Molders looking to both monitor an injection molding process effectively and manage production can definitely do both with tools available today, but the question is how best to tackle these twin challenges.
Each molecule in the molded product can have a different residence time. This variance is reflected in the Residence-Time Distribution, which you can learn how to determine below.
Failing to calculate and accurately account for residence time can compromise material integrity before it’s even injected.
Save time and money by properly controlling the feed-throat temperature. In some cases—but not all—it can help you solve a bridging problem.
Focus on six key metrics to help you determine when a process is lined out and stable enough to start production.
Press shutdown procedures have a significant impact on achieving smooth machine startups and restarts to improve uptime. Here’s a procedure you might want to deploy in your molding operation.
Establishing a process with the widest possible cosmetic window can help put your injection molding on cruise control.
Injection molding’s most common defects can have inverse correlation, where correcting one causes the other, leading to the “chase.”
Keeping your workers safe from the coronavirus makes it extremely important to institute a sanitizing procedure on all touch surfaces of the controller, screen and operating panel. I did some research and here’s what I found.
Duplicating a process from one injection machine to another is frustrating and time-consuming. Develop a mold-specific setup sheet that works in all kinds of presses by differentiating plastic parameters from machine parameters and duplicating those plastic conditions from machine to machine, electric or hydraulic.
You have developed a proper process; now you need to monitor that process to ensure its stability through a run.
Many injection machines use ramp time to control the transition from injection pressure to hold pressure and reduce over-travel. Do you know how to set yours?
Are you sure your press is doing what you want? Visit your controller often to ensure your machines plot the pressure vs. time graph for all your processes. Here let’s focus on pack and hold.
Decompression—aka suckback—is a very important setting on an injection molding machine. On today’s machines, molders typically get the option to set decompression before and after screw rotation/recovery. Are they using this feature to their advantage?
For a quick check of your process setup, the injection-pressure-vs.-time graph is your best tool.
In injection molding, a seemingly minor change in a setpoint can have a significant impact on part quality and process robustness and repeatability. That’s why Scientific Molding focuses on process outputs, not setpoints.
Taking time to sweat the details of clamping is not much fun, but they do make a difference in a company’s bottom line.