Lect 3. Lean Manufacturing - Injection Molding.pptx

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1. ADVANCED MANUFACTURING SYSTEMS (ME-431) Lecture – 3 Lean Manufacturing – Injection Molding Course Instructor: Dr. Ammar ul Hassan Email Id: [email protected] Department of Mechanical Engineering, University of Engineering & Technology, Taxila

2. Injection Molding Injection Molding is a combination of two words injection (the forceful insertion of a substance under pressure) and moulding (to convert something into a particular shape by pressing or putting into a mould ). Injection Molding is a manufacturing process/ system for producing parts by injecting molten material into a mold.

3. Injection Molding Injection Molding is the method of obtaining molded products (in desired shape) by injecting the plastic material (pallets) molten by heat into a mould , followed by cooling and solidifying. Injection moulding is a manufacturing process that allows for parts to be produced in large volumes. It works by injecting molten materials into a mould . It is typically used as a mass production process to manufacture thousands of identical items.

4. Injection Molding Metals, glasses, elastomers, most commonly thermoplastic and thermosetting polymers. Material for the part is fed into a heated barrel, mixed, and forced into a mold cavity, where it cools and hardens to the configuration of the cavity.

5. Injection Molding - Components Clamping Unit Injection Unit Drive Unit Mould Hydraulic System Control System Hopper Heaters Cooling Channels

6. Injection Molding - Resources Material Machine Mould Manpower

7. Injection Molding Process

8. Injection Molding Process

9. Injection Molding Process

10. Injection Molding Process

11. Injection Molding Process

12. Injection Molding Process

13. Key Parameters Injection pressure:  The force applied to push the molten plastic into the mold cavity, ensuring complete filling.  Injection speed:  How fast the plastic is injected into the mold , affecting surface quality and flow performance.  Mold temperature:  The temperature of the mold , crucial for preventing defects.  Back pressure:  Pressure applied to the molten plastic within the barrel, helping to improve material consistency and reduce warpage.  Cooling time:  The duration the part spends in the mold to solidify properly.  Injection time:  The time taken to inject the molten plastic into the mold cavity.  Melt temperature:  The temperature of the molten plastic.  Barrel temperature:  The temperature settings within the barrel of the machine where the plastic is melted.  Holding pressure:  Pressure applied to the part after filling to ensure proper packing and reduce shrinkage.  Ejection force:  The force used to remove the molded part from the mold

14. Types of Injection Molding Machines Hand/ Manual Injection Moulding Machine Semi-automatic Injection Moulding machine Automatic Injection moulding Machine

15. Types of Injection Molding Machines Hand/ Manual Injection Moulding Machine It is a vertical machine consists of a barrel, plunger (push rod), heaters, rack and pinion system to move push rod up and down, clamping unit and a mould

16. Hand/ Manual Injection Moulding Machine

17. Types of Injection Molding Machines Semi-automatic and Automatic Injection Moulding machine Both of these are similar in working . The only difference between these two is that in Semi-automatic machine material is injected into mould by plunger and clamping of mold and ejection of product is done manually (actuated by levers). In automatic molding machine everything and step of operation is performed automatically as per the time set by the operator. It has a reciprocating screw mechanism to feed the plastic into the mould .

18. Types of Injection Molding Machines

19. Injection Molding - Applications Writing instruments components (pen etc ) Plastic Parts used in daily life like tub, container, chair, oil cans etc Computer electronics Automotive components Aerospace components Toys etc

20. Injection Molding - Advantages Fast Production Low labour costs Design flexibility High-output production Good dimensional control

21. Injection Molding - Disadvantages High initial tooling and machinery cost Part design restrictions

22. https://www.youtube.com/watch?v=2SkqRP7rTrw Video

23. The End