Injection Molding Machines
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1 Friedrich Johannaber Injection Molding Machines A User's Guide 4th Edition HANSER Carl Hanser Publishers, Munich «Hanser Gardner Publications, Cincinnati
2 Contents Foreword Preface to the Fourth Edition V VII 1 Introduction The Economic Significance of Injection Molding History of Injection Molding 4 2 Materials for Injection Molding Processing Data for Thermoplastics Temperatures Pressures Drying of Thermoplastics Mixing and Coloring of Thermoplastics During Injection Molding Processing Data for Thermosets Processing Data for Elastomers (Rubber) 26 3 General Design and Function Characterization of the Injection Molding Process Functional Process Steps Injection Molding Cycle Significance of Pressure Influence of Temperature on the Molding Process Temperature of the Hydraulic Oil Melt Temperature Mold Temperature Velocity, Speed Physical Description of the Molding Process Effect of Molding Technique on Properties Dimensional Stability Mechanical and Physical Properties 49 4 Injection Unit Performance Parameters of the Injection Unit Injection Pressure Feeding Stroke Injection Volume Screw Speed/Circumferential Speed Plasticating Capacity Torque Screw Standard Screws for Thermoplastics Special Screws for Thermoplastics 86
3 X Contents Special Plastication Units for Thermoplastics Screws for Rigid PVC Screws for Vented Barrels Screws for Thermosets Screws for Elastomers Screws for Processing Silicones Screw Tips Non-Return Valve (Check Valve) Barrel Nozzle Open Nozzles Ill Shut-Off Nozzles Nozzles with Material Filters Internally Heated Nozzles Nozzles with Mixing Functions Wear and Wear Protection Causes of Wear Wear Protection Measures Screw Drive Systems Translational Drive System for Screws Rotatory Screw Drive System Carriage Guide for the Injection Unit Accessories for the Injection Unit The Clamping Unit Clamping Sequence During Opening and Closing Clamping Force, Locking Force, Reaction Force Designs of Clamping Units Mechanical Clamping Hydraulic Clamping Systems Tie-Bar-Less Clamping Units Special Clamping Units for Production of Compact Discs Accessories for the Clamping Unit Ejector Systems Removal Equipment for Tie-Bars Clamping Systems for Molds Unscrewing Equipment for Cores Inside the Mold Magnetic Mold Clamping Standard Equipment for Clamping Units The Drive Unit Electrohydraulic Drives Pump Drives Speed-Controlled Drive Unit Hydraulic Drive Systems Featuring an Accumulator Elements of Hydromechanical Drives 195
4 Contents XI 6.2 Electromechanical Drives Mechanical Gears for Electromechanical Drives Elements of Electromechanical Drives 219 The Control System Process Control Methods Open-Loop Control Closed-Loop Control Temperature Control Temperature Measurement Temperature Controls Pressure Control Pressure in Front of the Screw Tip Hydraulic Pressure Cavity Pressure During Injection Molding Force Measurement Displacement (Position) Measurement Control Unit Standard Control Unit Control Panel and Display Objectives of Process Control Components of the Control Unit Disturbances Methods of Process Control Electronic Data Processing in Injection Molding Computer-Controlled Automatic Injection Molding Installation 268 Efficiency and Energy Consumption Hydromechanical Drives Electromechanical Drives Comparison of Hydromechanical and Electromechanical Injection Molding Machines 280 Injection Molding Machines for Special Processes (Special Machines) Modifications of Standard Injection Molding Machines Plunger Injection Molding Machine Plunger Injection Molding Machines with Plunger Preplastication Plunger Injection Molding Machines with Screw Preplastication and Plunger Injection Screw Preplastication with Plunger Metering (Accumulator) and Plunger Injection Multi-Station Injection Molding Machines Multi-Station Machines with Horizontal Clamping Unit Tandem Injection Molding Machines Two-Platen Injection Molding Machines (Tandem Arrangement) with Opposed Injection Units 295
5 XII Contents 9.4 Small Injection Molding Machines and Micro Injection Molding Machines Terminology of Micro Injection Molding Machines Mini and Micro Injection Molding Machine Designs Multi-Component Injection Molding Machines Machine Technologies Nozzle Technology Mold Technology Sandwich (Two-Component) Injection Molding Machines Injection Molding Machines for In-Mold Decoration (IMD) and In-Mold Lamination (IML) Gas- or Fluid-Assisted Injection Molding Machines Equipment for Gas-Assisted Injection Molding (GIT) Surface Gas Pressure Process Water-Assisted Injection Molding Technology (WIT) Injection Molding Machines with Compounding Functions Injection Molding Machines for Processing Polyester Molding Compounds Injection Molding Machines for Processing Elastomers Injection Molding Machines for Rubber Processing LSR Injection Molding Machines Low-Pressure Injection Molding Low-Pressure Injection Molding Machines for Recycled Thermoplastics Structural Foam Injection Molding Machines Machines for Producing Microcellular Foams High-Pressure Injection Molding Machines Push-Pull Injection Molding Machines Fusible-Core Technology Ceramic and Metal Injection Molding Machines Powder Injection Molding (PIM) Thixomolding (Magnesium Injection Molding: THIM) Machine Sizes and Performance Data Machine Sizes Performance Data Performance Data of the Injection Unit Performance Data of the Clamping Unit General Performance Data Accessories Injection Molds Auxiliary Equipment for Automation Heat Exchanger 368 Index 375
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