Practical Injection Molding
by Bernie A. Olmsted

This straightforward, practical guide focuses on the factors critical to successful injection molding, including knowledge of plastic materials and how they melt, the importance of mold design, the role of the screw, and the correct use of the controls of an injection molding machine.

This book provides operating personnel with a clear understanding of the basics of injection molding, resulting in more efficient processing, reduced cycle times, and better part quality with fewer rejects!

This is a most needed fundamental reference guide for injection molding machine operators, set-up personnel, and technicians who have hands-on operational responsibility in injection molding; molding supervisors and engineers; sales personnel involved in providing plastics materials, molding machines, auxiliary equipment, and other products and services to the industry; and educators in the molding process.

Practical Injection Molding

• contains the ten keys to successful molding that every molder should know
• explains how the melting characteristics of plastic materials affect the molding process
• discusses the impact of various additives on molding, including fillers, reinforcements, plasticizers, heat stabilizers, and colorants
• provides a detailed explanation of the injection unit and its components
• details the elements of screw design and how each element influences success in molding
• describes the types and functions of current clamp units
• emphasizes the importance of machine controls to simplify and improve the molding process
• presents the safety requirements of ANSI B151.1 in easy-to-understand language
• and more!

Contents:

1. Elements of the Injection Molding Process
   Summarizing the Elements

2. Plastics
   Thermoplastics
   Thermosets
   Crystalline vs. Amorphous Materials
   How Plastics affect the Molding Process
   
   • Melting Characteristics
   • Thermal Conductivity
   • Shear Sensitivity
   • Viscosity (melt index)

3. Additives
   Fillers and Reinforcements
   Plasticizers
   Stabilizers
   Flame Retardants
   Colorants
   Adding the Additives

4. Loaders and Dryers
   Hopper Loaders and Conveying Systems
   Dryers
   
   • Hot Air Dryers
   • Dessicant Dryers

5. Injection Unit
   The Barrel
   End Cap and Nozzle
   Heater Bands
   Non-Return Valve
   Screw
   
   • Length-to-Diameter Ratio
   • Screw Profile
   • Compression Ratio
   • Helix Angle
   • Drive Design
   Injection Pressure

6. Clamp Unit
   Hydraulic Clamp System
   Hydro-Mechanical System
   Clamp Unit Specifications
   Ejector System

7. Mold
   Mold Components
   Types of Molds
   
   • Cold Runner Molds
   • Hot Runner Molds
   • Other Types of Molds
   Ejection
   Projected Area
   Mold Venting
   Mold Cooling

8. Control
   Processing Functions
   Control Functions
   Process Control

9. Robotics and Granulators
   Robotics
   Granulators

10. Getting Started
    Mold Setup
    Process Methods
    Process Setup
    Mold Start-Up
    Process Documentation

11. Overview: The Cycle
    The Cycle Defined
    The Importance of Cycle Time
    The Greater Importance of "Good Production"

12. Ten Keys to Successful Molding
    Adequate Mold Venting
    Proper Mold Cooling
    Using the Right Screw
    Selecting the Appropiate Valve
    Controlling the Heat Profile
    Using Back Pressure Wisely
    Controlling the Injection Rate
    Managing Screw RPM and Residence Time
    Performance Measurement
    Preventative Maintenance Program

13. Thermoset Molding
    Thermoset Materials
    Machine Modifications
    Processing Modifications

14. Safety
    Safety Requirements of ANSI B151.1
    Safety Rules to Follow

15. Recognizing Molding Problems
    Process Problems
    
    • Brittleness of Parts
    • Bubbles and Voids
    • Burned Material
    • Cloudy or Hazy Parts
    • Drool
    • Flash
    • Flow Lines
    • Gate Blush
    • Inadequate Color Mixing
    • Jetting
    • Knit Lines
    • Part Deformation
    • Poor Screw Recovery
    • Short Shots
    • Sink Marks
    • Splay
    • Warped Parts Component Wear Problems

16. Terminology
    Molding Notes
    Special Molding Processes
    
    • Two Color Molding
    • Turret Molding
    • Gas Assist Molding
    • Powder Injection Molding
    • Intrusion Molding
    • Other Molding Processes
    Molding Operation Items

    Appendices
    Index

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    ORDER NOW Practical Injection Molding by Bernie A. Olmsted and Martin E. Davis 232 pages � $128.95 + shipping Texas residents please add 6.75 % sales tax