

Steady-state

Monitor parisons carefully-frequent die adjustments are necessary on

extruder.

Monitor flash conditions and ensure proper cooling prior to transfer

of part to trimmer.

Keep trimming blades sharp, properly aligned.

Monitor air, water supplies and eliminate contaminants.

Shutdown

Discontinue supply of parisons-see injection molding shutdown.

For premade parisons, empty and turn off oven.

After trimming last part, run mold cooling system unitil mold is fully cooled.

Shut down air system, bleed pressure and moisture.

Safety

Hot parts- use protective clothing, tools. Moving parts-use caution. Use wood,

plastic, or brass push sticks, never hands, keep clear of cutting heads and pinch

points. Use caution when working with water and electrical lines. Use caution with 24
compressed air

2

Process Procedures Extrusion Moulding

14

Start up Safety

23

Start up Steady-state Shutdown

Heat up slowly.

Allow enough time to preheat the entire system, but don't overcook material

already in the system.

Heat from outlet towards inlet.

Tighten head and die screws on hot, stopped machine.

Feed material in small doses to empty hopper, to prevent bridging.

Engage screw at lowest speed, and increase slowly while monitoring screw

ammeter.

Use a threading aid (string, cloth, old product) to quickly and safely start the

takeoff system.

Open pull nips to allow blobs through until steady flow is achieved.

Steady-state

Monitor ammeters, pressure gauges.

Measure output in weight per hour and rpm.

Watch for bridging in the hopper.

Shutdown

Know whether the material requires stopping with a full system, an empty screws
and full head and die, or fully cleaned system.
If cleaning, of heads, screen packs, and dies must be as quick as possible.
Start disassembly as soon as the motor stops and clean all parts simultaneously.
Purge with high-viscosity, highly stabilized material.
In ant case, shutdown should include cleaning the first few flights of the screw to
reduce bridging on restart.

Safety

Do not look into vents or dies without face shield-gas buildup can eject molten
plastic. Do not allow materials to degrade in the system. Dangerous gases or
particulates can form. Keep fire extinguishers and burn treatments on hand and
readily available. Use proper protection when working near hot surfaces. Ensure
proper maintenance on drive system. Ensure safety electrical installation and keep
cords properly maintained. Use wood, plastic, or brass poke sticks on hopper and
vents, Never Hands. Use and maintain proper guards and emergency switches 25
around moving parts.

2

Process Procedures The Thermoforming Moulding

14

Start up Safety

23

Steady-state Shutdown

Start up

Turn on heating system (with door closed) and set proper oven temperature.

Turn on vacuum pump.

Turn on compressed air.

Install mould and any necessary plug or air assist system.

Adjust material clamping ring for desired blank size.

Check mould/clamping ring alignment.

Place material in clamping ring.

Slide sheet carrier into oven.

When sheet reaches proper temperature and sag, remove from oven and form

the part.

When part cooled, remove from mould and clamping ring.

Trim flash.

Steady-state

Maintain recommended lubrication/release of mould and moving parts.

Adjust oven temperature as needed.

Keep trimming area clean of scraps.

Shutdown

After forming last part,
Turn off compressed air.
Turn off vacuum pump.
Turn off heating systems.
Return air cylinder(mould lifters, plug assist cylinders, etc) to their relaxed
positions.

Safety

Use caution when handling freshly formed parts-they will be hot.
Maintain vacuum, compressed air lines as needed.
Avoid contact with heaters and live electric lines-high voltages are likely.
Use proper safety procedures and equipment when trimming parts.

26

2

i. List four steps procedures processing plastics.
ii. Explain the procedures processing plastic by using Injection

moulding.
Student can check answer by peer review

27

MINI INJECTION
3 MOULDING

MACHINE

On completion of this course, students should be able to:
i. Recognize Mini Vertical Injection Machine components and

control panel.

28

MINI INJECTION
3 MOULDING

MACHINE

1 4

Injection Cylinder Hopper

2 5

Heating Barrel Control Panel

3 6

Chiller, Cooling Mold Engage
system Button

Figure 15: Mini Vertical Injection Moulding Machine

29

3 CONTROL PANEL
OF MACHINE:
MK110

4

Monitor
Screen

1 5

Numerical keypads Parameter
setting screen
2
keypard

6

Directional
keypads

Mode Selection 7

3 Motor ON/OFF

Mechanism setting 8
keypads

Not applicable for Emergency
this machine model Stop

Figure 16: Control Panel Mini Vertical Injection Moulding Machine

30

3

i. List SIX (6) Components of Mini Injection Moulding Machine.
ii. Lists EIGHT (8) Components of the Control Panel MK110.

Student can check answer by peer review

31

4
RUN STEP BY STEP
MINI INJECTION
MOULDING MACHINE

On completion of this course, students should be able to:
i. Perform plastic processes by run correct step by step.

32

4
RUN STEP BY STEP
MINI INJECTION
MOULDING MACHINE

33

4

STEP 1

Process Stage



Pull down to switch on three phase power
supply.

34

4

STEP 2

STEP 2

Process Stage



PSrwoictcehssonStPaogweer supply of Mini Injection
Moulding Machine

Switch ON power sup
ply of Mini Injection
moulding Machine.

35

4

STEP 2

STEP 3

Process Stage
Process Stage

Switch on Power supply of Mini Injection

Moulding Machine
Switch ON power su
pply of Cooling system
(Industrial Chiller).

36

4

STEP 4

Process Stage



SwPirtcohceosnsPSotwageer supply of Mini Injection
Moulding Machine

Pull EMERGENCY sw
itch to on screen

monitor

37

4

STEP 6

Process Stage



PSrwoictcehssonStPaogweer supply of Mini Injection
Moulding Machine

Press button MONITO
R to active screen

monitor display

38

4

STEP 7

Process Stage



SPwroitccehsosnSPtaogweer supply of Mini Injection
Moulding Machine

Press button MANUA
L to switch machine

to manual mode

39

4

STEP 8

Process StageProcess Stage



PrSewssitcbhutotnonPMoMowOueTlrdOsinRugpOMpNlya/cOohfFinMFetinoi sInwjietcchtioonn
hydraulic system


40

4

STEP 9

Process Stage
Process Stage

SPwrietcshs obnutPtoonweMrOsLuDppOlyPoEfNMini Injection
to move tMheouulpdpinegr
Mclaamchpinuepward

and

MOLD CLOSE only available when press
button MOLD ADJ

41

4

STEP 10

Process Stage



PSrwoictcehssoSntPaMogoweuelrdsinugpMplyacohfinMeini Injection
Press button MOLD A
DJ to bring down
mold close can be activated

42

4

g STEP 11

Fill in material PPPrHocoemsospSltyamgeer into

HOPPER


Switch on Power supply of Mini Injection

Moulding Machine




43

4

STEP 12

Process Stage



ProScweistcshSotangPeower supply of Mini Injection
Moulding Machine

Press button HEATER ON
/OFF to turn on

heater

44

4

STEP 13 45

Process Stage
Process
Stage
Switch on PMoowuelrdsinugp
MplyacohfinMeini Injection
Press button TEMP to
trigger temperature
parameter set up screen




Keyin temperature parameter 180 celsius




Wait temperature to reach as per setting




PP: 200 - 280 Celsius Material Temperature

(Manual,2021)