The IML injection molding machines are a crucial part of industries today. This is a bit similar to die casting but differs in the use of raw materials. In die casting, only those metals are used which require a high temperature for melting. But in the case of injection molding, it is mostly carried on elastomers, glasses, thermosetting and thermoplastic polymers. This technique is mostly used for the fabrication of thermoplastic materials. The process is done by heating the raw materials and then injecting them into the mold cavity. This is done by applying pressure at a particular temperature without making any changes in its chemical composition.
Important parts of the injection molding
machine
The main parts in an IML Injection Molding Machine are an injection or rotating screw-type plunger, material hopper, movable pattern, barrel, heating device, mold inside the mold cavity, and ejectors. Generally, these machines are operated horizontally. Injection molding machines consist of a cylindrical pipe that is known as a barrel. A rotating screw or hydraulic ram is run by an electrical motor. This electrical motor is situated inside the barrel. Also, a heating element is attached to the barrel. This is used for melting the molding material that comes down from the hopper. On the other side of the barrel, a mold cavity is attached. This mold is situated inside the mold cavity and also a movable pattern will be used in the manufacturing. This mold is generally made of aluminum, steel, and copper. The life cycle of these molds depends on their materials. The materials are selected as per the given requirement.
Working of Injection molding machine
The working of an injection molding machine is
similar to extrusion and it operates like an injection. A feeding device is
then used to pour the raw materials into the hopper. After this, molding
materials will move to the cylinder or barrel. A heater is used to melt the
material, the powdered form of raw material also starts melting once it is
poured down in the barrel. A rotating screw or hydraulic ram pushes the
material into the mold by applying pressure. Melted plastic is injected into
the closed mold that is attached to the side of the barrel. Here split mold is
used.
The pressure is applied by the hydraulic system, this pressure generally ranges from 100-150 Pa. After the injection, it will be locked at the same position with some force, or the pressure is applied for some time. Once the process is done, the parts manufactured are cooled. The mold will open and ejectors will be used to properly remove the parts without damaging them. After removing the part, the mold is closed again. This process is relatively fast and automatically repeated. Complex shaped parts are manufactured by this process. The production capacity of injection molding is 12-16 thousand parts per cycle.
The various process parameters
- The process of parameters varies according to the
requirements and conditions.
- The weight of all the parts produced through this
process is generally 100 to 500 g.
- Cycle time for producing a single part is mostly 5 to
60 seconds, depending upon the part that is manufactured.
Advantages of injection molding machines
- The major advantage of this process is that complex
components with small thickness can be easily molded. They can be easily
removed from the die without damage.
- The parts which are produced by injection molding have
good dimensional tolerance.
- The major benefit of this technique is that the scrap
that is produced by this is very little as compared to some other
processes.
- Parts that are manufactured by the injection molding
process are competing with the parts made by the investment complex and
casting machining parts.
- This process carries a high production rate when compared to other techniques.
Disadvantages of injection molding machines
- The initial set-up cost of this process is high because
of the testing, tooling, and design of the whole equipment. The investment
may cost you a lot but the products are worth investing in. The cost is
more for most of the businesses which have to produce fewer parts.
- Investment molding has its limitations. It is limited
to special kinds of materials like polymers and thermoplastic materials.
Since the process is limited to just these materials, many business owners
find it tough to settle the machine for their production processes.
- The tooling cost is high for this kind of process. The mold is produced by several testing and processes and thus the overall cost of the production is high. Here different kinds of mold are required for different parts.
Application of the machines
- Injection molding is used for producing several complex
parts, it can be of many shapes and sizes with less wall thickness.
- The parts like toys, cups, plumbing fittings, containers, electrical components, toys, bottle caps, telephone receivers, and automotive parts are manufactured by this process.
These are the advantages and benefits of IML
injection molding machines. If you are a Plastic Machinery Manufacturer,
looking for a reliable machine for the part, you must consider this one. Make
sure to note down your requirements before deciding on the machines. You must
check different machines, their working, capacity, and benefits of all the
available machines to make a uniform decision. Checking all the parameters before
making a purchase is crucial for your production since you will know if the
machine is suitable for your industry.