CDB 4423

Polymer Process Engineering

May 2017

LAB REPORT

EXPERIMENT 4 : INJECTION MOULDING MACHINE

GROUP : 3
GROUP MEMBERS : KOI ZI KANG 18868
NORANISAH BINTI JAMIAN 19339
SADADINE MAHAMAT YOUSSOUF 17839
LECTURER : DR WAN ZAIREEN NISA YAHYA
DATE OF EXPERIMENT : 10th JULY 2017
Table of Contents

Chapter 1: Introduction
1.1 Abstract .................................................................................................................... 1
1.2 Objectives ................................................................................................................ 1

Chapter 2: Literature Review

2.1 Molecular Weight Distribution and Material Processing ........................................ 2
2.2 Molding Processes ................................................................................................... 3

Chapter 3: Methodology ............................................................................................................ 4

Chapter 4: Results and Discussions

4.1 Results ...................................................................................................................... 5
4.2 Discussions ...........................................................................................................5-6

Chapter 5: Conclusion ............................................................................................................... 6

References .................................................................................................................................. 7
CHAPTER 1: INTRODUCTION

1.1 Abstract

Injection molding is the most commonly used process for the manufacturing of plastic material.
A wide variety of products are manufactured using injection molding such as containers,
toothbrush and plastic toys. The products vary greatly in terms of their sizes, complexity and
application. Basically, injection molding process requires the use of an injection molding
machine, raw plastic material and a mold. The raw material is melted in the injection molding
machine and then injected into the mold, where it cools and solidifies. Common raw materials
used for injection molding include polyethylene, polypropylene, polycarbonate, acrylonitrile
butadiene styrene and acrylics. This experiment was designed to improve understanding on
working principles of injection molding machine.

1.2 Objectives

The objective of this experiment is improve understanding on working principles of injection

molding machine which is one of the most common methods used to shape plastic resins.

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CHAPTER 2: LITERATURE REVIEW

2.1 Molecular Weight Distribution and Material Processing

Molecular weight is a major parameter that influences polymers flow behavior at temperatures
above glass transition temperature or melting point (TA Instruments, n.d.). Normally, polymers
are composed of polymer chains with various chain lengths or different molecular weights after
polymerization which result in a continuous molecular weight distribution (McCrum, Buckley,
& Bucknall, 1988). There are two types of molecular weight distributions which are single
modal and bimodal as shown in Figure 2.1.

Figure 2.1: Single Modal and Bimodal Molecular Weight Distribution

For single modal molecular weight distribution, the curve could be either a broad curve or a
narrow curve as shown in Figure 2.2 (McCrum, Buckley, & Bucknall, 1988). Polymers with
bimodal or broad molecular weight distribution are suitable for extrusion process as the shorter
polymer chains will melt quickly and contribute to the flow while the longer polymer chains
will hold the materials together. Polymers with narrow molecular weight distribution are
suitable for injection molding process that requires the feed to melt at the same temperature.

Figure 2.2: Narrow and Broad Molecular Weight Distribution

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2.2 Molding Processes

There are several existing commercial polymer molding processes in which the selection of
any process is depending on ones budget, expertise and resources. Although injection molding
process is the most commonly used manufacturing process, other processes including blow
molding, compression molding, rotational molding, thermoforming and extrusion are also
widely used for production of different types of products. Few examples of molding processes
and their common uses are listed in Table 2.1 (Fibertech Plastics, 2015).

Table 2.1 Molding Processes and Their Common Uses

No. Molding Process Common Uses

1 Injection Molding
2 Blow Molding
3 Compression Molding
4 Extrusion Molding
5 Thermoforming
Produce high volume custom plastic parts
Large injection molding machines can produce car parts
Production of bottles, plastic drums and fuel tanks
Commonly used for production of small parts in very
high volume
Heavily used in automotive industry as final product is
very strong and durable
Production of PVC piping, straws and hoses
Manufacturing of disposable cups, containers, lids,
trays, blisters, clamshells and other products for food
and general retail industries

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CHAPTER 3: METHODOLOGY

The experimental procedure of this experiment is as follows:

1. All the safety devices were ensured to be operational and the EMERGENCY STOP button
was under awareness.

2. The chiller unit was switched on. The cooling unit and the water pump indicator were being
confirmed to be in ON position.

3. The RESET button was released and menu screen was switched on.

4. The required temperature was set and the heater key was turned on.

5. The menu screen was being monitored until the temperature was raised to the required
temperature set earlier.

6. Then, the raw material polymer, polypropylene (PP) was filled into the hopper.

7. The safety gate was then closed.

8. The MOULD CLOSE key was pressed until the mould was locked up.

9. Next, the NOZZLE ADVANCE key was pressed until the nozzle was pressed tightly
against the mould. The sensing ring was then moved until it was sensed by the nozzle
forward proximity switch.

10. To fill the polymer in the screw position, the CHARGE key was pressed. Then, the INJECT
key was pressed to fill the mould cavity and the cooling process was let to happen.

11. The MOULD OPEN key was pressed and the EJECTOR ADVANCE key was pressed
twice to eject the moulding product.

12. The product was examined and the pressure, temperature, stroke and time were adjusted as
needed. The procedure was repeated until satisfying product was obtained.

13. The raw material was then changed to high density polyethylene (HDPE) and steps 1 to 12
were repeated.

14. The RESET button was pressed to shut down the system.

15. The isolator was switch off and the cleaning process was carried out.

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CHAPTER 4: RESULTS AND DISCUSSIONS

4.1 Results

Figure 4.1: Dog-Bone-Shaped PP and HDPE Produced via Injection Molding

4.2 Discussions

1. Explain the principle of injection moulding machine.

The type of injection moulding machine used in this experiment is a single-screw injection
moulding machine as shown in Figure 4.2 (McCrum, Buckley, & Bucknall, 1988). First, the
raw material of polymer in pellet form is fed into the charging barrel by using a hopper and
is pushed forward by the rotating screw through a heating element that melts the solid
polymer feed (Scarlet, 2011). The homogeneous melting process is also contributed by the
heat produced from intense friction between the polymer feed and the barrel while the feed
is being pushed. Then, during moulding process, the screw stops rotating and is rammed
forward to inject the fused polymer into mold cavity through a nozzle after the mold is
closed (McCrum, Buckley, & Bucknall, 1988). The scheduled pressure during molding
process is well maintained until injected material cools (McCrum, Buckley, & Bucknall,
1988; Scarlet, 2011). After the molded polymer completely solidifies, the solid polymer is
ejected from the mold while screw moves backward and the mold opens (Scarlet, 2011).

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 Figure 4.2: An Illustration of a Single-Screw Injection Molding Machine

2. Can we mix polymer A and polymer B to produce a polymer blend AB? Explain your
answer.
Yes, we can. The polymers used for this experiment are HDPE and PP in which both have
the same melt flow index (8 gm/10 min), are miscible and exist as a single phase (Salih,
Hamood & Alsalam, 2013). Therefore, they can be mixed to form a polymer blend and used
in injection molding machine. Nevertheless, it is important to note that only polymer with
narrow molecular weight distribution is suitable for injection molding because the process
requires the feed polymer to be melted at the same temperature so that no obstruction could
happen when the feed is pushed forward through the charging barrel or when it is being
injected through the nozzle. Also, polymer with broad or bimodal molecular weight
distribution product is not suitable for injection molding because the components in the
polymer with different chain lengths will cool down and solidify at different rates which
could result in production of irregular-shaped product.

CHAPTER 5: CONCLUSION

From this experiment, we were exposed to the working principles of injection molding machine
through practical experience. Adjustment of parameters such as temperature, pressure, stroke
and time are important to make sure that satisfactory product that has regular shape is obtained.
Two dog-bone-shaped PP and HDPE materials were produced from this experiment and will
be used in the next experiment for tensile stress testing. The possibility of mixing the two
polymers used in this experiment was discussed.

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REFERENCES

Fibertech Plastics. (2015). A Simple Guide To Plastic Molding Is Rotational Molding Right
For You? Retrived July 16, 2017 from http://fibertechinc.net/custom-rotational-
molding/a-simple-guide-to-plastic-molding/

McCrum, N. G., Buckley, C. P., & Bucknall, C. B. (1988). Principles of Polymer

Engineering: Oxford University Press.

Salih, Hamood & Alsalam. (2013). Comparison of the Characteristics of LDPE : PP and
HDPE : PP Polymer Blends. Modern Applied Science, 7(3), 33-42. doi:
10.5539/mas.v7n3p33

Scarlet, Q. Y. (2011). Basic Principles of Injection Molding Machine. Retrieved July 16,
2017 from https://hongchaomould.wordpress.com/2011/04/01/basic-principles-of-
injection-molding-machine/

TA Instruments. (n.d.). Understanding Rheology of Thermoplastic Polymers. Retrieved July

16, 2017 from
http://www.tainstruments.com/pdf/literature/AAN013_V_1_U_Thermoplast.pdf