PocketBook Demag ENG

No other publication enjoys such a long tradition as a key
source of information as the "Injection Moulding Pocketbook".

We realise from the many requests we have for copies of the
booklet from right across the injection moulding industry that a
new edition is now needed. This latest publication represents
the completion of our reference work on the subject of injection
moulding.
Technological developments are not so much the focal point
here. It is the complete optimisation of the injection moulding
machine, which includes the evaluation and selection of process parameters and the elimination of surface defects, that is
central to this handbook.
We should like to thank Martin Bichler, Gunter Seibold,
Ansgar Jaeger, Fritz RoBner and Dr. Sabine Pahlke for their
active support.
Principii
Prima reglare a unei masini de injectie
2.1
Pregatiri.......
2.2
Pregatirea masinii.......
2.2.1 Reglarea unitatilor de inchidere cu articulatie
2.2.2 Reglarea unitatilor de inchidere hidraulice
10
2.3
Reglarea unitatii de injectie
11
2.4
Inceperea productiei
12
Desfasurarea ciclului de injectie la o masina ERGOtech
3.1
Inchiderea unitatii de inchidere
14
3.2
Faza de injectie si cea de presiune ulterioara
16
3.3
Dozare, snec si retragerea unitatii de injectie
18
3.4
Deschiderea unitatii de inchidere
20
Mic indrumar despre materiale
4.1
Indicatii la prelucrarea celor mai importanti polimeri
22
4.2
Caracteristici de recunoastere a maselor plastice
74
4.3
Temperaturi de prelucrare si pre-uscarea
78
Optimizarea procesului la masina de injectie
5.1
Caracteristici de calitate si parametrii de proces
81
5.2
Calcularea timpului de racire
91
Evaluarea corecta si alegerea parametrilor importanti

din punct de vedere al calitatii pentru asigurarea calitatii
pieselor injectate
97
Injection Moulding Pocketbook

Special publication from
Mannesmann Demag Kunststofftechnik
1st edition 10/97, circulation 20.000
Copyright6 1997 by Mannesmann Demag Kunststofftechnik
Id. no.: 183 790 65
Procesul de injectie.......................
Identificarea si eliminarea defectelor de suprafata

la piesele injectate
119
Exemplu de calcul al fortei de inchidere
125
Instructiuni de operare cu sistemul de control

ERGOtech NC4
137
Procesul de injectie matritata
In ultimele decenii procesul de injectie matritata si tot ceea ce este

in legatura cu acesta, s-a dezvoltat mai puternic decat aproape
toate celelalte procese de fabricatie cuprinzand o varietate din ce
in ce mai larga de produse. Avantajele sunt clare:
material convenabil
consum redus de energie la matritare datorat temperaturilor
scazute de procesare
cale directa de la materia prima la produsul finit (operatiune
intr-un singur pas, fara finisari ulterioare)
Exista o multitudine de factori de influenta care se pot combina pentru
a obtine eficienta si inalta calitate si, daca sunt corect selctionati si
folositi, conduc la obtinerea, prin injectare matritata, a unor produse
de prima clasa.
Factorii de influenta in productia prin injectie sunt clasificati dupa
cum urmeaza:
1. Om
Motivare, calificare, flexibilitate, experienta ...
2. Masina pentru injectat
Ergonomicitate, eficienta, acuratete, fiabilitate, proiectare corecta,
optiuni de monitorizare ...
3. Matrita
Componenta orientata catre material si exact proiectata,
proiectare termica, rigiditate, intretinere ...
4. Materia prima
Corect aleasa, curata, pre-uscata,
5. Periferice
Unitati control temperatura, control canale calde ...
6. Mediul ambiant
Siguranta, influentele mediului ...
Omul este unicul factor de influenta ce are abilitatea de a invata si de a
reactiona. Acest fapt il pune intr-o pozitie delicata si odata cu cresterea in
complexitate a procesului de injectie el are nevoie din ce in ce mai mult
de un suport pe masura.
Princii
Acuratetea si ordinea sunt strict necesare pentru aplicarea unei

metode sistematice de lucru. Aceasta poate incepe cu repunerea
capacului pe palnia de alimentare sau resigilarea sacilor deschisi
de materia si incheiat cu intocmirea documentatiei informative
folositoare pentru fiecare pas din optimizarea procesului.
Este deasemenea important sa acordati atentie influentelor
constante ale mediului si a se evita lasarea usilor deschise, ventilatoare sau unitati de incalzire pornite in vecinatatea masinii.
Intregul echipament din sectia de productie trebuie intretinut cu
regularitate. Inclusiv masina, matrita si toate unitatile periferice
Din motive de siguranta urmatoarele lucruri trebuie supravegheate
pe parcursul productiei:
Sa se lucreze la matrita deschisa numai atunci cand pompa
este oprita.
Sa se utilizeze manusi si incaltaminte de protectie si sa se
foloseasca o tija de cupru cand se lucreaza la canalele calde.
Toate mecanismele de siguranta ale masinilor se verifica la
intervale regulate.
Avand toate aceste indatoriri, atunci cand se face reglarea masinii,
reglorul trebuie sa fie capabil sa acorde toata atentia masinii si procesului. Similar, operatiunea de reglare nu trebuie sa fie doar o
operatie de citire a unor tabele si formule, ci fiecare valoare se
considera in mod logic si se analizeaza. Observand aceste reguli
de baza si urmatoarele indrumari in procesare si punandu-le in practica
ve-ti dispune de toate cele necesare procesului de prelucrare prin
injectie a maselor plastice.
Speram ca ve-ti parcurge cu placere acest indrumar si va uram
succes in reglarea masinii dumneavoastra de injectie.
Obiectivul acestei Carti de Buzunar este de a oferi ceva din acest suport.
Reglarea primara a unei

imasini de injectie mase plastice
2.1 Preliminar - lista de verificare
Machine
Articol injectat
Is the proposed machine available for the production

target date?
Am mai produs acest reper in trecut ?
Is the maximum clamping force sufficient?
Pe ce tip de masina?
Has the necessary maintenance work been carried out?
Datele de reglaj sunt deja disponibile pe un hard disk, floppy disk etc.?
Has the machine been running problem-free lately?
Cate repere sunt necesare?

Pana cand?
Is the appropriate screw cylinder available

(cylinder head volume, injection pressure)?
Este necesar echipament special pentru masurare?
Material
Materialul, dimensiunile si greutatea reperului?
Is there sufficient material for the job?
Matrita
Where is the material stored?
Unde este matrita depozitata?
Does the material need to be pre-dried?
Aceasta matrita necesita reparatii sau reparatiile au fost deja facute?
Is there a supply of masterbatch, if required?
Cum poate fi transportata si ridicata pe masina?

Ce dispozitiv de prindere este necesar pentru fixarea matritei pe
masina?
Parametrii urmatori au fost urmariti pentru a verifica compatibilitatea
matritei cu masina folosita?
it
dimensiunile de fixare a matritei

cercul de centrare
capacitatea de injectie
tija aruncatorului si cuplajul masinii (dimensiuni pentru conectare)
nozzle radius and bore and corresponding sprue bush size
additional equipment (core pullers etc.)
Are peripheral units required such as temperature control units,

cooling units, hot runner controllers, conveyor belt?
Are the fittings on the cooling water connections on the
machine and the mould compatible?
Has the mould been leak-tested in the cooling water region?
2.2
Preparing the machine
2.2.1 Setting up the clamping unit for

ERGOtech toggle machines 125 to 1300
Attention!
All mould adjustments to be made in set-up mode only
(For pressure and speeds see screen page 10 on NC4 IBED)

1. Extend the toggle. The ACTUAL value for*mould stroke
must be "0".
2. Using the "Mould height" function keys,'set platen distance
slightly greater than the mould height.
3. Move the moving platen to maximum opening distance.
10. Enter clamping force. When the Start key is pressed the
clamp unit moves automatically to approx. 75% of the set
value of the clamp force. In automatic mode, when clamp
force control is fitted, clamp force is regulated in stages to
100% of the pre-selected value. If necessary, clamp force
can be increased or decreased using the "Mould height"
function key.
11. Now move the clamp unit in set-up mode until platen
contact is made and read off the ACTUAL value for mould
stroke.
The stroke point for "Mould protection end" must be set
approx. 0.5 mm higher than the ACTUAL value displayed,
in order to be able to lock the mould.
4. Attach the mould securely to the lifting gear.

The mould must hang straight. Make sure that the mould
halves cannot slide apart.
12. The speeds and change-over points for the mould and
the ejector must be compatible with the specification of
the mould (see comments in chapter on Cycle Sequence).
5. Protect the machine tie bars from damage during mould

installation.
13. When clamp force is set, tighten the clamps up on the

mould. If necessary, heat the mould beforehand.
6. Position the mould on the fixed platen, centre and attach.

If the mould is to be fixed using clamping shoes ensure a
proper fit.
7. Extend the toggle. Mould stroke on the IBED must indicate
"0". Take care that the ejector rod moves into the ejector
coupling without being forced. Now by using mould height
adjustment move the moving mould half until platen contact
is made. Clamping force is now "0" kN.
8. Tighten the mould half on the moving platen. Remove
safety strap from mould, if used. Connect the ejector rod
with the ejector coupling using the slide mechanism.
9. Open the mould far enough to allow the moulding to fall
out safely in due course. An accurate setting of the opening
stroke can be made later when optimising the injection
moulding process.
2.2.2 Setting up fully hydraulic machines

ERGOtech 25 to 110
Attention!
All mould adjustments to be made in set-up mode only
1. Move clamp unit to maximum opening distance.
2. Attach the mould securely to the lifting gear. The mould
must hang straight. Make sure that the mould halves cannot
slide apart.
''
3. Protect the machine tie bars from damage during mould
installation.
2.3 Setting the injection unit

Follow instructions in the operating manual to change the
screw cylinder.
1. Enter the material-related temperatures required for the
cylinder heating zones and for flange temperature control.
2. Turn on water supply to the machine.
3. Switch on cylinder heating.
4. Set reference point for injection unit.
All heating zones must be up to SET temperature and the
mould must be locked.
4. Position the mould on the fixed platen, centre and attach.

If the mould is to be fixed using clamping shoes, ensure a
proper fit.
5. In set-up mode, move the nozzle to contact with the mould.

Then set to zero using program switch "Reference point IU".
5. Move the clamp unit until platen contact is made, taking

care that the ejector rod moves into the ejector coupling
without being forced.
7. Enter nozzle contact pressure, strokes and speeds for the

injection unit.
6. Check nozzle radius centring and dipping depth.
6. Set mould height using the program switch. ACTUAL mould

stroke is indicated as 2 mm.
8. Enter metering stroke according to the necessary shot

weight. Calculate, if need be, taking into account the necessary melt cushion.
7. Tighten the mould half on the moving platen. Remove

safety strap from mould, if used. Connect the ejector rod
with the ejector coupling using the slide mechanism.
9. Enter injection pressure, injection speed, follow-up pressure,

follow-up pressure time, cooling time, back pressure and
screw speed. See Chapter 4.1 "Processing Guidelines".
8. Enter required clamp force.

On Compact machines the required hydraulic pressure must
also be set using a manually operated valve to correspond
with the value displayed under "Clamp force".
9. To achieve clamping pressure, stroke point
"Mould protection end" must be approx. 0.5 mm higher
than the set mould height.
10. The speeds and change-over points for the mould and the
ejector must be compatible with the specification of the
mould (see comments in chapter on Cycle Sequence).
10. Switch on program switch "Change over to follow-up pressure dependent on volume" (pN volume).
11. Enter stroke point for "Follow-up pressure start". Follow-up
pressure start should occur at around 80 to 90 % of the
shot volume. As a rule, we recommend that a mould filling
study be made on new moulds to determine the exact
change-over point. In this case, follow-up pressure should
be set to "0".
12. If necessary, set decompression to release pressure of melt
in the cylinder if an open nozzle is used.
11. When clamp force is set, tighten the clamps up on the

mould. If necessary, heat the mould beforehand.
10
11
2.4 Starting the injection process
When all settings have been checked the machine can be

switched to the "semi-automatic" program. To enable the
machine cycle to commence once the Start key has been
pressed, the following start conditions must be fulfilled:
Mould open stop reached
Ejector back
Dosing Stop reached (dose manually beforehand and, if
necessary, depending on the type of material, purge the
material a few times). If one or several of the start conditions
is not met, alarms will be raised on theiBED.
As a rule, no monitoring functions or tolerances should be set
during the start-up phase.
The machine can be switched to "fully automatic" after a few
cycles, once the mouldings are being ejected and falling clear.
At this point process optimisation can begin (more detailed
information can be found in Chapter 5 "Process Optimisation
on the injection moulding machine"). The following sequence
is recommended:
optimise dosing
optimise injection speed
determine follow-up pressure and follow-up pressure time
limit injection pressure
determine cooling time
ensure smooth operation of clamping unit
optimise clamping force
carry out checks on mouldings
When the mouldings have reached the required quality standard

and the cycle time is satisfactory, the important parameters can
be monitored by setting tolerance limits using process control.
Safeguard the set machine data by storing the programme on
floppy disk. Also produce a hard copy.
12
13
The cycle sequence on

an ERGOtech machine
3.1 Closing the clamping unit
Operating sequence
Assuming that the machine is an ERGOtech compact or system

model to standard design, the cycle will proceed as follows:
(see Fig. 1)
Fig. 1
Presiune
Viteza
Pozitie
Start conditions:
if
Mould open stop

Hydraulic ejector back stop
Guard door closed
Cylinder up to temperature
Start key depressed
All Start conditions must be met to enable the clamp unit to

be started (in semi- or fully automatic operation). (See Fig. 1)
The clamp unit moves from Pos. [1] - "Mould open Stop" to
Pos. [2] on high pressure and at speed "Mould close V1".
if At Pos. [2] "Mould close" there is a change of speed to
"Mould close V2".
At Pos. [3] "Mould close" there is a change of speed to
"Mould close V3".
Pos. [3] should be set so that speed V3 comes into effect at
the very latest by the start of reduced mould clamping pressure at Pos. [4],
i If Pos. [3] is set after Pos. [4] there will be an automatic
change over to V3 at Pos. [4],
Pos. [4] - "Mould protection start" - reduced mould clamping pressure begins. This switch over point should occur
30-60 mm before platen contact or, in the case of a sliding
splits mould, before the angled dowel moves into the splits.
it Reduced mould clamping pressure should be set just high
enough for the mould to close.
is On platen contact - Pos. [5] - the high pressure must be
switched on again at the control panel at "Mould protection
end" to achieve the set clamping force.
At the same time as the mould closing movement "Mould
protection time" (determined empirically") starts at Pos. [4]
and should not have finished by Pos, [5]. Otherwise, the
cycle would be interrupted. (Exception: activation of "Mould
protection repeat" program).
= = s . = iii SB is!
14
15
3.2 Injection and follow-up pressure phase
Fig. 2
Injection stages - max. 10

Follow-up pressure stages - max. 10
Operating sequence
When start conditions have been met (see Fig. 2) the injection unit moves forward to Pos. [8] on speed "IU forward V".
At Pos. [8] there is a change over to speed "IU forward V2".
The injection unit now moves forward on speed V2 until the
cylinder nozzle makes contact with the sprue bush on the
mould Pos. [9],
Nozzle contact pressure now starts to build. When the given
nozzle contact pressure is reached, this initiates the command for injection.
The set values for "Injection pressure" and "Injection speed"
are also required.
"Follow-up pressure start" at Pos. [10] initiates stroke
dependent change-over from injection pressure to follow-up
pressure. Alternatively, the change-over to follow-up pressure
can occur depending on time or pressure.
If it is necessary to inject at varying speeds, the process can
operate on up to 10 different speeds. The speeds and
stroke-dependent change-over points required can be set
on the "Injection profile" page.
The follow-up pressure phase is operative from Pos. [10]
to Pos. [11]. If follow-up pressure needs to be stepped, this
can be set on the "Follow-up pressure profile" page.
in A reading for the actual melt cushion can be taken from the
Process Optimisation page.
The actual value for the melt cushion should not be much
above or below the tolerance limits. The tolerances are set
on the "Process control" page.
Start conditions:
a
Clamp force reached

Guard door closed
Injection unit guard door closed
Cylinder up to temperature
Dosing Stop and "Screw back" reached
16
17
3.3 Dosing, screw and injection unit back after dosing
Fig. 3
Dosing - max. 6 stages

Back pressure - max. 6 stages
Operating sequence
When the "Follow-up pressure times" have finished, "Cooling
time" begins. Dosing (melt processing) begins at Pos. [12]
when "Delayed feed" (Time) is over. Fig. 3.
Dosing begins at "Screw speed" Stage 1 and "Back
pressure" Stage 1 and ends at "Dosing Stop" Pos. [13].
It is possible, however, to operate on up to 6 different screw
speeds and 6 different screw back pressures per cycle. The
relevant change-over points can be set on the "Dosing profiles" page,
Next, if set, comes screw decompression with "Screw back
after dosing" up to Pos. [14].
If the program "III back after dosing" is switched on, the
injection unit can be moved back on 2 speeds.
When time "IU back delayed" has elapsed, the injection unit
moves back on speed "IU back V1". At Pos. [15] there is a
change over to the second speed "IU back V2". The injection
unit now moves back on speed V2 as far as Pos. [16]
IU back stop".
Start conditions:
All activated follow-up pressure times have elapsed
Delayed feed has finished
"Screw back before dosing" has been completed, if sef
"IU back after dosing" program
18
19
3.4 Opening the clamping unit
Fig. 4
Operating sequence
When start conditions have been met (Fig. 4) the clamping
unit opens from Pos. [17] to Pos. [18] on speed "Mould
openVI".
The slow speed facilitates the gentle demoulding of parts
from the fixed mould half.
a With a sliding splits mould the change-over point
"Mould open V1-V2" up to Pos. [18] is only activated after
the angled dowel is clear of the splits.
The clamping unit then moves to Pos. [19] on speed
"Mould open V2".
$ At Pos. [19] there is another change-over from speed
"Mould open V2" to "Mould open V3" to ensure smooth
running of the machine.
The machine runs on this speed to Pos. [20]
"Mould open stop".
The entire opening stroke occurs at high pressure.
The speeds for mould opening and mould closing and their
dedicated start points are shown on the "Speed profiles"
page.
Start conditions:
a
a
Dosing stop
"Screw back after dosing" is completed
Injection unit back stop
Cooling time is finished
20
21
Small material science
4.1 Processing guidelines for the most important plastics
Polypropylene, PP
This chapter sets out basic, relevant data for the treatment and
processing of the most important plastics.
Structure:
Partially crystalline
Density:
Material
Page
PP
PE
.'
:
23
26
0.91-0.93 g/cm3
Thermal, optical, mechanical properties:
Material is harder and more heat resistant than PE, but is less
resistant to low temperature (special low-temperature resistant
grade available). Particularly suitable for hinges. Hard, non-fragile,
excellent dielectric properties, non-toxic, not odour-proof.
PS
29
ABS
32
SAN
35
PA
38
acids, alkaline solutions, salt solutions, alcohol, petrol,

fruit juices, oil, milk
POM
42
not resistant to
PC
46
chlorinated hydrocarbons, avoid contact with copper,

slight tendency towards stress cracking
PMMA
49
Material identification:
PPO
52
PP is highly flammable, drips and continues to burn; burns brightly

with blue core, strong smell of paraffin (tar-like).
ABS/PC
55
PBTP
58
PETP
61
MH 1 160-250 C / * 2 0 0 C
CA
64
MH 2
PVC-U
67
PVC-P
70
Chemical properties:
resistant to
Cylinder temperature:
Flange
30- 50 C / *50 C
200-300 C / *220 C
MH 3
220-300 C / *240 C
MH 4
220-300 C / *240 C
DH
220-300 C / *240 C
* These temperature profiles are valid for stroke utilisation of between 35 and 65 % and
for parts with a flow length/wall thickness ratio of between 50:1 and 100:1.
Si ~ S
22
B IB
23
Melt temperature:
Pre-drying:
220-280 C
Not necessary; under poor storage conditions perhaps 1 hour

at80C.
Reduced cylinder temperature:

220 C
Re-processing:
Up to 100 % regrind can be processed.
Injection pressure:
There is no build up of very high injection pressure
(800-1400 bar), since flow characteristics are generally good.
Exceptions are thin-walled packaging parts. An injection pressure of up to 1800 bar can result on these parts.
Shrinkage:
1.2-2.5 %. Final shrinkage can only be assessed after
24 hours.
Gating:
Follow-up pressure and follow-up pressure time:

Very long follow-up pressure times are necessary to avoid sink
marks (approx. 30 % of the cycle time).
Follow-up pressure approx. 30-60 % of the required injection
pressure.
Back pressure:
Pin gate or multi-point pin gate, hot runner, insulated runner,

ante-chamber; gate at the strongest point of the moulding.
Machine shut-down:
No other material is required to follow up. PP is very resistant to
high temperatures.
50-200 bar
Cylinder equipment:
Injection speed:
Standard screw; for packaging parts special geometry L:D 25:1

with shear and mixing section. Open nozzle, non-return valve.
Fast injection speeds are needed (accumulator) for thin-walled

packaging parts. Under other circumstances average injection
speeds suffice.
Screw speed:
Peripheral velocity of 1.3 m/sec is the maximum screw speed
on the machine. However, this should only be set as fast as is
necessary for the plasticising process to finish before cooling
time expires.
Recommended min. and max. dosing stroke:
0.5-4.0 D dosing stroke can be utilised.
Residual melt cushion:
2-6 mm, depending on dosing stroke and screw diameter.
24
25
Polyethylene, PE (HDPE)
Melt temperature:
220-280 C
Structure:
Density:
220 C
0.92-0.96 g/cm
Thermal, optical, mechanical properties;

Material is flexible to soft, resistant to terjiperatures up to
-40 C depending on density, impact resistant, indestructible.
Good dielectric properties, low water absorption, non-toxic,
not odour-proof.
resistant to
acids, alkaline solutions, solvents, alcohol, petrol, fruit juices,
oil, milk
not resistant to
aromatic solvents, chlorinated hydrocarbons, risk of stress
cracking
Injection pressure:
There is no build-up of very high injection pressure
(800-1400 bar), since flowability is good. Exceptions are
thin-walled packaging parts. An injection pressure of up to
1800 bar can result on these parts.
Long follow-up pressure times on dimensionaiiy accurate parts
due to relatively extensive shrinkage. Pressure approx. 30-60 %
of injection pressure.
Back pressure:
50-200 bar. Too little back pressure results in uneven moulding
weight or poor pigment dispersion during colouring.
Injection speed:
Fast injection speed (accumulator) required for thin-walled

packaging parts. Otherwise, average injection speed better.
PE is highly flammable, continues to burn when removed from

source of heat, drips. Luminous flame with blue core, smells like
paraffin (snuffed candles).
Screw speed:
Flange
30- 50 C / *50 C
MH1
160-250 C/*200C
MH 2
200-300 C/*210C
MH 3
220-300 C/*230C
MH4
220-300 C/*240 C
DH
220-300 C /*240 C
Peripheral velocity of 1.3 m/sec is max. setting for screw speed

on the machine. However, this should only be set as fast as is
necessary for the piasticising process to finish before cooling
time expires. Required screw torque is low.
2-8 mm depending on dosing stroke and screw diameter.
* These temperature profiles are valid for stroke utilisation of between 35 and 65 %
and for parts with a flow length/wall thickness ratio of between 50:1 and 100:1.
2i iji.
26
27
Pre-drying:
Not necessary. Under poor storage conditions, perhaps 1 hour
at 80 C.
Polystyrene, PS
Structure:
Amorphous
Re-processing:
Density:
1.05 g/cm 3
Shrinkage:
1.5-2.5 %, substantial shrinkage, substantial warpage. Final
shrinkage can only be assessed after 24 hours. (After-shrink-

Hard, stiff, fragile, very good dielectric properties, low water
absorption, good dimensional stability, crystal clear, brilliant,
good pigmentability, no smell or taste.
Gating:
Pin gate, hot runner, insulated runner, ante-chamber pin gate.
Relatively small cross sections suffice.
resistant to
acids, alkaline solutions, alcohol, grease, oil, salt solutions
Machine shut-down:
No other material is required to follow up. PE is very resistant to
high temperatures.
not resistant to
petrol, benzene, large number of solvents, risk of stress
cracking
Cylinder equipment:
Standard geometry for packaging parts; special geometry L:D
25:1 with shear and mixing section; open nozzle, non-return
valve.
PS is highly flammable, burns bright yellow, produces a lot of
black smoke, and typically smells slightly sweet (styrene).
Flange
30- 50 C / *50 C
MH 1
160-220 C / * 2 0 0 C
MH 2
180-240 C / * 2 1 0 C
MH 3
210-280 C / * 2 3 0 C
MH 4
220-280 C/*230 C
DH
220-280 C /*230 C
28
29
Melt temperature:
Re-processing:
220-280 C
Shrinkage:
220 C
0.3-0.6 %
Injection pressure:
Gating:
There is no build-up of very high injection pressure

(800-1400 bar), because flowability is good.
Pin gate, hot runner, insulated runner, ante-chamber. Relatively

small cross sections suffice.
Machine shut-down:
Relatively short follow-up pressure time. Pressure level

30-60 % of injection pressure.
No other material is required to follow up. PS is resistant to high

temperatures.
Back pressure:
Cylinder equipment:
50-100 bar. If back pressure is set too low, this can result in
air burns in the melt (displayed as grey or black streaks in the
moulding).
Standard screw
Open nozzle
Non-return valve
Injection speed:
Generally fast. Stepped depending on shape of moulding.
For thin-walled packaging parts, as fast as possible; partly with
accumulator.
Screw speed:
Fast screw speeds can be set up to a max. 1.3 m/sec peripheral velocity. However, plasticising is best carried out slowly
to suit cooling time.
Pre-drying:
1 hour at 80 C if material has not been properly stored.
30
31
Acrylonitrile-butadiene-styrene, ABS
Melt temperature:
Structure:
220-250 C
Amorphous
Density:
200 C
1.06-1.19 g/cm3
Injection pressure:
1000-1500 bar
Hard, tough even at -40 C, good resistance to changes in

temperature, resistance to low temperatures or heat (+100 C)
depending on type, limited weather resistance, low water
absorption, non-toxic, electroplatable. Special purpose material
also crystal clear.
resistant to
acids, alkaline solutions, hydrocarbons, oils, fats, petrol
not resistant to
acetone, ether, ethyl benzene, ethyl chloride, ethylene chloride,
aniline, aniseed oil, benzene
ABS is highly flammable, burns bright yellow, produces black
smoke and typically smells slightly sweet (styrene).
Flange
Relatively short follow-up pressure time. Pressure level

30-60 % of injection pressure.
Back pressure:
moulding).
Injection speed:
Best stepped, slow injection to begin with, then fast (frontal
flow). Fast injection speed is good for achieving glossy, sparkling surfaces, a good, strong weld line and only a slight weld
line mark. Venting channels are required on the weld line.
Screw speed:
Peripheral velocity of 0.6 m/sec is max. setting for screw speed.
However, it is better to set screw speed sufficiently slow so that
piasticising finishes shortly before cooling time expires.
40- 60 C / *50 C
MH 1 160-180 C/*180 C
MH2
180-230 C/*210C
MH 3
210-260 C/*240 C
MH 4
210-260 C/*240 C
DH
210-260 C/*240C
a ii!
32
ill
11! 11!
ill -Si IS
ill
!!!
s z, 81
Si
s m i!r 18
= a
= = m s
33
Machine shut-down:
No more material is required to follow up.
Pre-drying:
To some extent ABS can be processed direct from the original
bags without pre-drying. Otherwise, pre-dry for 3 hours at
80 C. Damp material causes stripes, streaks or blisters on the
moulding.
Styrene-acrylonitrile copolymer, SAN

Structure:
Amorphous
Density:
1.08 g/cm3
Re-processing:
Providing the material has not already been charred, up to 30 %
regrind can be added to virgin material.
Shrinkage:
Excellent transparency and high gloss, good stiffness and

hardness. Good resistance to changes in temperature, good
chemical resistance, good heat resistance.
0.4-0.7 %
resistant to
Gating:
acids, alkaline solutions, saturated hydrocarbons, mineral oils,

vegetable and animal fats
Pin gate possible, likewise hot runner. Wall thickness should not
be less than 0.7 mm.
not resistant to
Machine shut-down:
concentrated mineral acids, aromatic hydrocarbons and chlorinated hydrocarbons, ester, ether and ketone
No more material is required to follow up.

Cylinder equipment:
Standard screw
iii Non-return valve
Open nozzle
SAN is highly flammable, burns bright yellow, is very smoky and
smells typically of styrene.
Flange
30- 50 C / *50 C
MH 1 160-180 C/*180C
MH2
180-230 C/*210C
MH3
210-260 C/*240C
MH 4
220-260 C /*240 C
DH
220-260 C /*240 C
34
35
Melt temperature:
Pre-drying:
220-250 C
200 C
If SAN is not stored or transported under the right conditions,

it will absorb moisture. This can cause streaks, stripes or small
blisters to appear on the surface of the moulding during
processing.
Injection pressure:
Re-processing:
1000-1500 bar
Providing no charring has occurred during initial processing,

up to 30 % regrind can be added to the virgin material. For high
quality parts, however, virgin material should always be used.

Relatively short follow-up pressure time. Pressure 30-60 % of
injection pressure.
Shrinkage:
0.4-0.7 %
Back pressure:
moulding).
In principle, all types of gating systems can be used, and

likewise for hot runners.
Injection speed:
Machine shut-down:
Fast injection speed is good for achieving glossy, sparkling

surfaces, a good, strong weld line and only a slight weld line
mark.
No other material is required to follow up.
Screw speed:
Max. screw speed equivalent to 0.6 m/sec peripheral velocity.
Screw speed should always be set, however, so that plasticising
finishes just before cooling time expires. Average screw torque
required.
Gating:
Cylinder equipment:
Standard screw
Non-return valve
Open nozzle

36
37
Polyamide, PA
PA 6.6
Structure:
Flange
MH 1 260-290 C/*280 C
MH2
Density:
60- 90 C / *80 C
260-290 C/*280C
MH 3
280-290 C/*290C
MH4
280-290 C/*290C
DH
280-290 C /*290 C
In balanced humidity (2-3 %), very tough. In dry conditions,

brittle. Hard, stiff, abrasion resistant, good frictional characteristics. Good pigmentability, non-toxic, adhesive properties.
1.14 g/cm3
resistant to
oils, petrol, benzene, alkaline solutions, solvents, chlorinated
hydrocarbons, esters, ketone
Feed performance is most strongly affected by the flange temperatures and

the temperatures in zone MH 1. By raising these temperatures, feed performance
becomes more uniform.
Melt temperature:
PA 6
240-250 C
PA 6.6
270-290 C

not resistant to
ozone, hydrochloric acid, sulphuric acid, hydrogen peroxide
PA is flammable. It continues to burn when removed from
source of heat, drips and blisters, becomes stringy. Blue flame
with yellow rim. Smells like burnt bone.
PA 6
Flange
60- 90 C / *70 C
MH 1 230-240 C/*240C
PA 6
220 C
PA 6.6
250 C
Injection pressure:
1000-1600 bar; on thin-walled articles with long flow paths
(cable clip) up to 1800 bar.
Normally, approx. 50 % of the resulting injection pressure. Short
follow-up pressure times are sufficient, as the material solidifies
relatively quickly. As follow-up pressure decays, so the stress in
the moulding reduces.
MH 2
230-240 C/*240C
Back pressure:
MH3
240-250 C/*250 C
MH 4
240-250 C/*250 C
Set very accurately. 20-80 bar, as excessive back pressure

leads to uneven plasticising.
DH
230-240 C/*250 C
Injection speed:
Inject relatively quickly. Ensure that the mould is properly
vented, otherwise charring occurs on the moulding.
38
39
Screw speed:
Gating:
Fast screw speed possible up to 1 m/sec peripheral velocity.

However, it is better to set the screw speed slow enough, so
that plasticising finishes shortly before cooling time expires.
Low screw torque required.
Possible gating systems include pin gate, tunnel gate, film gate,
sprue gate. Blind holes are recommended for cold siugs.
PA can also be processed using a hot runner. The temperature
in the hot runner must be accurately controlled, as the melt
solidifies within a limited temperature range.

0.5-3.5 D dosing stroke.
Machine shut-down:
No other material is required to follow up. Melt dwell time in the

cylinder is possible up to 20 mins, thereafter thermal degradation of melt occurs.
Small melt cushion (2-6 mm), depending on dosing stroke and

screw diameter.
Pre-drying:
Polyamides are hygroscopic, so store in moisture-proof
containers. Close feed hopper!
A moisture content of more than 0.25 % creates processing
difficulties. Process directly from canister, otherwise pre-dry for
4 hours at 80 C.
Cylinder equipment:
Standard screw
Non-return valve
Open nozzle
Wear resistant cylinder equipment is required for glass fibre
reinforced materials.
Re-processing:
10 % regrind can be added to virgin material.
Shrinkage:
PA 6
0.7-2.0%
PA 6.6
0.3-0.8%
PA 6-GF30
0.7-2.0%
PA 6.6-GF30
0.4-0.7%
Parts with operating temperatures above 60 C must be annealed. Annealing cuts down after-shrinkage i.e. the parts are
dimensionaily more stable and have lower stress. Steam treatment works best. Polyamide mouldings can be checked for
stress using soldering fluid.
40
41
Polyacetal, POM
Structure:
Melt temperature:
205-215 C
150 C
Density:
1.41-1.42 g/cm3
Hard, stiff, tough, indestructible up to -40 C, good heat resistance, good abrasion resistance, good frictional characteristics,
low moisture absorption, non-toxic.
resistant to
weak acids, weak alkaline solutions, petrol, benzene, oils,
alcohol
not resistant to
strong acids
Highly flammable, bluish flame, drips and continues to burn,
smells like formaldehyde.
Injection pressure:
1000-1500 bar.
For thick walled technical parts with a wall thickness of
3-4 mm, injection pressure amounts to approx. 1000 bar;
for thin-walled parts it can rise to approx. 1500 bar.
Dependent on the wall thickness of the moulding and on mould
temperature. The longer the follow-up pressure, the less the
shrinkage on the mouldings. Follow-up pressure should amount
to approx. 800-1000 bar to achieve a pressure of around
600-700 bar in the mould. Where precision mouldings are concerned, it is useful if injection and follow-up pressure are the
same (no drops in pressure). Extend follow-up pressure time for
the same total cycle time. Weigh mouldings until weight stabilises and optimum follow-up pressure time is established. More
often than not follow-up pressure time amounts to approx. 30%
of the total cycle time. A moulding reaching 95% ideal weight
shrinks by 2.3%. A moulding reaching 100% ideal weight
shrinks by 1.85%. Slight, even shrinkage signifies consistant
part size.
Flange
40- 50 C / *50 C
MH 1
160-180 C/*180 C
Back pressure:
MH 2
180-205 C/*190 C
50-100 bar
MH 3
185-205 C/*200 C
MH4
195-215 C/*205 C
DH
190-215 C/*205 C
Most favourable processing temperature around 210 C.
Injection speed:
Average injection speed. If injection is too slow, pores appear
on the surface of the mouldings. If mould or melt temperature
is too low, the same thing happens.

42
43
Screw speed:
Cylinder equipment:
Max. equivalent to peripheral velocity of only approx. 0.7 m/sec.

Advisable to set it so that plasticising finishes just before cooling
time expires. Average screw torque required.
Standard screw
Open nozzle
Non-return valve

0.5-3.5 D dosing stroke.
2- 6 mm depending on dosing strode and screw diameter.
Pre-drying:
Not necessary. If material has become moist, dry for approx.
4 hours at 100 C.
Re-processing:
100 % for less important applications. Up to 20 % regrind
possible for precision parts.
Shrinkage:
Approx. 2 % (1.8-3.0)
Final shrinkage only determined after 24 hours.
Gating:
Pin gate can be used for small parts with uniform wall thickness.
Select gate thickness to 50-60 % of the most concentrated wall
thickness on the moulding. It is helpful to inject against some
form of resistance in the mould cavity (core, wall), because of
the laminar flow. Processing with hot runner moulds is state of
the art.
Machine shut-down:
Switch off heating and set back pressure to "0" 5-10 minutes
before production ends. Purge cylinder. When overmoulding
with another material e.g. PA or PC, PE should be run through
in between, as it has a broad processing latitude.
s i m a
44
45
Polycarbonate, PC
Melt temperature:
Structure:
280-310C
Amorphous
Density:
200 C
1.2g/cm3
Injection pressure:
Thermal, optical, mechanical properties:*
Very high injection pressures are needed, as material does not

flow well (1300-1800 bar).
Hard, stiff, impact resistant up to -100 C, good heat resistance,

crystal clear, non-toxic, good pigmentability, low moisture
absorption, weather resistant.
resistant to
oil, petrol, dilute acids, alcohol
not resistant to
strong acids, alkaline solutions, benzene
Does not burn easily, sample extinguishes away from source of
heat, burns bright yellow, is smoky, chars, blisters, has no
typical smell.

Approx. 40-60 % of the required injection pressure. The lower
the follow-up pressure, the lower the stress in the mouldings.
Back pressure:
100-150 bar
Injection speed:
Dependent on flow length and wall thickness. Fast injection for
thin-walled parts. If good surface quality is required, use
stepped (slow-fast) injection speed.
Screw speed:
Max. 0.6 m/sec peripheral velocity. Adjust plasticising time

to suit cooling time. High torque is required on the screw.
Flange
70- 90 C / *80 C
MH 1 230-270 C/*250 C
MH 2
260-310 C/*270 C
MH 3
280-310 C/*290C
MH 4
290-320 C /*290 C
DH
300-320 C/*290C

Residual'melt cushion:
Pre-drying:
3 hours at 120 C. Optimum mechanical properties if water
content is less than 0.02 %.
m m a ; ~ s
46
47
Re-processing:
Polymethyl methacrylate, PMMA
Up to 20 % regrind can be mixed with virgin material. Heat

resistance is also maintained if regrind quota is increased,
but the mechanical properties deteriorate.
Amorphous
Shrinkage:
Density:
0.6-0.8 %
1.18 g/cm3
0.2-0.4 % glass fibre reinforced
Gating:
Hard, brittle, very strong, scratch-proof, crystal clear, good

optical quality, high gloss, extremely weather resistant, good
pigmentability, non-toxic.
The diameter of the gate should correspond to at least 60-70 %

of the most concentrated wall thickness on the moulding, but
1.2 mm is the smallest gate diameter (gate - angle of cone 3-5,
on a good surface 2). Pin gate can be used for smaller components with uniform wall thicknesses.
Machine shut-down:
Where breaks in production occur during the night, empty
the cylinder and drop temperatures to approx. 200 C. When
cleaning the cylinder it is useful to inject through with highviscosity PE. Draw the screw out of the heated barrel and
remove residual material from the screw using a wire brush.
Cylinder equipment:
a Standard screw
B Non-return valve
Open nozzle
Structure:
resistant to
weak acids, weak alkaline solutions, fats and oils
not resistant to
strong acids and alkaline solutions, chlorinated hydrocarbons,
risk of stress cracking
Highly flammable, burns brightly even when removed from
source of heat, crackling flame, rather smoky, sweet fruity
smell.
Flange
60- 80 C / *70 C
MH 1
150-200 C/*190 C
MH 2
180-220 C/*210C
MH3
200-250 C/*230C
MH 4
200-250 C /*230 C
DH
200-250 C /*230 C
48
49
Melt temperature:
Re-processing:
220-250 C
Possible with properly pre-dried and pigmented material. Crystal

clear regrind no longer produces parts with good optical quality.
170C
Shrinkage:
0.3-0.7 %
Injection pressure:
High pressures needed due to poor flow characteristics
(1000-1700 bar).
Very long and high follow-up pressure needed (2-3 mins) for
thick walled parts (lenses etc.). Follow-up pressure in general
amounts to 40-60 % of injection pressure.
Back pressure:
Relatively high back pressure required. 100-300 bar. Insufficient
back pressure causes gas bubbles in the moulding.
Injection speed:
Dependent on wall thickness and flow length. For thick walled
articles initial injection should be extremely slow to achieve perfect frontal flow. Stepped injection speed (slow-fast) to obtain
good surface quality near the gate.
Gating:
Large gates required, as material does not flow easily. For lenses,
gate must be 0.5 mm smaller than wall thickness on the outer
edge of the lenses. Smallest gate diameter - most concentrated
wall thickness on moulding. To achieve good surface quality
near the gate it is important to avoid sharp edges between the
gate and the moulding. Short, round or square gate cross-section needed for good, long pressure transfer. Wide, thin gates
are not advisable.
Machine shut-down:
No other material is required to follow up.
Cylinder equipment:
Standard screw; in some cases, special geometry
Non-return valve
Open nozzle
Screw speed:
Plasticise as slowly as possible according to cooling time.
Screw requires high torque, max. 0.6 m/sec peripheral velocity.
Pre-drying:
PMMA absorbs up to 1 % water. Pre-dry for 4 hours at
approx. 80 C.
50
51
Polyphenylene oxide, PPO
Melt temperature:
Structure:
270-290 C
Amorphous
Density:
200 C
1.05-1.1 g/cm3
Injection pressure:
1000-1400 bar
Hard, stiff, good frictional and abrasion characteristics, good

heat resistance, low water absorption, good scratch resistance,
non-toxic.

40-60 % of injection pressure
Back pressure:
resistant to
30-100 bar
acids, alkaline solutions, alcohol, fats, oils
Injection speed:
not resistant to
Mouldings with long flow paths require fast injection speed;

in such instances, however, it is important to ensure adequate
mould venting.
benzene, chlorinated hydrocarbons

Does not ignite easily, flame extinguishes away from source,
does not drip, smoky, luminous flame, pungent smell. PPO is
not transparent.
Screw speed:
Average screw speeds. Max. peripheral velocity 0.6 m/sec.
Flange
40- 60 C / *50 C
MH 1 240-280 C/*250 C
MH 2
280-300 C /*280 C
MH 3
280-300 C /*280 C
MH4
280-300 C/*280C
DH
280-300 C/*280 C
52

Pre-drying:
2 hours at 110 C
Re-processing:
Can be reprocessed as regrind providing the material has not
been charred.
53
Shrinkage:
Acrylonitrile-butadiene-styrene + polycarbonate, ABS + PC
0.8-1.5 %
Structure:
Gating:
Amorphous
Pin/tunnel gate for small mouldings, otherwise sprue gate,

diaphragm gate, hot runner.
Density:
1.15 g/cm3
Machine shut-down:
Switch off heating; where screw back pressure is low, dose
several times and purge cylinder.

Impact resistant, high gloss, light resistant, electroplatable, heat
resistant, good fracture resistance.
Cylinder equipment:
Standard screw
Non-return valve
Open nozzle
resistant to
limited hydrolysis resistance
not resistant to
ketone, ester, chlorinated hydrocarbon
Flange
50- 70 C / *70 C
MH 1 230-250 C / *250 C
MH 2
250-260 C / *260 C
MH 3
250-270 C / *265 C
MH 4
250-270 C / *265 C
DH
250-270 C / *270 C
Melt temperature:
260-270 C
200 C
Injection pressure:
800-1500 bar
54
55
Shrinkage:
Approx. 40-50 % of the required injection pressure in order to

avoid sink marks appearing. Follow-up pressure must be set as
low as possible to produce low-stress mouldings.
Shrinkage is almost identical in all axes and amounts to

0.5-0.7 %; 0.2-0.4 % on glass reinforced types.
Gating:
Back pressure:
Only around 50-100 bar in order to avoid frictional heat.
Any recognised type of gate can be used. When injecting via

hot runner, temperature in the hot runner must be accurately
controlled.
Injection speed:
Machine shut-down:
Average injection speed (up to 60 mm/sec) to keep frictional

heat down. Partially stepped - slow-fast.
Switch off heating. Purge cylinder.
Screw speed:
Cylinder equipment:
Max. screw speed corresponding to approx. 0.4 m/sec

peripheral velocity.
Standard screw up to 50 mm diameter. Where larger screw

diameters are concerned, use screw with lower compression
and shorter metering section.
Non-return valve
Open nozzle

1.0-3.0 D dosing stroke because the melt is susceptible to
overheating or because of excessive melt dwell time in the plasticising cylinder. Dwell time for the melt in the cylinder should
not exceed 6 mins.
2-5 mm depending on screw diameter and dosing stroke.
Pre-drying:
4 hours at 80 C.
Re-processing:
Up to 20 % regrind can be added, provided it has been properly
pre-dried and is not charred. It is better to use regrind for parts
where strength requirements are not so stringent.
56
57
Polybutylene terephthalate, PBTP
Melt temperature:
Structure:
250-260 C, narrow processing range

below 240 C danger of freezing
above 270 C material becomes charred
Density:
1.30 g/cm3
210 C
Injection pressure:
Good heat resistance, good stiffness and hardness, low water

absorption, good resistance to stress cracking, excellent frictional characteristics and abrasion resistance, good dimensional
stability, non-toxic.
Injection pressure of 1000-1400 bar can result. Follow-up

pressure should amount to 50-60 % of the resulting injection
pressure.
Back pressure:
resistant to
Only approx. 50-100 bar in order to avoid frictional heat.
oils, fats, alcohol, ether, petrol, weak acids, weak alkaline

solutions
Injection speed:
not resistant to
benzene, alkalis, strong acids, strong alkaline solutions, ketone
Fast injection speeds are required because of melt setting

speed and the rate of crystallisation. Cooling or setting of the
melt during injection must be avoided. Ensure mould is well
vented, otherwise there will be signs of charring at the end of
the flow path as a result of compressed air.
Material does not ignite easily, extinguishes when removed from

flame, luminous flame, yellowy orange, smoky, slightly sweet
aromatic smell.
Screw speed:
Recommended min, and max. dosing stroke:
Flange
50- 70 C / *70 C
MH 1
230-250 C /*240 C
MH 2
240-260 C/*250 C
0.5-3.5D dosing stroke because melt is susceptible to overheating or because of excessive melt dwell time in the plasticising cylinder. Dwell time for the melt in the cylinder should not
exceed 5 mins.
MH 3
250-260 C/*260 C
MH 4
250-260 C/*260 C
DH
250-260 C/*260C
58


Pre-drying:
4 hours at 120 C.
59
Re-processing:
Polyethylene terephthalate, PETP
Up to 10 % regrind can be added for material types containing

flame retardants, providing the material has not been charred
and has been properly pre-dried. Up to 20 % for material types
without flame retardants.
Structure:
Shrinkage:
1.35 g/cm3
Very dependent on mould temperature. The higher the mould

temperature, the greater the shrinkage - 1-.4-2.0 %.
0.4-0.6 % for 30 % GF.
Gating:
Do not use concentric sprue or pin gate with glass fibre reinforced materials. Injection point should be selected so that the
cavity is filled evenly. When gating via hot runner, temperature
must be accurateiy controlled in the hot runner.
Density:

Good impact strength, extreme hardness and stiffness (slightly
more so than PBTP), good dimensional stability, low water
absorption, only slight internal stress, good flowability.
resistant to
oils, fats, alcohol, ether, petrol, weak acids, weak alkaline
solutions
Machine shut-down:
Switch off heating. Empty cylinder. During breaks in production
and before restarting the machine, squirt the melt out until it is
free from bubbles.
not resistant to
benzene, alkalis, strong acids, strong alkaline solutions, ketone
Cylinder equipment:
Standard screw
s Non-return valve
Open nozzle
The material is difficult to ignite, extinguishes away from flame,

luminous flame, yellowy orange, smoky, slightly sweet aromatic
smell.
Flange
50- 70 C / *70 C
MH 1 240-260 C/*250 C
MH 2
240-260 C /*250 C
MH3
250-290 C/*270C
MH 4
250-290 C/*270 C
DH
250-290 C /*270 C
60
61
Melt temperature:
270-280 C
Pre-drying:
220 C
4 hours at 140 C.
Injection pressure:
Re-processing:
For thin walled articles, injection pressure up to 1600 bar can

result.
Max. 20 % regrind can be added providing it has not been

charred and has been properly pre-dried. Not possible to
achieve the same tensile, flexural and impact strength as when
virgin material is used.

Approx. 50-70 % of the required injection pressure in order to
avoid sink marks. Set follow-up pressure time only for as long
as is necessary. With amorphous materials in particular, excessive follow-up pressure times cause increased stress, which
reduces the impact strength of the mouldings.
Varies greatly depending on material type, wall thickness, mould

temperature, follow-up pressure and follow-up pressure time 1.2-2.0 %, or 0.4-0.6 % with 30 % GF.
Back pressure:
Gating:
Only around 50-100 bar in order to avoid frictional heat.
Shrinkage:
Injection speed:
Any weil-known type of gate can be used. When injecting via

hot runner, temperature in the hot runner must be accurately
controlled.
Fast injection speeds are required because of melt setting

speed and the rate of crystallisation. Cooling or setting of the
melt during injection must be avoided. Ensure mould is well
vented, otherwise there will be signs of charring at the end of
the flow path as a result of compressed air.
Switch off heating. Empty cylinder. When changing to another

thermoplastic material it is advisable to flush through with PE
or PP beforehand.
Screw speed:
Cylinder equipment:

Standard screw
a Non-return valve
Machine shut-down:

0.5-3.5 D dosing stroke because melt is susceptible to overheating or because of excessive melt dwell time in the plasticising cylinder. Dwell time for the melt in the cylinder should not
exceed 5 mins.
62
63
Cellulose acetate, CA
Melt temperature:
Structure:
200-210 C
Amorphous
Colour change in the melt indicates that melt temperature is too

high. If melt temperature is too low, surface gloss and transparency deteriorate.
Density:
1.2-1.3 g/cm3
160C
Tough, resistant to boiling water, difficult to break, good scratch

resistance and self-polishing effect, low electrical charging,
non-toxic, good surface gloss. The strength of this material
makes it suitable for embedding metal parts (screw driver).
800-1200 bar
resistant to
Injection pressure:
oils, fats, benzene, petrol
40-70 % of the injection pressure. Not too high if internal stress

is to be avoided. Relatively long follow-up pressure for thick
walled parts.
not resistant to
Back pressure:
vinegar, acids, alkaline solutions
50-100 bar
Injection speed:
Does not ignite easily, extinguishes away from flame, smoky

with greenish yellow flame, smells of burnt paper and vinegar.
Fast injection speed for thin walled parts. Inject slowly for thick
walled parts.
Screw speed:
Flange
Average screw speed, corresponding to max. 0.6 m/sec

starting speed.
30- 40 C / MO C
MH 1 140-160 C/*150 C
MH 2
160-185 C/*170 C
MH 3
170-200 C/*180 C
MH 4
170-200 C/*180 C
DH
170-200 C/*180 C
Pre-drying:
3 hours at 70 C.
64
65
Re-processing:
Polyvinyl chloride unplasticised, PVC-U
Up to 20 % regrind can be added, providing it has not been

charred and is properly pre-dried.
Structure:
Amorphous
Shrinkage:
0.4-0.7 %
0.4 % in direction of flow
0.6- 0.7 % across the direction of flow
Gating:
Pin/tunnel gate. Avoid jetting by spring actuated auxiliary core,
otherwise surface defects will occur near the gate.
Machine shut-down:
Density:
1.35 g/cm3
Stiff, hard, transparent to opaque, good bonding properties,
certain formulations non-toxic.
resistant to
Switch off heating. Plasticise several times without back

pressure and squirt melt out.
acids, alkaline solutions, oils, fats, petrol
Cylinder equipment:
benzene, ketone, ester, stain removers
Standard geometry, in some cases special geometry

a Non-return valve
Open nozzle
not resistant to
Does not ignite easily, smoky, burns green, sputters, smells of
hydrochloric acid, self extinguishing.
Flange
30- 50 C / *50 C
MH 1
140-160 C/*150 C
MH 2
165-180 C/*170 C
MH 3
180-210 C/*190C
MH 4
180-210 C/*200C
DH
180-210 C/*200C
Melt temperature:
210-220 C
66
67
Pre-drying:
120 C
1 hour at 70 C (only necessary if material has not been stored

properly).
Injection pressure:
800-1600 bar
Re-processing:
Can be reused providing material has not been charred.

Do not set too high. 40-60 % of injection pressure to suit the
moulding and the gate.
Shrinkage:
Back pressure:
Gating:
It is very important with PVC to select the right setting, because

the material is heat sensitive. Heat from the friction of the screw,
when properly directed, is better than heat from the cylinder
heater bands. Back pressure up to 300 bar is possible.
Sprue, film and diaphragm gates advisable. The gate must be

radiused towards the moulding. Pin gate possible for small
parts.
0.5-0.7 %
Machine shut-down:
Injection speed:
Do not set too high. Make sure that the material has not
sheared. For this reason, stepped injection is advisable.
Switch off heating. Plasticise without back pressure, let the melt
stand for 2-3 minutes and then squirt it out slowly. Repeat the
process until cylinder temperature has fallen to 160 C, then
empty the cylinder.
Screw speed:
Set as low as possible, corresponding to max. speed 0.2 m/sec
peripheral velocity. With long cooling times and despite slow
screw speed, delayed plasticising can be used to ensure that
dosing finishes just before cooling time expires. High, even
torque is required.
Cylinder equipment:
Screw geometry for rigid PVC
B Flighted or unflighted screw tip
Open nozzle

1-5 mm depending on dosing stroke and screw diameter. Keep
cushion small and make sure axial screw clearance is minimal.
68
69
Polyvinyl chloride plasticised (PVC-P)
Melt temperature:
Structure:
200-220 C
Amorphous

120 C
Density:
3
1.1-1.4 g/cm
Injection pressure:
800-1200 bar
The material is flexible, rubbery-elastic, non-toxic.
resistant to
30-50 % of the necessary injection pressure.
acids, alkaline solutions, detergents ,oils, fats

not resistant to
petrol, ester, chlorinated hydrocarbons
Does not ignite easily, smoky, burns green, sputters, smells of
hydrochloric acid with plasticiser.
Back pressure:
50-100 bar
Injection speed:
Do not inject too fast if good surface quality is required (stepped injection, perhaps).
Screw speed:
Set average screw speed; max. equal to 0.5 m/sec peripheral

velocity.
Flange
30- 50 C / *50 C
MH 1 140-160 C/*150C
MH 2
150-180 C/*165 C
MH 3
160-220 C/*180 C
MH 4
160-220 C/*190 C
DH
160-220 C/*200 C

Pre-drying:
1 hour at 70 C (only if material has not been properly stored).
Re-processing:
Can be reused providing material has not been charred.
Shrinkage:
1-2.5 %
iS B
70
71
Gating:
The gate must be radiused towards the moulding. Pin gate
possible for small parts.
Machine shut-down:
Switch off heating. Plasticise several times without back
pressure and squirt melt out.
Cylinder equipment:
Standard screw
Open nozzle
Non-return valve
72
73
4.2 Distinguishing characteristics of plastics 1

"
.
Distinguishing characteristics
Appearance
Fracture
Float test
Burn test
Flame
Smell during burn test
Finger nail scratch test
74
Material
transparent/opaque
crystal clear
no fracture
stress-whitening/tough
brittle fracture
floats
sinks
highly flammable
slow to ignite
self-extinguishing
continues to burn
smoky
not smoky
drips
does not drip
luminous yellow
bright with blue core
bluish
greenish/yellow
waxy/paraffin
burnt bone
slightly sweet
tar-like
pungent/formaldehyde
like fish
ike paper and vinegar
like styrene
fruity
like hydrochloric acid
not typical
scratch-proof
not scratch-proof
POM PMMA
PA
PE
pp
PS
SAN
ABS
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
__^
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
75
4.2 Distinguishing characteristics of plastics 2
;
Material
Distinguishing characteristics
Appearance
transparent/opaque
crystal ctear
Fracture
no fracture
stress-whitening/tough
brittle fracture
Float test
floats
sinks
Burn test
highly flammable
slow to ignite
self-extinguishing
continues to burn
smoky
not smoky
drips
does not drip
Flame
uminous yellow
bright with blue core
bluish
greenish/yellow
Smell during burn test
waxy/paraffin
burnt bone
slightly sweet
tar-like
pungent/formaldehyde
ike fish
like paper and vinegar
like styrene
fruity
like hydrochloric acid
not typical
Finger nail scratch test
scratch-proof
not scratch-proof
Si iSS
76
PC
CA
X
X
X
PPO
PETP
PBTP
ABS
PC
PVC-U PVC-P
X
X
X
* X
X
X
x
X
x
X
ill a ill
if
isi iii
::.
77
Optimizarea procesului la o
masina de injectie mase plastice
Principii:
1. Cand se optimizeaza parametrii este foarte important sa nu
se modifice mai mult de un parametru odata, pana cand nu se
realizeaza efectul acelui parametru asupra calitatii produsului
Sunt multe schimbari ce pot fi facute asupra parametrilor iar
influenta acestora apare imediat.
5.1 Corelatia dintre caracteristicile calitatii si parametrii de

proces prezentate ca profil al presiunii in cavitate
Faza de Injectie
Faza de
compresie
Faza de Mentinere in presiune

.
Suprafata
(rugozitate, stralucire, culoare)
structura, orientare la suprafata,
cristalinitate
definire contur
formare structura,
greutate,
deviatii
dimensionale
greutate, deviatii dimensionale

contractie, goluri in structura
striatii, orientare
interna
Viteza de injectie
Temperatura
Temperatura matritei
punctul de
comutare
temperatura
cilindrului
temperatura
matritei
presiunea de mentinere
timpul presiunii de mentinere
temperatura cilindrului
temperatura matritei
Timpul de injectie
Presiunea integrala de injectie
Temperatura topiturii
Temperatura matritei
presiunea max.
hidr. sau a cavitati
presiunea integrala in cavitate

temperatura topiturii
temperatura matritei
2. Optimizarea trebuie sa inceapa intotdeauna cu calitatea

injectiei in minte. Legaturile fundamentale dintre caracteristicile
calitatii si setarea parametrilor, sunt suficient de bine cunoscute.
(vezi diagrama in pagina alaturata). Este important sa realizati
o evaluare atenta a caracteristicilor calitatii si ale limitelor acesteia.
Apoi stabilitatea si calitatea procesului trebuie optimizata
pe baza parametrilor si a distributiei curgerii.Numai dupa ce
acestea au fost realizate se poate face optimizarea timpului de ciclu.
3. In sistemul de control NC4 exista o pagina pentru optimizarea
procesului, pagina unde sunt comasati toti parametrii importanti.
Toti pasii esentiali pentru optimizare pot fi modificati in aceasta pagina.
Afisate in aceasta pagina sunt si toate valorile ACTUALE relevante.
Un sistem integrat de achizitii de date este disponibil pentru a permite
operatorului sa optimizeze profilele de presiune hidraulica si
presiune in cavitate pentru fazele in care efectul asupra calitatii
este semnificativ si decisiv.
Parametrii importanti pentru optimizarea procesului pot fi considerati
urmatorii:
1. Temperatura cilindrului de plastifiere si a topiturii
2. Temperatura matritei
3. Viteza de injectie
4. Volumul de comutare
5. Timpul de mentinere in presiune
6. Presiunea de mentinere
7. Timpul de racire
8. Viteza de dozare
9. Contra-presiunea
10. Decompresia (retragerea snecului)
11. Monitorizarea parametrilor
80
81
1. Temperatura cilindrului de plastifiere si a topiturii
2. Temperatura matritei
Temperaturile pre-setate ale cilindrului, impreuna cu forta de frecare

indusa de viteza snecului, asigura caldura suficienta pentru a
topi materialul plastic (plastifiere).
Temperaturile matritei asigura curgerea libera a materialului

pana ce cavitatea este complet umpluta.
Recomandarile de setare pot fi gasite in datele de setare individuale

ale materialelor (vezi Capitolul 4 al carticelei).
Recomandari pentru setarea temperaturilor matritei poti fi

gasite in Capitolul 4.3 al acestei carticele.
In principiu:
Valabil pentru toate materialele:

Temperatura topiturii prea mare:
Degradare termica
Diferente de culoare/schimbare de culoare
Contractie marita/variatii dimensionale
Prelungirea timpului de racire
Proprietati mecanice inferioare
Temperatura topiturii prea mica:
Topitura neomogena
Tensionare ridicata in piesa injectata
Presiunea de injectie necesara este ridicata
Liniile de curgere si cele de imbinare sunt clar vizibile
Uzual, temperaturile cilindrului sunt setate in profil crescator

(exceptie: PA). Primele doua zone de incalzire (MH1 si MH2)
strebuiesc setate la limita inferioara deoarece acolo este cursa cu
utilizare minima si la limitele superioare pentru cursele intens utilizate.
82
O temperatura mare a matritei asigura:
Contractie post-injectie redusa

Orientare redusa, tensionare interna mica
Necesita presiune scazuta
Cristalinitate crescuta
Temperatura prea mare a matritei:

Timp de racire prelungit (2%/1 C)
Deviatii dimensionale
Temperatura prea mica a matritei:
Suprafata mata
Efect de unda
Linii de curgere / linii de imbinare vizibile clar
Tensionare crescuta in piesa injectata
O unitate de control al temperaturii de inalta performanta se
poate folosi pentru a mentine temp. constanta in matrita. Temp.
matritei este unul din cei mai importanti parametrii si trebuie mentinut
in limite de toleranta foarte stranse. Pentru piese cu proprietati de
contractie (ex. piese tehnice), este recomandat sa se foloseasca
unitati de control temp. integrate, ale carei valori setate pot fi
memorate si monitorizate de catre IBED (ErgoControl).
83
Re. 3 Viteza de injectie
Re. 4 Comutare in functie de volum (punct de comutare)
Viteza de injectie influenteaza rata de dispersie a topiturii in

matrita. In principiu, trebuie setata cat de rapid posibil.
Comutarea pe presiune de mentinere reprezinta tranzitia de la

reglajul dependent de viteza din timpul injectiei la reglajul dependent
de presiune din timpul fazei de mentinere in presiune.
In cazul pieselor cu variatii in grosimea peretilor poate fi necesar

setarea unui profil in trepte. In faza start si, respectiv, sfarsit de
umplere poate fi nevoie de un profil ascendent si,respectiv, descendent.
Viteza de injectie prea mare:
bavura
defecte de suprafata langa duza
arsuri la capatul caii de curgere
necesar de forta de inchidere mare
Viteza de injectie prea mica:
efect de unda
piesa umpluta partial
deformare
linii de imbinare vizibile
Inainte de toate, monitorizarea presiunii trebuie setata la maximum pentru

a optimiza viteza de injectie. Cand presiunea de injectie limita este atinsa,
aceasta este indicata in ecranul de achizitii de date, se datoreaza faptului
ca a fost schimbata viteza de injectie (valorile setate) iar timpul de injectie a
ramas neschimbat.
84
In general, comutarea trebuie sa aiba loc atunci cand aprox. 95 %

din volumul cavitatii a fost umplut. La piesele cu pereti subtiri poate
fi necesar sa se umple chiar 98 % din volumul cavitatii.
Comutare prea devreme:
urme specifice de comutare

cavitate umpluta incomplet
supturi
subdimensionare
urme pe liniile de imbinare
Comutare intarziata:
bavura
supradimensionare
probleme la demulare
tensionare ridicata in piesa injectata
La inceput trebuie selectat un punct de comutare devreme. Gradual

acesta se seteaza intarziat (studiu al umplerii mattritei) pana ce
umplerea volumului este aproape realizata. Aceasta procedura
furnizeaza informatii valoroase cu privire la profilul frontului de curgere
in matrita si descoperirea urmelor de curgere si de imbinare.
85
Re. 5 Timp de mentinere in presiune
Re. 6 Presiunea de mentinere
Dupa umplerea volumetrica, contractia este stabilizata in timpul

mentinerii in presiune prin racirea cavitatii matritei.
Presiunea de mentinere este presiunea hidraulica activa pe

durata timpului de mentinere si are menirea de a combate
formarea urmelor de tip suptura.
Timpul de mentinere in presiune se seteaza ca durata necesara

topiturii sa se solidifice langa duza.
De regula, presiunea de mentinereeste de 30-50 % din

presiunea necesara de injectie.
Timp de mentinere in presiune prea lung:

timp rezidual insuficient ramas pentru plastifiere
consum de energie crescut
Timp de mentinere in presiune prea scurt:
supturi, goluri
variatii in greutate a pieselor
subdimensionare
topitura curege inapoi in cilindru
fluctuatii ale pernei de material
Pentru stabilirea timpului optim de mentinere in presiune cresteti

continuu valoarea setata pana ce piesele, fara culee, nu mai cresc in
greutate. Concluzie: Determinarea timpului optim de mentinere in
presiune se face prin controlul greutatii.
Presiunea de mentinere prea mare:
bavura
tensionare ridicata in piesa injectata
supradimensionare
probleme la demulare
urme de ejector
Presiunea de mentinere prea mica:
supturi, goluri
subdimensionare
contractie mare de volum
fluctuatii mari in greutate
Re. 7 Timp de racire

Timpul de racire reprezinta perioada finala de racire a piesei
in cavitate pana ce se atinge stabilitatea dimensionala suficienta
pentru demulare. Caracteristicile urmarite aici sunt dimensiunile si
deformarea pieselor.
Timp de racire prea lung:
creste timpul de ciclu
Timp de racire prea scurt:
0
1012
1 4 1 6 Timp de mentinere (s)
deformare
urme de aruncator
creste contractia post-injectie
Verificati si Capitolul 5.2 - Calculul timpului de racire.
86
87
Re. 8 Viteza de rotatie a snecului
Re. 10 Decompresiea (retragerea snecului)
Viteza snecului este responsabila pentru plastifiere, adica pentru

pregatirea termica, mecanica si omogenizare a materiei prime.
Decompresia serveste la reducerea presiunii topiturii in spatiul

din fata snecului, dupa dozare. Trebuie sa fie aprox. 4 % din
volumul de dozare dar, ca valoare, sa nu fie mai putin de 10 %
din diametrul snecului. Pentru mai multe detalii vezi Capitolul
4.1 "Indrumar de procesare pentru cele mai importante
materiale plastice".
Limita superioara setata a vitezei snecului este forta periferica

maxima admisa de snec pentru diferite tipuri de material. Timpul de
dozare rezultat, nu trebuie sa fie cu mult mai scurt decat timpul de
racire, asta pentru a se realiza o plastifiere cat mai delicat posibil.
.
Decompresie prea mare:

Viteza de rotatie prea mica:
fluctuatii ale timpului de ciclu (in cazul t
bule de aer in jurul punctului de injectie

doz >
t racire)
Decompresie prea mica:
Viteza de rotatie prea mare:
scurgeri de material pe la duza sau duze calde
degradare termica si mecanica a materialului

diferente mari ale temperaturii topiturii dealungul lungimii snecului
creste uzura snecului si a valvei non-retur
Re. 11 Parametrii de monitorizare
Re. 9 Contra-presiunea
Contra-presiunea reprezinta presiunea din fata toprilei, impotriva careia
snecul trebuie sa lucreze pe parcursul dozarii.
Contra-presiune prea mare:
degaradarea materialului datorita frictiunii excesive
capacitate redusa de plastifiere, timp lung de dozare
Contra-presiune prea mica:
neomogenitate a topiturii
(fluctuatii mecanice si termice)
granule de material netopit
bule de aer
Parametrii pentru monitorizare se regleaza numai dupa ce toti

parametii importanti au fost optimizati si nivelul de calitate este
constant mentinut in limitele de toleranta.
a) Monitorizarea injectiei (limitarea presiunii de injectie)
In timpul fazei de umplere exista o dependenta intre pres.hidr.
si viteza de injectie setata, dependenta corelata cu rezistenta
la curgere a topiturii. In situatii normale acest profil de presiune
este repetitiv. Aceasta presiune poate creste involuntar numai
daca o defectiune are loc in timpul procesului sau daca unul
dintre parametrii fluctueaza.
Din acest motiv, presiunea de injectie limita este setata aprox.
10-15 % peste presiunea maxima de umplere. Daca aceasta
este depasita, apare un mesaj de eroare si masina se opreste
fara sa afecteze in nici un fel matrita sau duzele calde.
b) Monitorizarea injectiei
Deasemeni, in timpul fazei de umplere apare si un timp actual
de injectie dependent de viteza de injectie setata. Devierile
evidente de la acest timp inseamna o eroare in proces. Limita
timpului de injectie trebuie setata cu aprox. 10-15 % peste
timpul actual de injectie.
88
89
5.2 Cooling time
Typical pressure profile during mould filling
Cooling time is calculated using the following formula:

Pressure (p)
Injection pressure monitoring
Change-over
with
cooling time
wall thickness
effective thermal diffusivity
melt temperature
mean demoulding temperature
average cavity wall temperature (average value
derived from minimum and maximum cavity
wall temperature over the course of an injection
moulding cycle)
Time (t)
For an initial estimate of cooling time with the aid of a diagram,

the cooling time equations can be grouped according to the
different plastics. These groups are determined by taking as
a basis the average temperatures for melt, cavity wall and demoulding. (Compare with Chapter 4.1 "Processing guidelines
for plastics".)
Changes in melt temperature have no appreciable effect with
wall thicknesses up to 4 mm (< 1 sec).
Changes in cavity wall temperature, on the other hand, must
be taken into consideration.
90
91
Notes on producing the cooling time diagram
5.2 Cooling time as a function of wall thickness (1 to 2.5 mm)
Control equations:
PC:
toool = 2 . 1 7 x s
s = wail thickness [mm]
PA6, PBTP, LDPE
tcool = 2.64 x s
tcoo! = cooling time [sees]
ABS, PS, SAN, PA 6.6:t0OOl = 2.82 x s2

HDPE, PMMA
toool = 3.00 x s2
PP
tcool = 3.67 x s2
POM
toool = 4 . 1 8 x s 2
The curve points for the different groups of plastics are given in
the following table. These curve points are also entered on the
two subsequent diagrams, where s = 1 to 2.5 mm and s = 2.5
to 4 mm.
Wall thickness
Change in cavity wall
temperature by [C]
Change in cooling time
by [sees.]
s = 2 mm
+10 +5
+5
-5
s = 4 mm
-10 +10
+5
-5
-10
+2 -1.2 -2 +20 +7.5 -5
-9
Influence of cavity wall temperature on cooling time with

wall thicknesses of 2 and 4 mm
92
93
5.2 Cooling time as a function of wall thickness (2.5 to 4 mm)
94
95
The correct evaluation and selection

of process parameters for quality
assurance in injection moulding
Ever shorter innovation cycles, the growing complexity of products and increasingly stiff competition all call for economic
injection moulding production. Quality assurance and the ability
to reduce scrap to a minimum are becoming increasingly
important.
Only those processors who can accurately predict the output of
perfect mouldings will have costs under control, be able to meet
delivery deadlines and be acknowledged as reliable partners.
When it comes to quality control, the control and analysis
features on modern injection moulding machines are highly
efficient. The operator can have complete control over the
production process, carry out long-term statistical evaluations
or anticipate trends.
Of course, to make best use of these resources the setter
needs to know which machine and process parameters influence the quality of a moulding - and, most importantly, to what
extent.
Practice shows, however, that the significance of these parameters varies from application to application and is determined
by the demands of the particular moulding.
The following report and data tables are the result of extensive
long-term testing and the evaluation of a large number of individual cases. They assist in the selection and evaluation of the
correct parameters and in defining the required tolerances for
quality control on the machine.
96
97
The table opposite (Fig. 6.1) shows the 5 most significant quality
characteristics and their relative importance for the production
of different product groups. For technical precision parts, dimensional stability is clearly of greatest importance, while for optical
parts, for example, surface quality and melt homogeneity are
crucial factors.
Fig. 6.1
Of course, there are still a good many other quality characteristics -the "inherent properties", for example, like molecular
weight, orientation on the skin and the core, dispersion of fillers
and reinforcing materials etc. These selected criteria, however,
represent essential performance properties which can also be
subjected to direct and mainly non-destructive testing.
At this point, of course, there is still no indication of which
parameters are required for controlling the quality of the
mouldings.
98
99
Fig. 6.2 shows important process parameters and their relation

to the various quality characteristics. The correlation between
machine or setting parameters and the characteristics of the
mouldings is sometimes very complex. In almost all instances,
there are several setting parameters relating to a single quality
characteristic, which is why more than one parameter needs to
be controlled.
100
Fig. 6.2
101
ft ill
Si 81 Si
Fig. 6.3 illustrates the connection between quality characteristics

and process parameters with the aid of the (integral) cavity
pressure profile. It shows clearly how the majority of quality
characteristics are influenced during the follow-up pressure
phase. Consequently, the cavity pressure profile must fall within
specified tolerance limits during this phase. The diagram also
shows those setting and monitoring parameters relevant to
quality. The cavity pressure profile, mould temperature and melt
temperature are the most significant and informative factors
here.
In the injection phase cavity pressure is determined mainly

by flow resistance, viscosity of the moulding compound and
injection speed. During the compression phase the melt is
compressed up to the so-called change-over point, which then
initiates the follow-up pressure phase. In this latter phase, the
pressure rises in the mould initially, because the mould is now
completely filled. As the melt cools down, so the pressure falls
slowly. In conjunction with the cooling process, this phase is
decisive in terms of shrinkage and internal orientation, and also
for crystallisation in partially crystalline materials.
In 50 % of all cases cavity pressure monitoring proves very useful from a processing point of view, but it is only realistic in 3 %
of these, since the cost in terms of machine, mould and personnel is relatively high. Cavity pressure monitoring is applied
to around 20 % of mouldings, predominantly technical precision
and functional components, optical products and automotive
parts.
Fig. 6.3
The use of cavity pressure enables the setting parameters for

the machine and peripheral equipment to be largely indirectly
monitored, because the smallest changes or disruptions - to
mould or melt temperature, to the function of the non-return
valve, to the change-over point to follow-up pressure or to the
batch of material - all have an effect on cavity pressure. Very
often it is possible to monitor several settings via one single
parameter and also to document them in accordance with
DIN ISO 9000.
The time profile for cavity pressure can be divided into three
phases. These are the injection, compression and follow-up
pressure phases.
102
103
Si Si Si Si it Hi
iii f! Si
01
Pressure transducers have been used in the mould for more

than 20 years and at the moment are probably the simplest
form of total control, without directly including the characteristics of the moulded part. Care should be taken to ensure that
the cavity pressure sensor is located at a quality-determining
point - as close to the sprue as possible - approx. 30-40 % of
the way along the flow path. A pressure sensor can also be
integrated in the hydraulic circuit (in or on the hydraulic injection
cylinder).
Fig. 6.4
Fig. 6.4 shows a characteristic profile of hydraulic and cavity

pressure. If, for example, the hydraulic pressure (upper curve)
rises during the injection phase as a result of a lower mould
temperature (caused by increased flow resistance during injection), then cavity pressure falls - (with hydraulic pressure remaining constant during the follow-up pressure phase) - due to the
reduced pressure transfer performance of the low-viscosity
melt. The result is a lower integral cavity pressure. If it were only
the hydraulic pressure being monitored, no indication would be
given as to the quality of the mouldings. The rise in hydraulic
pressure during the injection phase would indeed be noticeable,
but the effects of this increase once change-over has occurred
could not be monitored, since hydraulic pressure during this
phase is regulated at a constant level. By selecting integral
cavity pressure with suitable integral limits, however, the qualityrelated phases can be accurately monitored.
The most important factors for technical precision parts are
dimensional stability, melt homogeneity and low warpage, which
means that the parameters for monitoring must be selected
from relevant phases in the process. Dimensional stability and
warpage are mainly influenced during the follow-up pressure
phase, which is why integral cavity pressure is particularly
suitable.
Changes in melt homogeneity occur during the dosing phase
due to fluctuations in screw speed and/or back pressure, and
these can be diagnosed by monitoring the above-mentioned
parameters. Where particularly sensitive materials are concerned, the dosing operation can also be monitored via the
screw load.
104
105
Selection criteria
On the assumption that the machine has been optimally set

prior to the start of the production cycle, the following selection
criteria have emerged in the course of daily practice for the
8 most significant process parameters which need to be kept
constant.
In general, cycle time says little about component quality,
apart from when processing thermally sensitive materials in
semi-automatic operation.
Consistent injection time is important for short injection times
and for parts with stringent surface requirements.
Ideally, a constant dosing time should be observed, particularly
when processing (plasticising) material blends (LDPE-HDPE),
blends for automotive parts and regrind. It is also important
where irregularities occur during plasticising as a result of the
material (PA-PMMA), and when colouring using pigment paste
or masterbatch.
A decreasing melt cushion when processing with filled materials
indicates wear on the non-return valve. Fluctuations are often a
sign of inhomogenous melt. Where there is only very slight fluctuation in the melt cushion and the non-return valve is functioning correctly, the dimensions of the moulded part will then
remain constant. For products with relatively dense wall thicknesses requiring a correspondingly long, high and uniform
follow-up pressure profile, integral cavity pressure is the first
choice.
Maximum cavity pressure is informative for products with
small wall thicknesses and a short follow-up pressure time or
high injection pressure.
In order to be able to put these findings to practical use, it is

necessary first of all to evaluate the relative importance of the
individual process parameters for the different product groups
and to establish the tolerances.
Fig. 6.5 summarises the selection criteria and also evaluates the
extent of the influence of the individual process parameters on
the quality of the various product groups. The quality characteristic here is the percentage weight fluctuation which can be
achieved on the mouldings. The data shown is a recommendation as to the level of quality to which the mouldings in the
different product groups can be manufactured.
" 1 " denotes a parameter with the largest influence on quality,
while "8" denotes minimum influence. These should not, however, be seen as absolute values for comparison between the
various product groups, but as being based on a specific
characteristic value for each product group.
Fig. 6.6 goes one step further by showing the permissible percentage deviations (+/- tolerances) for each of the parameters.
The variation in values is as a result of varying processing conditions for the respective products. For example, the mould
temperature for technical functional parts is around 80 C, while
for high speed precision parts it is only 25 C. Thus, when converted to absolute values, the permissible deviations are almost
identical.
The percentage values also utilise the evaluation capacity of
modern injection moulding machines. Modern control systems
such as NC4, enable deviations to be represented in percentages (see fig. 6.10). The recommended values can be directly
compared with the current Actual values. If the deviations fall
within the tolerance limits, the component quality is acceptable.
Melt temperature is important for thermally sensitive materials.

This is equally so for materials with a narrow processing range
or for materials whose properties change at the slightest variation in temperature.
Finally, accurate mould temperatures are required, particularly
when processing any of the engineering materials (PC, PA,
POM, PMMA ...), for example, for the production of optical
lenses in PMMA or gear wheels in POM.
106
107
Fig. 6.5
108
Fig. 6.6
109
Even if the quality depends essentially on the constancy of the

8 previously mentioned parameters - and even if, in general,
3-5 of these would suffice - it is still necessary for the less
important parameters to adhere to specific tolerances (fig. 6.7).
Fig. 6.7
Piasticising time
1.0
5.0
Injection time
1.0%
2.0
5.0
Cycle time
1.0%
2.0
3.0
Dosing stop
0.1%
0.2%
0.3%
Change-over point for follow-up pressure
1.0%
1.5%
2.0%
Residual melt cushion
2.0
3.0
4.0
Mould open - stop
0.1
0.2
0.3
Mould temperature
2.0
3.0
4.0
Flange temperature
2.0
4.0
Cylinder temperature
1.0%
2.0%
Melt temperature
1.0%
2.0%
Hot runner temperature
Hydraulic oil temperature
3.0
%
%
10.0%
Room temperature
2.0
3.0
3.0%
3.0%
2.0
4.0
3.0
5.0
15.0%
%
%
20.0%
Injection pressure
2.0
4.0
6.0
Follow-up pressure
2.0
3.0
4.0
Back pressure
5.0%
Max. cavity pressure
1.0%
Intecj-al cavity pressure
3.0
6.0
8.0
Clamping; force
2.0
3.0
4.0
2.0
4.0
8.0
M o u l d fill t;i ii i 11 ! 11 i. i i i 1 1 '
110
1.0
.: : i n m o u l d
8.0%
2.0
%
%
10.0%
3.0
%
%
111
Quality control on the machine
Fig. 6.8
When activating quality control it is important to establish

whether the process is normally distributed i.e. without influences inherent in the system. Quality control is only possible
with normal distribution. A mean value and independent upper
and lower tolerance limits are then specified for the qualitydetermining process parameters.
Fig. 6.8 shows a screen page from the new NC4 control system
which was introduced with the ERGOtech machine range.
Using this page the machine setter can select from a total of
25 available parameters those which are most important for a
particular moulding. The Process Statistics page can display
up to 20 parameters, and the selected parameters can then be
controlled either continuously (CPC) or statistically (SPC).
112
113
38 38
Fig. 6.9 shows the maximum injection pressure in an unstable

process and how dosing time fluctuations depend on and influence the residual melt cushion. In a stable process the statistical evaluation reveals only minor fluctuations for all relevant
process parameters.
With the aid of just 2 statistics pages the machine setter can
easily monitor process constancy. "Process Statistics 1" indicates the ACTUAL values for the last 16 cycles. The penultimate
line also shows the mean value, and theiast line the range of
measured values. The control system provides not only tabular
displays, but also a wide range of control features in graph
form.
Fig. 6.9
114
fit
At the touch of a key the system not only provides graphic

evaluation, but also percentage deviation from the mean value,
and the statistical distribution - (black bars to the right of the
screen) - over the last 100 cycles for each selected process
parameter (injection time, dosing time, hydraulic pressure, melt
cushion, cycle time ...). A thermal printer integrated in the operator terminal is also available as optional equipment for printing
out all screen pages. It enables the relevant quality data and
proof of quality to be documented directly at the machine.
Fig. 6.10
115
Fig. 6.11 looks at tolerance settings for the selected process

parameters, (parameters selected are indicated by a black
square in the column headed "permissible deviation"). In addition to the upper and lower tolerances, the permissible number
of deviations per 1000 parts is also indicated. If a variable
exceeds its set tolerances, by using selected parameters reject
indication can be given and this is then shown in the deviation
counter.
Fig. 6.11
In such cases, providing tolerance deviation is switched on,

mouldings can be automatically sorted by means of mechanical
quality flaps or a robot fitted with a reject signal. Only the most
advanced machine control systems can offer such a comprehensive range of possibilities for keeping processing parameters
constant over long periods of production. Such systems can
indicate the effects of any emerging influences by deviations
in the process parameters and enable statistical evaluation.
This represents the first step towards our aim of "Total Quality
Control".
116
117
Recognition and elimination of

surface defects in the injection
moulding process
Injection moulding is an extremely complex process, in which

the quality of the moulded parts is determined by a variety of
factors which differ from one application to the next.
Flaws in quality can be caused by machine or processing parameters being wrongly set and by incorrect mould or moulded part
design.
The causes of potential faults, unfortunately, are as diverse as
the injection moulding process itself. Starting with visual defects
such as streaks, sink marks or gloss variation, through to inadequate mechanical properties - entrapped air, voids or unmelted
material in the moulding, for example - and ending with all manner of dimensional deviations (see table on page 120).
This poses the question of what practical steps can be taken to
eliminate the wide variety of faults.
In order to narrow down the causes, the fault must be located
and accurately defined i.e. what it looks like, where, when and
how often it occurs. To do this you need to be familiar with the
machines and process parameters listed in the tables on pages
120-123 and be able to make a careful evaluation of their potential influence.
This will enable you to see at what stage in the injection moulding process a fault can occur. The cause of surface defects,
for instance, is to be found predominantly in the plasticising
and injection phase. Dimensional deviations and inadequate
mechanical properties, on the other hand, occur mainly during
plasticising and injection and in the follow-up pressure phase.
The design of the mould and moulded part also has a considerable effect on all types of fault, with clamp force, mould opening
and demoulding playing a secondary role.
118
119
Flaws in appearance
Charred streaks
Moisture streaks
Coloured streaks
Glass fibre streaks
Sink marks
Gloss, variations in gloss
Unmelted material pellets in the moulding (non-homogeneity)
Weld line, flow lines
Jetting
Diesel effect, charring
Visible ejector imprints
Ripple effect
Dark spots
Matt spots near the gate
Delamination of surface layer
Cold slug, cold flow marks
Grey/black clouds
Dimensional deviations
Mouldings not completely filled
Moulding overpacked (flash formation)
Deformation on demoulding
Component warpage
Dimensional variations on the moulding
Inadequate mechanical properties
Stress cracking on the moulding, stress whitening
Entrapped air, blistering
Voids
Charred melt
Unmelted material pellets in the moulding (non-homogeneity)
120
X
X
X
X
X
X
X
Mould
X
X
Demouiing
X
X
Open mould
Clamp force
Follow-up
pressure
Injection
At what stage do surface defects or mechanical and

dimensional defects occur on the injection moulded part?
Piasticising
Process phase
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
121
Correct procedure for the elimination of moulding defects
122
Clamp force
Screw retraction
Moisture in material
Venting
Change-over point for

follow-up pressure
Follow-up pressure time
Screw speed
Injection speed
Back pressure
Follow-up pressure
Gate cross section
Mould temperature
Increase parameter value

Decrease parameter value
Melt temperature
Procedure:
Change only one parameter at a
time in the suggested sequence
Stepped injection speed
Defect:
Moisture streaks
Charred streaks
Glass fibre streaks
Coloured streaks
Grey clouds
Sink marks
Voids
Blistering, entrapped air
Charring, diesei effect
(surface)
Flow line, weld line
Ripple effect
Gloss, variation in gloss
(polished surface)
Gloss, variation in gloss
(textured surface)
Jetting
Unmelted material particles,
poor pigment dispersion
Delamination
Dark spots on the moulding
Cold slug
Moulding not filled
Moulding overpacked
Moulding too small
Moulding too large
Moulding too brittle
123
Example of clamp force calculation
Example of clamp force calculation

1. Establish the projected area of the moulded part
(projected moulding area x number of impressions)
2. Material: flow characteristics and melt flow index
3. Establish required cavity pressure
Wall thickness
Flow length/wall thickness ratio
Flow length
4. The required clamp force is then calculated from:
required cavity pressure x proj. moulding area
124
125
Example of calculation for a flowerpot
Calculation process:
Flow length/wall thickness ratio:
150 : 0.55 = 275 : 1
Effective cavity pressure:

(see diagram on page 133)
600 bar
Mould design:
single impression
Proj. moulding area x effective cavity pressure =

162 cm2 x 600 =
972000 N = 972 kN
Result:
Article description:
Flowerpot
Material:
PP
Melt flow index:
MFI 35 230C/5 [g/10 min]
Proj. moulding area:
162 cm2
Flow length:
150 mm
Average wall thickness:
0.55 mm
Flow length/wall thickness:
275 : 1
126
Clamp unit
ERGOtech 110
Clamp force reserve
approx. 13 %
127
Example of calculation for a 10 litre bucket
Calculation process:
Effective cavity pressure required:
(see diagram on page 133)
570 bar
Proj. moulding area x cavity pressure = clamp force

572 cm2 x 570 bar
= 3260400 N
= 3260 kN
selected:
Clamp force reserve
Flow length:
380 mm
Average wall thickness:
1.10 mm
ERGOtech 330
1 %
Flow length/wall thickness ratio: 340 : 1

Proj. moulding area:
572 cm2
Available cavity pressure

ref. ERGOtech 330:
577 bar
128
129
Effective pressure location dependent on position of gate and

component geometry
Wall thickness zones requiring use of accumulator injection and

follow-up pressure
Beaker:
gate
effective
pressure
location close to gate
Plate:
gate
effective pressure location at halfway point along flow path
The difference in viscosity in the individual materials and the

varying injection speeds cause a pressure gradient to develop
during injection. When calculating the parts, calculate the prevailing pressure at the point where the effective pressure applies.
130
2.7
2.6
2.5
2.4
2.3
2.2
2.1
2.0
1.9
1.8
1.7
1.6
1.5
1.4
1.3
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
Follow-up pressure higher than injection pressure
Injection and follow-up pressure the same
Check need for

accumulator
Injection pressure
higher than
follow-up pressure
Accumulator
required
131
Cavity pressures required for articles from different product groups

Product group
1
Packaging parts
2
3
Tech. precision parts

multi-point connectors
Tech. functional parts
Optical parts
High speed precision parts
Medical parts
Automotive parts
Tech. packaging parts
Office supplies
10
Gen. purpose functional parts
11
12
Rigid PVC parts

Toys
132
Article
Yoghurt cartons
Containers
Aerosol caps
Buckets
Plugs, sockets,
PBTP
Gear wheels,
program control cylinders
Lenses
Rear light fittings
Disposable razors
Slide frames
Cable ties
Disposable syringes
Pipettes
Radiator grills
Instrument panels
Bumpers
Music cassettes
Video cassettes
CD packaging
Rulers
Set squares
Housings
Covers
Vacuum cleaner housings
Storage cases
Fittings
Articles with limited
requirements for surface
quality and dimensions
Material
PS
PE
PP
PP
PA, PC
POM, PA
PBTP
PMMA
PS
PS
PA
PE
PP
PP
ABS
blends
PS
ABS
PS
PS, SAN
CAB
PP
ABS
PP
PS
PVC
PE
PP
PS
Cavity pressure (bar)

600- 800
500- 700
400- 600
500- 700
500- 700
600- 800
700- 800
700- 800
600- 800
500- 700
400- 500
400- 500
800-1200
400- 500
500- 600
400- 500
400- 500
400- 500
350- 450
300- 400
400- 500
400- 500
400300400300400-
500
400
500
400
500
250- 350
133
Effective cavity pressure for component group dependent on

component wall thickness and flow length/wall thickness ratio
134
135
Operating instructions for

ERGOtech NC4 control system
Operating instructions for ERGOtech NC4 control system
The performance of the ERGOtech NC4 control system is based

essentially on the use of microprocessor controls. To ensure
reliability of operation all disruptive influences must be kept well
away from the controls. By screening electrical equipment and
laying screened cable, the manufacturer has suppressed any
disturbances which might possibly be generated by the machine
itself.
Attention!
Do not use suppressor adapters with LEDs (24 V test lamps) on
any proportional valves between the solenoid plugs and plug-in
boards. The diodes in the adapters cause the valves to malfunction. The machine operator must take appropriate steps to
avoid any potential external disturbance e.g. by screening peripheral units (attenuators). Please refer to instructions in the
operating manual.
136
137
The IBED control panel
1 LCD display
2 Function group keys
3 Numeric keypad
4 Manual function keys
5 Mode selection switches (IMM)
6 Q key
7 EMERGENCY STOP
8 Integral printer
9 Floppy drive, floppy disk box
10 Pump, cylinder heating, mould heating ON - OFF
11 Start button
12 Keys for robot
13 Special function keys
14 Cursor keys
15 Function group keys
16 Softkeys for menu selection
138
139
Page selection
Overview of page selection using function group keys:

-
00 Main menu
Mould
Hydr. ejector
Pneu. valves
Speed profile
When a function group key is pressed, the pages relating to the

function group are listed for selection.
Process optimisation - Dosing profiles

Injection profile
- Follow-up pressure profile
Injection unit
- Data acquisition
Intrusion
The individual pages within the function group can then be

called up using the softkeys.
- Cylinder temperature - Hot runner

- Temp, control unit - Mould heating
The screen unit comprises 3 sections:

The LCD display
Softkeys to call up pages within a function group
Function group keys
- Machine
- Cores
- Cores IN
- Cores OUT
Example:
When the function group for "Mould" is selected, the page for
mould parameters is called up. By pressing the relevant softkeys, other mould-related pages can now be selected.
LCDdisplay
- Program pre-select - Switch-on program

- Start-up program
- Purge program
- Switch-off matrix
- Mould catalogue
- Prog, inputs
- Prog, outputs
- Process statistics 1 - Process statistics 2
- Process control
- Statistics configuration
- Product counter
- SPC configuration - SPC control chart
- Quality monitoring - CAP job
- CAP - next job '
- CAP shift
- CAP reject
- CAP statistics
- Fast mould clamping system
- Handling
- Robot program
- Robot diagnosis
-
Softkeys
for menu
selection
Function
group keys
140
Function
group
keys
Page layout
Gen. data 1
Print
Service
- Set-up IBED
- Gen. data 2
- Password
- Amendment report
- Function check
- Putting into operation
- Control parameters - Bit control
- Alarms
141
Mode selection switches
Cursor keys and numeric keypad

Input variable
larger
Input keys
Input variable
smaller
Enter/
acceptance
key
Clear key
Up
Cursor keys,
next
line/column
to...
left
right
Home position
down
Having selected a page, the cursor can be used to select any of
the parameters, and set values can be entered via the numeric
keypad.
The specified value is then stored in the IBED memory by pressing the E (Enter) key. When a set value is being entered, the
top section of the screen shows the permitted minimum and
maximum for that particular field. It also shows the value previously stored for that field.
Operating modes can be set via the Mode Selection switches,

as follows:
1
2
3
4
5
Set up
Manual
Semi-automatic
Automatic
Quality key
The Quality key triggers a quality log after a pre-selected
number of shots.
The number of shots can be specified on page
"60 Quality monitoring".
Operating mode for robot:

6 Step:
stepping mode for each axis
7 Reference: all axes move to base position

8 Set stop:
the robot remains in the waiting position after

the next completed command
9 I/O:
robot ON/OFF
To speed the setting process, the arrow keys on the numeric

keypad can be used to increase or decrease the selected value.
The cursor keys have the normal repeat function i.e. cursor
movement on screen is accelerated when the cursor key is held
down.
The arrow key in the centre of the cursor pad moves the cursor
back to home position.
142
143
Manual function keys
1 Open - close mould
Manual function keys
9 Printer - hardcopy
2 Hydr. ejector forward - back
10 Reference
3 Move cores in - out
11 Switch to upper/lower case with text input for

Help functions
4 Open - close automatic safety guard

5 Mould height larger - smaller
6 Nozzle forward-back
7 Injection, hydr. screw retraction
8 Dosing
The manual function (symbol) keys are used for set-up and
manual operation of individual machine functions.
144
12 Switch to alphabetic text input

13 Pneumatic valves 1-4
14 F1-F16 for special functions
The 'F' keys are reserved for special functions. The 'ABC...' key
switches the manual and 'F' keys over to ASCII characters. The
'Shift' key switches between upper and lower case.
These functions are only active on pages used for text input
(e.g. Gen. data, Mould catalogue ...)
145
Emergency Stop, mould heating, cylinder heating and pump ON/OFF
When the Emergency Stop button is pressed the machine shuts

down immediately. This includes
pump motor- Off
cylinder heating - Off
mould heating - Off
Each of the following functions is switched on by pressing the

green keys:
i pump
cylinder heating
i mould heating
When the corresponding red buttons are pressed these
functions are switched off.
Start button:
When the Start button is pressed in "semi-automatic" and
"automatic" modes, this initiates the automatic machine cycle.
In "semi-automatic" mode the machine runs for only one cycle.
The Start button must be pressed to initiate each cycle.
1 EMERGENCY STOP
In "automatic" mode the machine runs continuously.
2 Cylinder heating ON-OFF

3 Mould heating
4 Pump ON-OFF
5 Start button
6 Integral printer
7 Floppy drive, floppy disk box
146
Attention!
Start-up can only occur when the following conditions have
been met:
mould fully open

hydr. ejector back
cores moved out
dosing stop reached
147
MANNESMANN
DEMAG
Injection Moulding
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No other publication enjoys such a long tradition as a key

source of information as the "Injection Moulding Pocketbook".

Prima reglare a unei masini de injectie

2.2.1 Reglarea unitatilor de inchidere cu articulatie

2.2.2 Reglarea unitatilor de inchidere hidraulice

Reglarea unitatii de injectie

Desfasurarea ciclului de injectie la o masina ERGOtech

Inchiderea unitatii de inchidere

Faza de injectie si cea de presiune ulterioara

Dozare, snec si retragerea unitatii de injectie

Deschiderea unitatii de inchidere

Mic indrumar despre materiale

Indicatii la prelucrarea celor mai importanti polimeri

Caracteristici de recunoastere a maselor plastice

Temperaturi de prelucrare si pre-uscarea

Optimizarea procesului la masina de injectie

Caracteristici de calitate si parametrii de proces

Calcularea timpului de racire

Evaluarea corecta si alegerea parametrilor importanti

Injection Moulding Pocketbook

Identificarea si eliminarea defectelor de suprafata

Exemplu de calcul al fortei de inchidere

Instructiuni de operare cu sistemul de control

Procesul de injectie matritata

In ultimele decenii procesul de injectie matritata si tot ceea ce este

Acuratetea si ordinea sunt strict necesare pentru aplicarea unei

Reglarea primara a unei

2.1 Preliminar - lista de verificare

Is the proposed machine available for the production

Am mai produs acest reper in trecut ?

Is the maximum clamping force sufficient?

Has the necessary maintenance work been carried out?

Has the machine been running problem-free lately?

Cate repere sunt necesare?

Is the appropriate screw cylinder available

Este necesar echipament special pentru masurare?

Materialul, dimensiunile si greutatea reperului?

Is there sufficient material for the job?

Where is the material stored?

Unde este matrita depozitata?

Does the material need to be pre-dried?

Aceasta matrita necesita reparatii sau reparatiile au fost deja facute?

Is there a supply of masterbatch, if required?

Cum poate fi transportata si ridicata pe masina?

dimensiunile de fixare a matritei

Are peripheral units required such as temperature control units,

Preparing the machine

2.2.1 Setting up the clamping unit for

(For pressure and speeds see screen page 10 on NC4 IBED)

4. Attach the mould securely to the lifting gear.

5. Protect the machine tie bars from damage during mould

13. When clamp force is set, tighten the clamps up on the

6. Position the mould on the fixed platen, centre and attach.

2.2.2 Setting up fully hydraulic machines

2.3 Setting the injection unit

4. Position the mould on the fixed platen, centre and attach.

5. In set-up mode, move the nozzle to contact with the mould.

5. Move the clamp unit until platen contact is made, taking

7. Enter nozzle contact pressure, strokes and speeds for the