(Arburg) Troubleshooting Injection Moulding

ISSN: 0889-3144
Rapra Review Reports Troubleshooting Injection

Moulding
An Guide
Edited by V. Goodship
Volume 15, Number 4, 2004
Expert overviews covering the

science and technology of rubber
and plastics
Troubleshooting
Injection Moulding
Vannessa Goodship
(Warwick Manufacturing Group)
ISBN 1-85957-470-X
Troubleshooting Injection Moulding
Contents
1. Introduction .............................................................................................................................................. 5
1.1 Optimising the Moulding Part ........................................................................................................ 5
2. Detection, Classification and Troubleshooting Defects ........................................................................ 5

2.1 Classification .................................................................................................................................. 5
2.2 Flow Charts for Troubleshooting .................................................................................................... 5
2.3 Sink Marks ...................................................................................................................................... 6
2.3.1 Physical Cause .................................................................................................................... 6
2.3.2 Correcting Sink Marks ....................................................................................................... 6
2.4 Streaks ............................................................................................................................................. 6
2.4.1 Burnt Streaks (Brown or Silver) ......................................................................................... 8
2.4.2 Moisture Streaks ............................................................................................................... 10
2.4.3 Colour Streaks ...................................................................................................................11
2.4.4 Air Streaks/Air Hooks ...................................................................................................... 12
2.4.5 Glass Fibre Streaks ........................................................................................................... 15
2.5 Gloss/Gloss Differences ............................................................................................................... 16
2.5.1 Physical Cause .................................................................................................................. 16
2.5.2 Correcting Gloss/Gloss Differences ................................................................................. 17
2.6 Weld Line (Visible Notch or Colour Change) .............................................................................. 18
2.6.1 Physical Cause .................................................................................................................. 18
2.6.2 Improving a Weld Line (Visible Notch or Colour Change) ............................................. 18
2.7 Jetting ............................................................................................................................................ 18
2.7.1 Physical Cause .................................................................................................................. 18
2.7.2 Correcting Jetting ............................................................................................................. 21
2.8 Diesel Effect (Burns) .................................................................................................................... 21
2.8.1 Physical Cause .................................................................................................................. 21
2.8.2 Correcting Diesel Effect (Burns) ...................................................................................... 23
2.9 Record Grooves Effect .................................................................................................................. 23
2.9.1 Physical Cause .................................................................................................................. 23
2.9.2 Correcting Record Grooves Effect ................................................................................... 24
2.10 Stress Whitening/Stress Cracks .................................................................................................... 25
2.10.1 Physical Cause .................................................................................................................. 25
2.10.2 Correcting Stress Whitening/Stress Cracks ..................................................................... 26
2.11 Incompletely Filled Parts .............................................................................................................. 26
2.11.1 Physical Cause .................................................................................................................. 27
2.11.2 Correcting Incompletely Filled Parts ............................................................................... 27
2.12 Oversprayed Parts (Flashes) ......................................................................................................... 27
2.12.1 Physical Cause .................................................................................................................. 27
2.12.2 Correcting Oversprayed Parts (Flashes) ........................................................................... 29
1
2.13 Visible Ejector Marks ................................................................................................................... 29

2.13.1 Physical Cause .................................................................................................................. 30
2.13.2 Correcting Visible Ejector Marks ..................................................................................... 30
2.14 Deformation During Demoulding ................................................................................................ 30
2.14.1 Physical Cause .................................................................................................................. 30
2.14.2 Correcting Deformation During Demoulding .................................................................. 32
2.15 Flaking of the Surface Layer ........................................................................................................ 32
2.15.1 Physical Cause .................................................................................................................. 32
2.15.2 Correcting Flaking of the Surface Layer .......................................................................... 32
2.16 Cold Slugs/Cold Flow Lines ......................................................................................................... 32
2.16.1 Physical Cause .................................................................................................................. 32
2.16.2 Correcting Cold Slug/Cold Flow Lines ............................................................................ 34
2.17 Entrapped Air (Blister Formation) ................................................................................................ 34
2.17.1 Physical Cause .................................................................................................................. 34
2.17.2 Correcting Entrapped Air (Blister Formation) ................................................................. 36
2.18 Dark Spots ..................................................................................................................................... 36
2.18.1 Physical Cause .................................................................................................................. 36
2.18.2 Correcting Dark Spots ...................................................................................................... 36
2.19 Dull Spots Near the Sprue ............................................................................................................ 38
2.19.1 Physical Cause .................................................................................................................. 38
2.19.2 Correcting Dull Spots Near the Sprue .............................................................................. 38
3. Case Studies of Injection Moulded Components ................................................................................ 39
3.1 Threaded Connecting Sleeves for Ink Drafting Apparatus .......................................................... 39
3.2 Meter Cases ................................................................................................................................... 39
3.3 Wristwatch Glass .......................................................................................................................... 39
3.4 Alarm Clock Glass ........................................................................................................................ 39
3.5 Glass Cover for Digital Gauge ..................................................................................................... 39
3.6 Plug Boards with Insert Pins ........................................................................................................ 40
4. Effects of Injection Moulding Parameters .......................................................................................... 40

4.1 Internal Mould Temperature and Pressure .................................................................................... 40
4.2 Relationship of Injection and Mould Cavity Pressures ................................................................ 41
4.3 Injection Pressure and Injection Time .......................................................................................... 42
4.4 Filling Speed ................................................................................................................................. 43
4.5 Filling Speed and Orientation ....................................................................................................... 43
4.6 Effects of Too High Filling Speed ................................................................................................ 44
5. Machine Specifications .......................................................................................................................... 44

5.1 Clamp Force .................................................................................................................................. 44
5.2 Injection Unit ................................................................................................................................ 44
2
5.3 Feeding Hopper ............................................................................................................................. 46

5.4 Barrel Residence Time .................................................................................................................. 46
5.5 Precompression of the Melt .......................................................................................................... 46
5.6 Check Valve .................................................................................................................................. 47
5.7 The Nozzle .................................................................................................................................... 47
5.8 The Feed System ........................................................................................................................... 47
5.9 The Mould Temperature ............................................................................................................... 47
5.10 The Importance of Adequate Venting ........................................................................................... 49
5.11 Multi-Cavity Moulds .................................................................................................................... 49
5.12 General Information on Wear and Tear ........................................................................................ 49
6. Conclusion .............................................................................................................................................. 49
Abbreviations and Acronyms ....................................................................................................................... 50
Abstracts from the Polymer Library Database .......................................................................................... 51
Subject Index ............................................................................................................................................... 123
Company Index ............................................................................................................................................ 135
The views and opinions expressed by authors in Rapra Review Reports do not necessarily reflect those of
Rapra Technology Limited or the editor. The series is published on the basis that no responsibility or
liability of any nature shall attach to Rapra Technology Limited arising out of or in connection with any
utilisation in any form of any material contained therein.
3
4
1 Introduction 4. Weld line (Section 2.6)
5. Jetting (Section 2.7)

Sometimes, problems occur in injection moulding parts
of the desired quality. In most cases, the surface quality 6. Diesel effect (burns) (Section 2.8)
is the main criterion. Due to the complex
7. Record grooves effect (Section 2.9)
interrelationship between the moulded part and the
mould, the moulding compound and the processing, it 8. Stress-whitening/stress cracks (Section 2.10)
is often very hard to recognise the origin of problems
and thus to take immediate action. The guide that follows 9. Incompletely filled parts (Section 2.11)
aims to help with the practical work and to consider
factors affecting the quality of injection moulding parts 10. Oversprayed parts (flashes) (Section 2.12)
such as the process, the machinery and the mould. 11. Visible ejector marks (Section 2.13)
12. Deformation during demoulding (Section 2.14)

1.1 Optimising the Moulding Part 13. Flaking of the surface layer (Section 2.15)
Machine specifications and injection moulding 14. Cold slugs/cold flow lines (Section 2.16)
parameters are critical in determining the quality of 15. Entrapped air (blister formation) (Section 2.17)
moulded parts.
16. Dark spots (Section 2.18)
This troubleshooting guide is designed to help analyse
17. Dull spots near the sprue (Section 2.19)
surface defects in the injection moulding and to provide
hints on avoiding and/or reducing defects. The core of
this review was written during a three-year team In order to eliminate surface defects, knowledge
project, which involved intensive work by 30 about the causes of the defects is essential. This
companies. It consists of descriptions, pictures and section gives some important notes on economical
notes about the different defects, which helps to classify and quick optimisation of the moulding process and
the problem. It provides a short explanation of possible on avoiding defects.
physical causes for the defect. Flow diagrams are also
included containing hints on avoiding or reducing
defects. Remedy and hints are given, concerning the 2.2 Flow Charts for Troubleshooting
process, the moulded part, the mould design and the
moulding compound. Getting rid of surface defects can be a hard task, due to
the different physical causes. In order to help the
processor, this section contains flow charts which
systematically show how to eliminate the defect. The
2 Detection, Classification and aim is to reach the desired quality by varying the
Troubleshooting Defects process parameters.
For each defect, the diagram slides into different

2.1 Classification
branches, according to the questions. Only one
parameter should be changed at a time, in order to avoid
Moulding defects are classified into seventeen types: mutual influence. Afterwards several cycles should be
completed to ensure stable working conditions. In some
1. Sink marks (Section 2.3) cases various solutions are possible, but tendencies (+)
or (-) are given. Should one parameter variation fail,
2. Streaks (Section 2.4) go through the questions again and apply, if possible,
Burnt streaks one remedy after another.
Moisture streaks
Colour streaks These diagrams only offer suggestions and cannot
Air streaks/air hooks consider all eventualities. The diagram helps to decide
Glass fibre streaks whether the defect can be eliminated by changing the
machine settings, or whether the mould or the part has
3. Gloss/gloss differences (Section 2.5) to be changed.
5
2.3 Sink Marks to avoid premature solidification of the sprue and gate
system, sufficient dimensioning is necessary.
2.3.1 Physical Cause
Sink marks appear for example near material
Sink marks occur during the cooling process, if the accumulations as depressions on the surface of the
thermal contraction (shrinkage) of the plastic cannot moulded part, if the thermal contraction (shrinkage) cannot
be compensated in certain areas. If the outside walls of be compensated as illustrated by Figure 2 and Figure 3.
the moulded part are not stable enough, due to
insufficient cooling, the outer layer is drawn inside by
cooling stresses as shown in Figure 1. 2.3.2 Correcting Sink Marks
There are three fundamental cases: Check and/or change machine settings. Change mould
or moulding compound. Start new cycle and work
solidification too slow through Flow Chart 1.
effective holding pressure time too short

2.4 Streaks
not enough holding pressure transfer, because flow
resistances in the mould are too high. Streaks caused by burning moisture or air can look very
similar making classification difficult if not impossible.
For optimum holding pressure transfer the moulded The signs listed here do not have to appear, they only
part should be gated to the largest cross-section. In order give reason to suspect a certain type of streak.
Figure 1
Moulded part with sink marks (gating at the thin wall)
Sink marks Sink marks
Figure 2 Figure 3
Sink marks due to wall thickness variations Sink marks on the cylindrical core whose
temperature was not controlled correctly
6
Inquiry*
Residual melt cushion too small?** Yes (1) increase metering stroke
(2) check non-return valve
No
(1) optimise holding pressure time

(2) increase holding pressure
Sink marks near the gate or (maybe short overpacking)
Yes
thick-wall areas? (3) change mould wall temperature (-)
(4) change melt temperature (-)
(5) change injection rate (-)
No

Sink marks away from the gate or (maybe short overpacking)
Yes
in thin-wall area? (3) change injection rate (+)
(4) change melt temperature (+)
(5) change mould wall temperature (+)
No
Sink marks directly after

demoulding? (1) check ventilation
(2) check sprue and gate dimensions
(3) check granules condition
(4) adapt mould temperature control
Yes
(5) remove material accumulations
No (6) consider wall thickness/rib ratio
(7) add blowing agent
(8) use plastic with low shrinkage
(1) increase cooling time
* Important! Check if there are voids in the moulded part after removing sink marks
** Residual melt cushion should be at least 2-5 mm
Flow Chart 1
Correcting sink marks
7
2.4.1 Burnt Streaks (Brown or Silver) the mould is equipped with a hot runner
2.4.1.1 Signs for Burnt Streaks the mould is equipped with a shut-off nozzle.
the streak appears periodically Examples of mouldings with burnt streaks are shown
in Figure 4.
the streak appears behind narrow cross-sections
(shear points) or sharp edges in the mould
the melt temperature is near the upper processing limit 2.4.1.2 Physical Cause
lowering the screw advance speed has a positive Burnt streaks are caused by thermal damage to the melt.
impact on the defect The result can be a decrease of the length of the
molecule chain (silvery discoloration) or a change of
lowering the melt temperature has a positive impact the macromolecules (brownish discoloration).
on the defect
Possible causes of thermal damage:
long residence time in the plasticising unit or the
space in front of the screw (due to e.g., cycle breaks
or low shot volumes) temperature too high or residence time too long
during predrying
high reclaim content, or a part of the material has
already been melted several times before melt temperature too high

Figure 4
Examples of burnt streaks
Top left: Burnt streaks due to excessive residence time in the plasticising cylinder
Top right: Burnt streaks due to high shearing heat in the gate;
Bottom left: Burnt streaks due to excessive residence time in the plasticising cylinder
8
Inquiry
reduce melt temperature

Melt temperature above the (1) vary cylinder temperature (-)
Yes
processing range? (2) vary screw speed (-)
(3) reduce back pressure
No
(1) reduce cycle time

(2) increase plasticising time delay
Is the melt residence time within
Yes (3) use the machine to higher
the critical range?
capacity: increase screw stroke
(4) reduce reclaim
No
(1) avoid dead spots and flow impeding

Burnt streaks appearing areas in the gate system and in the
periodically or visible after Yes plasticising unit
injecting 'into the air'? (2) check plasticising unit for wear
(3) check granules condition and feed
No
(1) lower injection rate (injection

Burnt streaks near the gate? Yes profile slow-fast)
(2) check hot runner
(3) avoid sharp edges in the gate system
No
* use rheological mould design

(1) lower injection rate
** thermal damage possible due to excessively long or
(2) avoid sharp edges
hot drying process
(3) avoid small runners*
(4) check sprue and gate system*
(5) check nozzle cross-section
(6) check functioning of shut-off nozzle
(7) check pre-drying of material**
(8) reduce reclaim part
(9) use moulding compound or colouring Flow Chart 2
agents with higher thermal stability
Correcting burnt streaks
9
shearing in the plasticising unit too high (e.g., screw the solidified flow front of a partial filling shows
speed too high) crater-like structures
residence time in the plasticising unit too long the moisture content of the material before the
processing is very high.
shearing in the mould too high (e.g., injection rate
too high).
2.4.2.2 Physical Cause
In order to check the melt temperature inject into the
air . Measure temperature with a needle thermometer. During storage or processing, moisture is absorbed by
the granules, forming water vapour in the melt
Thermal degradation of the plastic has a negative (Figure 5). Due to the velocity profile at the flow front,
impact on its mechanical properties, even if no damage gas blisters are pushed to the surface of the melt as shown
is visible on the surface. in Figure 6. As the pressure changes, the blisters are
deformed by the moving flow front and burst and freeze
at the mould wall.
2.4.1.3 Correcting Burnt Streaks (Brown or Silver)
Possible causes for moisture streaks:
Check and/or change machine settings, change mould
or moulding compound, start new cycle and work (1) Moisture on the mould surface
through Flow Chart 2 again reducing melt temperature.
leaky mould temperature control system
condensation water on the mould walls.
2.4.2 Moisture Streaks
(2) Moisture in/on the granules
2.4.2.1 Signs for Moisture Streaks
insufficient pre-drying of the material
the material tends to absorb moisture (e.g.,
polyamide (PA), acrylonitrile-butadiene-styrene wrong storage of the material.
(ABS), cellulose acetate (CA), polybutylene
terephthalate (PBTB), polycarbonate (PC),
polymethyl methacrylate (PMMA), styrene- 2.4.2.3 Correcting Moisture Streaks
acrylonitrile (SAN))
when slowly injecting the melt into the air, the melt or moulding compound, start new cycle and go through
shows blisters and/or is steaming Flow Chart 3.

Figure 5
Examples of moisture streaks
Left: Streaks due to moisture granules; Right: Streaks due to moisture on the mould surface
10
Figure 6
Flow of water vapour blisters near the flow front
Inquiry
(1) check mould cooling for leaks

Moisture on mould surface? Yes (2) increase mould wall temperature
(3) use dry-air-curtain system*
No
* application appropriate if:

Reduce moisture content: shorter cooling and cycle times can be achieved by lower
(1) sufficiently pre-dry material** temperature of the temperature control medium
(2) check packaging optimum temperature of the temperature control medium
(3) check storage of material cannot be maintained due to condensed moisture
(4) reduce residence time in material hopper*** ** pay attention to drying instructions by the raw material producer
(5) use vented plasticising unit *** if possible, feed directly from the dryer in a closed system
Flow Chart 3
Correcting moisture streaks
2.4.3 Colour Streaks Similar to thermoplastics, pigments and dyes are

sensitive to excessive processing temperature and
2.4.3.1 Physical Cause residence times. If thermal damage is the reason for
colour streaks, they should be considered as
burnt streaks.
During pigmentation, pigment agglomerations can
lead to differences in the concentration. To some
extent this can be mitigated by an increase in shearing Extensive stress or warpage can also cause colour
as shown in Figure 7 and increases in back pressure differences. The deformed areas break the light in a
can be applied during the plastication stage to increase different manner than other areas.
mixing. This kind of poor distribution can be caused
by the plastic, the processing parameters, adhesives If using masterbatches for colouring, make sure the
and other additives. With in-plant colouring using substrate is compatible with the plastic to be coloured.
dyes, the defect can occur due to uncompleted solution The effect of the use of an incompatible masterbatch
of the dye particles in the melt. is shown in Figure 8.
11
Figure 7
Smaller differences in concentration due to higher shearing

Figure 8
Colour streaks
Left: Colour streaks due to an incompatible masterbatch
Right: Orientation of metal-effect pigments caused by the flow
2.4.3.2 Correcting Colour Streaks 2.4.4.2 Physical Cause
Check and/or change machine settings, change mould Air which cannot escape in time during mould
or moulding compound, start new cycle and go through filling, is drawn to the surface and stretched in the
Flow Chart 4. direction of the flow. Especially near writing, ribs,
domes and depressions, the air can be rolled over
and thus entrapped by the melt as shown in
2.4.4 Air Streaks/Air Hooks Figure 9. The result is the formation of air streaks
or air hooks.
2.4.4.1 Signs for Air Streaks
If air is sucked into the area in front of the screw
the moisture content in the environment is very during decompression, air streaks will appear near
high (especially in combination with cold moulds the gate. Here, air is transported into the cavity
and cold granules) during the injection, and is then pushed towards the
mould wall where it freezes.
the defect becomes smaller with lower decompression
the defect becomes smaller with lower screw

2.4.4.3 Correcting Air Streaks/
advance speed
Air Hooks
blisters are visible in the injected material
the solidified front flow of a partial filling shows or moulding compound, start new cycle and go through
crater-like structures. Flow Chart 5.
12
Inquiry
Improve mechanical melt homogeneity:

Does the processing range of the (1) increase back pressure and adapt
material allow higher shearing Yes screw speed*
(danger of thermal damage)? (2) increase injection rate
(3) use smaller gate
No
Pigmentation:
(1) use smaller pigments
Are modifications of the colouring (2) use pigment paste or masterbatches**
Yes
process possible? Colouring with dye:
(1) use smaller particles
(2) check solubility of the dye
No
Can other granules be used? Yes (1) use smaller granules
No
* pay attention to processing instructions by

the raw material and machine producers
Changing the machine or the plasticising unit***: ** MFI-value of the substrate must be the
(1) increasing the L/D ratio same as that of the plastic
(2) use shearing and blending devices *** when choosing plasticising unit make sure
(3) use non-return valves with intensive mixers melt homogeneity is sufficient (shear and blend
devices must not damage plastic and dye)
Flow Chart 4
Correcting colour streaks
Figure 9
Formation of an air streak behind an engraving
13
Inquiry
(1) adapt injection rate (-)
Are there air hooks? Yes (2) avoid sharp edges on transitions
(3) reduce depth of engraving
No
(1) reduce screw return speed during

decompression
Air streaks near the gate? Yes
(2) reduce decompression
(3) use shut-off nozzle
No
(1) adapt injection rate (-)

(2) increase back pressure
(3) avoid sharp edged transitions
(4) check nozzle sealing Flow Chart 5
(5) move gate
Correcting air streaks/air hooks

Figure 10
Air streaks/air hooks
Top left: Air streak behind a wall thickness variation; Top right: Air streak (near the sprue) due to sucked in air
during decompression; Bottom: Air streak due to entrained and stretched air near rib
14
2.4.5 Glass Fibre Streaks In addition to that, the surface can turn rough because
of the big differences in shrinkage (glass fibre:
2.4.5.1 Physical Cause plastic = 1:200). The glass fibres impede shrinkage
of the cooling plastic, especially in the longitudinal
Due to their length, glass fibres orientate themselves in direction of the fibre, thus producing an uneven
the direction of flow during injection. If the melt surface as shown in Figure 11. Figure 12 illustrates
suddenly freezes when touching the mould wall, the glass the effects that fibre orientation can have on
fibres may not yet be sufficiently surrounded with melt. moulded parts.
Figure 11
Formation of a rough surface due to different shrinkages
Figure 12
Glass fibre streaks
Top left: Glass fibre streaks: clearly visible weld line; Top right: Moulded part with rough silvery surface;
Bottom: Glass fibre streak due to orientation near sprue
15
Inquiry
Glass fibre streaks
(1) increase injection rate

(2) increase mould wall temperature*
(3) increase melt temperature OK
Still streaks
(1) use shorter glass fibres

Can the filler be modified? Yes
(2) use glass beads
No
move gate (move weld line to

Streaks near the weld line? Yes
invisible area)
No
* significant improvement of the defect possible;

Check application of clearly negative impact on cycle time
two-component process
Flow Chart 6
Correcting glass fibre streaks
2.4.5.2 Correcting Glass Fibre Streaks surface, its direction will change (refraction of light).
While one part of the light will be reflected on the
Check and/or change machine settings, change mould surface, another part will reflect inside the part or
or moulding compound, start new cycle and go through penetrate it with different intensities. The impression of
Flow Chart 6. gloss is at an optimum, the lower the surface roughness.
To achieve this, a polished mould wall should be as good
as possible, a textured mould wall would not be effective.
2.5 Gloss/Gloss Differences This is illustrated in Figure 13.
2.5.1 Physical Cause Gloss differences are caused by different projection

behaviours of the plastic at the mould wall, due to
The gloss of a moulded part is the appearance of its different cooling conditions and shrinkage
surface when exposed to light. If a ray of light hits the differences.
16
Figure 13
Different glosses
Left: Very glossy impression due to reflection on the polished surface
Right: Only slightly glossy impression due to reflection on a rough surface and on filler materials
Different gloss gives

streak like appearance
Different gloss levels
Figure 14
Examples of gloss related defects
Top left: Gloss differences near weld lines; Top right: Gloss differences due to wall thickness variations
Bottom left: Gloss differences near ribs
Stretching of already cooled areas (e.g., due to 2.5.2 Correcting Gloss/Gloss Differences
warpage) can be another reason for gloss differences.
Various examples of gloss related defects are shown Check and/or change machine settings, change mould
or moulding compound, start new cycle and go through
in Figure 14.
Flow Charts 7 and 8.
17
Inquiry Polished surfaces:

(1) increase mould wall temperature
(2) increase melt temperature
(3) increase injection rate
Not enough gloss on the surface of (4) improve polish of mould wall
Yes
the moulded part? Textured surfaces:
(1) reduce mould wall temperature
(2) reduce melt temperature
(3) reduce injection rate
(4) apply finer surface structure
No
Improve thermal melt homogeneity:

(1) reduce residual melt cushion
Gloss differences on polished (2) increase back pressure and adapt
Yes screw speed
surfaces?
(3) increase nozzle temperature
(4) apply even surface polish
(5) check plasticising unit
No
Gloss differences on textured

Yes See Flow Chart 8
surfaces?
Flow Chart 7
Correcting gloss/gloss differences (1)
2.6 Weld Line (Visible Notch or Colour Change) Increasing the mould wall temperature increases the
cycle time by approximately 2% per C.
Weld lines are created when two or more melt flows 2.6.2 Improving a Weld Line
meet. The rounded flow fronts of the melt streams are (Visible Notch or Colour Change)
flattened and bonded when touching each other. This
is shown in Figure 15 and Figure 16. This process Check and/or change machine settings, change mould
requires stretching of the already highly viscous flow or moulding compound, start new cycle and go through
fronts. If temperature and pressure are not high enough, Flow Chart 9.
the corners of the flow fronts will not completely
develop, creating a notch. Furthermore, the flow fronts
no longer melt together homogeneously, possibly
producing an optical and mechanical weak spot as 2.7 Jetting
shown in Figure 17. If moulding compounds
containing additives (e.g., colour pigments) are used, 2.7.1 Physical Cause
strong orientations of these additives near the weld line
are possible. This can lead to colour changes near the Jetting is caused by an undeveloped frontal flow of
weld line. Notches are particularly visible on dark or melt in the cavity. A melt strand is developed which,
transparent parts with smooth, highly polished surfaces. starting at the gate, enters the cavity with uncontrolled
Colour changes are particularly visible on parts with movements. During this phase the melt strand has
metallic pigments (161). Significant improvements can cooled down to such a degree that it cannot be fused
only be reached by high mould wall temperatures. homogeneously with the rest of the moulding
18
Inquiry Avoid pressure peaks in the mould:

(1) optimise change-over timing
(2) reduce holding pressure
Gloss differences at ejectors or slides? Yes
(3) reduce holding pressure time
(4) even mould temperature
(5) change ejector design or system
No
(1) adapt geometry of perforation

Gloss differences at perforations? Yes
(2) move gate
No

Gloss differences at weld lines? Yes (2) increase injection rate
(3) move gate
No
Even temperature at corners of the
moulded part
(1) reduce temperature of moving half
Gloss differences at corners of the
Yes of the mould
moulded part?
(2) change geometry of corners
(e.g., round off corners)
(3) change thermal mould design
No

Gloss differences at ribs? Yes
(3) change geometry of the moulded part
(4) change thermal mould design
No

Gloss differences at wall thickness
Yes (3) adapt injection profile to geometry
variations?
(4) try to attain continuous wall thickness
variations
No
(1) change colour of material

(2) reduce glass fibre content Flow Chart 8
(3) reduce filler material content Correcting gloss/gloss differences (2)
19
Figure 15 Figure 16
Flow fronts before touching each other Stretching of the rounded flow fronts
Notch effect
Figure 17
Visible notch on the top and bottom side of a transparent part
Inquiry
(1) use smaller pigments

Colour change near weld line? Yes (2) use spherical pigments
(3) use lighter material
No
(1) increase mould wall temperature*

(2) increase injection rate * High mould wall temperatures can significantly
(3) increase melt temperature reduce the defect, but need a much longer cycle time
(4) increase holding pressure (approximately 2% per C). Changing points (2) - (4)
(5) check ventilation only have little influence.
(6) use mould wall with higher roughness
(7) move gate (move weld line to invisible area)
Flow Chart 9
Improving a weld line
20
Figure 18
Mould filling frontal flow and jetting
Figure 19
Jetting starting at the gate, spreading over the entire part
compound. This often happens with discontinuously 2.8 Diesel Effect (Burns)
increasing cross-sections of the moulding part in
conjunction with high injection speeds. Jetting is 2.8.1 Physical Cause
illustrated in Figures 18 and 19. Often jetting causes
differences in colour and gloss. In some cases there The diesel effect is a pure venting problem. It can
are similarities to the record grooves effect. Jetting occur near blind holes, fillets, the end of flow paths
can also be influenced by the position of the mould. and near points where several flow fronts fuse. It
In order to avoid defects, the cavity should not be happens whenever the air cannot escape or not quick
filled from top to bottom. enough via commissures, venting channels or ejector
fits. Towards the end of the injection process, the air
is compressed and thus heated to a high degree. The
2.7.2 Correcting Jetting result is very high temperatures which can cause burn
marks on the plastic as shown in Figures 20 and 21.
Check and/or change machine settings, change mould Due to the burning of the plastic, aggressive
or moulding compound, start new cycle and go through decomposition products may be created, which often
Flow Chart 10. attack the mould surface.
21
Inquiry
(1) reduce injection speed or

Can injection speed be reduced? Yes
injection profile (slow-fast)
No
Can the melt temperature be changed? Yes (1) change melt temperature (+)
No
(1) check position of mould

(2) round off transition gate-moulded part
(3) increase gate diameter
(4) move gate (create flow resistance)
(5) use impact die
Flow Chart 10
Correcting jetting
Diesel effect
Figure 20 Figure 21
Sheet with diesel effect (filling pattern) Diesel effect (burns) due to merging of several
(s indicates the flow fronts) flow fronts
22
Inquiry
Does the defect occur suddenly during

Yes (1) check venting channels for dirt
production?
No
Can clamping force be reduced? Yes (1) reduce clamping force of the machine*
No
* The clamping force of the machine is only

to be reduced to a safety factor of 1.2 for
(1) reduce injection speed
overspraying.
(2) ensure sufficient ventilation
(3) avoid entrapped air by changing flow profile
Flow Chart 11
Correcting diesel effect (burns)
2.8.2 Correcting Diesel Effect (Burns)
Check and/or change machine settings. Change mould

Flow Chart 11.
2.9 Record Grooves Effect
In this effect very fine grooves show up on the moulded

part, which are very similar to those of records.
Concentric rings appear near pin-point gates, while Figure 22
markings are parallel towards the end of the flowpath
and/or behind the gate. This is shown in Figure 22. Concentric record grooves

When injecting the moulding compound into a cold
mould, a solidified peripheral layer will be formed
high cooling velocity behind the flow front due to the high cooling rate. The
cooling of the peripheral layer also causes cooling of
melt temperature too low
flow front areas near the mould wall. If this cooling is
injection speed too low very high (especially with low injection speeds) these
very high viscosity or frozen flow front areas can
mould wall temperature too low. impede the direct frontal flow of the melt to the wall.
23
Figure 23 Figure 24 Figure 25

Flow front has cooled down Cooled down peripheral layer Flow front touches mould
near the wall impedes direct frontal flow to wall again
the wall
Thus the following hot melt will not be pushed towards 2.9.2 Correcting Record Grooves Effect
the wall as usual, but it will cause an elongation of the
flow front in the middle. From a certain pressure the Check and/or change machine settings, change mould
flow front will again touch the wall. The cooled down or moulding compound, start new cycle and go through
peripheral areas of the flow front have no contact with Flow Chart 12.
the wall (see Figures 23-25).
Inquiry
Can injection speed be increased? Yes (1) increase injection speed
No
Is the maximum injection pressure

Yes (1) increase maximum injection pressure
reached?
No

(3) avoid small runners
Flow Chart 12
Correcting record grooves effect
24
2.10 Stress Whitening/Stress Cracks wetting, diffusion and swelling processes. This may
especially favour stress cracks. Besides internal cooling
2.10.1 Physical Cause stresses and stresses due to flow, internal stresses due
to expansion are another main reason for internal
stresses. External expansion stress is created by
Stress whitening or stress cracks occur when
demoulding under residual pressure, when the moulded
exceeding the maximum deformation (e.g., due to
part suddenly shifts from residual pressure to
external stress or warpage). The maximum atmospheric pressure. Thus the inner layers of the
deformation depends on the type of material used, moulded part put stress on the outer layers. The main
the molecular structure, the processing and the reasons for demoulding under residual pressure are
surrounding climate of the moulded part. insufficiently dimensioned moulds and/or high cavity
pressures. The formation of stress is shown in Figure
The strength against external and internal stresses can 26 and the physical manifestations on the moulding in
be drastically reduced through physical processes Figure 27. If aggressive substances are used (e.g., alkali
depending on time and temperature. In this case, the solutions, grease, etc.) stress whitening and stress
linkage forces of the molecules are reduced through cracks often appear after a very long time of operation.
(a) (b) (c)
Figure 26
(a) unstressed, felted molecule structure; (b) orientation of molecules due to force;
(c) destroyed molecules due to additional force
Figure 27
Stress whitening
Left: Stress whitening on an integral hinge
Right: Stress cracks on salad servers (damage visible several weeks after purchase)
25
2.10.2 Correcting Stress Whitening/Stress Cracks 2.11 Incompletely Filled Parts
Check and/or change machine settings, change mould Injection moulded parts with incompletely developed
or moulding compound, start new cycle and go through outer profiles are called incompletely filled parts (or
Flow Chart 13. short shots). An example is shown in Figure 28. This
Inquiry
Stress whitening due to strong deformations? Yes (1) reduce external stress*
No
(1) earlier change over to holding pressure

Demoulding under residual pressure? Yes (3) reduce demoulding temperature
(increase cooling time)
(4) stiffen mould by changing design
No
(1) reduce mould wall temperature

Partially crystalline thermoplastic? Yes
(2) reduce melt temperature
No

Amorphous thermoplastic? Yes (3) reduce holding pressure
(4) change injection speed (+)**
(5) reduce cooling time**
No
(1) choose compound under consideration

of the surrounding material
Can another moulding compound be used? Yes (2) use partially crystalline material
(3) high molecular weight or narrow
distribution of molecular weight desirable
No
* deformation (e.g. integral hinges) should occur in warm condition
** only for demoulding without residual pressure
*** e.g., rounding off edges, avoiding wall thickness variations, etc.
(1) ensure constant mould temperature
(2) ensure even filling
(3) change geometry of moulded part*** Flow Chart 13
Correcting stress whitening/stress cracks
26
Figure 28
Housing with incompletely demoulded lattice
Figure 29
Filling problems near thin ribs
kind of defect often appears far from the gate if there 2.11.2 Correcting Incompletely Filled Parts
are long flow distances, or on thin walls (e.g., ribs as
shown in Figure 29). Due to insufficient mould Check and/or change machine settings, change mould
venting, this defect can also occur in other areas. or moulding compound. start new cycle and go through
Flow Chart 14.

2.12 Oversprayed Parts (Flashes)
There are several physical causes for incomplete filling:
Flashes are often created near commissures, sealing
injected compound volume too small (e.g., shot faces, venting channels or ejectors. They look like a more
volume too small) or less developed film-like plastic edge. Fine flashes are
not often immediately visible. Large area thick flashes
melt flow impeded due to venting problems on the other hand sometimes stick out several centimetres
over the nominal profile as shown in Figure 30.
injection pressure not sufficient
premature freezing of a channel cross-section (e.g., 2.12.1 Physical Cause

low injection speed or wrong temperature control
in the mould). The different possibilities can be divided into four
main groups:
Incomplete filling due to venting problems does not
necessarily cause the diesel effect (see Section 2.8). allowed gap widths exceeded (mould tightness
Therefore the cause for the defect is often hard insufficient, production tolerances too large or
to determine. damaged sealing faces)
27
Inquiry
(1) increase dosage

Screw at the very front? Yes
(2) check non-return valve
No
(1) increase maximum injection

Is maximum injection pressure reached? Yes pressure
No
(1) belated pressure change-over

Is there a drop in pressure during the increase change-over pressure
Yes
filling? increase change-over distance
increase change-over time
No
(1) change injection speed (+)

(3) improve venting
(4) change gate geometry Flow Chart 14
(5) check nozzle bore and temperature
Correcting incomplete filling
clamping force of the machine insufficient or set

to low (mould opening force higher than clamping
force, mould cannot be kept close; clamping force
deforms platens and mould)
internal mould pressures too high (shaping pressure

at the gap is so high that the melt is pushed even
into very small gaps)
viscosity of moulding compound too low (high

internal mould pressures and low flow resistances
favour flash formation).
Figure 30
Flash formation can occur very quickly (few cycles)
Large area overspraying (flash) and damage the sealing faces (parting surface).
28
Inquiry
Can clamping force be increased? Yes Increase clamping force
No
Avoid pressure peaks in the mould:

(1) optimise change over point
High mould deformation? Yes (2) reduce holding pressure
(3) change clamping force
(4) stiffen mould
No
lower injection speed or injection

Overspraying near the gate? Yes
profile slow-fast
No
(1) earlier change over to holding pressure

(2) lower injection speed or injection profile
slow-fast-slow
(3) reduce melt temperature Flow Chart 15
(4) reduce mould wall temperature Correcting oversprayed parts (flashes)
2.12.2 Correcting Oversprayed Parts (Flashes)


Flow Chart 15.

2.13 Visible Ejector Marks
Ejector marks are depressions or elevations on the

ejector side of the moulded part surface. These wall
thickness variations can cause gloss differences and Figure 31
depressions on the visible surface of the moulding as
shown in Figures 31 and 32. Gloss differences near the ejector
29
2.13.2 Correcting Visible Ejector Marks

Flow Chart 16.
2.14 Deformation During Demoulding
Depending on the degree of damage there is a

classification into extraction marking, cracks,
fractures, overstretched areas and deeply depressed
ejectors. Critical are moulded parts with undercuts,
Figure 32 which are demoulded without movable parts
(e.g., slides). Examples of two defective mouldings
Shrinkage near an overheated and poorly fitted ejector are shown in Figure 33.
2.13.1 Physical Cause 2.14.1 Physical Cause
The different possibilities can be divided into four The causes of deformations can be classified as follows:
main groups:
the forces necessary for demoulding cannot be
process-related causes (e.g., premature demoulding applied to the moulded part without damaging it
or high demoulding forces due to unfavourable
machine settings) the demoulding movement is disturbed.
geometric causes (e.g., wrong fitting or wrong
The amount of demoulding force applied is a crucial
ejector length)
criterion and should thus be kept small. Beside other
mechanical or strength-related (e.g., faulty factors the shrinkage of the moulded part has a direct
dimensioning and design of the mould, the moulded impact on the demoulding forces. Shrinkage and
part or the demoulding system) demoulding force can be influenced considerably by
varying the process parameters. It is to be considered
thermal causes (high temperature differences though that the geometry of the moulded part is a very
between ejector and mould wall). important influencing factor.
Figure 33
Deformation during demoulding
Left: Demoulding grooves on a textured surface; Right: Defomation due to forced demoulding at an undercut
30
Inquiry
Avoid pressure peaks inside the mould:
Gloss differences? Yes
(4) constant mould temperature
(5) change ejector design/system
No
(1) fit in ejector

Ejector not evenly fitted or axial
Yes (2) check indentations and bearing surfaces
clearance?
of ejector heads
No
Raised ejector marks? Yes (1) use longer ejectors
No
Premature demoulding? Yes (1) increase cooling time
No
Avoid pressure peaks inside the mould:

High degree of mould deformation? Yes
(3) stiffen mould
No
(1) vary holding pressure

High demoulding forces? (2) vary cooling time
Yes
(3) improve core ventilation
(4) check drafts and undercuts
No

Flow Chart 16
(3) reduce mould wall temperature Correcting visible ejector marks
31
In general, low shrinkage is desirable for sleeve and

box-shaped parts, since these parts tend to shrink onto
the core (==> increase holding pressure or reduce
cooling time).
Near ribs, the shrinkage retracts on the demoulding

force, because the ribs are being detached from the
mould walls (==> decrease holding pressure or increase
Figure 35
cooling time).
Flaking on a cross-section of a moulded part with
different structure formation
2.14.2 Correcting Deformation During
Demoulding
Check and/or change machine settings, change mould High shear stresses and thermal damage can be
or moulding compound, start new cycle and go through caused by:
Flow Chart 17.
high injection speeds
high melt temperatures.
2.15 Flaking of the Surface Layer
Inhomogeneities can be caused by:
The layers of material are not homogeneously joined
together and start flaking. This can occur at the gate or impurities or other materials among the granules
on the moulded part, and can be either large or very incompatible dye or master batch
small and thin, depending on the intensity. Examples
of both are shown in Figure 34. moisture in/on the granules
poorly melted moulding compound.

2.15.2 Correcting Flaking of the Surface Layer
Flaking of surface layers is due to insufficient bonding
of adjacent surface layers. The different layers are Check and/or change machine settings, change mould
formed by different flow effects and cooling conditions or moulding compound, start new cycle and go through
over the cross-section. Shear stresses and Flow Chart 18.
inhomogeneities can reduce the bonding of these layers
to such a degree that single surface layers start flaking
off as shown in Figure 35.
2.16 Cold Slugs/Cold Flow Lines
Cold slugs are formed when melt solidifies in the gate

or in the nozzle before the compound is injected, and
is transported into the mould with the following shot
sequence. If the cold slugs do not melt again, they
will cause markings which look like comet tails. They
can be spread all over the moulded part. The cold slug
can also jam a runner, forcing the melt to part. The
results are surface defects similar to weld lines. An
example is shown in Figure 36. Cold slugs are often
caused by a wrong nozzle temperature or belated
retraction of the plasticising unit. Small nozzle
Figure 34
diameters can also have a negative effect. An
Flaking illustration of the mechanism is shown in Figure 37.
32
Inquiry
(1) earlier change-over to holding pressure
(2) decrease holding pressure
Demoulding under residual pressure? Yes
(4) stiffen mould
No
Penetrated ejectors? Yes (1) increase cooling time
No
(1) reduce cooling time

Deformations due to or on undercuts? Yes
(2) check demoulding system
No

Extraction markings? Yes (2) increase cooling time
(3) check surface structure of mould walls
No
(1) reduce cooling time

Strong demoulding forces due to
Yes (2) increase holding pressure
shrinkage on the core?
No

Strongly ribbed moulded part? Yes (2) reduce holding pressure time
No
(1) vary mould wall temperature

(2) increase ejector speed
(3) check core venting
(4) check demoulding system
(5) check drafts
Flow Chart 17
(6) use mould release agent Correcting deformation during demoulding
33
Inquiry (1) check granules for impurities of

other materials
Does the defect occur after a change (2) check compatibility of dye
Yes
of material or colour? (3) check moisture content
(4) check melt homogeneity and
plasticising performance
No
(1) reduce injection speed

(2) reduce melt temperature Flow Chart 18
Correcting flaking of the surface layer
2.16.2 Correcting Cold Slug/Cold Flow Lines

Flow Chart 19.
2.17 Entrapped Air (Blister Formation)

Figure 36
During injection, air is entrapped in the melt and appears
Cold slug near the sprue
as a hollow (air blister) on the moulded part. Primarily
there are two factors responsible for this defect:
decompression too high or too fast

plasticising performance too low.
There are two types of hollows, entrapped air and voids.

Voids are vacuole hollows, formed by the shrinkage of the
moulding compound (see sink marks). Distinguishing
between the two is very hard, because of their similar
appearance. The following hints might be helpful:
when opening the hollow in a fluid, a void

(vacuum) shows no gaseous bubbles
entrapped air defects can be reduced by using no

decompression
changing the holding pressure or the holding

pressure time has no effect on the size of the hollows.
Figure 37 Moulded parts with hollows are usually not as strong

as parts without. Non-transparent parts should be
Cold slug is transported into the mould by the randomly tested by opening them. Examples of trapped
flow front air are shown in Figure 38.
34
Inquiry
Can the decompression be

Yes reduce decompression
reduced?
No
Can the plasticising unit be

Yes retract plasticising unit earlier
retracted earlier?
No
(1) check nozzle temperature

(e.g., fixing of heating elements)
(2) increase nozzle temperature
(3) increase nozzle cross-section
(4) apply longer gate extension
(5) use shut-off nozzle
Flow Chart 19
Correcting cold slug/cold flow lines
Figure 38
Entrapped air
Left: Air bubbles (solidified while flowing around the core); Right: blisters due to injected air
35
Inquiry
Can the decompression be Slow down or reduce

Yes
reduced? decompression (screw return)
No
Does the defect occur suddenly

Yes Check granule feed
during the process?
No
(1) increase back pressure and adapt * the metering stroke should be 1-3 times
screw speed the screw diameter
(2) reduce metering stroke*
(3) check plasticising unit
Flow Chart 20
Correcting entrapped air (blister formation)
2.17.2 Correcting Entrapped Air (Blister Mould-related causes, e.g., dirty gate system or
Formation) wear (dead edges) in the hot-runner system.
Check and/or change machine settings, change mould Machine-related causes, e.g., dirty plasticising unit
or moulding compound, start new cycle and go through or worn screw and cylinder.
Flow Chart 20.
Caused by polymer or dyeing, e.g., impurities in
the granule, high reclaim content or unsuitable dye/
masterbatch.
2.18 Dark Spots
Figure 39 shows dark spots resulting from thermal
damage to the polymer.
Black or dark spots appear on the surface due to wear,
thermal damage or dirt. Different factors can cause the
formation of dark spots or speckled parts: 2.18.2 Correcting Dark Spots
Process-related causes, e.g., melt temperature too high Check and/or change machine settings, change mould
or residence time in the plasticising unit too long; or moulding compound, start new cycle and go through
wrong temperature profile in the hot-runner system. Flow Chart 21.
36
Figure 39
Dark spots due to thermal damage
Inquiry
Impurities in the granule? Yes Check granule for impurities
No
Do dark spots appear after a change of

Yes Clean plasticising unit
material?
No
Reduce melt temperature:

Is the melt temperature exceeding the (1) vary cylinder temperature (-)
Yes
processing range? (2) vary screw speed (-)
(3) reduce back pressure
No
(1) reduce cycle time

Is the residence time of the melt within
Yes (2) increase plasticising time delay
the critical range?
(3) check dimensions of plasticising unit
No
(1) check hot runner temperature

(2) reduce reclaim content
(3) check dye for compatibility
(4) check plasticising system, gate system and Flow Chart 21
hot runner for impurities, wear and dead edges Correcting dark spots
37
2.19 Dull Spots Near the Sprue
Dull spots near the sprue are mainly caused by:
small gates
high injection speeds.
Figure 40
Due to high injection speeds, small gate cross-sections Melt flows into the cracked peripheral layer
and bypasses behind the gate, extremely strong (formation of micronotches)
orientations of the molecule chains are formed during
injection. If there is not enough relaxation time directly
behind the gate, so the peripheral layers of the melt are
frozen while still strongly oriented. Such peripheral
layers can only be stretched to a minimum degree and 2.19.2 Correcting Dull Spots Near
crack under the impact of the high shear stresses. the Sprue
The hot melt inside flows to the mould wall and forms Check and/or change machine settings, change mould
very small notches as shown in Figure 40. The dull or moulding compound, start new cycle and go through
appearance is caused by the widespread reflection in Flow Chart 22.
this area.
Inquiry
reduce injection speed or use

Can the injection speed be reduced? Yes
injection profile (slow-fast)
No
(1) round off transition from gate to cavity

Can the gate be modified? Yes (2) increase gate diameter
(3) move gate*
No
* The gate should be placed so that the melt does

(1) increase melt temperature** not have to flow around sharp edges
(2) vary mould wall temperature (-)** ** The effect of these parameters is small
Flow Chart 22
Correcting dull spots near the sprue
38
3 Case Studies of Injection Moulded not too high, and which is satisfactorily set, guarantees
better air venting.
Components
Moreover, the equipment is looked after better: the
The following examples highlight potential errors that lower the mould clamping force, the lower the wear.
can be made in injection moulded components as well
as solutions to overcoming them.
3.3 Wristwatch Glass
3.1 Threaded Connecting Sleeves for Ink A glass for a wristwatch displayed convergence points
Drafting Apparatus opposite the runner, i.e., very visible joint lines. It was
possible to establish clearly, after a filling sequence
With this thin-cavity three-plate mould arrangement, with this mould, that no uniform flow front was formed.
series injection took place in the parting plane. The
filling process and the pressure ratios in the two cavities When the sample components were measured later,
were thus different. The effect of this was that the there were thickness variations of 0.1-0.15 mm. The
component did not have a good surface. Moreover, very variations in wall thickness were overcome by
narrow tolerances could not be maintained. These supplementary work on the core.
effects could be overcome by correcting the flow path
lengths in the runner. Identical flow path lengths on Now a uniform flow front could be generated, and the
multiple equipment in the mould are the basic faults caused by the joint lines are a thing of the past.
prerequisite for maintaining narrow tolerances.
After the fault referred to above had been eliminated,
This basic principle is generally valid in injection there was still some dissatisfaction with the surface
moulding technology. lustre of the watch glass, although the mould inserts
were high-gloss polished. The required surface gloss
could not be obtained until new mould inserts had been
manufactured from non-porous vacuum steel (in
3.2 Meter Cases
accordance with the vacuum arc refining process).
On this meter case, there are dovetail guides on the
four side faces. The varying wall thickness caused the
meeting of flowpaths resulting in an air blister in the 3.4 Alarm Clock Glass
vicinity of the gate. The following measures were
adopted to try and remove this air blister: In the manufacture of an alarm clock glass, the
following problem arose during sampling: a uniform
1. Reduction of initial injection speed; however, a flow front was not being formed, due to the edges being
hole now appeared at a new point, where the some tenths of a millimetre thicker, and an air blister
compound was no longer coalescing. was formed on the side of the component opposite the
runner. Since there were electroplated inserts in the core
2. Raising the compound temperature; initially this and the mould insert, it was not possible to correct the
was a success, in that, by raising the compound wall thickness by secondary work. The electroplated
temperature step by step, it was possible to reduce inserts would have had to be manufactured again.
the initial injection speed as much as possible.
It was decided to remove the air blister by a simpler
method. A gas vent was ground, 8.0 mm wide and
However, after a certain amount of time, warping
0.3 mm thick. The convergence point, with the air,
occurred, which can clearly be traced back to very high
could now be forced out, and it was possible to
internal orientation stresses resulting from excessively
manufacture good components.
slow filling.
In order to remove the air blister even at faster initial

injection speeds, the mould clamping force, which had 3.5 Glass Cover for Digital Gauge
previously been set very high (too high) was reduced
until satisfactory running was achieved again. This This component displayed slight sink marks on the face,
example shows that a mould clamping force which is above the fins, especially on the side away from the gate.
39
Injection was carried out with a film gate into the parting viscosity of the melt, temperature changes in the mould,
plane. However the film runner was produced in such a viscosity changes of the hydraulic fluid and changes in
way that the cross-runner to part space was too large. In the characteristics of the plastic.
addition, the runner cross-section was too small.
The causes through which these negative factors may
By moving the cross-runner closer to the component arise are, for example, machine start-up after a long
(shorter gate) and by better formation of the period of non-operation (12), changes in material
accumulation base, it was arranged that the gate stayed properties in the processing of a new lot or a different
open longer. colour, and environmental influences such as the
ambient temperature at the time of processing.
This not only made it possible to avoid the sink marks,
but it was also no longer necessary to select such high
melt temperatures and initial injection pressures. This 4.1 Internal Mould Temperature and Pressure
also improved the quality of the component.
The decisive factor for all quality features that are
concerned with dimension and weight, is the internal
3.6 Plug Boards with Insert Pins pressure of the mould (68). Constant maintenance of
this pressure curve in every cycle guarantees uniformity
On this component, despite all the technical skills that of the quality of injection moulded parts. If the mould
injection moulding technology can offer, voids were internal pressure curve is maintained at a constant, all
forming in the centre of the moulding. The reason why of the negative factors mentioned above are
the voids had formed was because the components had compensated, this can mean:
been directly connected to the cross-runner. Since a
gate point of this kind very quickly freezes, the holding Significant reduction in start-up cycles. The
pressure was not able to act for long enough. required consistency in quality characteristics is
achieved after just a few cycles.
It is generally true in injection moulding technology
that gates should start in the centre of the runner or the Better reproducibility of the parts. The deviation
runner system, so that a plastic flow can form properly spread of the various dimensions lies significantly
from the gate outwards. Direct connections from the below that of a non-regulated machine.
runner are thus very unfavourable.
Cycle-time reduction. By the ability to visualise
the internal pressure signal, the sealing point can
be determined much more easily and accurately.
4 Effects of Injection Moulding Restarts. If the same internal pressure curve is applied
Parameters at a restart, the resulting parts are exactly alike.
This section will discuss the importance of the various Improved quality of the parts through effective
injection moulding parameters and their effect on the speed and pressure profiles. Internal pressure
overall quality of an injection moulded part. Process profiles without spikes make possible the
stability and product quality are also affected by the production of parts with low residual stresses.
machine specification itself. Switch-over as a function of internal pressure
prevents overinjection of the part, regardless of the
The properties of an injection moulded part depend upon selected dosage stroke.
the working material and on the processing conditions.
In the production of a series of parts, a certain deviation The enormous significance of a mould internal pressure
in quality features such as weight, dimensional curve is characterised by the large number of
consistency and surface characteristics may always parameters that can influence the appearance of the
occur. The size of this deviation will vary from machine curve, the most important influencing factors are:
to machine and from material to material. Furthermore,
external influences or negative factors have an effect on In the injection phase: the injection speed, the flow
the quality of an injection moulded part. Examples of resistance as a function of the type of plastic, the
such negative factors may include changes in the material temperature and the mould wall temperature.
40
In the pressure holding phase: the material For the process parameter settings the following points
temperature, the mould temperature, the level of can be generally applied:
the holding pressure and the duration of the
holding pressure. screw injection speed as high as possible,
In relation to the maximum mould internal pressure: compound temperature as high as possible.
the injection speed, the material temperatures, the
switch-over point and the material flow. High temperatures result in low viscosity for the
compound flowing in, low pressure losses, and thus
The internal pressure curve additionally affects the low pressure differences and short filling times.
following quality data:
In practical machine setting, there are naturally limits
In the injection phase: the appearance, the surface here. Here are just a few examples.
characteristics, the orientation and the degree of
crystallinity of the moulded part. It will not always be possible to take the injection speed
right up to the machines performance capability limit.
In the pressure holding phase: the formation of As the injection speed rises, the tendency to free jet
ridges, the weight, dimensions, shrinkage, shrink formation and thus to the occurrence of surface faults
holes and sink marks and the orientation. increases. If assistance cannot be provided here by
suitable mould design, the machine must be operated
The properties and the quality of a component are at a low injection speed it may be that two or three
predominantly determined by the moulding process in speed stages will be available for injection. The
the mould. The dominating limiting quantities here are compound temperature must naturally not become so
the pressure and temperature cycles in the mould cavity. high that heat damage occurs. The more sensitive the
It would be ideal if pressure and temperature were compound, the better to select a larger safety margin
uniform at any point in the cavity, and if the temporal from the upper temperature limits.
pressure and temperature cycle also remained the same
from batch to batch. Then shrinkage would be the same Too much caution can bring about the exact opposite
in all component batches, there would be no internal of the desired effect: low temperatures increase the
stresses and no tendency towards warping in the viscosity, and thus cause higher flow losses due to
component, and one component would fall out in just friction which heats up the compound again as it is
the same condition as another. injected into the mould. In this way, cylinder
temperatures that are too low can actually lead to higher
This ideal pressure and temperature distribution within compound temperatures in the mould than in materials
the mould, as uniform as possible, is practically where the cylinder temperature was set higher.
impossible to achieve with injection moulding, as a
pressure drop is bound to occur while the mould is The higher the mould temperature is set, the longer the
being filled, due to the flow resistance. Temperature cooling-off lasts and the longer the cycle time is.
differences will also arise because filling takes a finite Therefore a temperature should be chosen which is only
time, even if this is usually very short. To get close to as high as the desired quality demands in order to be
an ideal state, i.e., to aim for the most uniform possible able to produce components as economically as
filling process, the flow resistance during the filling of possible. Figure 41 provides a summary of the most
the mould plays a decisive role. The lower the flow important factors in producing quality components.
resistance, the faster the mould is filled, and the smaller
are the local pressure differences in the mould.
These factors have corresponding consequences for the 4.2 Relationship of Injection and Mould
design of the component and mould, and the process Cavity Pressures
parameters chosen.
The internal mould pressure follows the injection
As regards the influence of the mould geometry, the pressure, with a time delay. The internal cavity pressure
following is generally valid: the flow resistance should can be measured by sensors within the mould, and can
be kept as low as possible, e.g., by avoiding sharp edges be indicated, or visually displayed, using an
in the component (pressure losses due to abrupt turning oscilloscope or a pen recorder. The pressure cycle in
by the compound flow). the vicinity of the gate is the most informative factor
41
Machine parameter Process parameter

(adjusted value)
Interfacial parameter Target parameter
(in injection unit) (in the mould)
Pressures
(injection pressure,
holding pressure)
Injection pressure curve
Injection pressure
Time Fill time
curve in screw
(injection time, Max. pressure
antechamber
holding time) Remaining pressure
Injection speed
Cylinder and nozzle

temperature
Screw RPM
Material
Material temperature
temperature curve
Back pressure curve in screw
Demoulding
antechamber
temperature
Dosage stroke,
material cushion
Cycle time
Cooling time Mould wall

temperature curve
Outlet temperature of
heat transfer fluid
Figure 41
Important parameters for part formation
(arrows indicate which parameters affect other parameters)
here. First the cavity is volumetrically filled, and then can be pushed back, right to the residual pressure,
the compound is packed in the mould. The maximum when the mould is opened.
internal mould pressure is not reached until some time
after the maximum injection pressure is obtained.
4.3 Injection Pressure and Injection Time
Even if the injection pressure stays the same, the
internal mould pressure drops slightly, as a result of The injection pressure and holding pressure selected
shrinkage of the compound. From here the pressure must be as high as necessary to fill the cavity
drops rather faster, because now no more compound sufficiently fast, completely and efficiently, but, on the
42
other hand, as low as necessary to produce low-stressed Too low a filling speed causes a greater temperature
injection moulded components and avoid difficulties variation between those parts of the preform near the
when the components are ejected from the mould. gate and those far from it, due to increased cooling off
of the compound while the cavity is being filled. The
The injection time (injection time and holding time), higher viscosity of the colder compounds also requires
i.e., the duration of effect of the injection pressure, must higher injection pressures, which in turn require
be selected to be just long enough to solidify (seal) the stronger locking pressures.
gate. If the injection time is too short, compound can
flow back out of the cavity, sink marks occur, and in An excessive filling speed can also lead to surface
general there are larger tolerance variations. Overlong faults. If compound which has already solidified onto
times are uneconomic and increase the internal stresses the mould wall is displaced by a subsequent filling,
of the injection moulded component, especially close cross-grooves occur vertically to the direction of flow
to the gate. The correct injection time can be determined (gramophone record effect, Section 2.9).
by weight measurement.
With injection times greater or equal to curing time, 4.5 Filling Speed and Orientation
the injection moulded component weight remains
practically the same (does not increase). With
During the filling of the mould, orientation effects can
injection times less than curing time, the injection
arise, especially through friction influences. The
moulded component weight decreases. The
molecules initially lying randomly in the compound are
occurrence of sink marks is also a sure indication that
now stretched and orientated in the direction of flow.
the injection time (duration of effect of pressure) is
Such orientations lead to non-uniform shrinkage and
shorter than the curing time.
non-uniform preform properties (anisotropy). The higher
the shear rates that are exerted on the molecules, the
With amorphous thermoplastics holding pressure
greater the resultant orientation of the polymer chains.
reduction is necessary. This can avoid difficulties in
Also, the higher the filling speed and the greater the
ejecting the parts and is necessary to get low-stress
viscosity of the compound, the higher the shear rate that
injection moulded parts.
is produced. Thus, higher filling speeds are bound to
lead to an increased tendency to orientation.
With semi-crystalline thermoplastics a constant holding
pressure is recommended in order to ensure an
However, the higher the compound temperature is, and
undisturbed crystallisation process.
therefore the lower the viscosity value, the less negative
effect a high filling speed will have. A high compound
temperature, in connection with a high mould wall
4.4 Filling Speed temperature, will cause the oriented molecules to lose
their orientation after the filling process has ended
The smaller the flow path cross-section is in relation (relaxation). This reduces orientations, along with their
to the screw/piston surface, the higher the filling speed negative effects. Therefore, before any reduction in the
is. A larger injection cylinder in the same injection unit filling speed, a check should be made on whether
thus produces a higher filling speed for the same initial orientation phenomena can be reduced by increasing
injection speed. The initial injection speed, and with it the compound temperature and the mould temperature.
the filling speed, should be selected to be as high as Here also, preference should be given to compound
possible, so that the mould is filled as quickly as temperatures and mould temperatures that are as high
possible with compound with as uniform a temperature as possible (as already stated when dealing with the
as possible. Then the temperature and pressure most favourable injection pressure).
variations in the mould are slight, and low-stress
components can be obtained. In this way, the In terms of the flowability of the materials themselves,
component should be filled as uniformly as possible, sometimes material suppliers illustrate the relationship
with the flow head moving away from the gate. Free between wall thickness and injection speed as a flow
jet formation is to be avoided by suitable design. path/wall thickness ratio (L/s). If a ratio of 100:1 is
given, this means for a wall thickness of 1 mm, then
For thin-walled parts (69), the optimum filling speed the length of flow from the gate will be 100 mm.
is higher than for thick-walled parts, so as to obtain Because flow is dependent on wall thickness a variety
uniform filling of the moulding through the flow head. of mould wall thickness may be quoted. If the material
43
is required to flow further, e.g., 125:1, more pressure temperature is too low, and thus the melt viscosity is
will be required to fill the cavity and more orientation higher. In certain circumstances, heating due to
in the material will result. Therefore, ideally moulds constriction losses can become so great that, when the
should be designed with consideration of flow path set cylinder temperatures are reduced, the compound
lengths and wall thickness ratio in mind. temperature in the mould cavity does not fall, but rises.
This matter will be referred to again in connection with
the cylinder temperatures.
4.6 Effects of Too High Filling Speed
A high filling speed causes a high shear rate between

the compound in the core and the compound on the 5 Machine Specifications
mould wall. The shear stress arising under such
conditions can lead to impairment of the plastic (shear Problems can arise if the machine being used in
fracture). Particularly high shear stresses arise if the unsuitable for the moulding product. To select the
compound has to turn sham corners, especially with correct machine, consideration should be given to the
abrupt changes in the cross-section. This should be projected area, the shot weight, the injection pressure
taken into account in the design of the moulding. and the design of the cylinder assembly.
Many plastics display particularly high shear fracture

sensitivity, e.g., fluoroplastics such as Teflon. But,
PMMA or PC also display more pronounced tendencies 5.1 Clamp Force
to shear fracture than, for example, the polystyrenes.
The projected area is all surfaces of the part that are
If the filling speed is high, the air must be removed normal (at 90 degrees) to the injection unit and is
from the cavity sufficiently quickly. If this is not the required to calculate the clamp force required by the
case, the compression, and thus the heating of the air machine. This is done by multiplying the projected area
increases (Diesel effect, see Section 1.8). This can lead by the material specific tonnage per cm 2 . This
to heat damage of the material, or can even cause burns. information can be obtained from the polymer supplier.
So care should be taken to ensure that the air removal
system in the parts of the mould filled last works well. In simple terms, the clamp force required is the force
Under certain circumstances, it is sufficient to reduce required to hold the mould closed during the injection
the mould clamping force to the necessary level, if the stage. Generally, 0.4 tons per cm2 should be applied
air can be extracted through the parting plane. for amorphous plastics and 0.6-0.7 tons per cm2 for
semi-crystalline polymers. In very thin walled parts
A high filling speed can cause non-uniform mould consideration must also be given to the flow length as
filling due to: the tonnage demands are higher (92, 107).
free jet formation at gate (sausage injection

moulding), which results in surface faults, and/or 5.2 Injection Unit (56, 60, 70)
splitting of the compound flow, which leads to The first aim of the injection unit is to produce a
unnecessary joint line formation, and/or homogeneous melt for the next stage where the material
enters the mould. A second important function of the
tearing loose of batches already solidified, which injection unit is the actual injection into the mould. Here,
causes a deterioration in the surface finish and it is important that injection speeds are reproducible as
usually in the mechanical properties as well. slight changes can cause variations in the end product.
The reciprocating screw piston injection unit is the most
These faults can usually be avoided by suitable common type of unit and will be the basis for further
construction design, even at high speed. discussion in this section. Thermoplastics as well as
thermosets and classical elastomers can be processed
Finally, high filling speeds can lead to uncontrolled with screw piston injection units. In most cases a general
and excessive heating of the compound, due to strong purpose screw will achieve the desired homogeneous
constrictions in runner cross-sections that are too small. melt; however some polymers run better on screws with
This is particularly the case if the working compound modified characteristics.
44
As examples, ABS and acetal require very different Screw and cylinder outfitting must be adapted to
screw configurations for optimum moulding efficiency. suit the raw material being processed. The
In cases like these therefore, running a material on a geometry of screw must be correct and the screw
non-specific screw can cause problems. Insufficient should be of a suitable corrosion resistance (e.g.,
homogeneity or mixing may result if the screw does nitride, Arbid, bimetallic).
not mix effectively, or degradation of the material and
poor performance in service life if the screw is too The dosage volume should be approx. 20-80% (41).
severe. In both cases an inferior moulding is produced.
Dosage capacity and melt capacity must be
In the screw piston injection unit, the material is sufficient for processing requirements
plasticised and dosed simultaneously. Important
parameters for these screws are: Whether a mixing cylinder (screw) is required for
use with colour additives
The diameter (D) of the screw and its ratio to the
length (L) (L/D ratio). For example a general Whether a hydraulic accumulator is necessary for
purpose screw for thermoplastics may have an L/ moulding with long lines of flow.
D ratio of 20:1, or 14:1 with thermosets, elastomers
and liquid silicone rubber (LSR).
It is the design of the screw that is most important
for plasticising.
For extended plasticising screws the L/D may be
24:1. This is usually used for thermoplastics with
The design of the screw along its length is not constant
colour additives, especially with PP and PE. This
but varies. Generally screws are designed with three
enables better mixing of the colorant. On fast cycle
distinct regions: a feed section (1), a melting transition
machines with increased capacity, a higher L/D
region (2-compression region) (2) and a metering
ratio may also be beneficial.
section (3). The size of these regions will vary
depending upon the characteristics of the material it
Shot capacity. The shot capacity is the full amount
was designed for.
as a weight or volume of material injected during
moulding from the screw. This is usually given as
a shot capacity for polystyrene, and will vary with The compression ratio can be defined as the ratio of
material. The shot size is the amount of material the flight depth in the feed section to that in the metering
required to fully fill a moulding tool. section. As an example a screw for a polyamide material
for may have a compression ratio of 3:1 on a 20L/D
screw with a 30 mm diameter.
Plasticising rate (plasticising capacity). This is the
maximum rate at which the injection unit can
deliver polymer melt. In extrusion this is a A standard compression ratio is roughly 2:1 for
continuous process. However, it should be thermoplastics, for sensitive thermoplastics such as
remembered that injection is an intermittent PVC or with metal/ceramic-powder this may drop to
process; therefore the plasticising rate will be lower. 1.6:1. Compressionless screws with a compression ratio
To calculate the melting rate consideration should of 1 are used for processing materials such as
be given to the overall cycle. elastomers and LSR.
Injection pressure. This is the force that the screw In cases where an increased mixing ability in the screw
can exert upon the plastic during filling and packing is required, such as with the use of colorants (50, 164)
of the moulded part. The larger the diameter of the there are two potential solutions: to add mixing
screw being used then the lower the injection elements or to use an extended screw design. The latter
pressure that will be available. This type of is suitable:
information can be found in machine specifications.
1. If a high melting capacity is required (raw material
To select the correct configuration of injection unit for with a high specific thermal capacity, e.g.,
a particular material or material range, consideration polyethylene, polypropylene and polyamide).
must be given to the following factors:
2. If masterbatch is used for colouring purposes and
The selection of the correct nozzle type, e.g., flat, the homogeneity of the colours is of great
radius or shut-off. importance.
45
3. If the temperature level during the moulding to pass through the system will vary depending on flow,
process must be reduced or peak temperatures must the geometry of the injection barrel and whether there
be eliminated. are areas where material can become trapped.
The combination of cylinder and screw depends on the Each plastic material has particular processing
specific case requirements. requirements in terms of barrel temperature. This will
include both the temperature range and the exposure
Mixing screws are unsuitable for long fibre materials time to the temperature. Overexposure can lead to
as they break up the fibres. For these materials a general degradation. This can be of particular importance if
purpose screw is more appropriate (29). using a small shot size on a larger machine. If residence
times are excessive, switching production to a smaller
The overall effectiveness of the plastication stage will machine is advised.
depend on the shot size, cylinder capacity, screw design,
screw speed and heater band power. It will also vary The potential barrel residence time can be calculated
from material to material. However, before the material either by experiment (1) or by taking into account the
enters the cylinder it has to pass through the hopper design of the barrel (2):
which can bring problems of its own.
(1) A common method employed to calculate the
residence time is to pour a small amount of pigment
concentrate onto the screw, once shot metering is
5.3 Feeding Hopper
complete. Moulding then re-commences, counting
each moulding produced, until the pigment becomes
Many plastics are hygroscopic and require drying
visible in the moulded part. Since the pigment will
before moulding. Large amounts of hygroscopic
probably be distributed across a number of shots, it
materials left for long periods in the hopper will soon
is the moulding having the deepest colour intensity
reabsorb water and this should be avoided. The hopper
that is used in the following calculations.
must be designed to avoid material bridging in the
throat so as to let gravity feed the material, and material
hold up spots must be avoided. With standard polymers Mean residence time =
this should not present a problem but additives, Number of shots Cycle time
especially when they are different weights to the
polymer, may tend to accumulate and be fed (2) To calculate the residence time it is necessary to
inconsistently. This can lead to variations in melt know the screw channel volume, the shot volume
quality. The hopper may contain magnets to collect and the cycle time.
metal contamination, which must be prevented from
entering the feed system (87). It may also contain grids Residence time =
to prevent large particulates from entering and blocking
the feeding system, especially important if using 0.8 x Screw flight volume
Cycle time
recyclate materials. Attention to the temperature of the Shot volume (weight/density)
hopper throat is also important, if material begins to
melt in the throat of the feeding system it may stick to
the sides and in extreme cases block the machine
completely. 5.5 Precompression of the Melt (18)
Long fibre moulding can produce its own unique A particular problem associated with thin-walled
problems (29) as these tend to be longer than standard moulding is that of the flow length which requires much
pellets and flow can be impeded by magnets. higher injection pressures to achieve filling than would
normally be required. Unlike standard injection
moulding, with thin-walled parts the cooling cycle is
not the dominant issue as cooling can occur extremely
5.4 Barrel Residence Time (19) quickly; likewise the holding phase is also of less
importance. The use of precompression enables higher
The residence time of a material is the time required flow ratios relative to the wall thickness to be achieved.
for the material to pass from one end of the plastication It works by compressing the material during the
unit to the nozzle or hot runner. This tends to be an injection stage and not opening the shut-off nozzle until
average value since in reality the time a granule takes the desired filling injection pressure has been achieved.
46
An alternative to generating sufficient pressure is to be more acute in the moulding of amorphous materials
use a pressure accumulator unit (45) to give a large since they generally require bigger gates than
and constant rate of injection force. semicrystalline materials (24, 37, 55, 61, 74, 75, 111,
123, 134). It is better to design a tool with the material
already chosen and specified so that tooling can meet
the specific demands of the material.
5.6 Check Valve
The check valve assembly is required to allow the screw

to act as a metering pump, to melt and convey the 5.9 The Mould Temperature
plastic, and as a ram, to inject the plastic into the mould.
Many materials require the use of a valve with a check The mould temperature or mould wall temperature is
ring to be fitted to the end of the screw to prevent one of the most important process parameters (142, 153).
backflow. They also help to ensure the constant cavity The mould temperature influences the shrinkage and thus
pressure discussed in Section 2.1.1 is maintained. The the dimensioning of the compound in the mould, the
most important design consideration is that they should surface finish and the orientations in the injection
avoid flow restrictions or hold up of the melt flow. Non- equipment and also, not least, the cycle time through
return valves are more prone to wear than other the cooling off time and thus the component costs.
components, so it must be ensured that suitably
toughened materials are used in manufacture. Economic quality improvement in injection moulding
is not possible without good, repeatable and uniform
temperatures in the mould. Even with a more
expensive injection process control or adjustment
5.7 The Nozzle
system, the negative influence of unsatisfactory mould
temperatures cannot usually be balanced out. If it is a
The nozzle provides the connection between the injection question of narrowing the tolerances of the
cylinder and the mould tool. Its job is to convey the components, the first step is to check the mould
material with minimal pressure or heat change. temperature data. A prerequisite is the measurement
of the mould temperature.
The nozzle itself may not necessarily be made of just
one piece. A tip that is screwed into the nozzle body can The optimal mould temperature level is a parameter
be replaced or repaired. This may need to be an abrasion specific to the material and should be obtained from
and corrosion resistant tool steel tip. For optimum flow the plastics manufacturer.
conditions, there must be no material hang-ups.
Therefore the flow must be streamlined. The land length
High mould temperatures cause the component to cool
is generally kept to a minimum dictated by the strength
slowly, which is necessary, for example, with the
requirements. For high pressure applications an increased
majority of semicrystalline thermoplastics, in order to
flange diameter may be required.
obtain components that are to size and have constant
dimensions. The crystallisation of these compounds must
It is essential that the temperature of the nozzle be be completed in the mould, i.e., it must be over before
controlled. The location of the heating and control is the components are ejected from the mould. Otherwise,
equally important else material degradation or aftercrystallisation occurs over the course of time, which
premature material freezing (cold slugs) may occur. A in every case causes alterations in dimensions, and
thermocouple can be used close to the gate and heater. frequently leads to warping of the component.
Thermocouples may also extend into the melt rather
than measuring the temperature of the nozzle.
High mould temperatures improve the flow behaviour
of the compound in the mould, and the injection
pressure requirements are lower. The surface finish of
5.8 The Feed System the components improves. High mould temperatures
break down orientations that arise during the filling of
The design of the feed system must be suitable for the the mould, and there are thus fewer orientations in the
material being moulded. This includes gates, runners moulded component.
and sprues. For example an insufficient gate depth can
cause considerable moulding problems such as short The upper limit for the mould temperature is
shots and increased cycle times. This problem tends to determined by the maximum temperature at which
47
the components can be ejected from the mould, which Satisfactory results can only be obtained from mould
is specific to each material, e.g., for amorphous temperature control if the performance of the
thermoplastics it lies at least 10 C below the freezing temperature control unit is suitable for the quantities
temperature. High mould temperatures lead to slower of heat to be exchanged in the mould. For example,
cooling, which means longer cooling times, and if the temperature control unit not only operates
therefore longer cycle times, and thus they make the basically well, but also sufficiently rapidly, so that
injection equipment dearer. only slight temperature variations occur in the mould
(38, 125, 136, 149).
Thus in the selection of the mould temperature level,
a choice often has to be made between higher quality Unfortunately, the transmission pressure on a
and a more favourable price for the components. A number of temperature control units on the market
semi-optimum temperature level will very often lead today is insufficient. A safety valve is frequently built
to an economically acceptable solution. into such units, which opens a parallel circuit within
the unit, once a limiting pressure has been exceeded.
The level of the mould temperature influences the Unfortunately this is not always noticeable to the
shrinkage, and thus the later dimensions of the user. Only a fraction of the flow delivery then flows
through the mould, and the temperature control
component. Local temperature differences can cause
suffers accordingly. Naturally, the flow resistances
parts to warp (27). Mould temperatures that do not
of the temperature control circuits should be kept as
remain the same from batch to batch lead to
low as possible. To this end, there should be
dimensional variations through varying shrinkage.
sufficiently thick hoses, as short as possible, between
Uniformity has two aspects here the spatial
the temperature control unit and the mould. The
temperature distribution in the mould and the temporal
temperature control channels in the mould must be
temperature behaviour in the production cycle.
of suitable dimensions.
Uniform temperature distribution in the mould is It is also important that the heat transfer ratios on the
essentially dependent upon the mould temperature walls of the temperature control flues do not
system. Adequate and uniform temperatures are of deteriorate over the course of time. The temperature
importance, not only in relation to the warping control channels must be suitably maintained and must
tendency, but also for economic reasons from the point be checked for cleanness after each mould change at
of view of the unit time. It is necessary to wait until least. If water is used for temperature control, then
even the hottest part of the component has cooled special attention must be paid to rust deposits and also,
enough before ejecting the component from the at higher temperatures, to scale formation.
mould. Thus, a uniform intensity of temperature
becomes a pre-requisite for economic manufacture. Most information concerning the injection process
With cores, when adequate temperature patterns often cycle can be supplied by a temperature measurement
cost more to achieve, there are often signs of omission point mounted directly in the moulding nest wall
in the mould design. The mould certainly becomes (mould wall temperature). During the cycle, this
cheaper then, but it means that a substantial increase temperature value can be observed during the
in the cycle time often up to 100% and more must compression phase and a lower value during ejection.
usually be taken into account. The lower value can give a good guide for the
ejection temperature. A measurement point position
The temperature systems must be matched to the like this is not suitable for regulating the mould
mould as regards their production capacity, i.e., they temperature, because of the temperature variations
must be in a position to supply or extract the necessary that occur here. The temperature gauge should
amounts of heat sufficiently quickly. In order to therefore be sufficiently far away from the mould
guarantee a repeatable, uniform temperature wall, so that at the measuring point the temperature
distribution in the mould, even after a change of mould variations have already been sufficiently dampened.
or a refit, the inlet and outlet paths of the temperature But it should also be an adequate distance away from
control fluid at the mould must be unambiguously the temperature control channels, so as to exclude
marked. If the connections are mixed up, this will reverse effects from this side.
certainly alter the temperature conditions, which,
admittedly, need not always have a negative effect, If no fixed temperature measuring point is
but which can often lead to substantial deterioration, incorporated in the mould, it is possible, to use probe
especially in cooling cores. thermometers as an aid. To carry out any
48
measurements in the cavity, you will be forced to 5.12 General Information on Wear and Tear
interrupt the cycle. The negative effects, which thus
arise on the security of measurement and the Whilst the importance of everyday machine
production cycle must not be left out of maintenance should not be underestimated (137, 144),
consideration. But in no case should the there are also several causes of wear and tear including:
measurement of the mould temperature at least at
one specific comparison point or reference point incorrect adjustment of process parameters, e.g.,
be neglected. back pressure too high, dosage speed too high, no
dosage delay, incorrect adjustment and setting of
A sufficiently uniform spatial temperature temperatures for plasticising cylinder and feed yoke.
distribution can be obtained in the mould if the inlet
and outlet temperatures of the temperature control wear and tear generated by raw materials, e.g.,
medium do not differ by more than 5 C from one mechanical wear caused by fibre glass, glass
another. In order to achieve this, a sufficiently high spheres, stone powder, metallic powder, ceramic
throughput volume of the temperature control powder (31, 36, 79).
medium is required.
chemical corrosion, e.g., with additives, flame
resistant materials, materials containing fluorides.
5.10 The Importance of Adequate Venting
There are several ways to determine any mechanical
An important design aspect of injection mould tooling wear and/or chemical corrosion. Mechanical wear can
is the need to provide vents for compressed air and be seen by grooves and surface abrasion in one
gases to escape during moulding (13, 46, 82). Trapped direction. Chemical corrosion can leave large and small
air and gases can cause a variety of moulding defects holes in different areas and directions as well as surface
which are more fully described in Section 2. To remove deposits. To determine the wear of the screw and barrel
such defects it is common practice to slow down consideration must be given to the original heat
injection to give air a chance to escape. However, a treatment method used. With nitride and Arbid methods
reduction in injection speed may cause other problems the surface thickness can be measured. With bimetal
such as insufficient packing, to leave sink marks. outfitting the surface can be examined. Generally if
the heat treated surface has worn down this signifies
Common venting methods are to provide parting line that the units have worn out.
vents, vent plugs and pins. More recent developments
include the use of porous metals that allow gas to escape There are ways to minimise wear and tear on the
but not the polymer. These materials also often allow injection units by use of proper process parameter
for the venting area to be increased. As a general rule, adjustment, the correct selection of barrel and screw
runner vents tend to be deeper than part vents and depend for the job and suitable heat treatment outfitting. Unit
on the material being used in the moulding process. Vents hardening treatments include nitride, Arbid, BMA,
should be placed near weld lines and near the last areas BMK, VSX, PH and PK.
of the cavity to be filled and should be located on the
mating surface of one of the mould halves.
6 Conclusion
5.11 Multi-Cavity Moulds
Successful troubleshooting of injection moulding
There are a large number of variables in injection should begin not when a defect part is produced on
moulding, as can be seen from the examples previously the shop floor but when a part is conceived at the
introduced. Multi-cavity tools present even more of a design stage. With consideration for correct mould
challenge due to both shot to shot variations (119) and design, ideally constructed for use with the materials
cavity to cavity variations (30, 42, 138, 282). Mould of choice in mind, a large number of potential pitfalls
variations can be caused by shear induced flow are instantly eliminated.
imbalances which occur even in balanced runners.
Different cooling effects across the mould and Likewise on the production shop floor, care and
mouldings of different physical sizes can also cause maintenance of machinery and tooling is paramount
imbalances in mouldings. for an efficient moulding environment. The choice of
49
suitable equipment for the job at hand, such as machine

size and screw configuration further reduces potential
problems, as does attention to preparation of materials
and processing recommendations from material
manufacturers which are readily available.
Once production has commenced, attention can

therefore be focused on optimising the machine
parameters based on the experience of the machine
setter, ensuring that major costly downtimes can be
minimised or avoided altogether.
Abbreviations and Acronyms
ABS acrylonitrile-butadiene-styrene
CA cellulose acetate
L/D length/diameter
LSR liquid silicone rubber
MFI melt flow index
PA polyamide
PBTB polybutylene terephthalate
PC polycarbonate
PE polyethylene
PMMA polymethyl methacrylate
PP polypropylene
RPM revolutions per minute
SAN styrene-acrylonitrile
50
References and Abstracts
Abstracts from the Polymer Library Database
Item 1 WELD LINES? WHAT WELD LINES? GETTING

Injection Molding BETTER APPEARANCE FROM METALLIC
12, No.2, Feb.2004, p.32-4 PIGMENTED MOULDINGS
MATERIALS ANALYST: PART 61. THE Wheeler I R
EQUIVALENCE OF MATERIAL PROPERTIES Silberline Ltd.
AND DESIGN (Rapra Technology Ltd.)
Sepe M
Metal flake pigments are an increasingly common constituent
Dickten & Masch Mfg.Co.
of moulded plastics. Unfortunately, due to their asymmetric
When a product fails to perform as expected, the problems shape, their use can make weld lines significantly more
can always be traced to shortcomings in one or more areas: visible in the moulded article. Recent work to establish the
tool design, part design, material selection and processing. degree to which the severity of weld lines may be reduced
A table illustrates a general scheme for determining the role by judicious choice of pigment type, loading and injection
of design, material property and application environmental moulding machine parameters is discussed. It is briefly
influences on part performance. Highlighting the distinction shown why metal flake pigments make weld lines more
between brittle and ductile behaviour is useful because when prominent than other pigment classes. This is followed by
products fail, it almost always involves an unexpected illustrations of the nature of the problem and a description
manifestation of brittle behaviour. A case study is presented of a purpose-built injection moulding tool. Systematic
involving products moulded from HDPE. A small percentage changes to pigment particle size, shape and concentration,
of the parts cracked when placed under the flexural load plus moulding machine parameters, chiefly temperatures,
that was a normal part of use. Failure occurred at a design injection speed and injection and holding pressures are
feature that contained a sharp corner. It is shown that covered, and, finally, the effect of polymer transparency and
increasing the radius in a corner detail has the same effect as polymer melt flow index are considered. Observations made
the manipulations to material properties. during the study are brought together to demonstrate synergy
USA capable of virtually eliminating visible weld lines in many
Accession no.906380 formulations. 15 refs.
EUROPEAN COMMUNITY; EUROPEAN UNION; UK;
WESTERN EUROPE
Item 2 Accession no.905532
Kunststoffe Plast Europe
93, No.11, 2003, p.23-4
GETTING THE COMBINATION RIGHT Item 4
Hickmann T; Klemp E Injection Molding
Eisenhuth GmbH KG Praezisionsformenbau; Bosch- 11, No.13, Dec.2003, p.62-3
Siemens Hausgeraete GmbH TROUBLESHOOTER PART 63: MASTERING
CYCLE TIME ESTIMATION
Problems in the production of injection moulds are Hatch B
discussed and it is shown that none of the standard mould- Prime Alliance Inc.
making techniques combines the requirements for rapid,
flexible, inexpensive and durable mould production. The This article discusses cycle time determination. A good place
possibility of combining the various standard processes to start is with a cooling rate chart that sets out how long it
with new ones is examined and hybrid moulding is takes for the material being moulded to go from a fluid to a
described. A hybrid mould consists essentially of metal/ solid at a given wall thickness. The cooling rate, plus the
laser-sintered mould inserts and steel inserts produced time to inject the plastic, open and close the mould, and add
from standard mould frames and elements by high-speed in any insert loading or other operator activities will add to
cutting. (For graphs/tables, see German version in the cycle time. A cycle time estimation programme was
Kunststoffe, ibid, p.60/3) included as part of IDES Costmate part quoting programme
EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; and is a very useful tool. The accuracy of cycle time
WESTERN EUROPE calculations depends on an optimised mould: correct barrel
Accession no.905724 heats, injection pressures and mould temperatures.
USA

Addcon World 2003. Proceedings of a conference held
Vienna, Austria, 21st-22nd Oct.2003. Item 5
Shawbury, Rapra Technology Ltd., 2003, Paper 19, Injection Molding
p.167-86, 29cm. 012 11, No.13, Dec.2003, p.42-5
Copyright 2004 Rapra Technology Limited 51

MATERIALS ANALYST: PART 60 Item 8

Sepe M Asian Plastics News
Dickten & Masch Mfg. Sept.2003, p.33-4
English; Chinese
Frequently when a part fails, a client will focus on one of
FEED SYSTEM TOO SMALL
two issues: moisture in the raw material at the time of
Wilkinson R; Poppe E A; Leidig K; Schirmer K
melt processing or use of regrind. Poor control over either
DuPont
of these factors can result in degraded polymer, resulting
in brittle behaviour in the material and the possibility of Parts made of engineering polymers nowadays are
failure. In spite of all the impressive analytical tools that designed with the help of complex methods such as CAD,
can be brought to bear on a problem, reconstructing the finite element analysis and mould-flow calculations.
moisture content or the regrind content in the raw material Though useful, they sometimes fail to take enough
at the time a part was moulded is not possible. account of the importance of the correct design of the
USA feed system. This article considers the basic elements of
Accession no.904734 correct feed system design for semi-crystalline polymers.
These elements need to be applied in combination with a
correctly positioned gate and the right hold time.
Item 6
USA
Asian Plastics News
Nov.2003, p.33-4 Accession no.895731
English; Chinese
HOLD TIME TOO SHORT Item 9
Wilkinson R; Poppe E A; Leidig K; Schirmer K Kunststoffe Plast Europe
DuPont 93, No.7, 2003, p.30-1
In practice, many injection moulders, working from their ABSOLUTE TRANSPARENCY
experience of amorphous polymers, tend to use shorter hold Cuttat K P
pressure times and longer cooling times. Unfortunately, The use of insulated hot runners for gentle processing of
this approach also tends to be used for semi-crystalline thermally-sensitive moulding compounds is discussed. It
polymers such as POM, PA, PBTP and PETP. This article is shown that transparent speck-free polycarbonate cups
discusses the most important points to help machine setters can be manufactured using a two-cavity, hot runner
choose the most suitable hold pressure time. injection mould. The selection of runner system is
USA considered and it is demonstrated that closed hot runner
Accession no.900917 manifold blocks are generally unsuitable for processing
thermally sensitive transparent polymer melts. The
necessity of avoiding flow shadows in the melt, as these
Item 7
result in a high reject rate due to trapped degradation
Injection Molding
products, is emphasised and the use of the flow-
11, No.12, Nov.2003, p.67
promoting, insulated hot runner is shown to avoid this
EJECTOR DESIGN CURES HANGUPS IN
problem. (For tables, see German version in Kunststoffe,
ELASTOMER SPRUES
p.62-4)
Neilley R
EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY;
The use of materials like thermoplastic elastomers and WESTERN EUROPE
liquid silicone rubber is steadily growing. Their flexibility Accession no.895365
and elasticity, which make these materials logical choices
for applications such as housing seals and grips, can be
Item 10
anything but an advantage when a traditional gate design
Injection Molding
is used to effect automatic separation of the sprue from
11, No.9, Aug.2003, p.67-9
the part during demoulding. Elastomeric material can be
TROUBLESHOOTER PART 61: CARING FOR
stretched out of the conical undercut of the tunnel gate
HOT RUNNER SYSTEMS
when the intention is to hold it there firmly. The entire
Hatch B
sprue can thus remain stuck inside the sprue bushing on
Prime Alliance Inc.
the nozzle side. Arburg has come up with a specific design
for a sleeved ejector pin that solves the problem. So far, this series of articles has worked its way through
Undercuts on the ejector pin tip hold the elastomer as the the five basic elements of troubleshooting an injection
mould opens. moulding problem: nozzle, sprue, runner, gate and vents.
ARBURG GMBH Connected with the nozzle section are the problems most
EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; commonly associated with heated sprue bushings and hot
WESTERN EUROPE runner systems. First of all, the moulding machine nozzle
Accession no.900892 must be drilled out or opened to match the flow tube
52 Copyright 2004 Rapra Technology Limited

diameter of the heated sprue bushing or hot runner Item 13

manifold. Problem number two is gate sizing and the Injection Molding
relationship of the diameter to the angle of the taper. Many 11, No.7, June 2003, p.88/92
moulding problems associated with heated sprue bushings TROUBLESHOOTER PART 60: VENTING
or hot runner systems, such as hard-to-fill parts, flashing Hatch B
of mould vents and material additives plating out on the Prime Alliance Inc.
core of the mould, are connected to improper sizing of
The runner and each cavity must be vented extremely
the material flow path. Equally as important as sizing the
well in order to get rid of the air in the runner channels
flow path is following the correct design according to the
and in the part cavities. Runners are vented at the sprue
gate type selected.
puller and at the end of each runner. Part vents can be
USA
individual or perimeter types. Blind pocket vents are also
Accession no.894427 discussed.
USA
Materials World
11, No.8, Aug.2003, p.18-20
Item 14
LIVING IT LARGE: INJECTION MOULDING
AIRCRAFT CANOPIES
93, No.3, 2003, p.70-1; p.A73-5
Cleevely S T
English; German
The first injection moulded polycarbonate canopy will SAFELY WARP-FREE
take to the skies later this year aboard the US Air Forces Budinger M; Sundermann M; Reisinger A
T-38 training jet. Moulded windshields for the F/A-22 Resin Express GmbH; Coko-Werk GmbH; Butz-Ieper
will be tested and flown in 2004. EnviroTech, Boeing Automotive GmbH
and the Air Force have succeeded in manufacturing
Top of the range vehicles must be fitted out with a luxurious
aircraft transparencies with the required thickness (up to
but practical interior. For winter holidays, this includes the
66mm thick), structural properties and optical clarity. The
facility to easily stow two pairs of skis in a limousine
first optically-correct part was made in January 2003,
without compromising passenger comfort, road behaviour
following the development of a new method to polish the
and the vehicles exterior appearance. The BMW 7 series
moulds. The two-stage bulk injection moulding process
accommodates this need by means of a ski bag integrated
can produce a canopy every hour. One of the most
challenging tasks was to in-mould the large fixing inserts. into the rear seat backrest, with a lockable loading hatch
This was a major factor in reducing the assembly time of integrated into the centre armrest. The ski bag, developed
the canopy to the aircraft fuselage. and supplied by Butz-Ieper Automotive of Langenfeld,
Germany consists of a cover with a sliding frame in the
ENVIROTECH CORP. boot and an open panel with cover in the rear-seat backrest.
USA
The folded ski bag is accommodated in the interspace that
Accession no.892425 this creates. With the armrest folded down, the panel in the
rear-seat backrest becomes accessible. The ski bag can be
Item 12 drawn out after the cover in the panel is opened. The
Plastics Technology injection moulded parts of the cover and panel are made of
49, No.7, July 2003, p.46-7 ABS Magnum from Dow, supplied by Resin Express.
INJECTION MOLDING TROUBLESHOOTER - Mould design was supported and verified by simulation of
AVOID COMMON MOLD SET-UP MISTAKES mould filling and warpage. Because of this preliminary
Lamb D; Andrist B work, the product could go into mass production rapidly
Donnelly Custom Manufacturing Co. and with no start-up problems.
This article is one of a series of troubleshooting reports EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY;
WESTERN EUROPE
relating to injection moulding. This one deals in particular
with the mistakes most commonly made when setting up Accession no.889375
the mould. Six tips are offered from a company which
has mastered the art of smooth mould-changeover, Item 15
Donnelly Custom Manufacturing: avoid unnecessary Growing Thermoset Technology in a Competitive
idling, organise mould storage, follow a check-list, World. Proceedings of a conference held Research
commit to training, communicate effectively, and dont Triangle Park, NC, 11th-12th March 2003.
neglect maintenance. Brookfield, Ct., SPE, 2003, p.79-84, 27 cm, 012
INTERNATIONAL PLASTICS CONSULTING CORP. THERMAL INSULATION IN THE THERMOSET
USA MOLDING. INTRODUCTION
Accession no.891010 Polito J

Albany International Corp. cause of these variations, thus causing long-term issues
(SPE,Thermoset Div.; SPE,Piedmont Coastal Section) throughout the production life. A new mould
commissioning strategy and recent advancements in
Thermal insulation, as it is used in thermoset moulding,
melt-management technologies help to correctly
is examined. The basics of insulation theory are described,
diagnose and quantify these variations and minimise the
through to addressing problems facing moulders today.
overall part-to-production lead time. 5 refs.
Comparisons are made between the different materials
USA
commonly used, showing their advantages and
disadvantages. In conclusion, a moulding insulation case Accession no.889307
study of a large manufacturer showing its problems, its
needs, the solution chosen and the benefits realised are Item 17
presented. Some company information is included on Popular Plastics and Packaging
Albany International, explaining who the company is, 48, No.5, May 2003, p.56-62
what it does, where its technology comes from, and where STACK MOULDS
it gets its expertise in thermal insulation. An overview is Batra R C
presented of insulation theory, together with a study of
different insulation materials, showing benefits of The problem facing a plastics processor was production
insulation. The thermal/mechanical requirements in of a large number of two-part disposable syringes on a
industrial applications and the tradeoffs made to achieve 60 ton injection moulding machine, having a shot weight
an acceptable balance are addressed. A specific study is of 110g in PP. Whereas it was possible to run a 24 cavity
outlined of materials commonly used today in thermoset mould for the syringe barrel satisfactorily - both the
moulding (primarily glass fibre-reinforced polyester and clamping force and shot weight were adequate - the mould
calcium silicate), showing their advantages and for the plunger could contain only 12 cavities because of
disadvantages. Pyropel is introduced, with direct the large projected area of the product, as placed in the
comparisons and explanations of the benefits it brings to mould. The moulding weighs only 2g, with a projected
moulders. A case study from a Honeywell thermoset area of 9 sq.cms. The solution was to use a 2x12 cavity
moulding facility is presented. stack mould. The accompanying design diagrams depict
all important features of the stack mould.
USA
Accession no.889308 WESTERN EUROPE
Accession no.887268
Item 16
Growing Thermoset Technology in a Competitive
Item 18
World. Proceedings of a conference held Research
British Plastics and Rubber
Triangle Park, NC, 11th-12th March 2003.
April 2003, p.18-9
Brookfield, Ct., SPE, 2003, p.65-78, 27 cm, 012
PRECOMPRESSION PREVENTS PROBLEMS IN
MELT MANAGEMENT TECHNOLOGIES & A
THIN WALL MOULDING
MOLD COMMISSIONING STRATEGY: TOOLS
DESIGNED TO REDUCE LEAD TIME Thin wall moulding has been adopted increasingly in
Hoffman D A recent years for packaging and also for technical
Beaumont Runner Technologies Inc. mouldings used in electronics. Netstals Applications
(SPE,Thermoset Div.; SPE,Piedmont Coastal Section) Department has carried out a series of comparative tests
into thin wall moulding focusing on the precompression
Competition within the plastics industry is growing
technique in which the compression of the melt is
fiercer every day. As a result, the demand for faster part-
disconnected from the injection phase. Melt
to-production lead times also continues to grow. Lead
precompression enables higher ratios of flow length to
times for new mould builds have decreased drastically
wall section - thinner walls can be filled safely.
over the past few years for a number of reasons.
However, all too often a great deal of time and money is NETSTAL
spent on sampling and debugging the mould and the WESTERN EUROPE
moulding process to produce acceptable product during
Accession no.886151
initial mould commissioning. The end result is typically
a part-to-production lead time increase of weeks to
months due to the problems experienced during the Item 19
mould commissioning stage of the production process. Injection Molding
These hindrances are often caused by cavity-to-cavity 11, No.4, 15th April 2003, p.50-1
variations hidden inside the mould. These variations take MATERIAL ANALYST. 57. HOW STABLE IS
a large amount of resources (including toolmakers, YOUR MATERIAL? II
processors and engineers) to diagnose and try to correct Sepe M
them. Often the proposed solutions do not solve the root Dickten & Masch Mfg.

The last article (part 1, ibid, March 2003) ended with a Item 21
brief discussion of materials that can degrade by either Revista de Plasticos Modernos
prolonged exposure to elevated melt temperature or the 83, No.550, April 2002, p.378/83
presence of excess moisture during processing. Polyesters, Spanish
polycarbonates, PUs and polyamides are the material RAPID APPROXIMATION TO AUTOMATIC
families of greatest concern. Not coincidentally, these are RUNNER BALANCING
the materials that fail with the greatest frequency due to Chen K C; Chang R Y; Hsu D C; Lin A S; Lu K
process-induced degradation. When these failures occur, a Yue Ki Industrial Co.Ltd.; National Tsing Hua
variety of methods that measure average molecular weight University; CoreTech System Co.Ltd.; Takaotec Corp.
can verify that degradation has occurred. However, with The flow balance index concept is proposed as an
greater emphasis placed on root cause analysis, it has approach to solving the problem of runner balancing for
become increasingly important to determine the exact multi-cavity injection moulds. An algorithm based on this
mechanism that produced the degraded polymer. While the concept is introduced, and its use with the Moldex-Expert
mode of degradation can sometimes be determined from computer aided engineering software developed by
IR spectroscopy, experience has shown that degradation CoreTech System is described. 3 refs.
must be significantly advanced before the IR spectrum will TAIWAN
show signs of the chemical modifications that can
Accession no.884062
distinguish between thermal and hydrolytic degradation.
In addition, the root cause is not always an either/or
proposition. Often excessive heat and moisture levels work Item 22
together to produce an effect that neither factor alone could. Polimery
However, with all of the materials mentioned above, one 48, No.2, 2003, p.100-5
factor is usually more important than the other. Actual Polish
experimentation using the moulding process and a simple SOME PROBLEMS OF POLYMER FLOW IN
method for evaluating the moulded parts can verify which INJECTION MOLD
factor is most critical. This knowledge, in turn, can be Sikora R; Bociaga E
translated into a control plan for preventing further Lublin,Polytechnic; Czestochowska,Politechnika
difficulties. Emphasis is placed on the moulding of PETP Descriptions of liquid polymer flow in injection mould
and PBTP with 30% loadings of glass fibre. channels in the literature are reviewed. The flow is shown
USA to be unstable and non-isothermal. The symmetrical model
Accession no.884535 is generally used to describe it, although this model is
true only under determined stable conditions. When
thermal or kinetic conditions at both sides of the channel
Item 20 vary, e.g. because of the differences of temperature or
Injection Molding surface roughness, thermokinetic flow asymmetry occurs.
11, No.3, March 2003, p.61-2 This asymmetry may also be caused by the change of
ADDITIVE ADDS EFFICIENCY PRECISION TO flow direction in the channels, e.g. in the area where the
EDM sprue joins the runner or in the cavities with inserts, bosses
Deligio A and ribs. In multicavity moulds, the polymer stream can
Makinos Die/Mold Technologies Group was working change direction several times, leading to non-uniform
with a client on a speaker grille application. Created using filling of cavities. The weld line areas are also areas of
EDM, the grilles tool, a P-20 mould with a hardness of polymer flow disturbances. Asymmetrical and non-
40 Rockwell C and a cavity perimeter of 12 x 18 in., was uniform flow affects the injection moulding efficiency
moulding parts reluctant to release despite a Teflon-nickel evaluated on the basis of determinations of functional
coating, lapping compound and wire-brush treatment, and properties and surface qualities of moulded parts. 32 refs.
a mould release application prior to every shot. In addition, EASTERN EUROPE; POLAND
the final step in the parts 72-second cycle involved a Accession no.882166
worker gingerly extracting it from the mould by hand
while trying not to cause any distortion or warpage. The Item 23
customer only had one description of this step for the Popular Plastics and Packaging
company - it was like peeling the skin off an orange. 48, No.3, March 2003, p.72-4
Peeling an orange can be a tedious, difficult process. TIPS FOR PLASTICS PROCESSORS - PART 2
Peeling a part proved equally time-consuming, and costly. Kulshreshtha A K
Scrap rates ranged from 30-40%. The methods employed Indian Petrochemicals Corp.Ltd.
in order to overcome this problem are described. This article discusses the causes of warpage in injection
MAKINO DIE/MOLD GROUP moulded products and the minimisation of weld lines.
USA INDIA
Accession no.884517 Accession no.881723

Item 24 the flow front, and out of flow mark regions were
Injection Molding associated with the walls closer to the flow front.
11, No.2, Feb.2003, p.44/6 Droplets of the dispersed phase were stretched into
TROUBLESHOOTER. LVIII. SIZING RUNNERS strands in the out of flow mark regions, the strands
Hatch R retracting on the way to the flow mark regions. Under
Prime Alliance certain conditions, the retraction was arrested by sheer
A method for sizing a runner, based on the type of material induced folding of the strands. It is proposed that the
being used, the wall thickness and the number of cavities, component rheologies maybe controlled to minimise the
is presented. Data are given on runner diameters in a onset of flowlines. 12 refs.
balanced mould for amorphous materials and USA
semicrystalline materials. It is shown that full-round Accession no.878320
runners are the best design for any gate, but half-round
or trapezoidal runners can be used with subgates. Item 27
USA ANTEC 2002. Proceedings of the 60th SPE Annual
Accession no.881165 Technical Conference held San Francisco, Ca., 5th-9th
May 2002.
Item 25 Brookfield, Ct., SPE, 2002, Paper 469, Session T45-
Materials World Injection Molding Student Session, pp.5, CD-ROM,
11, No.2, Feb.2003, p.32-3 012
SEEING IS BELIEVING - PLASTIC LENSES ROLE OF SIMULATION AND COMPUTER
FASTER AND WITH FEWER REJECTS AIDED ANALYSIS IN INJECTION MOLDED
PRODUCTS
Producing lenses for ophthalmic correction is one of the Adetunji P
most demanding procedures an injection moulding RMIT University
machine can be asked to perform. However, advances by (SPE)
Krauss Maffei in machine design have created a process
that is faster and produces fewer rejects. The innovative Injection moulded, rubber-modified polypropylene car
development showcased at last years K show in Germany mudguards exhibited variable surface finishes on either
could be set to revolutionise the production of optical side of a mark which resembled a weld line. To cure this
lenses in terms or quality and productivity. fault, injection moulding simulation software was used
to study the flow pattern during mould filling. It was
KRAUSS-MAFFEI AG
EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; shown that the fault was associated with different
WESTERN EUROPE shrinkages and degrees of crystallisation in different parts
Accession no.880378 of the product, caused by different flow rates and cooling
rates, arising from significant differences in product
thickness. Further simulations showed that a more
Item 26 uniform flow would result from a reduction in thickness
ANTEC 2002. Proceedings of the 60th SPE Annual difference from 1.3 to 0.5 mm, and a more gradual
Technical Conference held San Francisco, Ca., 5th-9th thickness transition. Implementation in production solved
May 2002. the surface appearance problem, and also reduced
Brookfield, Ct., SPE, 2002, Paper 485, Session T48-
materials consumption by 30% and reduced the cycle time
Alloys & Blends. Morphology Development, pp., CD-
by reducing the cooling time. 5 refs.
ROM, 012
AUSTRALIA
ANALYSIS OF TIGER STRIPING IN INJECTION
MOLDED TPO Accession no.878304
Jayaraman K; Papworth P; Shu C; Wolkowicz M D
Michigan,State University; Basell Polyolefins Item 28
(SPE) ANTEC 2002. Proceedings of the 60th SPE Annual
Alternating dull and glossy bands (tiger striping) on the Technical Conference held San Francisco, Ca., 5th-9th
surface of injection moulded components of two May 2002.
thermoplastic olefins (TPOs - blends of polypropylene Brookfield, Ct., SPE, 2002, Paper 468, Session T45-
and ethylene-propylene rubber) was investigated. Short Injection Molding Student Session, pp.4, CD-ROM, 012
shots from a standard tensile bar mould were sectioned INVESTIGATION OF STRESS CRACKING AND
and etched to remove the ethylene-propylene rubber FATIGUE FAILURE IN TWO-SHOT CAVITIES
phase, and the particle size, shape and distribution of the USING FINITE ELEMENT ANALYSIS
near wall dispersed phase determined. Asymmetric flow Camlin D D
was observed, with the flow front oscillating between the Pennsylvania,State University
walls. Flow marks formed along the walls furthest from (SPE)

Commercial finite analysis software was used to establish a result, manifolds manifolds may combine level changes
the cause of cracking in injection moulding H-13 tool at various branches within H or X branching patterns
steel cavity blocks. It was shown that the stresses arising to accommodate geometrical balances between cavities.
from contact with the valve gauge tip were sufficiently Despite the fact that hot runners use the geometrically
high to result in fatigue failure, and that the calculated balanced design, far too often a mould filling imbalance
location of maximum stress corresponded with the still exists. The results of a study demonstrating that a
observed crack position. major cause of flow imbalance in multi-cavity hot runner
USA moulds is the result of shear induced melt variations
Accession no.878303 created when flow is split at a runner branch are presented.
It is also shown how these shear induced variations can
be managed to achieve both balanced filling and balanced
Item 29 material properties in cold runners, hot runners and stack
Plastics Technology moulds. 6 refs.
49, No.1, Jan.2003, p.40-1
USA
INJECTION MOLDING TROUBLESHOOTER -
COMMON MISTAKES IN LONG-FIBER Accession no.877751
MOLDING
Miklos M; Gregory R Item 31
LNP Engineering Plastics Inc. Plastics Conference 2002. Proceedings of a conference
held Harlington, Tx., 21st-22nd Oct.2002.
This article is part of a series on injection moulding
Brookfield, Ct., SPE, 2002, Paper 4, p.1-11, 27 cm, 012
troubleshooting, and looks in particular at the moulding
COATINGS AND FINISHES FOR MOLD REPAIR
of long-fibre reinforced plastics, and eight commonly-
AND MAINTENANCE
made mistakes in this field: rough-and-tumble conveying,
Bales S
built-in clogging and bridging, too-small loaders,
Bales Mold Service Inc.
maintenance-prone filters, undersized injection units,
(SPE,Moldmaking/Mold Design Div.)
wrong screw, long narrow nozzles, and restricted flow
paths in the mould. Customer demands for shorter delivery times and
USA increased production, while maintaining high quality,
Accession no.878078 makes planning for maintenance or repair essential for
every successful mould making and moulding operation.
There are many important differences between finishes
Item 30 and coatings for moulds. Aspects covered include how
Plastics Conference 2002. Proceedings of a conference finishes affect lubricity, increase in production by pairing
held Harlington, Tx., 21st-22nd Oct.2002. effective finishes with precision protective coatings, how
Brookfield, Ct., SPE, 2002, Paper 5, p.1-11, 27 cm, 012 and when protective coatings should be used as wear
ADVANCES IN HOT RUNNER TECHNOLOGY indicators for optimum maintenance and mould aid
Beaumont J P; Hoffman D performance, and the more effective use of plating build-
Penn State University; Beaumont Runner Technologies ups. The objective is a greater understanding of the latest
Inc. finishing and coating technologies that will ultimately
(SPE,Moldmaking/Mold Design Div.) them meet tighter production deadlines with fewer
The use of hot runner systems can often have advantages problems and improved productivity.
over cold runner such as less material scrap or the USA
elimination of regrind, less tonnage required, and more Accession no.877750
versatile gating locations but they also introduce
additional variables to an already complicated injection
Item 32
moulding process. These added variables create more
Polymer Engineering and Science
challenges and generally require higher skilled personnel.
42, No.12, Dec.2002, p.2471-81
These variables also complicate the ability to identify the
DEVELOPMENT OF RAPID HEATING AND
true source of problems, such as mould filling imbalances,
COOLING SYSTEMS FOR INJECTION
when they do arise. Although fishbone or tree runner
MOLDING APPLICATIONS
layouts are occasionally used, most hot runner manifolds
Yao D; Kim B
are designed with more conventional geometrically
Oakland,University; Massachusetts,University
balanced designs to achieve uniform mould filling. In
many cases these layouts may be similar to those used in A novel method for alleviating thermal stress problems
cold runner moulds. However, as the runner does not have in injection moulding by utilising rapid heating and
to be ejected between cycles, the hot runner manifold cooling systems consisting of a metal heating layer and
provides more opportunities to improve upon the an oxide insulation layer with closely matched low
geometrically balanced methods used in cold runners. As thermal expansion coefficients is described. The effects

of various design parameters, such as layer thickness, line on the surface causes visible defects and requires post
power density and material properties, on the performance processing like painting to hide weld lines. Besides, weld
of mould inserts are explored with the help of heat transfer line also affects mechanical properties, such as tensile or
simulation and thermal stress simulation and rapid thermal impact strength. Many engineers have examined the
response mould inserts capable of raising temperatures dominant processing parameters and tried to improve the
from 25 to 250C in 2 seconds and cooling to 50C in 9 characteristic of the weld line by various methods. Details
seconds are constructed. 6 refs. are given of a new injection process, designated MmSH
USA (momentary mould surface heating), which can raise the
Accession no.876643 mould temperature over 200 deg.C with the usual cycle
time. The influence of MmSH on the visual characteristics
Item 33 of weld line is investigated. Weld line tensile strength is
ANTEC 2002. Proceedings of the 60th SPE Annual examined for samples from the process. 6 refs.
Technical Conference held San Francisco, Ca., 5th-9th KOREA
May 2002. Accession no.873707
Brookfield, Ct., SPE, 2002, Paper 306, Session T13-
Mold Making and Mold Design. Advances In Hot Item 35
Runner Technology, pp.4, CD-ROM, 012 Plastics Technology
ADVANCED SEQUENCING AND PROTECTION 48, No.11, Nov.2002, p.62/7
OF VALVE GATE SYSTEMS HOW TO INJECTION MOLD CYCLIC OLEFIN
Linehan T P COPOLYMERS
DME Co. Lamonte R R; McNally D; Music K; Hammond D
(SPE) Ticona
The enhanced flexibility and additional features offered This detailed article focuses on a new family of clear
by the use of computer-controlled valve gate sequencing engineering thermoplastics, Topas metallocene-
as an alternative to hard-wired systems are discussed. Time- catalysed cyclic olefin copolymers (COCs), from Ticona.
based or limit switch systems are less flexible and provided It looks in particular at how to injection mould the new
less control than those based upon screw position and cavity family, for optical and medical parts. Section headings
pressure. More flexible systems, operating multiple valve include: COC properties and moulding, equipment
gates, provide greater consistency and minimise weld lines. considerations, typical start-up conditions, machine
The addition of a signal interface between the machine settings, moulding guidelines, troubleshooting COC
control and the valve gate control can be used to prevent injection moulding, and secondary operations.
hot runner damage caused by such faults as valve gate USA
malfunction, and water cooling problems. Accession no.873057
USA
Accession no.874787 Item 36
Shawbury, Rapra Technology Ltd., 2002, pp.116, 29
Item 34 cm, Rapra Review Report, No. 150, vol. 13, No.6,
SPE Automotive TPO Global Conference 2002. 2002. NALOAN
Proceedings of a conference held Dearborn, Mi., 30th MOULD STICKING, FOULING AND CLEANING
Sept-2nd Oct.2002. Packham D E
Brookfield, Ct., SPE, 2002, Exterior Applications & Bath,University
Process Developments Session, p.305-11, 27cm, 012 Edited by: Humphreys S
IMPROVING THE AESTHETICS AND THE (Rapra Technology Ltd.)
MECHANICAL PROPERTIES OF THE Rapra.Review Report No.150
INJECTION MOULDED PARTS USING A
This review is concerned with the related problems of mould
MOULD WITH HIGH TEMPERATURE
sticking, fouling and cleaning associated with the moulding
Yoo Y-E; Park S; Lee S-H
of polymeric materials. The review discusses major studies
LG Chemical Ltd.
first of mould release followed by mould fouling, with the
(SPE,Detroit Section)
aim of elucidating the significant material and process
Injection moulding is cost effective and competitive for variables affecting the phenomena. Publications particularly
mass production. It can also be very useful to mould relevant to the practical guidance on the selection of surface
products in various applications. Moulded parts have treatment for moulds, the selection of release agents, the
become more complex in their shape and thinner in many cleaning of moulds and the measurement of mould release
cases. These require the use of multi-gated moulds and and fouling, are considered. 433 refs.
inserts, which result in weld line in the final product. Weld EUROPEAN COMMUNITY; EUROPEAN UNION; UK;
line, a common defect in injection moulding cannot often WESTERN EUROPE
be eliminated and causes some problems. First of all, weld Accession no.872183

Item 37 The application of root cause analysis in the identification

Injection Molding of polymer failures is described. Seven sequential steps
10, No.12, Nov.2002, p.74-6 are proposed: definition of required performance;
TROUBLESHOOTER PART 57: TOO MUCH OF establishing actual behaviour; identification of the
A GOOD THING problem; identifying what the problem is not; detailing
Hatch R the differences between the previous two steps;
Prime Alliance investigation of probable causes; and determining
corrective action. The procedure is illustrated by two
A series of troubleshooting reports from one of the spot
injection moulding case studies: breakage of an acrylic
problem solvers in the moulding industry is continued. The
clip; and breakage of a living hinge. 3 refs.
main issue for which requests are made to address is that
USA
of undersized gates. Materials such as PE, PP, unfilled
nylons and PBTP are compatible with small gates, but Accession no.870754
amorphous materials such as PS, ABS, ASA, SAN, acrylic
and polycarbonate require bigger gates. Since the gate depth Item 40
or diameter is based on the thickness of the wall into which European Rubber Journal
is being gated, and since gating should be made into the 184, No.11, Nov.2002, p.16-8
thickest wall section of the part, it is not difficult to calculate MODELLING INJECTION MOULDING
the depth or diameter of a gate. A case history is presented. PROCESSES
USA Shaw D
Accession no.871792 A new injection moulding software package has recently
been launched which appears to offer the rubber industry
Item 38 unmatched ability to model what happens in the mould
Kunststoffe Plast Europe chamber during both the injection phase and the curing
92, No.9, Sept.2002, p.50-2 phase. According to Sigma Engineering, the SigmaSoft
English; German software can help with the positioning of heaters, cooling
TRACING THE COST FACTORS. FAILURE channels, gate positions, runner balancing and flow paths
ANALYSIS IN THERMAL MOULD DESIGN within the mould, to avoid dead spots, weld lines and
Steinko W other problems with complex components. SigmaSoft is
GTT W.Steinko GmbH different from its rivals in that it calculates in three true
dimensions, as opposed to estimating some values based
The need for modern injection moulders to keep unit costs on two-dimensional flows. It also uses Napier-Stokes
constantly under surveillance in order to remain equations to calculate the flow within the mould.
competitive is discussed and the importance of careful
SIGMA ENGINEERING GMBH
design of the mould cooling system is emphasised. GTT
GmbHs consultancy work on analysis of the part, the WESTERN EUROPE
mould and the process, identification of the inadequacies Accession no.869233
responsible for deficient quality and cycle time, and their
documentation is described. The use of IR thermography
for thermal problem analysis in injection moulding is Item 41
considered. The German version of this article, which Modern Plastics International
appears on p.121-4, includes illustrations. 32, No.10, Oct.2002, p.93
OVERLY SMALL MOLDS, LARGE MACHINES
WESTERN EUROPE CAUSE DAMAGE
Accession no.871178 Dealey B
Dealeys Mold Engineering
Typically, if a mould is too big for an injection moulding
Item 39
machine, there is an obvious problem. However, a
ANTEC 2002. Proceedings of the 60th SPE Annual
machine that is too big for a mould is also a problem, as
Technical Conference held San Francisco, Ca., 5th-9th
is a mould that is too small for a machine. Ideally, the
May 2002.
shot size should be between one-third and two-thirds of
Brookfield, Ct., SPE, 2002, Paper 206, Session M40-
the barrel capacity. Mould-to-machine match is discussed.
Failure Analysis and Prevention. Case Studies I, pp.6,
CD-ROM, 012 USA
ROOT CAUSE ANALYSIS; FUNDAMENTALS Accession no.868178
AND APPLICATIONS
Elleithy R H Item 42
Polymer Diagnostics Inc. Modern Plastics International
(SPE) 32, No.10, Oct.2002, p.87-9

TECHNIQUES SOLVE MELT FLOW The benefits of introducing water into the gas channel
IMBALANCE FOR EVEN CAVITY FILLING during the gas-assisted injection moulding process were
Mapleston P investigated. A polypropylene plate (267 x 101 x 2.5 mm)
was moulded, using a machine which was modified to
One of the biggest bugbears of multicavity moulds is
allow water injection into the gas line. Moulding faults
getting balanced flow across all the cavities. One of the
were reduced and a more uniform wall thickness was
reasons is the variations in temperatures across runner
achieved. However, short shots were obtained, attributed
channels that often do not show up in flow simulation
to fast cooling, and the gas penetration lengths decreased
programmes. MeltFlipper technology from Beaumont
as the volume of injected water increased.
Runner Technologies aims to solve this problem. It
USA
currently works on cold-runner systems, but the company
plans to demonstrate a hot-runner manifold incorporating Accession no.867327
a new version of its technology at NPE2003.
BEAUMONT RUNNER TECHNOLOGIES INC. Item 45
USA Malterdingen, 2000, pp.20, 29 cm, 6/9/02
Accession no.868176 THE MULTI-COMPONENT AND MONO
SANDWICH MACHINES WITH CLAMPING
FORCES FROM 600 KN UP TO 4,500 KN.
Item 43 INNOVATIVE INJECTION MOULDING
ANTEC 2002. Proceedings of the 60th SPE Annual Ferromatik Milacron Maschinenbau GmbH
Technical Conference held San Francisco, Ca., 5th-9th
May 2002. Features and capabilities are described for the range of
Brookfield, Ct., SPE, 2002, Paper 126, Session M28- multi-component and monosandwich machines from
Injection Moulding Analysis, pp.5, CD-ROM, 012 Ferromatik Milacron in the 600 kN up to 4,500 kN
STUDY OF FLOW MARKS DURING INJECTION clamping force range. Productivity is the compelling
MOLDING argument in favour of multi-component injection moulding
Guojun Xu; Koelling K W machines from the company, which feature high injection
Ohio,State University rates and pressures as standard features, and a pressure
(SPE) accumulator unit to ensure a constant and high injection
rate. Examples are given of the large variety of process
Relationships between the process parameters and variations available in multi-colour injection moulding
alternating dull and glossy regions on the surface of machines. The patented Mono Sandwich process produces
injection moulded product was investigated. Rectangular sandwich structures from reclaim very simply, and requires
bars of 1 or 5.08 mm thickness were injection moulded only one injection stroke, thus eliminating the faults which
using polypropylene with melt and mould temperatures in may otherwise arise when changing over from skin to core
the ranges 190-260 C and 22-85 C, respectively; and high components. The patented process is described.
density polyethylene with melt and mould temperatures in EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY;
the ranges 180-240 C and 20-70 C, respectively. The WESTERN EUROPE
polymers were characterised by rheology measurements. Accession no.866950
Alternating flow marks did not occur at higher injection
speeds, and their generation was attributed to entry Item 46
viscoelastic instability. It was established that synchronous Injection Molding
flow marks were not caused by slip, and that they could be 10, No.10, Sept. 2002, p.76/9
alleviated by coating the mould surfaces. 18 refs. THE TROUBLESHOOTER. PART 56: EVEN FILL
USA WITH FLOW RESTRICTORS
Accession no.867330 Hatch B
Prime Alliance
Item 44 The manager of technical service and customer support
ANTEC 2002. Proceedings of the 60th SPE Annual at Prime Alliance offers advice on how to solve a problem
Technical Conference held San Francisco, Ca., 5th-9th with mould filling in the manufacture of ABS shower head
May 2002. handles, which were displaying surface defects, knitlines
Brookfield, Ct., SPE, 2002, Paper 123, Session M27- and sink marks. He identifies the problem as being caused
Injection Moulding. Gas Assist, pp.5, CD-ROM, 012 by the sprue and nozzle orifice being too small, an
EFFECT OF INTERNAL COOLING ON undersized flow path and moulded-in stress and suggests
FINGERING IN THE GAS-ASSISTED that it may be overcome by the proper venting of runners,
INJECTION MOLDING enlarging of the sprue and nozzle, the addition of a mould
Lee J S; Cha S; Lai F restrictor and the use of an open flow path.
Massachusetts,University USA
(SPE) Accession no.866512

Item 47 out and some of the results are discussed here. Graphs
Modern Plastics International relating to this article are included in the German version
32, No.9, Sept.2002, p.38-9 p.61-62.
PREVENTIVE PURGING HAS PRACTICAL EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY;
BENEFITS WESTERN EUROPE
Moore S Accession no.864082
Purging compound suppliers claim regularly-scheduled
purgings prevent quality problems and yield operational Item 50
benefits. These include fewer rejects, less scrap after ANTEC 2002. Proceedings of the 60th SPE Annual
purging, shorter purging cycles and, consequently, greater Technical Conference held San Francisco, Ca., 5th-9th
machine uptime. Dyna-Purge documented one case where May 2002.
an injection moulder cut the cost of purging by 87% by Brookfield, Ct., SPE, 2002, Paper 1, Session M1-Color
adopting Dyna-Purge M compound to scrub carbon and Appearance, pp.4, CD-ROM, 012
deposits from the barrel and nozzle. The user, Rexam in INJECTION MOULDING AND COLOUR: A
Antwerp, formerly used 400kg of virgin PP to remove BASIC LOOK AT DESIGN, PROCESSING, &
specks from a machine that moulded yellow food TROUBLESHOOTING
containers. Lost production time was reduced from 14 to Angel G
2 hours. Tackling potential carbon specks before they have PolyOne Corp.
a chance to form is one key in effective purging. (SPE)
WORLD The addition of colour at the injection moulding machine
Accession no.865460 is compared with the use of pre-coloured polymer in terms
of cost and processing. The causes of colour-related
Item 48 product problems are briefly reviewed in terms of
Plastics Technology machine, tooling design, and materials composition.
48, No.6, June 2002, p.45/7 USA
INJECTION MOLDING TROUBLESHOOTER - Accession no.863850
AVOID PITFALLS IN MULTI-MATERIAL
MOLDING Item 51
Ehritt J Melton Mowbray, 2000, pp.20, 29 cm, 18/6/02
Battenfeld of America EVOPRENE. EVOPRENE SUPER G; EVOPRENE
This article is part of a series on injection moulding G; EVOPRENE COGEE; EVOPRENE GC;
troubleshooting, and looks in particular at multi-material EVOPRENE. THERMOPLASTIC ELASTOMER
moulding. It explains the challenges faced when moulding COMPOUND SERIES. TECHNICAL MANUAL
with two or more different materials, the variables AlphaGary Ltd.
involved, factors to keep in consideration, and possible Comprehensive product data are presented for grades of
solutions to the commonest problems. Evoprene thermoplastic elastomers from AlphaGary Ltd.
USA Grades described are Evoprene Super G, Evoprene G,
Accession no.864728 Evoprene COGEE, Evoprene GC, and Evoprene general
purpose grades of styrenic TPEs. Property data are
tabulated for each grade, with details of features and
Item 49
benefits. In particular, the fluid resistance of Evoprene G
compounds is described, and Evoprene grades for the
92, No.8, Aug.2002, p.19-20
window gasket market are indicated. Flame retardant
CUTTING COSTS
grades are also discussed. A processing guide for both
Uske K injection moulding and extrusion is included with a
BASF AG troubleshooting guide for each.
Regrind is generated in thermoplastics injection moulding EUROPEAN COMMUNITY; EUROPEAN UNION; UK;
as a result of the granulation of sprues or reject parts into WESTERN EUROPE
particles just a few millimetres in size. In this form, the Accession no.858081
regrind can be recycled back into the injection moulding
process, so minimising scrap disposal requirements. In
Item 52
the production of moulded parts to high specifications
Orpington, 2001, pp.2, 27cm, 20/6/02
from high-quality engineering thermoplastics, the use of
MOLDFLOW PRODUCT GUIDE
regrind is possible only to a limited extent. The reason
Moldflow (Europe) Ltd.
for this restriction is the degradation of the moulding
material during injection moulding and granulation. A Details are given of Moldflows suite of software products,
series of trials with PBTP and polyamide 6 was carried designed for plastic part design and manufacturing engineers

to eliminate problems and costly downtime on the Item 55

manufacturing floor. Included are details of plasticszone.com, Injection Molding
the companys website; Moldflow Plastics Advisors, an 10, No.5, May 2002, p.70-1
advanced process simulation package; Moldflow Plastics THE TROUBLESHOOTER. PART 54: SIZING
Insight, in depth simulations which allow for the RUNNERS FOR PBT
determination of optimal combinations of part geometry, Hatch B
materials, mould design and processing parameters; Prime Alliance
Moldflow Plastics Xpert, which offers solutions to reduce A description is given of how problems encountered during
mould commissioning times; Moldflow EZ-Track for the injection moulding of small PBTP parts using an eight
production monitoring and reporting; Moldflow Shotscope cavity, cold runner were identified and solved. The problem,
for process and production monitoring; and Moldflow which entailed inconsistent filling of the mould cavity, was
Plastics Labs for state-of-the-art material testing services. solved by enlarging the nozzle, sprue, runners and gates,
EUROPEAN COMMUNITY; EUROPEAN UNION; UK; which eliminated the need for extra barrel heat and injection
WESTERN EUROPE
pressure, resulting in no short shots and faster cycle times.
Accession no.858060 USA
Accession no.853482
Item 53
Plastics News International Item 56
June 2002, p.25 Kunststoffe Plast Europe
VACUUM SYSTEM DISCHARGES GAS AND AIR 92, No.3, March 2002, p.14-8
TO REDUCE MOULDING DEFECTS AND PLASTICISING IN CRITICAL AREAS
MOULD CONTAMINATION Buerkle E; Wuertele M
Details are provided on a vacuum material supply system, Krauss-Maffei Kunststofftechnik GmbH
called Gas Cleaner, for reducing mould contamination An in-depth discussion is presented on the physical
and moulding defects caused by oxidation and burning, limitations of single-screw injection moulding machines
which are generated during injection moulding. The and methods of overcoming some of these limitations. The
results of trials on the system are outlined and the structure advantages of a novel injection moulding machine, the
and operation of the system are illustrated. Injection Moulding Compounder, from Krauss-Maffei,
Accession no.857222 which overcomes some of the problems encountered when
using single-screw injection moulding machines are also
discussed. This novel machine combine an extruder and
Item 54
an injection moulding machine into one unit, which allows
European Plastics News
for gentle, homogeneous compounding and mixing of fillers
29, No.6, June 2002, p.30-1
and additives. (Kunststoffe, 92, No.3, 2002, p.38-44)
BLOCK VOTE
Comini A WESTERN EUROPE
Lego has developed a larger, softer version of its bricks for Accession no.851004
younger children. These new bricks needed to be completely
harmless if thrown around, non-toxic, highly resistant to Item 57
impact, water and cleaning substances, stable in shape and Injection Moulding 2002. Proceedings of a conference
colour and moulded with high dimensional accuracy to held Barcelona, 18th-19th March 2002.
ensure the joins are perfect. Lego approached Italian moulder Barcelona, Rapra Technology Ltd., 2002, Paper 18,
Exo, which specialises in injection moulding EVA p.243-5, 30cm, 012
compounds for customers such as Nike. Most of the two- ORIGIN OF THE SURFACE DEFECT SLIP-
year study carried out by Exo has been devoted to solve the STICK ON INJECTION MOULDED PRODUCTS
problem of restraining and guiding the post-moulding Schepens A; Bulters M
expansion of the selected EVA compound. The company DSM Petrochemicals
has worked closely with machinery and mould maker Main (Rapra Technology Ltd.; ASCAMM)
Group and raw material producer API. A significant new An investigation was carried out into the influence of
feature of the Vega machines supplied for this application injection moulding parameters on the slip-stick effect
refers to the presence of the booster, located at the end of on the surface of filled PP in order to identify the cause
the plasticising barrel, to collect the material from the screw of this moulding fault. Flow instability at the melt front
and to perform the injection. was identified as the cause of the effect and a remedy for
LEGO GROUP; EXO; MAIN GROUP SPA eliminating this effect is suggested. 4 refs.
EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; EUROPEAN COMMUNITY; EUROPEAN UNION;
WESTERN EUROPE NETHERLANDS; SPAIN; UK; WESTERN EUROPE

Item 58 Westland believes that screw design plays a fundamental

Injection Moulding 2002. Proceedings of a conference role in high-quality moulding, although for many moulders,
held Barcelona, 18th-19th March 2002. screw and barrel design is not a high priority. Avon Plastic
Barcelona, Rapra Technology Ltd., 2002, Paper 17, Products is a custom moulder serving the automotive
p.231-42, 30cm, 012 interior and trim market. The company had successfully
SURFACE MARBLING IN MINERAL FILLED colour concentrated ABS and PP using the standard screws
NYLON: ORIGINS AND SOLUTIONS that came with its machines, but colour concentrating acetal
Legrix A; Fugler A; Greenhill D; Goodman R; Paynter C was causing problems. Westland specifically designed the
Imerys Minerals Ltd. Eagle screw for the process profiles that Avon required.
(Rapra Technology Ltd.; ASCAMM) The Eagles mixing section uses wiper flights with large
An investigation was carried out into the possible helix angles to force the melt over barrier lands or through
mechanisms responsible for gatemarking in injection one of six mixing notches. This motion encourages
moulded, calcined clay filled polyamide 6. The effects of thorough mixing without the excessive shear that can
processing conditions on the surface finish of the moulded degrade material. Avon says the benefits of switching to
plaques and the influence of thermal, rheological and these high-performance screws specifically designed for
mechanical properties on gatemarking were assessed and certain resin systems are tremendous.
a mechanism for gatemarking/marbling is proposed. WESTLAND CORP.; AVON PLASTIC PRODUCTS
Solutions and guidelines for improving the surface finish INC.
of the filled polyamides are also presented. 5 refs. USA
EUROPEAN COMMUNITY; EUROPEAN UNION; SPAIN; UK; Accession no.849582

WESTERN EUROPE
Revista de Plasticos Modernos
Item 59 81, No.540, June 2001, p.636/41
Plastics and Rubber Weekly Spanish
15th March 2002, p.1 HOT RUNNER SYSTEMS WITH GATE VALVES
DYSON STAFF SLAM MOULD SHOP WASTE Gauler K
Bagshaw S Incoe International Inc.
Dysons in-house mould shop is wasteful, inefficient and The technical advantages of hot runner injection mould
run by managers inexperienced in plastic component systems with gate valves are discussed. Applications of
production, according to staff at the Malmesbury plant. these systems in plastics injection moulding processes
Current employees say that had more attention been paid generally and in gas injection moulding, coinjection
to increasing efficiency in the Wiltshire factory, there moulding and structural foam moulding are described.
would have been less incentive to relocate vacuum cleaner USA
production to Malaysia. One mould shop employee said Accession no.849069
waste was widespread and undermined effectiveness. On
one occasion nine tonnes of lavender ABS is said to have Item 62
been just thrown away due to processing problems. Injection Molding
Standard mould shop practices are reported to have 9, No.12, Dec.2001, p.68/70
reduced further profitability. When a colour change is TROUBLESHOOTER - PART 52: SIZING SPOKE
carried out, the material system is not allowed to run out; RUNNERS
the machine is just stopped. Half a tonne of virgin material Hatch B
is disposed of every week due to this. According to the Prime Alliance
employee, the management has not looked at the plants
efficiency before deciding to move production. Some This article is part 52 of a series of troubleshooting reports
company information is presented. relating to injection moulding. It deals with sizing spoke
runners. A case history is included to illustrate the point-
DYSON APPLIANCES LTD.
in-hand. Details are given of the symptom and cause, the
WESTERN EUROPE solution, and the result.
Accession no.849893 USA
Accession no.848832
Item 60
Injection Molding Item 63
10, No.2, Feb.2002, p.61-3 Oberhausen, 2001, pp.4. 30cms. 5/2/2002
TAMING OF THE SCREW GUR PE-UHMW. SPECIALTY INJECTION
Deligio T MOLDING - GUR SPECIALTY PRODUCTS FOR

HIGHLY SPECIALIZED INJECTION MOLDED production monitoring via a standard web browser. iMPX
PARTS gives manufacturing managers the ability to remotely
Ticona GmbH monitor their production facilities and identify processing
problems before downtime becomes necessary.
Technical information is presented on GUR ultra-high
USA
molecular weight polyethylene, for use in the production
of specialised injection moulded parts. Parts manufactured Accession no.846353
from GUR 5113 and Hostalloy 731 feature high abrasion
resistance, self-lubrication, high notched impact strength, Item 66
good chemical resistance, low density, and good low Revue Generale des Caoutchoucs et Plastiques
temperature properties. The engineering polymers can be 78, No.797, Sept.2001, p.30/7
successfully used in chemical plants, conveyor systems, French
valves, fittings, pumps and other industrial, consumer and SURFACE DEFECTS IN INJECTION MOULDED
mechanical applications. Tables of data show typical PARTS
physical properties and optimum processing conditions Lacrampe M F; Pabiot J
for the materials, while a troubleshooting guide to possible Douai,Ecole des Mines
problems is also included.
Types of surface defects occurring in injection moulded
WESTERN EUROPE plastics parts are examined, and the influence of part
geometry, polymer type and properties and injection
Accession no.848809
moulding conditions on the development of such defects is
discussed. A number of studies which relate the appearance
Item 64 of surface defects to flow instability are reviewed. 12 refs.
Injection Molding EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE;
10, No.3, March 2002, p.66-8 WESTERN EUROPE
TROUBLESHOOTER PART 53: BLUSH WITH A Accession no.846238
FILLED PC
Hatch B
Item 67
Prime Alliance Inc.
160th ACS Rubber Division Meeting - Fall 2001.
A moulder was having problems with blush at the front tip Cleveland, Oh., 16th-18th October 2001, Paper 5,
of a glass-filled polycarbonate part. Upon examination of pp.16, 012
the tunnel portion of the subgate, it was found that the gate SELECTIVE SELF-ADHESIVE SILICONE FOR
was too restricted to shoot glass-filled polycarbonate LIQUID INJECTION MOLDING SYSTEM(LIMS)
through it. The trouble was that the pin gate sliver was Azechi S; Yamakawa N; Sekiguchi S; Meguriya N
only 0.060 inch thick where it contacted the part and 0.065 Shin-Etsu Chemical Co.Ltd.
inch where the subgate fed into it. The sliver was not thick (ACS,Rubber Div.)
enough to fill and pack the part without extra heat and
A selective self-adhesive silicone rubber was developed to
presure. Second, the subgate that fed the sliver was too
solve the adhesion problem in insert moulding with
small in diameter. The solution was to change the straight
thermoplastics by allowing the liquid injection moulding
pin gate to a wedge-shaped pin gate and open taper where
material to bond to the thermoplastic insert but not to the
the subgate feeds the thick section of the wedge gate.
metal surface of the mould. Adhesion was shown to take
USA
place even after a very short curing time so that the selective
Accession no.847817 self-adhesive silicone could be used in primerless insert
moulding or co-injection moulding to make a firmly
Item 65 integrated composite with thermoplastics. The composite
Wayland, Ma., 2001, pp.6. 30cms. 4/1/2002 prepared by this primerless insert moulding showed high
PLASTICS XPERT. CHANGING THE WAY adhesion durability in various types of severe conditions,
PLASTICS PARTS ARE MANUFACTURED such as high temp. (120C), high humidity (85C/85%
Moldflow Corp. relative humidity) and heat cycle (-40C to 120C). Even
after 300 hours under these conditions, more than 90%
Moldflow Plastics Xpert has been developed to automate cohesive failures within rubber were observed.
the process of injection moulding machine setup, JAPAN; USA
optimisation, and control. Its use allows moulding
Accession no.842946
machine operators to consistently and systematically set
up the process, perform an automated design of
experiments to determine a robust processing window, Item 68
and automatically correct the process should problems Revue Generale des Caoutchoucs et Plastiques
occur. In addition, use of iMPX extends the capabilities 78, No.796, June/July 2001, p.46/53
of Xpert by allowing for real-time, Internet-enabled French

MEASURING PRESSURE IN THE MOULD MATERIALS ANALYST: PART 49. THE COST OF
CAVITY TESTING AND NOT TESTING
Galland C Sepe M
Kistler SA Dickten & Masch Mfg.
The measurement of cavity pressure in the injection The idea of material analysis as part of the product
moulding process is discussed, and the use of pressure development process is not a popular notion. This arises
measurements as a means for the quality control of largely from the fact that analytical testing services come
moulded plastics parts is examined. from outside the moulding and mouldmaking facility and
EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; are therefore a visible cost. A case study is presented in
WESTERN EUROPE an attempt to capture the costs related to a particularly
Accession no.842594 troublesome programme launch and contrast those costs
with the dollars spent in the lab to actually find the root
Item 69 cause of the problem. The programme involved a large
Plastics Technology part weighing almost 9lb which was produced in a 90-
48, No.2, Feb.2002, p.46-7 second cycle. The mould used a hot runner system with
INJECTION MOLDING TROUBLESHOOTER - multiple gates. The material was a dark grey
SECRETS OF THIN-WALL MOLDING polycarbonate with a nominal MFR of 22g/10min. The
Weiss K problem on initial startup was an apparently incurable
GE Plastics splay. After about a week of at-the-press troubleshooting,
several material samples were sent for analysis. Testing
This article is part of a series on injection moulding showed up a melt stability problem, traced back to the
troubleshooting, and looks in particular at the process of omission of a stabiliser package that should have been
moulding thin-walled parts. It explains that thinner wall incorporated during colour compounding.
sections bring changes in processing requirements: higher USA
pressures ad speeds, faster cooling times, and
Accession no.839288
modifications to part-ejection and gate arrangements.
These changes in turn prompt new considerations in
mould, machinery, and part design. Item 72
USA Kunststoffe Plast Europe
Accession no.842544 91, No.11, Nov. 2001, p.17-21
TRANSPARENCY IN INJECTION MOULDING
Buerkle E; Klotz B; Lichtinger P
Item 70 Krauss-Maffei Kunststofftechnik GmbH
Nov.2001, p.39 Materials suitable for the manufacture of highly
SPECIAL SCREW GIVES RAPID RETURN transparent optical mouldings are examined and factors,
THROUGH CYCLE SAVINGS which can have major effects upon the quality of injection
moulded optical parts are considered. The use of injection-
The concept behind DuPonts development of the ELCee compression moulding techniques to manufacture optical
screw is to enable plasticising to take place faster, so that parts is also addressed and the advantages of horizontal
screw recovery time can be reduced by as much as 50%. injection moulding machines over vertical ones are briefly
Production savings are achieved at no cost to quality. The considered. (Kunststoffe, 91, No.11, 2001, p.17-21)
company has released few details of how the process
works, other than it is necessary to use a free-flow back WESTERN EUROPE
flow valve and limited back pressure. Examples of what
Accession no.837214
the ELCee screw has achieved in production on specific
materials are given. For Delrin acetal, a cycle time on a
128 cavity job reduced from 7.3 to 6.3 sec, giving an ROI Item 73
of 1.2 months. For Zytel nylon, lowered melt temperature Kunststoffe Plast Europe
which prevented sprue sticking. Screw retraction time 91, No.11, Nov. 2001, p.15-7
made more consistent. ROI less than two weeks. WHAT HARDENS SURFACES
DUPONT Thierfelder W; Hoffmann A; Schmidt S; Ohm F;
EUROPEAN COMMUNITY; EUROPEAN UNION; UK; Eulenstein T
WESTERN EUROPE Plansee AG; Reutte; Luedenscheid,Plastics Institute
Accession no.842280 The problem of wear of injection mould surfaces and
mould components is addressed and the use of a
Item 71 molybdenum alloy (a carbide-dispersion-hardened TZM
Injection Molding alloy) to make mould components hardened using novel
9, No.11, Nov.2001, p.44-7 SHN hardening treatment to provide surfaces with a high

surface hardness and reduced wear is demonstrated. The injection moulding cycle; Procedures; Troubleshooting;
results of wear trials carried out using mould components The specification sheet; Equipment information; Calendar/
made from these alloys and other materials are briefly Monthly planner; Phone numbers; Conclusion.
reported. (Kunststoffe, 91, No.11, 2001, p.15-7) USA
EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; Accession no.836997
WESTERN EUROPE
Injection Molding
Item 74 9, No.10, Oct. 2001, p.92/5
Kunststoffe Plast Europe TROUBLESHOOTER. PART 51: COPING WITH
91, No.11, Nov. 2001, p.11-2 GATE JETTING
SELF-INSULATING HOT-RUNNER WITH Hatch B
NEEDLE VALVES Prime Alliance
Lindner E; Cuttat K P The problem of gate jetting (snake tracks) starting at the
The use of a self-insulating hot-runner with hydraulically gate and continuing for 5 in. inside the gate in black ABS
operated needle valves to prevent problems occurring as parts is addressed. This problem is identified as edge gating
a result of colour change from dark to light during the coming off the side of a trapezoidal runner, which results in
manufacture of the ABS back wall of an alarm clock a high shear gate. The remedy suggested is changing from
housing is demonstrated. The heating system and colour the trapezoidal runner to a curved tunnel gate or tab gate
change technique are briefly described and the and resizing the sprue O-diameter and nozzle orifice to
demoulding stages for the manifold are illustrated. increase flow. Information on good gate design is included.
(Kunststoffe, 91, No.11, 2001, p.38-40) USA
EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; Accession no.833151

SWITZERLAND; WESTERN EUROPE
Injection Molding
9, No.10, Oct. 2001, p.54/6
Item 75
PART DESIGN - DEPTH OF HOLES
Trowbridge, Redwood Books, 2001, pp.vi, 354, 25cm,
Beall G
2831
Beall G.,Plastics Ltd.
HOT RUNNERS IN INJECTION MOULDS
Frenkler D; Zawistowski H Some recommendations are presented for avoiding core
deflection when injection moulding parts, such as
The aim of this book is to provide an objective view of
hypodermic needle sheaths, designed with deep holes.
the topic of hot runners in injection moulds based on the
Methods of minimising bending or increasing resistance
broad personal experiences of the authors. It introduces a to bending of core pins, which involve either allowing
logical division of hot runner systems, illustrates the high-pressure melt to impinge on both sides of the core
design of nozzles, manifolds and other system pin or supporting the core pin at both ends, are illustrated.
components, discusses the principles of selection, USA
building, installation and use, analyses the causes of faults
Accession no.833146
and suggests ways of eliminating them, and presents
examples of applications. Each chapter is well referenced.
Item 79
EASTERN EUROPE; EUROPEAN COMMUNITY; EUROPEAN
UNION; POLAND; UK; WESTERN EUROPE
Plast 21
No.101, April 2001, p.74-5
Accession no.837008
Spanish
INCREASING THE USEFUL LIFETIME OF
Item 76 MOULDS
Michigan, Guiness Technologies, 1994, 30cm, 831 Rodriguez R
INJECTION MOULDING SET-UP MANUAL Asociacion de la Industria Navarra
Wolfer S
Ion implantation is examined as a method for the surface
Guiness Technologies
treatment of injection moulds to increase their service
This loose leaf folder provides a compilation of information life, and the costs and technical aspects of this process
from the top 100 injection moulders in North America with are discussed in comparison with other surface treatment
regard to all aspects of setting up and using injection techniques.
moulding processes. The guide is split into 15 sections: EUROPEAN COMMUNITY; EUROPEAN UNION; SPAIN;
Safety; hand tools; Micrometers and callipers; Conversion WESTERN EUROPE
tables; Plastic materials; The mould; The machine; The Accession no.831328

Item 80 Item 83
Plastiques et Elastomeres Magazine Injection Molding
53, No.1, Jan./Feb.2001, p.29/34 9, No.8, Aug. 2001, p.58
French MATERIAL PRIMER: ACRYLICS
WAVE DEFECTS ON THE SURFACE OF Maniscalco M
INJECTION MOULDED PP: INFLUENCE OF
Some guidelines are presented for the injection moulding
PROCESSING PARAMETERS AND THE
of aesthetically pleasing parts from acrylics, whose
FOUNTAIN EFFECT
rigidity allows the design of thinner parts than is possible
Monasse B; Mathieu L; Stockman L; Vincent M;
with other transparent plastics. The cost benefits of
Haudin J M; Gazonnet J P; Durand V; Barthez J M;
acrylics over materials, such as PS or polycarbonate, are
Roux D; Charmeau J Y considered and advice on mould design, part design and
Paris,Ecole des Mines; Pole Europeen de Plasturgie; troubleshooting are given.
Ecole Superieure de Plasturgie
CYRO INDUSTRIES
Results are presented of injection moulding studies and USA
designed experiments undertaken to investigate the Accession no.830428
causes of wave defects on the surface of parts produced
from talc filled, EPM modified PP. The influence of
Item 84
moulding conditions, the fountain effect and flow
RUBBER INJECTION MOULDING - TODAYS
instability was examined.
TECHNOLOGY. Proceedings of a conference held
EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; Manchester, 20th November 2000.
WESTERN EUROPE
Shawbury, Rapra Technology Ltd., 2000, paper 7. 012
Accession no.831313 INJECTION MOULDING OF RUBBER -
PROBLEMS, CAUSES, SOLUTIONS
Item 81 Clarke C; Menting K-H; Mergenhagen T
Revista de Plasticos Modernos Schill & Seilacher GmbH
81, No.535, Jan.2001, p.44-6 (Rapra Technology Ltd.)
Spanish The production of rubber articles via injection moulding
PRODUCTION CYCLE OF THERMOPLASTICS techniques is discussed with reference to the complexity
INJECTION MOULDING. IV. of the overall process, and the variety of problems that
Reig M J can occur. This paper aims to give an overview of typical
Alcoy,Escuela Politecnica Superior problems encountered in injection moulding of rubber,
The effects of frozen layer formation on melt flow in their possible causes, and how these problems can be
injection moulds are examined, and the influence of flow solved without compromising the quality or properties
rate and injection temperature on the pressure required to of the product, or the economics of production. Topics
fill the cavity is discussed. (Parts I and II: Ibid., 80, covered include porosity, pebbling/crazing, bloom, poor
No.533, Nov.2000, p.527-30; Part III: Ibid., 80, No.534, knitting, shrinkage, backrinding, distortion, tearing on
Dec.2000, p.640-2). demoulding, and sticking and fouling.
EUROPEAN COMMUNITY; EUROPEAN UNION; SPAIN; EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY;
WESTERN EUROPE UK; WESTERN EUROPE
Item 82 Item 85
Injection Molding Advances in Polymer Technology
9, No.8, Aug. 2001, p.84/8 20, No.3, Fall 2001, p.202-15
THE TROUBLESHOOTER. PART 50: VENT MINIMISING THE SINKMARKS IN INJECTION-
BEFORE YOU MOULD MOULDED THERMOPLASTICS
Hatch B Liu S-J; Lin C-H; Wu Y-C
Chang Gung,University
A description is given of how a small cosmetic defect,
which looked like melt fracture or shear splay radiating The effects of several processing parameters on the
from the gate, in a thick walled, clear PS or SAN handle formation of sink marks in injection moulded
or knob was eliminated through adjustments to the thermoplastics (general-purpose PS and LDPE) was
gating and runner sizes and the venting of all runners investigated using a profile meter to characterise the sink
marks. Parameters examined included rib corner
and cavities.
geometry, rib width, melt-injection pressure, melt
USA
temperature, packing pressure and mould temperature.
Accession no.830434 Experimental design based on an orthogonal array of the

Taguchi method was employed in an attempt to minimise Sepe M

sink mark formation. It was found that ribs with undercut Dickten & Masch Mfg.Co.
geometries and a small width were most likely to produce This is part 38 of a series of articles designed to help
parts with the least sink marks. 12 refs. injection moulders understand how a few analytical tools
TAIWAN can help diagnose a part failure problem. It deals with
Accession no.825988 the myths of heat deflection temperature, and is part 3 in
a mini-series on this topic. The author recaps on ground
Item 86 already covered, (which included the deflection
Injection Molding temperature under load test), then looks in this article at
9, No.6, June 2001, p.90-4 a better method of determining the properties of materials
THE TROUBLESHOOTER: PART 49. TROUBLE at elevated temperatures.
IN TWO MOULDS USA
Accession no.818341
A description is given of how Bob Hatch from Prime
Alliance solved the problem of sinks in injection moulded
polycarbonate parts. Item 90
PRIME ALLIANCE Massachusetts, Kluwer Academic Publishers,
USA 1995,pp.xxii, 1145, 26cm
Accession no.820384 INJECTION MOLDING HANDBOOK - SECOND
EDITION
Donald D; Donald D
Item 87 Plastic Fallo; Rhode Island,School of Design
Popular Plastics and Packaging
This, the second edition of this practical handbook,
46, No.6, June 2001, p.86-7
provides a complete review of injection moulding. It
FAULT DUE TO METAL IN PLASTICS
examines technological advancements, particularly
Mankde M; Prayag H D
computer methods and provides insights into trends in
RIECO Industries Ltd.
the field. Main headings include: The complete injection
Some of the reasons for the presence of metal impurities moulding operation, Injection moulding machines,
in plastics and the problems occurring as a result are Plasticising screw process, Mold design and operation,
outlined and the use of metal separators to detect and designing products, Plastic moulding materials, Process
remove metal impurities from plastics is suggested. The control technology design features that influence
metal separator may be fitted to an injection moulding performance, Computer operations, Auxiliary equipment
machine above the hopper to remove any metal impurities and secondary operations, Troubleshooting, Testing and
from the plastics material being fed into the machine. quality controls, Statistical process and quality controls,
INDIA Effective costing and plant financial control, Specialised
Accession no.818665 injection moulding process, Competitive processes,
Moulding with profit. 179 refs.
USA
Item 88
Injection Molding Accession no.817927
8, No.12, Dec.2000, p.112/5
TROUBLESHOOTER - PART 45: ELIMINATING Item 91
SHEAR SPLAY Injection Molding
Hatch B 9, No.4, April 2001, p.94/6
Prime Alliance TROUBLESHOOTER PART 48. ACETALS
This detailed article is part 45 of a series of troubleshooting SPECIAL NEEDS
reports relating to injection moulding. This part deals with Hatch B
how to eliminate shear splay. A case history is included to An injection moulding troubleshooting exercise is
illustrate the point-in-hand. Details are given of the described, involving a copolymer acetal, but which could
symptom and cause, the solution, and the result. just as easily have been a homopolymer, and a four-cavity,
USA cold runner, two-plate mould with small parts. A metal
Accession no.818350 insert was moulded into each part, making them look like
little metal rods with moulded-on bushings. The complaint
was that the levels of moulded-in stress were too high
Item 89 and the dimensions were going out of the acceptable
Injection Molding tolerance range.
8, No.12, Dec.2000, p.52/8
PRIME ALLIANCE
DESIGN - MATERIALS ANALYST: PART 38
Accession no.815859

Item 92 Item 94
Injection Molding Injection Molding
9, No.4, April 2001, p.83-4 9, No.4, April 2001, p.44-6
LOWER-TONNAGE MOULDING STRATEGIES MATERIALS ANALYSIS. XXXXII. COMBINING
Guariglia V TECHNIQUES TO FIND CONTAMINATION
Sepe M
Moulders have traditionally used an equation that
determines the tonnage requirements for a given moulded
part. This rule of thumb has prevailed in the industry for An application has previously been highlighted where a
years, but recently moulders and machinery suppliers have semicrystalline material had contaminated parts moulded
begun to tweak this well-known calculation to bring new in PPO, causing a problem with a hot plate welding
flexibility to the moulding process. Robbins Scientific, a assembly process. Finding semicrystalline contaminants
captive moulder of laboratory disposables such as tubes, in an amorphous polymer is relatively simple because
trays and pipette tips was having trouble moulding a thin- semicrystalline materials have melting points that
wall tube plate made from general purpose PP. The part dominate a DSC test. Amorphous resins show only a glass
weighs in at a mere 18g. While technically the mould is transition, an event that is much less energetic. But when
single cavity, it is composed of several cores that make it there is contamination of one semicrystalline material by
unusually complex and challenging. The company another semicrystalline polymer and the two materials
required a smaller-tonnage press with larger tiebar have similar melting points, the problem is much more
spacing. The companys needs coincided with Huskys complex. In cases like this more work is often needed,
development of a new 100-ton hybrid injection machine. particularly if the client wants to know the exact source
Details are given. of the contamination. Multiple techniques can
complement one another in reaching a final answer. The
ROBBINS SCIENTIFIC CORP.; HUSKY INJECTION
use of thermogravimetric analysis, differential scanning
MOLDING SYSTEMS LTD.
CANADA; USA
calorimetry and IR spectroscopy to identify a
contaminating material, PETP, is described.
Accession no.815858
USA
Accession no.815855
Item 93
Injection Molding
9, No.4, April 2001, p.48-50 Item 95
PART DESIGN 301 - WELDLINES Plastics and Rubber Weekly
Beall G 18th May 2001, p.10
Beall G.,Plastics Ltd. OVERCOMING THAT STREAKING FEELING
Smith C
During the injection moulding process, melt flows from
the gate through the cavity. This is a melt flow process, The injection moulding sectors practice of relying on
and that imposes limitations on what can and cannot be machine setting adjustments to overcome basic processing
moulded. The ideal shape for an injection moulded part problems, such as mixing, rather than addressing root
is a poker chip with a centrally located gate. If the poker causes means many are missing out on considerable
chip has a uniform wall that is thick enough, the melt efficiency gains. Mixing problems usually only become
will flow uniformly from the gate and reach all of the apparent where on-machine colouring is being carried out
periphery of the cavity at the same time. This would be and show up in streaking on the part. A study has shown
an ideal situation. If that poker chip contains a deep recess that processors using a Sulzer static mixer in the nozzle
or a through hole, the melt would have to separate into to promote material mixing have been able to reduce their
two flow paths that would pass around those obstructions masterbatch addition levels by between 15 and 40%. The
and reunite on the other side. There would then be an study found that the ability to achieve good pigment
interruption in the flow, and the melt would not reach all dispersion at lower back-pressure, barrel temperature and
of the periphery of the cavity at the same time. Rotational screw speed settings means that melt temperature can be
moulding is a sintering process. Thermoforming and blow as much as 30C lower. This enables cycle times to be
moulding are stretching processes. These are not melt flow reduced by up to 36%.
processes. They can mould parts with thinner walls and SULZER CHEMTECH
no weld lines. In spite of its melt flow limitation, injection EUROPEAN COMMUNITY; EUROPEAN UNION; UK;
WESTERN EUROPE
moulding is the product designers most frequently
specified moulding process. Weld lines are an integral Accession no.814603
part of this process; aspects covered include materials
selection, moulding considerations and design guidelines. Item 96
USA Advances in Polymer Technology
Accession no.815856 20, No.1, Spring 2001, p.14-21

NUMERICAL SIMULATION OF THERMALLY pressure and holding time, on the shrinkage, degree of
INDUCED STRESS AND WARPAGE IN crystallinity and mechanical properties of PP specimens.
INJECTION-MOULDED THERMOPLASTICS 21 refs.
Gu Y; Li H; Shen C EUROPEAN COMMUNITY; EUROPEAN UNION; SPAIN;
Dalian,University of Technology; WESTERN EUROPE
Zhengzhou,University Accession no.807112
Thermally induced stress and the relevant warpage caused
by inappropriate mould design and processing conditions Item 99
are problems confounding overall success of injection Antec 2000.Conference proceedings.
moulding. Numerical simulation and finite element method Orlando, Fl., 7th-11th May, 2000, paper 726
are studied to predict thermally induced warpage and residual PRACTITIONER TRAINING PROGRAM FOR
stress of injection moulded parts generated during the cooling TROUBLESHOOTING INJECTION MOLDED
stage of the injection-moulding cycle. A thermorheologically PART DEFECTS
simple two-dimensional thermoviscoelastic material model Shanor M; Swantner D; Baird D T
is used in the numerical computing. The initial temperature Pennsylvania,State University
field of the analysis corresponds to the end of the filling (SPE)
stage. The fully time-dependent algorithm is based on the The cause and general solutions for a number of injection
calculation of the elastic response at every time step. moulding faults are described and illustrated by case
Numerical results are discussed with respect to temperature studies, including: vacuum voids, stuck parts, colour
and pressure, and compared with experiment results. 14 refs. streaks, and discoloration. Injection moulding trials were
CHINA conducted using a range of processing parameters to
Accession no.808582 establish the most significant factors creating the faults.
USA

79, No.527, May 2000, p.554-8 Item 100
Spanish Antec 2000.Conference proceedings.
STUDY OF THE SURFACE QUALITY OF PVC Orlando, Fl., 7th-11th May, 2000, paper 720
FITTINGS ON THE BASIS OF INJECTION TRAINING PROGRAM FOR TROUBLE-
MOULDING PARAMETERS SHOOTING INJECTION MOLDED DEFECTS
Castany F J; Llado J; Sanchez B; Javierre C; Aisa J Bloom D; Gorman C
Taller de Inyeccion de la Industria del Plastico; Pennsylvania,State University
Zaragoza,University (SPE)
The influence of injection moulding conditions on the The cause and general solutions for a number of injection
occurrence of surface defects on PVC pipe fittings was moulding faults are described and illustrated by case
studied experimentally and by finite element analysis. studies, including: burn marks, bubbles, splay and glass
Comparison of the experimental results with theoretical fibre streaks. Design of experiment techniques were used
predictions allowed optimisation of the processing to establish the most significant factors creating the faults.
conditions for the production of parts having the required USA
surface quality. 3 refs. Accession no.805728
EUROPEAN COMMUNITY; EUROPEAN UNION; SPAIN;
WESTERN EUROPE Item 101
Accession no.807113 Antec 2000.Conference proceedings.
Orlando, Fl., 7th-11th May, 2000, paper 719
PRACTITIONER TRAINING PROGRAM FOR
Item 98
TROUBLESHOOTING INJECTION MOLDED
PART DEFECTS
79, No.527, May 2000, p.550-3
Schickline A; Schmidt J
Spanish
Pennsylvania,State University
INFLUENCE OF GATE THICKNESS ON THE
(SPE)
MECHANICAL BEHAVIOUR OF
POLYPROPYLENE The cause and general solutions for a number of injection
Gordillo A; Santana O O; Miranda F; Martinez A B moulding faults are described and illustrated by case
Centre Catala del Plastic; Catalunya,Universidad studies, including: dimensional variations, flash, gate
Politecnica blush, and weld lines.
USA
Results are presented of a study of the effects of injection
moulding conditions, including gate thickness, holding Accession no.805727

Item 102 found to be in the nozzle orifice and the way it matched up
Antec 2000.Conference proceedings. to the sprue bushing.
Orlando, Fl., 7th-11th May, 2000, paper 694 USA
CAE APPROACH TO RELIEVE NOTEBOOK Accession no.805092
CONNECTOR AIR-TRAP PROBLEMS
Rong-Yeu Chang; Lin A S; Hsu D C; Fu-Ming Hsu Item 105
Taiwan,National Tsing Hua University; CoreTech Antec 2000.Conference proceedings.
System Co.Ltd.; Horn-Chi Precision Machinery Orlando, Fl., 7th-11th May, 2000, paper 511
Co.Ltd. USING CMM DATA TO QUANTIFY SINK
(SPE) MARKS
The use of computer aided engineering software to prevent Horton K; Keil M; Engelmann P; Lyth D; Monfore M
air trap problems, as an alternative to trial-and-error, in Western Michigan,University; Ralston Foods
the design of moulds for injection moulding applications (SPE)
is discussed, using the production of a notebook computer Sink marks of varying size were created on an injection
connector as a case study. Mould design modifications moulded part by varying the packing pressure. The dimensions
included: the introduction of an additional gate to facilitate of the marks were determined using a coordinate measuring
melt flow; the provision of gating at the original air trap machine, the parts being held in a jig consisting of a set of
position; and modifications of the gate dimensions to pins attached to a gauge plate. The influence of the part
balance flow. 6 refs. curvature was eliminated by fitting a second order polynomial
TAIWAN equation to each set of data. It was established that sink marks
Accession no.805702 could be quantified using a coordinate measuring machine, in
conjunction with a dedicated jig. 6 refs.
Item 103 USA
Antec 2000.Conference proceedings. Accession no.803358
THE IMPOSSIBLE PART - ON THE VERGE OF Item 106
FAILURE? Injection Molding
Golmanavich J; Hofmaster B 8, No.10, Oct.2000, p.114/5
Lucent Technologies TROUBLESHOOTER - PART 43: TAKING SINKS
(SPE) OUT OF ACRYLIC
The case history of a part with a web of 4.625 mm in Hatch B
diameter but only 0.125 mm in thickness, to be Prime Alliance
manufactured by injection moulding, is described. Flow This article is part 43 of a series of troubleshooting reports
software indicated that incomplete filling would occur. relating to injection moulding. It deals with sink in the
Nevertheless, a trial mould was produced, and with thick sections when moulding with acrylic. A case history
increasing injection speed, mould temperature and is included to illustrate the point-in-hand. Details are given
material temperature, filling using polycarbonate was of the symptom and cause, the solution, and the result.
eventually achieved. A change to a polycarbonate/ABS USA
blend with enhanced flow properties, and an increase in Accession no.802401
web thickness to 0.175 mm, gave further improvements,
leading to the commitment to produce an eight-cavity Item 107
production mould and the acceptance of the part for Injection Molding
production. 1 ref. 8, No.10, Oct.2000, p.62/6
USA BY DESIGN: PART DESIGN 202 - PROJECTION
Accession no.805701 HEIGHT
Beall G
Item 104 Glenn Beall Plastics Ltd.
Injection Molding This article examines an issue important to part design
9, No.1, Jan.2001, p.90-2 engineers and the moulding industry: projection height
TROUBLESHOOTER. ELUSIVE CURE FOR (projections being any structural detail that is attached to
SURFACE DEFECTS the nominal wall of the moulded part). Design faults leading
Hatch R to incomplete filling of moulds are discussed. Section
Prime Alliance headings include: melt flow, venting considerations,
ejection problems, and finally, length of projections.
A report is presented on a study of the problem of surface
USA
splay occurring on thick injection-moulded polycarbonate/
PETP parts with three cored-out holes. The answer was Accession no.802393

Item 108 also modelled using commercial modelling software.

Injection Molding Operating with the coolant temperature above the
8, No.10, Oct.2000, p.54/60 dewpoint prevented the formation of condensation. The
DESIGN - MATERIALS ANALYST: PART 36 cooling simulation accurately predicted the relationship
Sepe M between the core material, the coolant temperature and
Dickten & Masch MFG.Co. the temperature of external surfaces. The increase in
temperature in conjunction with the copper alloy core
This is part 36 of a series of articles designed to help
increased the cycle time by approximately 0.5 s. At
injection moulders understand how a few analytical tools
temperatures below the dewpoint, the steel core ran hotter
can help diagnose a part failure problem. It is the first part
than the copper alloy core, the warpage of the steel core-
of a short set of articles which deals with the myths of heat
moulded parts stabilising at cycle times of 2 s longer than
deflection temperature. The deflection temperature under
with copper cores. 7 refs.
load test is discussed in depth, and its limitations analysed.
USA
DOW CHEMICAL
USA Accession no.799723
Accession no.802392
Item 111
Medical Device Technology
Item 109
11, No.9, Nov.2000, p.36/40
Journal of Injection Molding Technology
MOULDING PROBLEMS: FEED SYSTEM TOO
4, No.4, Dec.2000, p.167-76
SMALL
DEFECTS IN SURFACE APPEARANCE OF
INJECTION MOULDED THERMOPLASTIC
DuPont
PARTS - REVIEW OF SOME PROBLEMS IN
SURFACE GLOSS DISTRIBUTION It is explained that, in order to produce good quality
Lacrampe M F; Pabiot J mouldings, manufacturers need to ensure that their feed
Ecole des Mines de Douai systems are designed correctly. This article outlines the
key characteristics of an efficient feed system when
A review is presented of surface defects occurring in making parts from semi-crystalline polymers.
injection moulded thermoplastic parts. The key
parameters affecting surface defects, including part and SWITZERLAND; UK; WESTERN EUROPE
mould cavity geometry, incidence of processing
Accession no.798905
parameters and incidence of the nature and properties of
the thermoplastic material, and possible mechanisms of
defect formation are discussed. 12 refs. Item 112
EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; Injection Molding
WESTERN EUROPE 8, No.11, Nov.2000, p.94/7
Accession no.801510 TROUBLESHOOTER PART
44:PREDICTABILITY OF GATE BLUSH
Hatch B
Item 110 Prime Alliance Inc.
Antec 2000.Conference proceedings.
Orlando, Fl., 7th-11th May, 2000, paper 203 A polycarbonate alloy part was displaying a line of splay
USE OF COPPER ALLOYS TO REDUCE MOLD oriented in line with the gate and blush at the gate. The
CONDENSATION PROBLEMS moulder was also experiencing screw slippage on the
Hayden K; Engelmann P; Shoemaker J; Monfore M; moulding machine which was lengthening the cycle. It was
Dealey R recommended that the moulder open the sprue O diameter
Western Michigan,University; Mouldflow Corp.; to at least 0.375 inch, shorten the gate land to no more than
Johnson Controls Inc.; Dealeys Mold Engineering 0.030 inch and lower the barrel heats. The changes were
(SPE) made and the parts improved and slippage was eliminated.
USA
The prospect was investigated of substituted higher
Accession no.797206
thermal conductivity copper alloy components for less
conductive steels in injection moulding moulds, so
permitting an increase in temperature of the cooling water, Item 113
which in turn would eliminate surface condensation Antec 2000.Conference proceedings.
problems. Using a single cavity 33 mm bottle cap mould Orlando, Fl., 7th-11th May, 2000, paper 133
with a C18000 copper alloy or type 420 stainless steel COVER PART AS AN APPLICATION EXAMPLE
core and cooling water temperatures of 10 C or 21 C FOR GAS-ASSISTED INJECTION MOLDED
(below and above the dewpoint, respectively), parts were PARTS
moulded using a propylene copolymer. The moulding was Hansen M

Mack Molding Co. Item 116

(SPE) Kunststoffe Plast Europe
90, No.10, Oct.2000, p.25-7
The process of gas-assisted injection moulding is briefly
E-MAIL FROM AN INJECTION MOULDING
described in terms of material properties, processing
MACHINE
parameters, part design, and the injection moulding
Schwab E; Marzineak R
technique, and procedures for tool design illustrated using
KMI; Markischen,Fachhochschule
the production of a cover part, 985 mm x 560 mm of 3
mm wall thickness, as an example. The importance of Internet technology has made available all communication
consistency in the filling phase, and difficulties associated possibilities required for remote maintenance applications
with gas distribution, the packing of areas remote from for injection moulding machines. With the aid of modern
the gas injection points, the avoidance of sink marks are communication technologies and systems that can detect
discussed. 5 refs. faults at an early stage, it is now possible to monitor
USA injection moulding machines from anywhere in the world,
Accession no.795488 carry out measurements and adjustments and evaluate
results. Details are given of technology available for
permanent plant monitoring, early detection of potential
Item 114
faults, and automatic routing of malfunction alarms to
Antec 2000.Conference proceedings.
control centres. 6 refs.
POLYMER RAW MATERIAL, PROCESS AND
WESTERN EUROPE
PRODUCTION FINGERPRINTS IN INJECTION
MOULDING Accession no.791851
Dawson A J; Key A; Coates P D
Bradford,University; Polymer Insights Item 117
(SPE) Plastics and Rubber Weekly
The use of in-line rheometers to monitor polymer 27th Oct.2000, p.13
consistency, and injection pressure-time relationships to UNIVERSITY CHALLENGE
monitor changes in material quality and process Volex Powercords makes 13a cords for various high
conditions during injection moulding are discussed. A profile OEMs, including manufacturers of computer and
pressure-time monitoring system was developed which office equipment, white goods, brown goods and power
condenses the data to a single value, giving a process tools. Most products are made from injection moulded,
index, and results are presented for the mean hydraulic flexible PVC. In 1995, batch-to-batch variations started
pressures obtained from a production machine moulding to cause major process problems. The company turned to
ABS. Following the setting of appropriate control limits, the Manchester Materials Science Centre which
the system is capable of rejecting products produced discovered there were differences in the rheology of the
outside process limits. 12 refs. materials at high shear rates. Volex found that by sourcing
EUROPEAN COMMUNITY; EUROPEAN UNION; UK; material from just one compounding machine, uniformity
WESTERN EUROPE
was significantly improved. A Teaching Company project
Accession no.795479 with Salford University involved flex testing of a cable/
plug attachment, while a project at Manchester
Item 115 Metropolitan University looked into the effect of additives
Antec 2000.Conference proceedings. and base polymer on heat dissipation in 13a plugs.
Orlando, Fl., 7th-11th May, 2000, paper 80 VOLEX POWERCORDS
PREVENTING SINK MARKS OF INJECTION EUROPEAN COMMUNITY; EUROPEAN UNION; UK;
MOULDED PARTS USING CAE ANALYSIS WESTERN EUROPE
Ni S Accession no.791062
Lexmark International Inc.
(SPE) Item 118
Commercial computer software was used to model the Polymer Engineering and Science
injection moulding of a small laser printer component, 40, No.10, Oct.2000, p.2161-74
so as to alleviate a sink problem. The predictions of the INVESTIGATION OF WAVELIKE FLOW
sink dimensions were in agreement with measurements MARKS IN INJECTION MOULDING: A NEW
on production parts, and the software was used to redesign HYPOTHESIS FOR THE GENERATION
the mould and to modify the process conditions to MECHANISM
eliminate the problem. 5 refs. Tredoux L; Satoh I; Kurosaki Y
USA Tokyo,Institute of Technology; Tokyo,University of
Accession no.793811 Electro-Communications

The results of flow visualisation studies during the continued, with emphasis on thick-walled parts and
injection moulding of PS and HDPE carried out to gating.
ascertain the way in which wavelike flow marks generate USA
are used to develop a flow mark generation hypothesis. Accession no.789947
This hypothesis is based on a mechanism of non-uniform
thermal contraction of the polymer in the solidifying layer
close behind the contact line. A mathematical model is Item 121
proposed to account for non-dimensional flow mark Plastics, Rubber and Composites
curvature in terms of processing conditions, thermal 29, No.1, 2000, p.23-30
properties of the polymer and mould and the interval of IN PROCESS MONITORING OF POLYMER
flow mark generation and the implications of the BATCH TO BATCH VARIATION IN INJECTION
hypothesis are considered. 15 refs. MOULDING
Kelly A L; Woodhead M; Rose R M; Coates P D
JAPAN
Bradford,University
Accession no.790459
Injection moulding studies are reported, during which in
process measurements are used to monitor batch-to-batch
Item 119
variation of several production grade polymers. Three
Polymer Process Engineering 99. Conference
materials are studied: a polyamide 6, a polyacetal and a
proceedings.
flexible PVC, all of which are commercial injection
London, June 1999, p.18-27
moulding polymers supplied by industrial collaborators.
MONITORING BATCH TO BATCH VARIATION
Instrumented high precision electric and servohydraulic
IN INJECTION MOULDING
moulding machines are used to mould parts inhouse from
Kelly A L; Dawson A J; Key A; Woodhead M; Coates P D
a number of different material batches. Moulding
Bradford,University
conditions are kept constant throughout and several
Edited by: Coates P D
process variables are monitored during injection,
(Institute of Materials; UK,Interdisciplinary Research
including melt pressure, melt temperature and viscosity
Centre in Polymer Science & Technology;
index - a specific pressure integral calculated from
Bradford,University)
primary injection. Part weights are measured to provide
Injection moulding studies are reported, using in-process an indication of part quality. Results show that in each
measurements to monitor batch-to-batch variation of a case, variations between batches produce a measurable
number of production grade polymers. Instrumented high- effect on part quality. These variations are detected by in
precision moulding machines (servo electric and servo process measurements, particularly by viscosity index,
hydraulic) are used to mould different batches of the same which track significant changes in part weight. Several
grade of material, while process variables are monitored. problem batches not identified by the compounders
These include specific injection pressure integrals, nozzle internal quality checks are detected, and the influence of
melt pressure and temperature. Three materials are studied regrind and a development compound are also clearly
- polyamide, acetal and flexible PVC - all taken from identified. No simple relationship between viscosity index
production runs by industrial collaborators. In-process and part quality is observed for the limited processing
measurements are found to be sensitive to variation range covered. Overall, the studies show the potential of
between batches of the same material, corresponding to in process measurements to provide a real time, sensitive
part quality measurements such as weight and dimensions. indication of process variation. 13 refs.
Several problem and development batches are EUROPEAN COMMUNITY; EUROPEAN UNION; UK;
successfully detected, in particular by specific pressure WESTERN EUROPE
integrals. 5 refs. Accession no.789906
WESTERN EUROPE
Item 122
Accession no.790077
4, No.3, Sept.2000, p.114-9
Item 120 PROCESS AND TOOLING FACTORS
Injection Molding AFFECTING SINK MARKS FOR AMORPHOUS
8, No.9, Sept.2000, p.94/6 AND CRYSTALLINE RESINS
TROUBLE SHOOTER. XXXXII. COPING WITH Tursi D; Bistany S P
THICK WALLS AND GATES Drexel,University; Montell Polyolefins
Hatch R
An investigation was carried out on the effects of material,
Prime Alliance
processing and tooling on sink mark formation during the
A series of troubleshooting reports from one of the leading injection moulding of a semi-crystalline PP and an
on-the-spot problem solvers in the moulding industry is amorphous polymer (Centrex 811) using a plaque tool

specially built to facilitate changing rib features. Processing In this article the author, who spends his time diagnosing
variables examined included melt temperature, mould moulding problems, offers his comments on water cooling
temperature, injection rate, holding pressure, holding time problems. After an introduction, section headings include:
and cooling time. A screening study was performed to hot and cold pockets, parallel or serial?, restrictions, and
determine the most influential factors affecting sink and a finally, flow is everything.
response surface study to better define the relationships. USA
The effects of beryllium copper rib-insert material and rib- Accession no.787869
base radius on sink depth were also evaluated and optical
microscopy and DSC were employed to determine
Item 126
crystallisation and molecular orientation differences
Injection Molding
between plaques having various degrees of sink. 11 refs.
8, No.7, July 2000, p.42/8
USA
DESIGN - MATERIALS ANALYST: PART 34
Accession no.789499 Sepe M
Item 123 This is part 34 of a series of articles designed to help
Canadian Plastics injection moulders understand how a few analytical tools
58, No.9, Sept. 2000, p.33/6 can help diagnose a part failure problem. It deals with
TAKING THE HEAT OFF HOT RUNNER the techniques required to carry out a full analysis of a
SELECTION compound, such as gel permeation chromatography
LeGault M (GPC), the oxidation induction time (OIT) test, and
The design and selection of hot runner systems is energy-dispersive X-ray spectroscopy.
discussed with reference to return on investments. USA
Dynisco HotRunners recommends using a worksheet to Accession no.787854
forecast which helps customers work out their ROI for a
hot runner by taking into account factors such as material
Item 127
costs, estimated scrap rates, moulding and machine
Plastics and Rubber Weekly
conditions, electricity rates, cycle time savings and costs No.1854, 15th Sept.2000, p.10
to run auxiliary equipment. Also recommended are mould TEST AND RESOLVE
flow software programs to optimise channel size, and Gavin P
Mold-Masters Internet-based system, Merlin.
A troubleshooting approach is recommended for finding
INCOE CORP.
NORTH AMERICA the possible causes of short mouldings in injection
moulding practices. Potential variables which might be
Accession no.788920
causing the short mouldings are discussed, and include:
the machine, the material, the tool, the ancillaries,
Item 124 technical staff, machine operator, and ambient conditions.
Injection Molding Any of the scenarios described can result in or appear to
8, No.7, July 2000, p.88/92 result in the fault known as a short, with all seven
TROUBLESHOOTER - PART 41: MOLDFILLING variables having a direct effect on the finished product.
ANALYSIS DERAILED The problem-solving method proposed involves a process
Hatch B of elimination.
Prime Alliance EUROPEAN COMMUNITY; EUROPEAN UNION; UK;
WESTERN EUROPE
This article is part 41 of a series of troubleshooting reports
relating to injection moulding. It deals with mould-filling Accession no.786533
analysis. A case history is included to illustrate the point-
in-hand. Details are given of the symptom and cause, the Item 128
solution, and the result. Canadian Plastics
USA 58, No.7, July 2000, p.36
Accession no.787871 VIEW FROM THE FLOOR
Anderton J
Item 125 This article discusses some problems which may be
Injection Molding encountered when injection moulding reinforced
8, No.7, July 2000, p.72/5 thermoplastics. Issues including part ejection, fibre
WATER BASICS FOR MOLDS orientation, shrinkage and fibre distribution are examined.
Tobin B CANADA
WJT Associates Accession no.785044

Item 129 EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY;

Modern Plastics International WESTERN EUROPE
30, No.5, May 2000, p.52/5 Accession no.780271
INJECTION TECHNOLOGIES CAST
SPOTLIGHT ON LENSES Item 132
Moore S Revista de Plasticos Modernos
Discussed in this detailed article is the production of 79, No.523, Jan.2000, p.34/7
optical lenses by injection moulding, with emphasis on Spanish
the reduction of cycle times and lowering of reject rates - INJECTION TEMPERATURE AND POST-
which can still run as high as 50 percent for difficult MOULD SHRINKAGE OF POLYAMIDES
lenses. Radici Group
NETSTAL MASCHINEN AG; Relationships between injection temperature in the
SINGAPORE,PRECISION ENGINEERING injection moulding of polyamides and the post-mould
APPLICATION CENTRE; SINGAPORE shrinkage of moulded parts are discussed. Data are
PRODUCTIVITY & STANDARDS BOARD; presented for the shrinkage of non-reinforced and glass
SAMSUNG ELECTRONICS CO.LTD.; APPLIED fibre-reinforced nylon-6,6 moulded at 30, 60 and 85C and
IMAGE GROUP/OPTICS; FERROMATIK; KONICA of glass fibre-reinforced nylon-6,6 after heat treatment at
OPTICS TECHNOLOGY CO.; NIPPON ZEON CO.; different temperatures.
TEIJIN BAYER POLYTEC; TEIJIN CHEMICALS; EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY;
BAYER AG; ROEHM GMBH; TICONA GMBH; WESTERN EUROPE
SUMITOMO HEAVY INDUSTRIES; SODICK CO. Accession no.780265
JAPAN; SINGAPORE; SOUTH KOREA; SWITZERLAND; USA;
WESTERN EUROPE Item 133
Canadian Plastics
Accession no.783384
58, No.5, May 2000, p.27/32
LIVIN LARGE
Item 130 Anderton J
Molding Systems
It is explained that moulders moving up to large tonnage
58, No.3, June 2000, p.34-9
injection moulding machines might be in for a few
UNDERSTANDING THERMOPLASTIC PART
surprises - such as the need to reinforce floors, upgrade
WARPAGE
cranes for larger moulds, and learn new techniques for
Saile R
filling large moulds successfully. This article looks in
LNP Engineering Plastics Inc.
detail at what is involved.
Thermoplastic part warpage is one of the most common VAN DORN DEMAG CORP.; STEPHEN SALES
problems encountered by injection moulders today. LTD.; ENGEL; HUSKY INJECTION MOLDING
Differential shrinkage is the primary cause of internal SYSTEMS LTD.; UBE MACHINERY INC.;
stresses in the part and can result from a variety of factors. DAIMLERCHRYSLER; TOSHIBA; JSW PLASTICS
Four areas must be considered: material, part design, tool MACHINERY INC.; HPM CORP.
design and processing. CANADA
Accession no.782590
Item 134
Item 131 Injection Molding
Revista de Plasticos Modernos 8, No.6, June 2000, p.128/30
79, No.523, Jan.2000, p.79-84 TROUBLESHOOTER PART 40: TAPERING
Spanish DROPS FOR GOOD FLOW
INFLUENCE OF MOULDING CONDITIONS ON Hatch B
PRODUCTIVITY Prime Alliance Inc.
Canovi P N ABS parts fed by a three-plate runner system exhibited
Processing New Technologies Consulting unacceptable blush at the gate. The mould core had
An examination is made of the influence of processing multiple levels, staggered in thickness, all of which is
conditions on productivity in the injection moulding of fed by a single gate. The problem was eliminated with
amorphous and semi-crystalline plastics and on the quality minor changes in sprue diameter, gate modifications and
of moulded parts. Processing parameters discussed process improvements.
include mould temperature, injection speed and pressure, USA
holding time and melt temperature. Accession no.775818

Item 135 Significant differences are commonly seen between parts

Plastics Newsletter moulded in multi-cavity injection moulds. The elimination
No.2, 2000, p.1-4 of these variations is complicated by the large number of
Chinese variables existing within the mould, the injection
COMMON DEFECTS OF GAS ASSISTED moulding process, and the material. A means of isolating
INJECTION MOULDINGS and quantifying the primary causes of these variations is
Zhu T-L; Wang M-J presented. By isolating the causes, the moulder can more
Dalian,University of Technology effectively and efficiently address the differences between
parts moulded in different cavities and thereby maximise
Defects of products moulded by gas-assist injection
productivity. 5 refs.
moulding are analysed. Corresponding methods to solve
USA
the problems of moulding defects are discussed in detail.
12 refs. Accession no.771542
CHINA
3, No.2, June 1999, p.67-72
Item 136
ANALYSIS OF HALO EFFECTS ON INJECTION
Plast 21
MOULDED PARTS
No.86, Nov.1999, p.58-60
Dharia A
Spanish
Solvay Engineered Polymers
MOULD COOLING IN THE INJECTION
MOULDING PROCESS The problem of a specific type of surface defect called
Barcelo A tiger stripes or halos on the injection moulded parts of
ASCAMM a thermoplastic olefin blend is investigated. First, the
method to reproduce such defects on the small parts is
The principles of heating and cooling in plastics injection
described, and then the results of a rheological method to
moulding are examined, and aspects of mould design for
predict materials prone to producing tiger stripes are
optimum cooling are discussed.
presented. Results indicate that both the molecular weight
WESTERN EUROPE
and relaxation behaviour are critical determinants.
Materials with large molecular weights, as predicted by
Accession no.773242
very high melt viscosity at zero shear rate and short
relaxation time, tend to form fewer tiger stripes. 14 refs.
Item 137 USA
Plastics and Rubber Weekly Accession no.771539
No.1831, 7th April 2000, p.11
GOOD MACHINE MAINTENANCE STARTS
OUT WITH A FEW BASICS Item 140
Dziech D Journal of Injection Molding Technology
Ferromatik Milacron 3, No.2, June 1999, p.54-60
ULTRASONIC DETECTION OF FILLER
Injection moulding machine maintenance is the subject CONCENTRATION IN PLASTIC INJECTION
of this article. A list is presented of nine basic MOULDING
recommendations that will help keep machine-related Ibrahim I A; Petersen P F
faults to a minimum. The list includes information on oil Cleveland,State University
contamination, filters, water quality, lubrication,
alignment checks, platens, heater bands, and safety The demand for precision moulded parts, such as
devices. automotive-electrical connectors and electronic circuit
NORTH AMERICA
holders, is becoming a major segment of the overall
plastics market. This new and fast-growing market
Accession no.772010
segment is placing stringent requirements on the
performance of polymer materials and is pushing the
Item 138 limits and capabilities of current manufacturing processes
Journal of Injection Molding Technology and controls. Raw material variations constitute a
3, No.2, June 1999, p.88-98 significant source of problems in processing. Variations
TROUBLESHOOTING CAVITY TO CAVITY caused by contamination, moisture content, regrind levels,
VARIATIONS IN MULTI-CAVITY INJECTION lot-to-lot variations, and filler concentration can
MOULDS significantly affect the performance and efficiency of the
Beaumont J; Ralston J; Shuttlewoth A; Carnovale M injection moulding process. In addition, the more stringent
Behrend College; Osram Sylvania Products Inc. quality requirements of todays products reduce the levels

of tolerable variations in the material properties. To this This article concerns an acrylic part with a very thick
end, a proprietary ultrasonic coupling device is developed wall in its middle section attached to a fairly thin wall.
to allow the use of ultrasonic sensors to detect the The moulder was having problems with airless voids in
variations of material properties prior to injection. 11 refs. the thick section and cracking where the thick part
USA attached to the thinner wall section. The solution was to
Accession no.771537 fill with injection pressure and raise packing pressure to
1100psi, and raise barrel heats and nozzle temperature to
Item 141 475F to aid material flow. Although the voids disappeared,
Polymer Composites the sprue and nozzle orifice remain too small for the
21, No.2, April 2000, p.322-31 volume requirements of the part, which slows cycle time.
OCCURRENCE OF SURFACE ROUGHNESS IN USA
GAS ASSIST INJECTION MOLDED NYLON Accession no.768547
COMPOSITES
Shih-Jung Liu; Jer-Haur Chang Item 144
Chang Gung,University Modern Plastics International
The surface roughness which may occur during gas- 30, No.2, Feb.2000, p.84-6
assisted injection moulding was investigated using 15% MACHINE MAINTENANCE: A NEGLECTED
and 35% glass fibre-filled polyamide-6 composites, PROFIT CENTRE
moulded using an 80-ton injection moulding machine with Snyder M R
a high-pressure nitrogen injection unit. The influence of Milacron claims that maintenance oversights cause injection
melt temperature, mould temperature, melt filling speed, moulders at least as many problems as mould and material
short-shot size, gas pressure, and gas injection delay time related issues. Maintenance conducted after a machine
on the surface quality of the moulded parts was measured breakdown costs three times as much as work done on a
using a roughness meter. The surface roughness was preventive basis. The cost of replaced components will be
mainly due to exposure of the glass fibre, which may have easily recovered by savings from better performance, longer
been caused by jetting and irregular flow of the polymer component life, less oil replacement, fewer repairs and more
melt during filling. 29 refs. uptime. Computerised maintenance management software
TAIWAN is commonly available.
Accession no.770553 WORLD
Accession no.766818
Item 142
Popular Plastics and Packaging Item 145
Special Issue, Suppl.Feb.2000, p.123-8 British Plastics and Rubber
TECHNOLOGICAL TOOLS FOR PART DESIGN, Feb.2000, p.27
MOULD DESIGN AND MANUFACTURING OF TURN YOUR TROUBLESHOOTER INTO A
MOULD MARKSMAN
Bolur P C Maier C
Power Plastic Consultants
Injection Moulding Troubleshooter is a new programme
Technological tools in injection moulding are described, with from training specialist BPTA which aims to make
emphasis on part design, mould design and mould troubleshooting more effective. Training mode
manufacture. Aspects covered include failure concentrates on fundamentals and is the learning part of
troubleshooting, steps for part and mould design, the programme. Fast Track mode is more a support tool
technological advancement in mould making, difficulties and for practical production troubleshooting. Both deal with
benefits of CAE and CAD technology, CAE as a powerful the same nine major injection moulding faults, but the
tool for moulder and learning environment, use of CAE, approach is different.
CAD/CAM, global trends in development of plastics parts BPTA
and mould and assembly and testing of moulds. EUROPEAN COMMUNITY; EUROPEAN UNION; UK;
INDIA WESTERN EUROPE
Item 143 Item 146

8, No.4, April 2000, p.100/5 8, No.3, March 2000, p.126/9
PACKING OUT THICK PARTS TROUBLESHOOTER: ACETAL FLOW LINES
Hatch B Hatch B
Prime Alliance Inc. Prime Alliance Inc.

A moulder running acetal copolymer was getting some polycarbonate/polyester alloy. Lowering the mould
flow lines on a round, flat surface just inside the gate on temperature below the minimum recommended by the
the part. After watching the process, it was found that the material manufacturer proved to be the cause of the
mould temperature was only 140F, too low to produce problem.
glossy, rigid parts from acetal. The data sheet provided USA
by the material supplier suggested mould temperatures Accession no.761532
from 75 to 180F. The mould temperature was raised to
180F and the flow lines disappeared.
Item 150
USA
Injection Molding
Accession no.764508 7, No.12, Dec.1999, p.74/8
HOW STRONG ARE YOUR CAVITIES?
Item 147 Tobin B
Troy, Mi., 1998, pp.8. 28 cms. 13/3/00 WJT Associates
SCREEN-PAC FILTERS FOR INJECTION
MOLDING MACHINES. PREVENTS PLUGGED A case history is described of a cavity failure in a two-
GATES AND ORIFICES cavity mould destined for the production of over a million
Incoe Corp. parts. Causes for the breakage are identified, and
recommendations are given for the avoidance of similar
Screen-Pac filters from Incoe Corp. are described with problems.
reference to their theory of operation and design features.
USA
They are barrel mounted tubular filters which protect tiny
mould gates used in runnerless moulds, from plugging Accession no.757691
and allow recycling of regrind. They have a negligible
pressure drop, and can be purged quickly. A list is included Item 151
which can be used to identify the most appropriate filter Injection Molding
for specific injection moulding machines. Technical 7, No.12, Dec.1999, p.44/8
product data are enclosed for machine mounted versions MATERIALS ANALYST: PART 27,
SPM-600 and 350, and in addition, a case history is CONTAMINATION SPRINGS FROM COST
included, in which a troubleshooting expert identifies the PRESSURES
need for a melt filter to remedy blocked valve gates. Sepe M
USA Dickten & Masch Mfg.
Accession no.764356 The current emphasis on cost reduction can lead to
problems with quality, it is suggested, and two examples
Item 148 of injection moulded parts are given which highlight this.
Injection Molding They both involve contamination of raw materials when
8, No.1, Jan.2000, p.94/9 sourced with price as the deciding factor, and both
TROUBLESHOOTER - PART 36: BALANCING illustrated that the longer term costs of rectifying problems
FAMILY MOLDS with contamination in terms of the possibility of down
Hatch B times and failure analysis outweigh any potential raw
Prime Alliance materials savings.
This article is part 36 of a series of troubleshooting reports USA
relating to injection moulding. It deals with the problem Accession no.757685
of balancing family moulds. A case history is included to
illustrate the point-in-hand. Details are given of the Item 152
symptom and cause, the solution, and the result. Addcon World 98. Conference proceedings.
USA London, 9th-10th Nov.1998, paper 13
Accession no.763284 INFLUENCE OF PIGMENTS ON THE
DIMENSIONAL STABILITY OF MOULDED
Item 149 PLATES
Injection Molding Tomlins P E; Banyard J; Butler B; Lord G
8, No.2, Feb.2000, p.94/7 UK,National Physical Laboratory
TROUBLESHOOTER: COLD MOULDING (Rapra Technology Ltd.)
CREATES CRACKS
Many of the vibrantly coloured inorganic pigments prized
Hatch B
for their colour fastness and thermal stability contain
Prime Alliance Inc.
heavy metals such as cadmium and are, or have been,
A part had been successfully moulded for several years phased out because of their environmental unacceptability.
before it began cracking. The material was a Some of the organic pigment replacements are renowned

for causing problems of dimensional instability in tool. Parts produced had a dull surface finish and had a
mouldings, particularly those manufactured from slow cycle time. Problems discovered on inspection of
polyolefins. The influence that pigments have on the in- the mould and analysis of the moulding cycle, included
plane shrinkage and warpage and out-of-plane distortion flow path restrictions, gating into thin sections, a small
of a plate moulding manufactured from HDPE is assessed. main runner, no venting, high injection pressure and a
Variables such as plate thickness and post-moulding cold mould. By opening up the flow path, venting the
treatment are considered as well as colour. 15 refs. tool and running at a lower temperature, glossy parts, with
EUROPEAN COMMUNITY; EUROPEAN UNION; UK; resin-rich surfaces and shorter moulding cycles was
WESTERN EUROPE achieved. Particular considerations relating to the
Accession no.757025 injection moulding of glass-filled materials, are discussed.
USA

Macplas
24, No.211, Sept.1999, p.71-3 Item 156
Italian Composites Science and Technology
PITFALLS IN THE DESIGN OF MOULDED 59, No.12, 1999, p.1923-31
PARTS WARPAGE OF CORNERS IN THE INJECTION
Spann J; Belski V MOULDING OF SHORT FIBRE-REINFORCED
C-Mold Inc.; Viadelo THERMOPLASTICS
Some common problems occurring in the design of Mlekusch B
moulds and plastics parts for injection moulding are Leoben,University
examined, and the value of computer simulation in design Short fibre-reinforced thermoplastics (SFRT) show
processes is discussed. significantly greater corner-warpage in injection moulding
EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; USA; compared with non-reinforced systems. It is suggested
WESTERN EUROPE
that this additional warpage effect is attributed to the
Accession no.754650 anisotropy of the material. According to the microstructure
of SFRT, which usually shows a boundary-core-boundary
Item 154 layer structure, a multi-layer model is used for calculating
Kunststoffe Plast Europe the thermoelastic problem of cooling a cylindrical
89, No.11, Nov.1999, p.13-4 segment. A generalised plane-strain state is assumed. The
MOULD TECHNOLOGY FOR THE AIRMOULD model predicts the full deformation state as well as the
CONTOUR PROCESS residual stresses. For each single layer an orthotropic
Jaroschek C; Hunold M; Blomeke C constitutive equation is used. The material data are
calculated from images of polished cross-sections together
With highly ribbed injection moulded parts in particular, with a micromechanical model. The model predictions
sink marks on the visible side are often a problem. By using are compared with the warpage of a specially designed
a special mould technology in airmould contour injection experimental component. This comparison shows that the
moulding, this risk can be eliminated. The process utilises additional warpage observed for short fibre-reinforced
gas pressure exerted on the surface of the product. In this materials can be attributed to the anisotropy of the
way, pressure can be applied over a large area of melt while material. 11 refs.
it is still plastic. If the ribbed reverse side of the moulding
AUSTRIA; WESTERN EUROPE
is chosen as the surface on which the pressure acts, a
deliberate sink mark can be produced in this way. Accession no.751375
BATTENFELD AG
EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; Item 157
WESTERN EUROPE Kunststoffe Plast Europe
Accession no.754264 89, No.7, July 1999, p.11-13
AVOIDANCE OF SURFACE DEFECTS IN GAS-
ASSIST INJECTION MOULDING
Item 155
von Riewel A; Eyerer P; Knoblauch M
Injection Molding
Fraunhofer-Institut fuer Chemische Technologie
7, No.11, Nov.1999, p.116-8
TROUBLESHOOTER, PART 35: GLASS-FILLED Characteristic surface defects in gas-assisted injection
NYLON PARTS moulding are described, including changeover marks, gas
Hatch B bubble marks, sink marks as a result of melt accumulation
Prime Alliance and fingering effect problems. Methods for avoiding these
This issue of The Troubleshooter deals with a glass-filled defects are recommended. 11 refs. (German version of this
nylon 6,6 part moulded using an eight-cavity cold runner paper, which includes graphs and tables, is on p.44/8)


WESTERN EUROPE Shawbury, Rapra Technology Ltd., 1999, pp.238. 52
Accession no.747372 METALLIC PIGMENTS IN POLYMERS
Wheeler I
Item 158 The purpose of this book is to bridge the technology gap
Injection Molding that has developed over the last 20 years by providing a
7, No.9, Sept.1999, p.106/11 comprehensive account of the nature, manufacture,
TROUBLESHOOTER PART 34: SINKS INSIDE A formulation and applications of the diverse metallic pigments
MOULDED PLUG commercially available today. Whilst the text concentrates
Hatch B on direct pigmentation of polymers there are also two
Prime Alliance Inc. chapters on metal pigment coatings for polymer substrates.
A moulder was having trouble with sink marks on the In addition to the familiar colouristic applications there is a
interior wall of a nylon plug. It was found that the small chapter on the many, often novel, functional applications in
nozzle orifice was forcing the moulder to run high melt which colour is either accidental or irrelevant.
temperatures, and the uniform runner dimensions were Accession no.743913
causing pressure losses and flow restrictions. Inadequate
cooling in the core of the mould was also adding to the
Item 162
problems. It was recommended that jumpers were
Revue Generale des Caoutchoucs et Plastiques
removed from mould cooling lines and cascade core
No.777, May 1999, p.39-45
bubblers be replaced with baffle-type bubblers. Part
French
venting should be increased and runner venting added.
DESIGN OF INJECTION MOULDED PARTS. I.
The main runner and feed opening in the sprue bushing
Hasenauer J; Kuper D; Laumeyer J E
should be enlarged.
Du Pont de Nemours E.I.,& Co.Inc.
USA
Accession no.747193 Aspects of design and materials selection for injection
moulded non-reinforced and fibre-reinforced thermoplastic
parts are discussed. The influence of design features such
Item 159 as wall thickness and ribs and of injection moulding
Plast 21 conditions on the properties of mouldings is examined.
No.81, May 1999, p.31-2 USA
Spanish
Accession no.742608
DETECTION OF COMMON DESIGN ERRORS
Pastorinni N
The causes of common errors in the design of plastics Item 163
products are discussed, with particular reference to parts Injection Molding
produced by injection moulding. 7, No.7, July 1999, p.42/5
MATERIALS ANALYSIS. XXII. STRESS
WESTERN EUROPE CRACKING: HOW TO AVOID THIS SILENT
KILLER. I
Accession no.745849
Sepe M
Item 160
Revista de Plasticos Modernos Stress cracking is one of the most common problems
77, No.514, April 1999, p.378-83 associated with field failures in plastic products. One estimate
Spanish from Rapra Technology states that in almost a third of all
SOLVING PROBLEMS IN THE INJECTION failed plastic applications the problem is stress cracking.
MOULDING OF PARTS FOR DOMESTIC Other anecdotal data from experienced plastic part designers
APPLIANCES tends to echo this testimony. It is illustrated how it is so
Gomez J L; Alonso J R; Campo J J; Martinez R difficult to predict when this problem will occur, and why is
Gaiker,Centro Tecnologico it so difficult to diagnose when it does present itself.
RAPRA TECHNOLOGY LTD.
Results are presented of a computer simulation study USA
undertaken by Gaiker to optimise the design and injection
Accession no.741798
mouldability of a PS tray for use in refrigerators produced
by Fagor Electrodomesticos.
FAGOR ELECTRODOMESTICOS Item 164
EUROPEAN COMMUNITY; EUROPEAN UNION; SPAIN; Injection Molding
WESTERN EUROPE 7, No.6, June 1999, p.86/93
Accession no.745765 GUIDE TO COLOUR TROUBLESHOOTING

Angel G Item 167

Hanna M.A.,Color Technical Center Kunststoffe Plast Europe
89, No.5, 1999, p.8.
Colouring plastics at the press is one of the most
PREVENTION INSTEAD OF STOPPAGES
functional, value added features a moulder can impart
Schwab E
to a moulded product. Self-colouring not only improves
aesthetic properties, it can also improve UV stability A new software program has been developed by
and make processing easier. Adding colour at the EuroKMI, (Plastics Machinery Institute for Europe
machine is also almost always less expensive than GmbH) called Win-IPS. It is designed to facilitate the
purchasing precoloured material from a supplier. There implementation of and use of preventative maintenance
is just one problem: once the colour system has been planning and control for injection moulding machines.
incorporated into the polymer matrix, it becomes an At specified intervals, an inspection order with
integral part of the material and may alter its engineering instructions for the individual machines and zones is
properties as well as its processability. As a result, it is automatically initiated, and each inspection is documented
important to be aware of some of the common problems according to ISO 9000, QS 9000 and VDA 6.1. Machine
availability is calculated for each machine, and any
involved with melt colouring plastics and how to avoid
problem areas can be identified. The core data for the
them. Generally, aesthetic flaws can be attributed to three
software are listed. (Translated from Kunststoffe 89
different causes: equipment, moulding and design/
(1999) 5, pp.48)
formulation. Details are given.
USA
EUROKMI GMBH
Accession no.739920
Item 165
Injection Molding Item 168
7, No.6, June 1999, p.78-80 Injection Molding
TROUBLESHOOTER. XXX1. LESSON IN 7, No.5, May 1999, p.54/60
MATERIAL SUBSTITUTION DESIGN - MATERIALS ANALYST: PART 20 -
Hatch R FINDING PROBLEMS IN HOT RUNNERS
Prime Alliance Inc. Sepe M
The continuation of a series of troubleshooting reports Dickten & Masch Mfg.
from one of the leading on-the-spot problem solvers in This is part 20 of a series of articles designed to help
the moulding industry. The optical quality problems injection moulders understand how a few analytical tools
encountered when injection moulding an acrylic medical can help diagnose a part failure problem. It deals with
device, following a material grade change, are described. finding problems in hot runners. Two case histories are
USA included, one entitled the case of the sticky residue and
Accession no.741685 the other the case of the plugged gate. Full details of
the problems and the solutions are presented.
USA
Item 166
7, No.6, June 1999, p.39/43
SINK MARKS IN NOMINAL WALLS Item 169
Beall G Plastverarbeiter
Beall G.,Plastics Ltd. 48, No.6, 1997, p.64
German
The importance of an injection moulded parts nominal
SMALL, SMALLER, AT ITS SMALLEST
wall has already been established. Selecting the optimum
Spork E
wall thickness and maintaining that thickness throughout
Guenther Heisskanaltechnik
the part have also been reviewed. Emphasis is placed on
sink marks in the nominal wall. Sink marks are an inherent This article is part II in a series of six about injection
part of the injection moulding process. They are the topic moulding small components and covers narrow
of endless debates among marketing, quality assurance, interspacing of cavities and the problems linked with it.
product designers and injection moulding suppliers. The During the set-up of hot channel systems injection
causes of sink marks, their indication of stress and moulding of small components requires other criteria than
minimisation of sink marks are discussed. articles with larger dimensions or weights. By using
moulding examples from screw injection moulding,
USA
medical and laboratory technology and devices produced
Accession no.741664 by the firms Guenther Heisskanaltechnik from

Frankenberg, Schosser from Knittlingen and Boehringer Item 172

Mannheim GmbH, the author shows what the user has to Cowbridge, 1998. pp.31. 12ins. 11/6/99.
look out for. INJECTION MOULDING OF SILASTIC LIQUID
BOEHRINGER MANNHEIM GMBH SILICONE RUBBER
EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; Dow Corning STI Ltd.
WESTERN EUROPE
The injection moulding of liquid silicone rubber is
Accession no.735816 discussed, together with details of the technological
advantages of Silastic LSR, and its potential
Item 170 applications. Characteristics and injection moulding are
Manchester, c.1999, pp.31. 12ins. 21/6/99. outlined, followed by principles of mould design for
INJECTION MOULDING OF SILASTIC LIQUID LSR, criteria for machine selection, details of two-
SILICONE RUBBER component injection moulding and injection moulding
Dow Corning STI Ltd. of one-component HCR Silastic RapidCure, and a
Fundamental guidelines are given for the injection section on troubleshooting.
moulding of Silastic liquid silicone rubber, (LSR) from EUROPEAN COMMUNITY; EUROPEAN UNION; UK;
Dow Corning. The characteristics and injection moulding WESTERN EUROPE
of LSR are discussed, followed by the principles of mould Accession no.734383
design for LSR, criteria for machine selection, production
and troubleshooting. Item 173
EUROPEAN COMMUNITY; EUROPEAN UNION; UK; Antec 99. Volume III. Conference proceedings.
WESTERN EUROPE
New York City, 2nd-6th May 1999, p.2959-63. 012
Accession no.735011 EFFICIENT COPING WITH PRODUCTION
BREAKDOWNS USING KNOWLEDGE-BASE
Item 171 APPROACH
Mouldmaking 95. Conference proceedings. Bluvband Z; Shavit A
Solihull, 2nd Feb.1995, paper 7. 83 ALD
PREDICTING MOULD FILLING FOR MOULD (SPE)
DESIGN
Leo V Injection moulding product quality is affected by many
Solvay & Cie.SA process parameters. The usual troubleshooting procedures
(BPF; Gauge & Toolmakers Assn.) suggest a list of possible corrective actions for each
potential failure of a product, without taking, into account
Flow analysis software is about twenty years old. possible side effects. There is one optimal corrective
Tremendous progress in the computer power-to-cost ratio, action, leading to the most stable process and product
as well as a better understanding of injection moulding, quality. A methodology that helps the operator to select
have led to the present situation where it is now difficult to the most efficient corrective action is presented, using
justify not using this sort of technology when designing a knowledge-base approach, relying on a Y-shape matrix
complex tool. The moulding industry itself has considerably (failure-cause-solution) with theoretical rules and
and the current most successful stories invariably involve practical statistics. 7 refs.
a concurrent engineering approach, where the part design, ISRAEL
the moulding tool definition and the process optimisation
Accession no.734277
itself are simultaneously addressed at the early stage of the
project. Dimensional, as well as mechanical, properties of
the part are a direct consequence of the material processing Item 174
history. The process involves different stages which were Antec 99.Volume 1.Conference proceedings.
addressed separately in the past, reflecting the development New York City, 2nd-6th May, 1999, p.1045-7.012
of the software technology. Today, the only correct approach PROPER UTILIZATION OF POROUS MOLD
is a global one, where the moulding process is regarded as STEEL TO SOLVE VENTING PROBLEMS
a complex physical problem involving very transient and Bowen R
strongly coupled thermal and rheological phenomena. International Mold Steel Inc.
Certainly, when talking about mould filling, the concept (SPE)
should be extended to the end of the packing phase, Porous mould steel, with 25vol% porosity, is manufactured
considering that during this pressure-controlled stage a by sintering stainless steel powder. Three grades are
significant amount of melt is still entering the cavity. Some available, with average pore sizes of 3, 7, or 20 micrometres.
of the essentials of the physics involved in the process are Benefits from the use of inserts of this steel in injection
reviewed, in order to present some of the capabilities of moulding moulds, in addition to self-venting, include:
the software, as well as some of the limitations. reductions in injection pressure, cycle times, shots size and
Accession no.734412 scrap rates; elimination of flow lines, short shots, and

material burning. Practical advice is given on the design Advice is provided to injection moulding companies on
and use of porous steel inserts. the technical assistance which can be provided by polymer
USA suppliers. Issues discussed include making the initial
Accession no.734093 contact with the supplier, published and non-published
literature, computer aided engineering services, part
failure analysis, testing and laboratory analysis, moulding
Item 175 trials, and training seminars.
Antec 99. Volume III. Conference proceedings.
USA
New York City, 2nd-6th May 1999, p.3665-9. 012
COOLING RATE EFFECTS ON SHRINKAGE Accession no.732986
Resler A E
Behrend College Item 178
(SPE) Antec 99. Volume 1. Conference proceedings.
New York City, 2nd-6th May,1999, p.675-9. 012
A study on how the cooling rate can produce variations
INJECTION MOLDS PROBLEMS SOLVED BY
in a plastic materials pressure-volume-temperature (PVT)
CAE ANALYSIS
characteristics, which are used in creating shrinkage data
Kalnin F A; Zluhan G P
for injection moulding simulation programs, is presented.
Brazil,Centro de Mecanica de Precisao de Joinville
Most available PVT data are created using a cooling rate
(SPE)
of only 3 deg.C/min. The problem with this data when
used to predict shrinkage is that during injection The benefits of commercially available computer aided
moulding, materials experience much faster cooling rates. engineering software in the design of injection moulded
The possibility of these variations in cooling rates parts are discussed, and demonstrated using two industrial
significantly affecting shrinkage values used by mould case studies. 4 refs.
filling analyses is discussed. 5 refs. BRAZIL
Accession no.733980
Item 179
Item 176 Antec 99. Volume 1. Conference proceedings.
Plastics Technology New York City, 2nd-6th May,1999, p.532-8. 012
45, No.3, March 1999, p.58-62 ANALYSIS OF HALO EFFECTS ON INJECTION
WHAT YOU CAN LEARN FROM SHOT MOLDED PARTS
PROFILES Dharia A
McAlister B Solvay Engineered Polymers
Branden Technologies Inc. (SPE)
The surface defect called tiger stripes or halos, seen
It is explained that, in injection moulding, there is no better
on automotive components which are injection moulded
tool than the electronic signature provided by process-
using blends of polypropylene and ethylene copolymers,
monitoring curves of cavity pressure and other variables.
consists of alternating concentric surface bands of high
The article provides seven real-world moulding case-
and low gloss. The influence of injection speed, mould
histories, as revealed through shot profiles. They are:
temperature, back pressure, melt temperature, and
correcting cold slugs, hard-to-hit transfer position, an
injection pressure on the incidence of this fault was
incapable machine, the case of the vanishing cushion,
investigated. It was concluded that the defect were caused
inconsistent screw starting position, controlling cavity
by melt flow instability, and the inability of the melt to
pressure with hydraulic pressure, and the case for robots.
recover from the stress changes at the cooling flow front.
VISION PLASTICS; TRIQUEST PRECISION 14 refs.
PLASTICS; STATISTICAL PLASTICS CORP. USA
USA
Accession no.732950
Accession no.733800
Item 180
Item 177 Antec 99. Volume 1. Conference proceedings.
Antec 99. Volume 1. Conference proceedings. New York City, 2nd-6th May,1999, p.486-90. 012
New York City, 2nd-6th May,1999, p.723-7. 012 OPTIMIZATION OF THE WELD LINE IN
UTILIZING AN ENGINEERING RESIN INJECTION MOULDING VIA AN
SUPPLIERS TECHNICAL SUPPORT EXPERIMENTAL DESIGN APPROACH
Jaarsma F C Chang T C; Faison E
Ticona LLC Iowa State University
(SPE) (SPE)

The Taguchi method was used to design an experimental TOOLING - KEEP THAT MOLD RUNNING
investigation into the influence of melt and mould Johnson S
temperatures, injection and hold pressures, cooling and Calmar Industries
holding times, and back pressure on the weld line width
This article discusses in detail proactive (or predictive)
and tensile impact properties of polyethylene injection
maintenance of injection moulding machinery, i.e. fixing
moulded dog-bone bars. The width of the weld line was
things before they break! It provides information on what
most affected by the melt temperature, and to a lesser is required to achieve this level of maintenance
degree by mould temperature and injection pressure. The organisation, which includes trained personnel on the
tensile impact properties were influenced most by the mould floor who can perform in-press servicing, and also
mould temperature, followed by melt temperature, a specific mould data documentation system.
injection pressure and cooling time. 17 refs.
TECHTRAX
USA
USA
Item 181
Antec 99. Volume 1. Conference proceedings. Item 184
New York City, 2nd-6th May,1999, p.461-6. 012 Injection Molding
TROUBLE SHOOTING CAVITY TO CAVITY 7, No.4, April 1999, p.58/64
VARIATIONS IN MULTICAVITY INJECTION DESIGN - MATERIALS ANALYST: PART 19
MOLDS Sepe M
Beaumont J; Ralston J; Shuttleworth A; Carnovale M Dickten & Masch Mfg.
Pennsylvania,State Erie; Osram Sylvania Products Inc. This is part 19 of a series of articles designed to help
(SPE) injection moulders understand how a few analytical tools
A procedure for isolating and quantifying the causes of can help diagnose a part failure problem. It deals with
variation from cavity to cavity in multi-cavity injection the particular case of exterior parts moulded from flexible
moulds was developed. Three causes were considered: PVC that developed black stains after a relatively short
flow induced imbalances in geometrically balanced period of time exposed to the elements. Full details of
runners; dimensional variations in the mould; and cooling the problem and the solution are presented.
effects. The weights of short shot moulded parts from USA
each cavity were compared, and it was concluded that Accession no.729317
short-filling to 80% was better than the common industrial
practice of filling to 95% when determining and solving Item 185
mould imbalances. 5 refs. Journal of Injection Molding Technology
USA 2, No.4, Dec.1998, p.184-91
Accession no.732936 DEVELOPMENT OF A METHODOLOGY FOR
DEFECT REDUCTION IN INJECTION
Item 182 MOULDING USING PROCESS SIMULATIONS.
Injection Molding PART II. A MULTI-FACTOR DESIGN OF
7, No.4, April 1999, p.117-8 EXPERIMENTS APPROACH
TROUBLESHOOTER - PART 30: A LESSON IN Patel S A; Mallick P K
SHEAR AND DIAMETERS Michigan,University
Hatch B The procedures developed in paper 1 are extended to find
Prime Alliance the effects of seven process variables on nine faults.
This article is part 30 of a series of troubleshooting reports Process variables are inlet melt temperature, coolant
relating to injection moulding. It deals with the case of a temperature, fill time, ejection temperature, fill/pack
torch housing made from ABS which the moulder could switchover by percentage of stroke, hold time and
not consistently fill out, and with which the moulder was injection rate. The defects were burn marks, sink marks,
experiencing a lot of rejects. Details are given of the warpage, shrinkage, degradation, short shots, flashing,
symptom and cause, the solution, and the result after weld lines and air traps. Evaluation and selection of the
changes were made. optimum solution is explained. 4 refs.
USA USA
Item 183 Item 186

Injection Molding International Polymer Processing
7, No.4, April 1999, p.92-4 14, No.1, March 1999, p.3-9

POLYMER PROCESSING PROBLEMS FROM equal dispersions. The article also examines the importance
NON-RHEOLOGICAL CAUSES of choosing appropriate external lubricants for good shape
Nakajima N forming. Calcium soap can be used, though this can result
Akron,University in delamination. This can be traced to the high viscosity of
the melted calcium stearate. Polyethylenes such as Loxiol
Problems and cause considered include (a) gels or fish
G70S are also used as external lubricants. Zinc can be used
eyes resulting from non-uniform distribution of giant
for internal and external lubrication, whereas lead is for
molecules, incomplete melting during extrusion,
internal. Dry blend lead is particularly used in thin-walled
crosslinking in the extruder or contamination of
fittings for drainage and sewage pipes. Only completely
machinery by material from a previous operation, (b) non-
homogenous systems guarantee results, hence the use of
uniform PP filaments coming from spinnerettes, (c)
granules. In receptors internal lubricants such as Loxiol
microscopic foreign objects causing stress cracking in
G60 are used, whereas Loxiol G32 is used externally. The
HDPE bottles, caused by changing grade of polymer to
USA and Japan lead the use of PVC in injection moulding.
reduce costs and overcome by polymerisation in dedicated
In the USA, PVC/ABS blends are common, using 50-70%
reactors for special objects, e.g. video and audio discs,
ABS and zinc as a lubricant. ABS increases the impact
(d) smear patterns in injection moulded fibre-filled
resistance and durability when heat formed, and PVC
polymers attributed to either non-uniform distribution of
reduces the flammability. Soft injection moulded PVC is
fibres or weld lines, (e) warping of blends resulting from
no longer a matter of interest in western Europe. Calcium-
immiscibility, (f) existence of pure polymer domains in
zinc stabiliser is an attractively priced and ever more
PVC/NBR blends caused by restricted miscibility range,
commonly used additive in soft PVC injection moulding.
(g) inconsistent processing due to morphological effects
It has no toxic side effects and has been used in the medical
in PVC and ABS, (h) reduced flow rate in HDPE caused
sector for decades.
by branching, (i) variation in weight and length of
polyoxymethylene extrudates resulting from degradation HENKEL KGAA
WESTERN EUROPE-GENERAL
and content of gas bubbles, (j) non-uniformity of
plasticised PVC resulting from melting and reforming of Accession no.728603
crystallites during production, (k) unexplainable
brittleness in rigid PVC containing small amounts of Item 188
plasticiser, (l) difficulties in explaining variations in Molding Systems
processing of successive batches of PTFE, and (m) 57, No.4, April 1999, p.34-8
difficulties moulding and extruding UHMWPE because PAY ATTENTION TO MAINTENANCE BASICS
it acts as a rubber rather than a true thermoplastic. Hilt R
Citations range from 1958 to 1986. 12 refs. Milacron Inc.
USA
This article discusses how to eliminate the eight chief
Accession no.728751 causes of injection moulding machine downtime. These
are oil cleanliness, control cabinet filters, water quality,
Item 187 toggle link lubrication, machine levelling, platen
Kunststoffe Synthetics squareness, heater band care and safety equipment.
No.2, 1998, p.26-9 USA
German Accession no.726031
RECEPTOR MIXTURE DECIDES THE
QUALITY
Klamann J-D Item 189
Plastics Technology
The article forms part of a series on PVC processing. This 44, No.12, Nov.1998, p.59/62
particular article examines injection moulding PVC, where CLEAN COOLING WATER CLEARS UP
shaping is down to the processor, not the plastic producer, MOLDING PROBLEMS
as is often the case in other plastics. In western Europe De Gaspari J
290,000 tonnes of PVC are injection moulded each year,
representing 6% of the total PVC used in Europe. Two thirds In this article it is explained that raising the quality of the
is solid PVC, of which most is used as fittings for the pipe cooling water in injection moulding systems translates
industry. PVC does not have a defined melting point and is into higher quality moulded parts. It examines closed-
better suited to extrusion and calendering. A stabilising of loop cooling, which provides tight temperature control
the rheology is needed to make it suitable for injection that in turn provides an improvement to moulding
moulding, lest such problems as deficient surface consistency. A closed-loop cooling system (such as that
tolerances, delamination in oven-testing and incomplete employed by Windsor Mold of the USA, an automotive
shape-forming are encountered. In western Europe injection moulder) is fully described.
stabilisation is based on lead or zinc. Fittings are made WINDSOR MOLD; AUTOPLAS; PRECISION
mostly from granules in order to keep homogeneity and AUTOMOTIVE PLASTICS; ENGINEERED

PROCESS COOLING SYSTEMS rheometrical measurements performed on injection

USA moulding machines.
Accession no.723869 EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY;
WESTERN EUROPE

Injection Molding
7, No.1, Jan.1999, p.92-5 Item 193
TROUBLESHOOTER - PART 29: THE SECRETS Kunststoff Journal
OF HOT RUNNER MOLDS 28, No.5, Oct.1994, p.42-3
Hatch B German
Prime Alliance CHALLENGE TO TOOL FAULTS
Thienel P; Hoster B; Kuerten C
Kunststoff-Institut Fur Die Mitt Wirts NRW GmbH
relating to injection moulding. It deals with hot runner
moulding problems. A case history is included where a Damage to tools when used for thermosetting materials
moulded part, a storage box, is of poor appearance. Details is often expensive and difficult to put right. The K.I.M.W.
are given of the problem, the solution, and the result. Plastics Institute at Ludenscheid, Germany is producing
MOLD-MASTERS; HUSKY; D-M-E the FAAS program (fault analysis and remedy system),
USA based on the actual experience of processors, raw material
Accession no.723639 manufacturers and machine manufacturers.
WESTERN EUROPE
Item 191
Accession no.721512
Injection Molding
7, No.3, March 1999, p.77
MELT FILTER PAYS OFF FOR VALVE GATE Item 194
Tobin B Molding Systems
57, No.2, Feb.1999, p.46-7
Problems with valve gates on injection moulding CONTROLLER HELPS ENSURE TOOL
machines are discussed. A case history is presented in QUALITY
which a company producing milk crates from low melt-
index-toughened polypropylene with some recycled Tycos Tool makes injection moulds for large automotive
content experienced clogging, and leaking valve gates in parts. To ensure tool quality, the company likes to fully
the mould and breaking valve pins. The problem was test its moulds before shipment to its customers. The
solved by the use of nozzle filters. Gammaflux Series 9500 hot-runner temperature
USA controller provides Tycos with the detailed tool analyses
Accession no.723167 it needs. The controller tests the performance of the
heaters and thermocouples in the hot-runner system and
diagnoses failing heaters and wiring problems. The
Item 192 software completes a performance analysis of the hot-
Plastverarbeiter runner manifold.
48, No.2, March 1997, p.74-6
TYCOS TOOL
German CANADA
PROBLEMS WITH PROCESSING
Accession no.721104
THERMOPLASTIC POLYURETHANES
Endres E; Zipp O; Kallweit J-H
Elastogran GmbH; Osnabrueck,Fachhochschule Item 195
This article forms Part II of a study on thermoplastic
38, No.12, Dec.1998, p.2020-8
polyurethanes (TPUs), relating particularly to TPU
WELD LINE MORPHOLOGY OF INJECTION
absorption of humidity. In Part I (Plastverarbeiter 46,
MOULDED POLYPROPYLENE
no.10, p.94 ff.) basic principles were explained for
Mielewski D F; Bauer D R; Schmitz P J; van Oene H
measuring permeation and absorption processes in
Ford Research Laboratory
TPUs. Also examined was the influence of
environmental parameters on the absorption of The goal of this work was to identify the cause of weld
humidity by TPU granules. The present Part II deals line weakness in PP systems. The morphology of weld
with which chemical and physical structures in TPUs lines in a high molecular weight PP (Profax 6823 from
influence hydrophilic properties and why absorbed Montell Polyolefins Inc) were studied. It was found that
humidity leads to increased material damage during the PP contained a hindered phenolic antioxidant additive
processing. The examination includes comment on that was not soluble in the polymer at the standard

processing conditions. TEM pictures revealed the additive Item 198

existing as a dispersed phase in the bulk polymer. Even Injection Molding
though very small concentrations of this additive are 6, No.11, Nov.1998, p.103/8
normally used (0.1 to 0.5%), large quantities were found MANUFACTURING - THE BASICS OF COLOR:
at weld lines in a band approximately 100 nm wide and PART II
penetrating about 10 micrometres into the surface of the
This is the second part of a two-part series where colour
part, hindering strength development at the weld line. X-
experts from two US companies share fundamental
ray photoelectron spectroscopy results confirm enhanced
knowledge about colour in moulded parts, to help
concentrations of antioxidant on the flow front and mould
designers and moulders avoid problems. The first part
wall surface of short shot samples. The mechanical
dealt with standards and metamerism. This article focuses
properties (Izod impact, TS) are measured for samples
on the issues of base resin and colour.
moulded at various processing conditions, varying
amounts of antioxidant additive and with and without weld TEKNOR COLOR CO.; MINOLTA CORP.
lines. The results are consistent with the presence of the USA
additive playing a key role in strength development at PP Accession no.711947
weld lines. Impact strength is reduced 50-75% by the
additive. 12 refs. Item 199
USA Injection Molding
Accession no.718718 6, No.11, Nov.1998, p.54/8
DESIGN - MATERIALS ANALYST: PART 15 -
DISTINGUISHING AMONG FILLERS
Item 196
Sepe M
Plastverarbeiter
Dickten & Masch Mfg.
46, No.4, April 1995, p.92-97
German This is part 15 of a series of articles designed to help
SURFACE DEFECTS IN THERMOPLASTIC injection moulders understand how a few analytical tools
MOULDINGS, PART I can help diagnose a part failure problem. It deals with
Thienel P; Broer E; Vitz Ch two types of detective work: identifying the
The authors present an overview of the most frequently composition of an unknown material, the properties of
occurring types of surface defects in injection-moulded which would be useful in a new product, and determining
products. The defects are described with regard to their if a formulation of a known material had changed when
external appearance, their physical cause is elucidated, products start to fail or perform uncharacteristically. Two
and a few possible ways of remedying them are given. case-histories are included to illustrate the points-in-hand.
Articles from this journal can be requested for translation USA
by subscribers to the Rapra produced International Accession no.711929
Polymer Science and Technology.
WESTERN EUROPE
Accession no.716847 85, No.11, Nov.1995, p.15-6
AVOIDING FAULTS ON MOULDINGS - WELD
Item 197 LINES, SHRINKAGE AND DISTORTION
Injection Molding Michaeli W; Wisinger G; Galuschka S; Zachert J
6, No.11, Nov.1998, p.119/22 RWTH; Petra GmbH Paul Braun; Widia GmbH; Institut
MANUFACTURING - TROUBLESHOOTER fuer Kunststoffverarbeitung
PART 27: MOLD FILL PROGRAMS DO A
Computer-assisted mould design is shown to be beneficial
PRETTY GOOD JOB
in realising and eliminating weak spots in the moulding
Hatch B
early in the design process. Examples are given which
Prime Alliance
describe the benefits and auxiliaries which are available
This article is part 27 of a series of troubleshooting reports to the mould designer, with particular reference to the
relating to injection moulding. It deals with the case of Cadmould-3D program. Consideration is given to the
parts made from polycarbonate where a swirl had selective location of weld lines, the avoidance of weld
developed at the end of the fill. The problem was found lines via the process technology, and the source of
to be related to the flow, and the solution was to optimise shrinkage and distortion in a 24-point edge connector
runner sizes for better flow. Full details are given. made of glass-reinforced PBTP. 3 refs.
EMPLAST EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY;
USA WESTERN EUROPE

Item 201 heed all the design aspects discussed. However, careless
Injection Molding errors are still made in the day-to-day routine of
6, No.12, Dec.1998, p.78/82 production. These could be reduced by carefully working
TROUBLESHOOTER PART 28: through the list of questions given. Any one of these
POLYCARBONATE MOLDING PROBLEMS questions answered with no can result in expensive post-
Hatch B modifications to the mould. The checklist can also be
Prime Alliance incorporated into a failure mode and effects analysis for
mould design. The individual problems are explained.
relating to injection moulding. It deals with appearance
WESTERN EUROPE
difficulties (weld lines) when moulding a polycarbonate
part. A case history is included to illustrate the point-in- Accession no.705893
hand.
USA Item 205
Accession no.706332 Injection Moulding International
3, No.6, Oct./Nov.1998, p.64-5
Item 202 TROUBLESHOOTING FLAT, FULL PARTS
Injection Molding Hatch R
6, No.12, Dec.1998, p.74/6 Prime Alliance Inc.
MANUFACTURING - WHY THIS PART WONT Problems in mould filling often result in cosmetic defects.
RUN IN THAT MACHINE Prime Alliance, a US-based resin distributor, gives some
Tobin B advice on keeping parts flat and full.
In this article, the author solves a common injection USA
moulding shop floor manufacturing problem - why a part Accession no.704754
will run in one machine but not in another. He does this
with the help of a case history illustrating the point-in-hand. Item 206
WJT ASSOCIATES Injection Moulding International
USA 3, No.6, Oct./Nov.1998, p.61-3
Accession no.706331 LASERS PROTECT MOULDS FROM DAMAGE
MMT, a rapidly growing injection moulding business near
Item 203
Milan, Italy, had a small but persistent case of a familiar
Injection Molding
problem: now and then a moulded part would not eject,
6, No.12, Dec.1998, p.40-3
or only partially eject, and the mould could be damaged
MATERIALS ANALYST: PART 16 - FOLLOWING
on the closing cycle. Apart from reworking the ejector
THE PATH OF A FAILED PART
system and/or the mould itself, the simplest solution was
Sepe M
to install a mould protection system. MMT technicians
Dickten & Masch MFG
did that, but they found that the optical sensors could
This is part 16 of a series of articles designed to help become blocked or out of alignment unpredictably, and
injection moulders understand how a few analytical tools the original problem returned as if the protection system
can help diagnose a part failure problem. It deals with how was not there. The company specialises in complex
amphorous and semi-crystalline materials handle fatigue. technical assemblies and wants parts production as
A case history is included to illustrate the point-in-hand. automated as possible, which is why mould protection
USA was originally installed. Seeking for a more reliable
Accession no.706312 solution, they turned to the newest division of their own
company, and solved the problem by using lasers in place
Item 204 of photo-optical systems. Details are given.
Kunststoffe Plast Europe MMT SRL
88, No.11, Nov.1998, p.10-1; p.2006-8 EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY;
English; German WESTERN EUROPE
TO THE POINT Accession no.704753
Nachtsheim E
Many years of practical experience, sometimes gained at Item 207
great expense, have shown that most errors in mould Injection Moulding International
design cart be attributed to gating. Expensive corrections 3, No.6, Oct./Nov.1998, p.48
can be avoided by systematically working through a MOUNTING LOCATIONS FOR MEASURING
design checklist prior to mould conception. Experienced CAVITY PRESSURE
professionals will certainly be familiar with and generally Kirkland C

Victorinox of Ibach, Switzerland, the famous maker of compensated for by a bulge in the cavity. The time-
the Swiss Army knife, and Kistler Instrumente have consuming and expensive change to the contours of the
enjoyed a co-operative customer/supplier relationship for mould has to be correctly dimensioned. The supplier has
more than 20 years. The very first Kistler sensor and therefore initiated a project with the aim of computer
charge amplifier used at Victorinox are still in use. modelling the rheological and thermal behaviour of the
Originally, Kistlers systems solved machine cycle moulding and mould, and their effects on shrinkage and
consistency problems and subsequent part quality troubles warpage. The results are used to derive the dimensions
in insert moulding the nylon cores of the knives around of the bulge. A bulge that is planned in advance and
the manually inserted knife blades at Victorinox. Based correctly dimensioned increases the cost of the mould by
on its initial successes, Victorinox wanted to mould its approx. 5 to 7%; in contrast, a bulge introduced
knife shells, but the 6 mm diameter Kistler transducers retrospectively or a modification occasioned by incorrect
available at the time were too big. As a result, Victorinox predictions, increases the cost by more than 30%. This
switched to indirect (behind-the-pin) force sensors using does not take into account the time delays and costs for
smaller, 2 mm diameter pins. Since then, Victorinox additional testing of samples. The expense for complete
Kistler have developed direct 2.5 mm sensors. Victorinox simulation, by contrast, is less than 5% of the mould costs.
and Kistler have subsequently developed a complex A central department at Siemens, Munich, which offers a
method to test in-mould performance of direct and indirect wide variety of computational techniques as an
cavity pressure sensors. Details are given. interdivisional service, has carried out computations using
VICTORINOX; KISTLER INSTRUMENTE AG Moldflow software. Siemens has employed injection
SWITZERLAND; WESTERN EUROPE moulding simulation processes since the beginning of
Accession no.704749 1981. The simulations have a proven record as a useful
and reliable aid for recognising problems in advance, as
early as in the development phase of mouldings. Details
Item 208
are given. Illustrations may be found in Kunststoffe, 85,
Injection Moulding International
No.1, 1995, p.44/7.
3, No.6, Oct./Nov.1998, p.32/4
CASE OF THE MISSING FILLER
WESTERN EUROPE
Sepe M
Dickten & Masch Mfg. Accession no.704431
Fillers and reinforcements provide a valuable option for

Item 210
improving the properties of many thermoplastics and
thermosets. Semicrystalline thermoplastics such as
85, No.2, Feb.1995, p.11-2
nylon, PP and polyester are especially big users of these
MELT FILTERS FOR INJECTION MOULDERS
additives, but they can also be found in amorphous
Rossback R
materials like polycarbonate and PPO. Glass fibre is one
of the most important reinforcements used to increase Thermoplastics waste provides a comprehensive source
strength, stiffness, creep resistance and fatigue of raw material for the plastics processing industry. It may
properties. When a processor or an end user specifies be divided into three categories according to origin:
that a part is to be made in a reinforced material, the manufacturing scrap, non-domestic post-consumer waste
percentage of that reinforcement is one of the key items and domestic post-consumer waste (heavily
that must be controlled in order to ensure that the contaminated). As a rule, domestic post-consumer waste
properties of the compound are consistent and achieve is contaminated and unsorted and so can be recycled for
desired levels. Quality problems experienced when further processing only via a central reprocessing unit.
injection moulding a 40% glass fibre-reinforced PP To ensure problem-free processing of all three types of
material are examined. waste, particularly in injection moulds with small gate
USA cross sections, hot runner moulds, three-plate moulds and
Accession no.704735 moulds with a tunnel gate, an optimum melt filter system
is indispensable. Such a system must be straightforward
to install and easy to clean while offering high filtration
Item 209
efficiency. It must prevent contaminants contained in the
thermoplastics waste from clogging gates in the injection
85, No.1, Jan.1995, p.9-10
mould. There are basically two different melt filter
INSIGHTS
systems which can be used in processing thermoplastics:
Bogensperger H
filter plates and filter inserts. Illustrations may be found
After demoulding, monitor ejection bezels may warp in in Kunststoffe, 85, No.2, 1995, p.193/5.
a similar way to a shoe box. During this process the upper EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY;
and lower edges are drawn inwards and the sides are WESTERN EUROPE
drawn outwards. The ensuing deformation may be Accession no.704421

Item 211 Item 214

Polymer Plastics Technology and Engineering Popular Plastics and Packaging
37, No.4, Nov.1998, p.509-25 43, No.9, Sept.1998, p.71/8
DIRECT SEARCH-BASED AUTOMATIC TROUBLESHOOTING IN POLYMER
MINIMISATION OF WELD LINES IN PROCESSING - PART 2
INJECTION MOULDED PARTS Kulshreshtha A K; Awasthi S K
Yao D; Kim B Indian Petrochemicals Corp.Ltd.
Massachusetts,University
In this paper, troubleshooting in injection moulding and
An automated design methodology for minimisation of in extrusion is considered in detail, and tips are offered
weld lines by optimising the part and mould design is for solutions to various problems than can arise during
described. Weld lines are quantitatively evaluated based processing. Also, approaches to solving problems arising
on their length and location and the melt front movement during PVC injection moulding, FRP processing, and
with the aid of commercial injection moulding simulation compression moulding of SMC, are also given. 37 refs.
software which provides an integrated analysis. A INDIA
combined implementation of the Complex method and
Accession no.703439
injection moulding simulation is developed to reduce and
relocate the weld line or to improve the weld line strength.
Two parts, Gillettes deodorant base and Cavalleros Item 215
capacitor can, are chosen for the weld line minimisation. Revue Generale des Caoutchoucs et Plastiques
Reduction and relocation of weld lines for the deodorant No.762, Oct.1997, p.29-32
base prevent the cracking problem in the original design. French
For the capacitor can, the original 15.5 mm weld line is TEN TOPICS CONCERNING THE INJECTION
minimised to zero and the burnt mark due to air trap is MOULDING OF ENGINEERING POLYMERS. V.
eliminated by optimising the gate location. The results of Poppe E A; Leidig K; Schirmer K; Jayle L
simulation based on the automated design methodology Du Pont de Nemours (Deutschland) GmbH; Du Pont de
agree well with the experimental findings. 23 refs. Nemours France SA
USA
Factors influencing the shrinkage and warpage of
Accession no.704286 components injection moulded from non-reinforced and
glass fibre-reinforced semi-crystalline engineering
Item 212 plastics are discussed, and causes of the formation of
Injection Molding deposits in mould cavities are also examined. Procedures
6, No.9, Sept.1998, p.111/3 which can be used to avoid these problems are reviewed.
MANUFACTURING: TROUBLESHOOTING (Part I: Ibid., No.757, March 1997, p.25-9; Part II: Ibid.,
TOOLKIT FOR INJECTION MOLDERS No.759, May 1997, p.27-30; Part III: Ibid., No.760, June/
This article discusses the need for a troubleshooting toolkit July 1997, p.41-4; Part IV: Ibid., No.761, Sept.1997,
for injection moulding problems. It then lists three sets p.27-30).
of tools necessary for troubleshooting ones own EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE;
operation, under the headings: basic tools, intermediate GERMANY; WESTERN EUROPE
tools, and advanced tools. Accession no.702492
DOW PLASTICS
USA Item 216
Accession no.703460 Gummi Fasern Kunststoffe
47, No.10, 1994,p.642-9
Item 213 German
Injection Molding IMPROVED TECHNOLOGIES FOR
6, No.9, Sept.1998, p.64/8 ELASTOMER PROCESSING. PART 3.
MATERIALS ANALYST: PART 13 EVACUATION AND INERT GAS FLUSHING OF
Sepe M INJECTION MOULDS
Dickten & Masch Mfg. Meiertoberens U; Herschbach Ch; Maass R
This is the thirteenth part of a series designed to help moulders The avoidance of moulding faults due to trapped air and
understand how a few analytical tools can help diagnose a oxygen is explained, and tests involving the use of
part failure problem. In this particular article, the relationship vacuum equipment and flushing with an inert gas are
between melt flow rate and molecular weight is explained. described. The effect of the inert gases (N2, CO2,Ar
An insert box also considers the relationship between and He) on the surfaces of the moulding and on the
molecular weight, toughness, and temperature. mechanical properties in the weld line region is
USA described. 25 refs. Articles from this journal can be
Accession no.703447 requested for translation by subscribers to the Rapra

produced International Polymer Science and at runner intersections, the flipper forces the melt stream
Technology. through changes in level and direction as it splits.
EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; PENN STATE ERIE
WESTERN EUROPE USA
Item 217 Item 220

Molding Systems Kunststoffe Plast Europe
56, No.7, Sept.1998, p.36-9 88, No.9, Sept.1998, p.20-1,1396/402
INJECTION MOULDING TROUBLESHOOTING German; English
DEMYSTIFIED CLEAN-ROOM PRODUCTION: CENTREPIECE
Bryce D M OF MEDICAL TECHNOLOGY. ECONOMICAL
Texas Plastic Technologies Inc. CLEAN-ROOM PRODUCTION
This article, part 5 of a series, concludes an investigation Kudlik N
of the potential causes and solutions for common Netstal-Maschinen AG
moulding defects. Excessive shrinkage, sink marks and The particular problems involved in injection moulding of
splay are examined. medical parts are discussed, with emphasis on the suitability
USA of the clean-room production system. The requirements
Accession no.700083 on the machine and peripheries and on operators and service
staff are described. The necessary rapid process control
Item 218 and detailed documentation are considered and expected
Injection Molding future developments are outlined. 5 refs.
6, No.10, Oct. 1998, p.144/8 SWITZERLAND; WESTERN EUROPE
TROUBLESHOOTER: PART 26: DISK GATES Accession no.699031
CAN BE TROUBLE
Hatch B Item 221
Prime Alliance Kunststoffe Plast Europe
This case history involves a valve cover injection moulded 88, No.9, Sept.1998, p.7-9,1338/42
from glass filled nylon 66 using a disk-gated single cavity German; English
mould. It is presented with surface defects and blemishes, MICRO-INJECTION MOULDING -
including flow marks and roughness, and also short shots TRANSGRESSING THE LIMITS OF THE
at the end of fill were being obtained. The problem was FEASIBLE
found to be that the disk gate was too small, the sprue Seidler D; Zelenka R
was too small, and the parting line was not vented. HB-Plastic GmbH
Solutions suggested involved an enlarged sprue and gate Problems in the injection moulding of micro plastics parts
area and the addition of venting, which resulted in an are discussed and the adoption and exploitation of new
improved appearance and better cycle time. technology which solves the problem of poor productivity
USA resulting from inadequate metering accuracy and
Accession no.699890 homogeneity of extremely small volumes of melt are
described. The advantages of the micro-injection
Item 219 moulding technology are illustrated by a direct
Plastics Technology comparison, using an operating pin of a microswitch
44, No.10, Sept.1998, p.47 (made from Vectra LCP) as an example. 3 refs.
FLIP THE MELT FOR BALANCED MOLD AUSTRIA; WESTERN EUROPE
FILLING Accession no.699024
Ogando J
Problems with filling imbalances of multi-cavity moulds Item 222
have been addressed by the development of the melt flipper. Kunststoffe Plast Europe
The device has been introduced following research at Penn 88, No.9, Sept.1998, p.6-7,1331/6
State Erie using mould trials and finite element analysis. German; English
The research traced flow imbalances to temperature MICRO-INJECTION MOULDING - THE AIMS
stratification within the melt stream caused by asymmetrical OF A PROJECT PARTNERSHIP
shear distribution. The melt flipper, intended for H-pattern Kukla C; Loibl H; Detter H; Hannenheim W
and other geometrically-balanced moulds of eight cavities Wiener Neustaedter Bildungs- und ForschungsgesmbH;
or more, changes the orientation of the melt stream. Located Vienna,Technical University

The work of an Austrian project partnership set up to solve Sloan J

the specific problems of micro-injection moulding is
This article looks at the initial difficulties experienced by
summarised. The problems discussed are related to the
Eastman Kodak, in the production of the grey 35mm film
machine, the mould, the process, quality control, further
canister lids so familiar to photographers. The problem
processing and packaging, and integration. The broad range
was that hot stainless steel cores were causing pulled
of applications of the process is briefly considered. 4 refs.
centres where the parts failed to eject. It describes tests
AUSTRIA; WESTERN EUROPE
carried out by the company to ascertain whether a copper
Accession no.699023 alloy, Ampcoloy 940, would be a preferable core material.
EASTMAN KODAK CO.
Item 223 USA
Revue Generale des Caoutchoucs et Plastiques Accession no.696131
No.761, Sept.1997, p.27-30
French
Item 226
TEN TOPICS CONCERNING THE INJECTION
Injection Molding
MOULDING OF ENGINEERING POLYMERS. IV.
6, No.8, Aug. 1998, p.92/9
Poppe E A; Leidig K; Schirmer K; Jayle L
TROUBLESHOOTER: PART 25: THIN-WALL
Du Pont de Nemours (Deutschland) GmbH; Du Pont de
ABS PARTS WITH SURFACE DEFECTS
Nemours (France) SA
Hatch B
An examination is made of the causes of surface defects Prime Alliance
in injection moulded semi-crystalline engineering plastics
components, and methods for overcoming these problems This months troubleshooting problem involves a thin-
are discussed. (Part I: Ibid., No.757, March 1997, p.25- walled end cover manufactured from ABS using a three-
9; Part II: Ibid., No.759, May 1997, p.27-30; Part III: Ibid., cavity, two-plate mould with edge gating. The finished
No.760, June/July 1997, p.41-4). product displayed blemishes and blushing, which were
found to be caused by the use of trapezoidal runners which
EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE;
GERMANY; WESTERN EUROPE were improperly sized, a too small gate size and too great
a thick-to-thin transition. The solution offered involved
Accession no.698952
recutting the runners to round, making the main runner
larger than the secondary one, enlarging the gate, and
Item 224 cutting venting into the mould.
Injection Moulding International USA
3, No.5, Aug/Sept.1998, p.60-2 Accession no.693221
SOLUTIONS TO COSMETIC DEFECTS, PART 3:
PLATING PROBLEMS FROM BLUSH AND
HAZE Item 227
Hatch B Injection Molding
Prime Alliance 6, No.8, Aug. 1998, p.89-90
BACKFLOW REVISITED: THE STREAK IN THE
Problems with surface defects on a plating grade of
RUNNER
injection moulded ABS are troubleshot. The part was an
Sloan J
oval shape which had haze on the curved section and blush
at the gate. Details are given of changes made to the size Statements questioning the existence of the backflow
of the runner to improve the flow path and run lower barrel phenomenon are challenged by Klay Schulz of Phillips
heats, and in addition, the runners were vented to get rid Plastics. He cites the example of an automotive
of excess air that was being forced through the gates and lightswitch cover, moulded in two shots in a two-material
overloading the parting line vents. The gates were found process. The first shot consists of a black ABS
to be undersized and were causing blush on the part. This overmoulded by a clear acrylic. Proof of backflow is
was rectified and the gates were perimeter vented. presented in the form of the acrylic runner which had a
Improved cycle time was achieved as well as an almost streak of black ABS running through the centre of it.
zero rejection rate from the plater. Efforts to solve the problem by alterations in holding time
USA are reported.
Accession no.696443 PHILLIPS PLASTICS
USA
Accession no.693219
Item 225
Injection Molding
6, No.6, June 1998, p.74/7 Item 228
KODAK COOLS CARTRIDGE COVER WITH Injection Molding
COPPER ALLOY CORES 6, No.8, Aug. 1998, p.74

MOUNTING LOCATIONS FOR MEASURING given of the troubleshooting employed with samples of
CAVITY PRESSURE subgates containing an ingredient that was shutting off
Kirkland C cavities at random in a high-production, 32-cavity tool.
Problems in the production of moulded nylon knife shells Some of the obstructions were partial and resulted in short
at Victorinox were solved by the use of direct pressure shots that had to be sorted out of the production. However,
transducers with threaded mounting nuts from Kistler most of the time the gates were completely plugged. If
Instrumente AG. The previous use of indirect sensors on the mould ran unattended for any length of time, the
the bottom moulds in shuttle- or rotary-table insert technician would return to find the mould running only
moulding machines, showed differences of up to 725.5 29 or 30 parts. The remaining cavities tended to be
psi in pressure gradients between the moulds even when overpacked which led to additional problems with poor
moulds with identical sensors were run under identical dimensional control and sticking of parts in the mould.
injection conditions. Details are given of the method The parts were being moulded in an unfilled propylene
devised by the two companies to test in-mould copolymer; details are given.
performance of direct and indirect cavity pressure sensors. USA
VICTORINOX; KISTLER INSTRUMENTE AG Accession no.692618

SWITZERLAND; WESTERN EUROPE
Injection Molding
Item 229 6, No.5, May 1998, p.102/4
Antec 98. Volume III. Conference proceedings. TROUBLESHOOTER PART 23:
Atlanta, Ga., 26th-30th April 1998, p.2586-8. 012 DELAMINATION AT A FAN GATE
METALLIC LOOKING PLASTICS WITH NEW Hatch B
SILVER AND COLOURED ALUMINIUM Prime Alliance
PIGMENTS This article continues a series of trouble-shooting reports
Bunge H-H from one of the leading problem-solvers in the injection
Eckart America LP moulding industry. This report provides a case history
(SPE) involving delamination at a fan gate, and reveals the cause
The use of aluminium pigments in plastics has presented and solution.
a problem in the past due to the flow line they caused in CINCINNATI MILACRON
injection moulded parts. By using aluminium pigments USA
with an average particle size of 60 to 330 mu and larger, Accession no.691766
it is possible to avoid these flow lines and produce plastic
parts with a metallic appearance. This concept has been
Item 232
taken one step further by depositing colourants on these
Injection Molding
aluminium pigments, thereby creating blue, green and
6, No.5, May 1998, p.48/52
golden metallic colourants that can be used in plastics
CAN THIS BE SAVED? PART 2: RIBS FOR
without flow lines. These pigments offer exceptional
STRUCTURE
styling effects by themselves and in combination with
Cramer R
other colourants, including bronze pigments. 1 ref.
Dow
USA
Accession no.692787 This is the second installment in a series of design guide-
lines based on engineering principles. It tackles one of
the thorniest problems for plastics - how to improve
Item 230 structural rigidity without adding undue thickness. 3 refs.
Injection Molding USA
6, No.7, July 1998, p.38-40
Accession no.691740
MATERIALS ANALYST. II. FINDING THE
CULPRIT IN PLUGGED SUBGATES
Sepe M Item 233
Dickten & Masch Mfg.Co. Injection Molding
6, No.5, May 1998, p.45-6
Polymer analysis is generally thought to involve
MATERIALS ANALYST: PART 9
sophisticated processes designed to probe the most
Sepe M
obscure details of molecular structure. It is rarely thought
Dickten & Masch Mfg.
that the same tools used by researchers to develop new
materials and study fundamental structure-property This is the ninth part of a series of articles designed to
relationships can also be used to solve a mundane help injection moulders understand how a few analytical
production problem like plugged sub-gates. Details are tools can help diagnose part failure problems. It looks at,

and explains, the processing window of thermoplastics, Ibid., No.757, March 1997, p.25-9; Part II: Ibid., No.759,
and discusses detecting the onset of degradation. A case May 1997, p.27-30).
history is included. EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE;
USA GERMANY; WESTERN EUROPE
Item 234 Item 237

Injection Molding Molding Systems
6, No.5, May 1998, p.24-5 56, No.6, Aug.1998, p.42-6
PRIMARY CAUSE OF HYDRAULIC SYSTEM INJECTION MOULDING TROUBLESHOOTING
FAILURE: DIRTY OIL DEMYSTIFIED
Sloan J Bryce D M
Texas Plastic Technologies Inc.
This reports on information given at a recent seminar in
Canada, where the president of Van Dorn Demag, the This article, part four of a five-part series investigating
injection moulding machine giant, explained that a study the potential causes and solutions for common
by his company had shown that 70-85 percent of all moulding defects, examines flash, flow lines, knit lines
hydraulic system failures and component wear problems and short shots.
can be attributed to solid-particulate contamination within USA
the hydraulic system. In this article we see how to avoid Accession no.690637
this problem.
TECH-TRAX; VAN DORN DEMAG Item 238
CANADA
Injection Moulding International
Accession no.691736 3, No.4, June/July 1998, p.39-41
PRINCIPLES OF DESIGN: HOW TO RELEASE
Item 235 UNDERCUTS
Revue Generale des Caoutchoucs et Plastiques Erhard G
No.760, June/July 1997, p.47-9 BASF AG
French Sometimes a designers attempts to integrate as many
EMBRITTLEMENT OF COMPOSITE PARTS functions as possible into a single component has an
Tancrez J P; Pabiot J undesirable consequence - often simple part release is
EUDIL; Douai,Ecole des Mines prevented by undercuts. Several parting lines and opening
A study was made of brittle fracture in injection moulded directions become necessary, thus making the mould more
short glass fibre-reinforced PP composite specimens. The expensive and prone to malfunctions. There are a number
influence of the type of PP matrix, coupling agents, fibre of ways to get around the problem, from simple to
content, length and orientation and injection moulding complex - forced ejection, mould-related measures,
conditions was investigated. 10 refs. releasing undercuts, avoiding undercuts, changing the
EUROPEAN COMMUNITY; EUROPEAN UNION; FRANCE; design and contacting or blocking core. Details are given.
WESTERN EUROPE EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY;
Accession no.687964
Item 236
Revue Generale des Caoutchoucs et Plastiques Item 239
No.760, June/July 1997, p.41-4 Injection Moulding International
French 3, No.4, June/July 1998, p.26-7
TEN TOPICS CONCERNING THE INJECTION ANALYSING BRITTLENESS
MOULDING OF ENGINEERING POLYMERS. Sepe M
III. Dickten & Masch
Poor final properties in a moulded part are often caused by
Du Pont de Nemours (Deutschland) GmbH; Du Pont de
degradation of the polymer during processing. As most
Nemours France SA
moulders know too well, this degradation can come from
The influence of melt temperature and mould temperature excessive heat and long barrel residence times, or it can be
on the quality of injection moulded semi-crystalline the result of exposure to high levels of moisture. However,
engineering plastics parts is examined. Recommended in some instances, both of these conditions can be carefully
processing conditions are presented for a number of non- controlled and a product still does not perform as expected.
reinforced and glass fibre-reinforced polymers. (Part I: The discovery of the problem is often made accidentally.

A person involved in assembling a product will notice that Halos are aesthetic defects that may occur on centre gated
a particular boss cracks with surprising ease. This typically parts made with multi-phase polymer systems. In general,
leads to a more quantitative evaluation by the quality control they are circular in shape, concentric with the gate, and
department. The use of analytical techniques to solve lower in gloss than the surrounding area. Halos are also
problems of brittleness in moulded parts is described. common in parts moulded with hot runner manifolds and
USA may even be seen in edge-gated parts (half halo).
Accession no.687950 Temperature gradients along the length of the feed system
to the part are shown to be a cause of this halo defect,
particularly gradients where the downstream temperature
Item 240 is colder than the upstream temperature. The effect of
Revue Generale des Caoutchoucs et Plastiques process conditions on halos is discussed along with a
No.759, May 1997, p.27-30 mechanism for their creation. 9 refs.
French
USA
TEN TOPICS CONCERNING THE INJECTION
MOULDING OF ENGINEERING POLYMERS. II. Accession no.684003
Du Pont de Nemours (Deutschland) GmbH; Du Pont de Item 243
Nemours France SA Molding Systems
The influence of the positioning of injection points and 56, No.5, May/June 1998, p.36-9
of holding times on the quality of injection moulded INJECTION MOULDING TROUBLESHOOTING
engineering plastics parts is examined. (Part I: Ibid., DEMYSTIFIED
No.757, March 1997, p.25-9). Bryce D M
GERMANY; WESTERN EUROPE This article discusses the causes of and solutions for
Accession no.686294 specific injection moulding defects. These include
brittleness and delamination, contamination, cracking and
Item 241 crazing, and discolouration.
Antec 98. Volume I. Conference proceedings. USA
Atlanta, Ga., 26th-30th April 1998, p.836-40. 012 Accession no.682396
GETTING HEAT OUT OF THE MOULD WHERE
WATER WONT GO Item 244
Engelmann P; Dawkins E; Dealey R; Monfore M Revue Generale des Caoutchoucs et Plastiques
Western Michigan,University; Dealeys Mold No.757, March 1997, p.25-9
Engineering; Ralston Foods French
(SPE) TEN TOPICS CONCERNING THE INJECTION
Removing heat from complex areas of an injection mould MOULDING OF ENGINEERING POLYMERS. I.
is difficult and often remains unresolved in production Poppe E A; Leidig K; Schirmer K; Jayle L
tooling. Cycle times and/or dimensional stability are often Du Pont de Nemours (Deutschland) GmbH; Du Pont de
sacrificed because of hot spots in the tool. A variety of Nemours France SA
strategies employing copper alloys with and without water
The importance of the drying of polymer granules for
to the mould core are investigated. Several surprises occur;
moisture removal and of injection channel design in the
one practical method for removing heat from non-watered
injection moulding of engineering plastics is discussed.
cores is identified. The application of high thermal
conductivity copper alloys to the correct combination of GERMANY; WESTERN EUROPE
components should allow mould engineers to solve both
Accession no.682350
current and future mould cooling problems. 5 refs.
USA
Popular Plastics and Packaging
42, No.12, Dec.1997, p.75-81
Item 242 TECHNOLOGICAL SOLUTIONS FOR TOTAL
Antec 98. Volume I. Conference proceedings. QUALITY IN INJECTION MOULDING OF
Atlanta, Ga., 26th-30th April 1998, p.515-19. 012 PLASTICS
HALO SURFACE DEFECTS ON INJECTION Bolur P C
MOULDED PARTS Powder Plast
Salaman B A; Koppi K A; Little J
Dow Plastics The problem-free running of injection moulding
(SPE) machines is discussed with reference to the use of

computer controls and computer aided design and Item 249

manufacturing techniques to ensure repeatability of the Injection Molding
process and the quality of the moulded goods. Typical 6, No.2, Feb.1998, p.92/6
problems arising with injection moulding are discussed TROUBLESHOOTER PART 20: WARPING AND
and details are given of possible mould- and machine- VOIDS IN NYLON
related causes. Mould design and filling techniques Hatch B
involving the use of computer analysis techniques are Prime Alliance
proposed. This article continues a series of trouble-shooting reports
INDIA from a leading on-the-spot problem solver in the moulding
Accession no.681273 industry. It deals with warping and voids in the shaft of a
glass-filed nylon part. A full explanation of the cause of
Item 246 the problem (orifice in heated sprue bushing too small;
Popular Plastics and Packaging gate feeding into part shaft too small), and also the solution
42, No.12, Dec.1997, p.69-74 to it, is provided.
TROUBLE SHOOTING IN INJECTION USA
MOULDING Accession no.677286
Shekar A R
DuPont India Item 250
Injection Molding
Typical problems occurring during injection moulding
6, No.2, Feb.1998, p.35-6
operations are examined and possible causes and remedial
DESIGN - CRACKING AROUND INSERTS
actions are suggested.
Cramer R
INDIA
Dow Materials Engineering Center
Accession no.681272
This is part one of a three-part series, and provides valuable
insights into eliminating cracks around metal inserts in
Item 247 injection moulded parts, by using sound design engineering
Molding Systems principles. The author draws on actual projects conducted
56, No.4, April 1998, p.24-7 with customers during his years as a senior development
INJECTION MOULDING TROUBLESHOOTING scientist with a leading company. 1 ref.
DEMYSTIFIED USA
Bryce D M
Accession no.677264
This second part of a five-part series looks at potential Item 251
causes and solutions for common injection moulding International Polymer Processing
defects. These defects are investigated as they are 12, No.4, Dec.1997, p.396-402
associated with the moulding machine, the injection IN-MOULD SHRINKAGE MEASUREMENTS OF
mould, the plastic material and the machine operator, in PS SAMPLES WITH STRAIN GAUGES
that order. Pantani R; Jansen K M B; Titomanlio G
USA Salerno,University
Accession no.680057 The problem of shrinkage in injection moulding is studied
by means of a new technique based on strain gauges
Item 248 placed on mould surface before injection. The local
Plastics and Rubber Weekly shrinkage development, from the moment it starts inside
No.1735, 8th May 1998, p.8 the mould to soon after ejection, can be followed by means
ION SURFACE TREATMENT CUTS WEAR of this method. With reference to a simple rectangular
PROBLEMS cavity, the effects of different holding pressures, of
geometrical constraints placed inside the mould, of
JBL Feedscrews is offering injection moulders ion position in the cavity and of total cavity length on local
implanted screws which can provide up to four times the shrinkage of injected PS samples are analysed. Shrinkage
durability of a conventional nitrided product in demanding inside the mould is registered: it starts later if higher
processing applications. Ion implantation is a low holding pressures are applied; furthermore, any factor
temperature metal treatment process that raises the which produces an enhancement of shrink age evolution
hardness of the surface layer. before complete solidification gives rise to a
JBL FEEDSCREWS LTD. corresponding increase of final shrinkage. 23 refs.
EUROPEAN COMMUNITY; EUROPEAN UNION; UK; EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY;
WESTERN EUROPE WESTERN EUROPE

Item 252 material rests on the bottom half of the runner, with the
Injection Molding cooler, high viscosity material on top.
6, No.4, April 1998, p.106/8 PENN STATE UNIVERSITY
TROUBLESHOOTER, PART 22: PARTING LINE USA
RUNNERS AND GATES Accession no.675524
Hatch B
Prime Alliance
Item 255
A small handle of glass filled nylon with voids in the Injection Molding
thick section of the part was investigated. The problem 6, No.3, March 1998, p.102/6
was shown to be caused by the flow path freezing off THE TROUBLESHOOTER. PART 21: FILL,
before the part fills, and the runner diameter and nozzle PACK, AND STICKING PROBLEMS
orifice were not large enough. The solution to the problem Hatch B
was to open up the runner to .250 inch, and drill the nozzle Prime Alliance
orifice out to .225 inch. This resulted in the voids
disappearing, a lowering of the barrel heat and injection A polypropylene utility cart wheel was injection moulded
pressure, and improved cycle times. using a hot runner mould with three channels per drop.
The moulded wheel exhibited surface defects including
USA
flow lines and voids in thick sections, and in addition,
Accession no.675529 was sticking in the front half of the mould. The problem
was diagnosed as being restricted flow paths, insufficient
Item 253 heat in the gate area, and residual mould spray causing a
Injection Molding vacuum and making the parts stick. A solution is offered
6, No.4, April 1998, p.97-8 and discussed, and includes increasing flow channels, the
IMPROVING UPTIME BY AVOIDING FAILURES addition of beryllium copper heater tips, and an
Kirkland C adjustment of the injection and holding pressures.
USA
Benefits of MicroPulse magnetostrictive transducers as
used at White Oak Plastics Inc. on their injection moulding Accession no.675338
machines are described. The company, a busy custom
moulder, can ill afford downtime on its machines, and Item 256
linear potentiometers were found to cause reliability and Injection Molding
accuracy problems due to dirt and wear. Details are given 6, No.3, March 1998, p.92/4
of the companys business. VARIABLE MACHINE CONDITIONS PRODUCE
WHITE OAK PLASTICS INC. CRITICAL MEDICAL PART WITH
USA CONSISTENT QUALITY
Accession no.675525 Sloan J
Problems arising from the injection moulding of a
Item 254 polycarbonate canister used to filter blood during heart
Injection Molding bypass operations were solved by the use of cavity
6, No.4, April 1998, p.85-8 pressure sensors. Optimisation of the part was achieved
MOLD IMBALANCE GOES WITH THE FLOW... by the use of variable machine conditions where the
Sloan J hydraulic profile was allowed to vary to meet the set cavity
pressure. By transferring on cavity pressure, less start-up
Theories surrounding the reasons why in an eight or
scrap was created, a lower reject rate, and more energy
greater cavity mould, heavier parts are always produced
from the inside cavities, are suggested, and a solution to efficient processing was achieved.
the problem in the form of the Runner Flipper from John DTM PRODUCTS INC.
Beaumont of Penn State University is proposed. The USA
problem is connected with the distribution of shear across Accession no.675336
the melt as it moves through the runner. The viscosity of
plastic is affected by temperature and shear, and in a Item 257
runner shear is greatest next to the outer wall, generating Plastics and Rubber Weekly
higher temperatures and decreasing the viscosity of the No.1728, 20th March 1998, p.9
melt, while material in the centre of the flow experiences TOP 10 MOULDING PROBLEMS
less shear, and therefore is cooler and more viscous. The Wilkinson R; Poppe E A; Leidig K; Schirmer K
use of the Runner Flipper designed by Beaumont, used DuPont Co.
as a runner insert, takes the melt through a series of dips,
twists and turns, to reorient the shear distribution, turning This article discusses the possible causes and remedies
the melt stream so that the high temperature, low viscosity for deposits on the mould surface when injection moulding

engineering thermoplastics such as POM, PA, PETP and Item 261

PBTP. The most common reasons for the formation of Injection Moulding International
mould deposits are thermal decomposition, excessive 3, No.1, Jan./Feb,1998, p.48-9
shear and inadequate venting. TROUBLESHOOTING HOT RUNNERS
USA Hatch B
Accession no.672988 Prime Alliance
This comprehensive article describes the possible
Item 258 problems that can occur with hot runners and heated sprue
Kunststoffe Plast Europe bushings, and outlines methods of preventing and solving
88, No.2, Feb.1998, p.15-6 them. The article focuses on gate diameter and land length
DEFECT ANALYSIS IN INJECTION MOULDING for hot runner moulds and optimised sprue bushing design,
Michaeli W; Zachert J for successfully moulding parts with hot runners.
RWTH; IKV USA
The use is discussed of computer simulation techniques Accession no.668678

to solve problems associated with the injection moulding
of a guide block for fibre optic plugs. Three-dimensional Item 262
calculation of the filling process offers new possibilities Injection Molding
in error analysis to the user, and processes at the flow- 6, No.1, Jan.1998, p.44/50
front and secondary flows can be calculated. This allows THE MATERIALS ANALYST: PART 5
potential solutions to problem zones to be worked out in Sepe M
the simulation. 10 refs. Dickten & Masch Mfg.
EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; This article comprises the fifth in a series designed to
WESTERN EUROPE
help moulders understand how analytical tools can help
Accession no.671865 diagnose a part failure problem. The article describes the
analytical techniques that can successfully determine the
Item 259 cause of a particular part failure problem, whether
British Plastics and Rubber material, additive, colourant, or process, saving
Feb.1998, p.29 unnecessary wastage of time, effort and cost.
MAINTENANCE AND REFURBISHMENT USA
Brooks C Accession no.668657
Marshall Tufflex
The value is discussed of investment in the training of Item 263
injection moulding operators in order to reduce downtime, International Composites Expo 97. Conference
increase productivity and profitability, by enabling machine proceedings.
operators to troubleshoot processing problems and for at least Nashville, Tn., 27th-29th Jan.1997, Paper 72. 627
half of the staff on each shift to be qualified as a tool setter. WARPAGE IN INJECTION MOULDED FRP:
The experiences of Marshall Tufflex in this area are reported. ESTABLISHING CAUSES AND CURES USING
EUROPEAN COMMUNITY; EUROPEAN UNION; UK; NUMERICAL ANALYSIS
WESTERN EUROPE Kukula S; Saito M; Kikuchi N; Shimeno T; Muranaka A
Accession no.669235 Kobe Steel Ltd.
(SPI,Composites Institute)
Item 260 Retail price wars in the computer and consumer
Plastics and Rubber Weekly electronics market have led to massive cost reductions in
No.1726, 6th March 1998, p.12 case manufacture. Injection moulded FRP costs have been
TOP 10 MOULDING PROBLEMS reduced by using thinner walls. However, this has
Wilkinson R; Poppe E A; Leidig K; Schirmer K increased the risk of warpage. While this can be predicted
DuPont Co. for given conditions, little work has been done on the
inverse problem; how to achieve minimum warpage. With
Partially crystalline engineering polymers such as POM,
product lifetimes as short as six months, reducing time
PA, PBTP and PETP tend to warp far more than
spent in the analysis loop by improving the accuracy of
amorphous ones. This point should be taken into account
the first guess is critical. A major cause of warpage in
at the outset when designing moulds and mouldings. This
short fibre-reinforced plastic is believed to be anisotropy
article discusses the causes of warpage and steps that can
in thermal expansion coefficients due to local fibre
be taken to prevent and reduce it.
orientation. A combined analytical and experimental
USA
research programme is carried out, examining the effects
Accession no.669096 of a wide range of structural and manufacturing variables

on warpage of injection moulded FRP. These include wall Item 266

thickness, gate position and mould temperature. The Injection Molding
analysis used an inhouse system to examine flow-induced 5, No.11, Nov.1997, p.98/105
effects on material properties and mechanical warpage TROUBLESHOOTER. XVIII. DIMPLES IN
for given injection conditions. These results are compared OVERMOULDED TPR
with samples from a specially-designed mould allowing Hatch R
variation of overall dimensions, thickness, gate position Prime Alliance
and layout, temperature and moulding speed. The aim is
The problem of dimples appearing at the gates of a glass-
to establish a reference catalogue for the causes of FRP
filled PP roller overmoulded with a thermoplastic
warpage, identifying preventative design measures and
elastomer material is described. Both moulds are eight-
reducing the time needed for design iteration. 6 refs.
cavity and each has a balanced runner feeding material
JAPAN
into the cavities. The troubleshooting process employed
Accession no.665449 to solve the problem is outlined.
USA
Injection Molding
5, No.12, Dec. 1997, p.86/91
Item 267
TROUBLESHOOTER. PART 19: DISK GATES
Injection Molding
FOR BIG PARTS
5, No.11, Nov.1997, p.84-5
Hatch B
CHRONIC HEATER BURNOUT LEADS TO
Prime Alliance
LOANER LEADS TO SOLUTION
This troubleshooting problem involves the moulding of Sloan J
a circular part 20 inches in diameter and .750 inches
Tradesco Mold delivered a mould late last year to moulder
thick made from black polypropylene. It was being
Medline Industries - a four-cavity tool with a hot runner
injection moulded using a single-cavity mould, with the
system, designed to mould PP water pitchers for hospital
disk gate fed from a cold sprue. The moulded part was
and healthcare use. However, the hot runner heaters kept
subjected to voids and warping. It was discovered that
burning out, not just on this particular tool but on several
the disk gate depth was too shallow, and restricted the
throughout the shop, up to one burnout every other week.
flow of the material causing barrel temperatures and
Medline is a moulder of disposable medical devices such
injection pressures to be raised too high. The suggested as bed pans, wash basins, water pitchers and carafes. Its
solution was to trim the core pin, leave the spreader on 500,000 sq.ft plant holds 40 presses ranging from 80-750
the end of the pin, increase the disk gate to .375 inch, tons. Shifts of the 120 employees work 24 hours a day,
lower the barrel heat, increase the mould temperature seven days a week. The material of choice is PP and
and raise the hold pressure. operations are supposed to be fast and efficient, with lots
USA of robots and dependent secondary operations. The
Accession no.664189 company was frustrated, and losing money over the heater
burnouts. Gammaflux offered to loan Medline one of its
Item 265 Series 9000 hot runner control systems, to see if it would
Plastics Technology control the problem; the success encountered using this
43, No.12, Dec. 1997, p.17/9 control equipment is described.
CANT AFFORD REJECTS? TRY REAL-TIME USA
CAVITY-PRESSURE CONTROL Accession no.661820
Naitove M H
Advantages to moulders of using a process regulation Item 268
system developed by Arburg are described. The system Injection Molding
is of value to moulders who wish to reduce their reject 5, No.11, Nov.1997, p.75/7
rate by use of cavity pressure regulation which corrects POROUS STEEL TAKES COOLING TO THE
each shot in real time while the part is being moulded. PART
The system is said to be most beneficial to producers of Sloan J
metal powder injection moulded parts, as well as some A considerable amount of time in any moulding cycle is
makers of medical products and other critical precision spent cooling the part. Therefore, the faster and better a
parts, where parts carry a high value, and precision part is cooled, the faster the cycle. The problem with
tolerances are tight. traditional cooling is that transfer of heat away from the
ARBURG INC. moulded part depends on the thermal conductivity of the
USA mould material, water temperature, the water flow rate
Accession no.664145 and the position of the water channel in the mould. All of

these variables, taken together, can make for inconsistent This is the fourth in a series of articles designed to address
or unstable cooling, leading to hot spots and thermal stress, the most common problems experienced by injection
which can prolong the cycle and cause part rejects. Aga moulders working with engineering polymers. The most
Gas has developed a way to transfer heat directly from important points to help machine setters chose the most
the surface of the part, bypassing the traditional water suitable hold pressure time to achieve optimum results
channel configuration. The technology that makes this are discussed. The effective hold time can be determined
possible is called Toolvac. It uses cores and cavities made on the machine by weighing a number of mouldings. To
of a sintered microporous tool steel combined with liquid obtain optimum moulded part properties, the hold time
CO2 gas. The tool surface temperature is controlled by should be determined by the weighing method and the
evaporating the liquid CO2 and transporting it through cooling time should be reduced to the required minimum.
the steels pores directly to the part. This speeds cooling, USA
which speeds the cycle. Details are given. Accession no.659330
AGA GAS; ELECTROLUX
USA
Item 272
Accession no.661817 Machine Design
69, No.17, 11th Sept.1997, p.76/8
Item 269 ART OF BALANCING MOULD RUNNERS
Plastics and Rubber Weekly Tyler D; White R
No.1716, 12th Dec.1997, p.8 Lexmark International Inc.
TOP 10 MOULDING PROBLEMS The problems of runner balancing are described. When
Wilkinson R; Poppe E A; Leidig K; Schirmer K the industrial designer hands over concept drawings to
DuPont Co. the mechanical design team, a topic that rarely comes up
This article is the sixth in a series of ten designed to is the location of weld or knit lines - points at which two
address the most common problems experienced by advancing waves of resin meet in a mould fed by multiple
injection moulders. When moulding semi-crystalline gates. Frequently, the subject is left to be resolved later,
engineering plastics such as POM, PA, PBTP and PETP, most typically in manufacturing. But the best approach
it is important to make sure than the surface temperature is to design the runner system early so the knit lines dont
of the tool is correct. The consequences of the wrong tool cause problems. Several reasons make it critical to
temperature are outlined and recommendations for setting visualise the construction of the tool throughout the design
the correct tool temperature are presented. process. This planning helps address many limiting
USA
factors, including the performance of runners. In the case
of the widely used Moldflow simulation software, cavity
Accession no.661592
analysis and runner design are two distinct steps. Accurate
simulation results require incorporation of proper
Item 270 moulding material data including shear dependent
Plastics and Rubber Weekly viscosity curves over the process window, the pressure-
No.1714, 28th Nov.1997, p.12 volume-temperature relationship, mechanical and thermal
TOP 10 MOULDING PROBLEMS properties, optimised moulding conditions and a finite-
Wilkinson R; Poppe E A; Leidig K; Schirmer K element mesh model of the part. Details are given.
DuPont Co. USA
Choosing the right melt temperature is vital for part quality Accession no.656978
when moulding semi-crystalline engineering polymers.
In this fifth chapter of a ten-part series, the question of Item 273
melt temperature is considered when moulding POM, PA, Design Engineering
PBTP and PETP. Temperatures that are too high degrade Oct. 1997, p.19
the polymer, while too low a temperature results in a MOULD PROBLEMS SOLVED
structure that fails to achieve the required homogeneity.
The value is discussed of using software to analyse sink
USA
mark and warpage problems in a PP injection moulded
Accession no.659448 internal trim panel for the bottom lip of a boot on a Ford
car. The surface showed sink marks directly above the
Item 271 internal ribs on the underside, caused by shrinkage at the
Plastics and Rubber Weekly junction of the rib and the main skin, and distortion of
No.1711, 7th Nov.1997, p.12 the trim panel used in the corner of the vehicles boot.
TOP 10 MOULDING PROBLEMS Moldflows MF/MFLOW software showed warpage was
Wilkinson R; Poppe E A; Leidig K; Schirmer K due to the inability to transmit packing pressure uniformly
DuPont Co. across the part causing non-uniform shrinkage, and

remedial measures included using an additional feed point Prime Alliance

plus a pressure profile during the packing phase to ensure
This article on troubleshooting is concerned with sink
all areas of the part froze at similar pressures, thus
marks and flow lines on injection moulded ABS parts.
reducing the warpage to an acceptable level. Packing
The problem is analysed by checking the sprue, runners,
analyses were also carried out using the various packing
gates and vents in turn. It was found that the sprue was
profiles to assess their effects on sink mark depth.
undersized, the depth of runners was alright, but the gates
FORD MOTOR CO. were undersized, and venting was virtually non-existent.
USA
On rectifying these problems, a slight increase in cycle
Accession no.655774 time was achieved, and no sink marks were produced.
USA
Injection Molding
5, No.10, Oct. 1997, p.115/7
TROUBLESHOOTER, PART 17: STRESS Item 277
CRACKS IN ABS Plastics and Rubber Weekly
Hatch B No.1708, 17th Oct.1997, p.12
Prime Alliance TOP TEN MOULDING PROBLEMS
This troubleshooting example refers to an injection
DuPont Co.
moulded ABS fan assembly which exhibited stress cracking
where the blades attach to the housing. The problems were This series of articles is designed to address the most
found to be the use of ABS which deteriorated in outdoor common problems experienced by injection moulders.
applications, and an unbalanced fill resulting in out-of- The position of the gate is decisive for the flow front
balance dynamics when the blade was rotated, thus stressing profile and the effectiveness of the holding pressure and,
the attachment points. Solutions are discussed, and include as a result, for the strength and other properties of the
the use of ASA for better UV protection, the use of five moulded part. The possible negative consequences of poor
gates to fill the five fan blades, added perimeter venting, gate position are discussed and recommendations for
balanced and vented runners, and a funnel-shaped disk gate optimum gate position are presented.
for the single-cavity mould. USA
Accession no.655673
Item 278
Item 275 Injection Molding
Injection Molding 5, No.4, April 1997, p.94/7
5, No.9, Sept. 1997, p.92/5 ACRYLIC BREAKAGE
TROUBLESHOOTER. PART 17: COSMETICS Batch B
Hatch B Prime Alliance Inc.
Prime Alliance
This article discusses the failure of an acrylic part due to
This part of the troubleshooting series for injection
restricted flow and cracking in the thick to thin transition.
moulders deals with cosmetics. The part is an ABS oval
The flow lines indicated that the gates were somewhat
shaped speaker cover that will be plated, and the tool is a
restricted for the flow properties of the material. As the
four-cavity, cold runner with a heated sprue bushing.
part was already being moulded in an easy-flow grade of
Symptoms included haze on the curved section and blush
acrylic, the flow path needed to be opened up. To optimise
at the gate that disturbed the plating process, and a slow
the tool, the sprue O diameter was resized, runner and
cycle time. A mould filling analysis had not indicated these
nozzle diameters were increased, sub gates were opened
problems. Problems discovered included the use of
up, and venting provided at the sprue puller, the end of
undersized runners and gates, and poor venting. Solutions
offered are discussed, and include the use of enlarged the main runners, the end of the sub runners and in the
runners and gates, venting of the parting line and part cavity itself.
perimeter, and decreased melt temperatures. USA

Accession no.655631
Item 279
Item 276 Plastics and Rubber Weekly
Injection Molding No.1704, 19th Sept.1997, p.9
5, No.8, Aug. 1997, p.92/5 TOP 10 MOULDING PROBLEMS
TROUBLESHOOTER. PART 16: COSMETICS Wilkinson R; Poppe E A; Leidig K; Schirmer K
Hatch B DuPont Co.

This article considers the basic elements of correct feed Item 282
system design for semi-crystalline polymers. If the gating Kunststoffe Plast Europe
system is too narrow, the holding pressure cannot remain 87, No.1, Jan.1997, p.15-6
effective beyond the desired holding pressure time. In that English; German
case, volume shrinkage cannot be adequately REPRESENTATIVE CAVITY TECHNIQUE
compensated, resulting in the formation of voids, sink REDUCES REJECTS
marks or pinholes. In designing the feed system, the first Potente H; Wischke T
point to be considered is the wall thickness of the moulded
What is meant by representative cavity is explained in
part. Nowhere should the diameter of the runner be less
an inset. The bulk of the article discusses the use of the
than the wall thickness of the injection moulding.
representative cavity principle which is easy to apply and
USA
simplifies quality assurance for injection moulding with
Accession no.649853 multi-cavity moulds. A practical case study is included.
Item 280 WESTERN EUROPE
Plastics and Rubber Asia Accession no.639458
12, No.72, July/Aug.1997, p.14
CINPRES SOLVES PHILIPS WARPAGE PROBLEM
Item 283
Omni Plastics experienced moulding problems with the Antec 97. Volume I. Conference proceedings.
production of a CD-ROM tray. It was found that due to Toronto, 27th April-2nd May 1997, p.989-93. 012
the differing wall sections, differential shrinkage occured USE OF POROUS STEEL TO ELIMINATE GAS
leading to distortion in both directions, across the length ENTRAPMENT AND MATERIAL BURNING
and across the width of the component. Cinpres became DURING MOULDING PROCESS
involved in the project only after the design of the Taylor L A
component was fixed and tooling underway. The use of International Mold Steel Inc.
gas injection technology has resulted in a moulding with (SPE)
a distortion of less than 0.07mm.
Since its introduction to the North American mouldmaking
CINPRES LTD.; OMNI PLASTICS
SINGAPORE
market, a new porous, self-venting mould steel has proved
to be remarkably successful. This porous steel has allowed
Accession no.647894
moulders to reduce injection pressure, cycle times, shot
size and scrap rates. Additional benefits have included
Item 281 elimination of flow fines, short shots, material burning,
Wear in Plastics Processing: How to Understand, and ghosting on the edges of textured parts. Sintokogio
Protect and Avoid. has introduced a sintered powder mould steel designated
Munich, Carl Hanser Verlag, 1995, p.298-332. 9522 Porcerax 111, that offers a revolutionary solution to venting
WEAR UNDER INDUSTRIAL CONDITIONS: problems. Its patented manufacturing process produces a
INJECTION MOULDING highly machinable mould steel that is 25% air by volume.
Johannaber F; Kaminski A; Schoenthaler W This results in a mould steel that contains an inter-connected
Edited by: Mennig G pore structure that, when properly installed and vented to
The economics of the injection moulding process for the atmosphere, allows trapped gasses to escape directly
producing moulded parts have been questioned due to through the steel, eliminating material burning, short shots
wear-related effects no later than the beginning of the and trapped gas problems. By using Porcerax II in
1960s with the introduction of short glass fibre-filled appropriate areas, gas build-up is eliminated, injection
thermoplastics. Solutions based on the requirements and pressure is reduced, cycle times are lowered and scrap and
economics were given equal attention. Initially, the rather reject rates are substantially reduced.
high investments for wear-resistant plasticating units USA
occupied the foreground. To the extent that downtime, Accession no.637353
resulting from problems associated with procurement of
replacement parts and the costs for the rejects produced,
gained in importance, the argument prevailed that Item 284
measures to prevent wear were necessary. Aspects covered Antec 97. Volume I. Conference proceedings.
include the problem of wear in this process, the injection Toronto, 27th April-2nd May 1997, p.588-91. 012
moulding manufacturing process, process-related loads, TROUBLESHOOTING MOULDING PROCESS
protection against wear in injection moulding and the Golmanavich J
economics of wear protection. Lucent Technologies
(SPE)
WESTERN EUROPE Investing in a monitoring system for an injection moulding
Accession no.641374 shop can result in some unexpected benefits. Systems are

built per the customers requirements and usually comprise DEUTSCHES KUNSTSTOFF-INSTITUT
production scheduling software and processing tools. The EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY;
system purchased by Lucent Technologies provides the WESTERN EUROPE
capability of reading machine hydraulic information along Accession no.635784
with cavity pressure data when transducers are installed
into moulds. There are two charts available to extract Item 287
information from the graphics screen - a summary chart Injection Moulding International
(upper) and a cycle chart (lower). The types of information 2, No.2, April/May 1997, p.46-8
collected can include fill time, peak cavity pressure, peak TWO WAYS TO AVOID WELD LINES WITH
hydraulic pressure, and several cycle integrals. As the HOT RUNNERS
system is being implemented, case histories are collected
which reveal information probably not available had it not A high percentage of todays larger moulded parts are
been for the monitoring system. This kind of information appearance parts: housings, cabinets, panels, bezels, etc.
is typically not available from system suppliers. Examples To the products potential buyers, appearance is the most
demonstrate how a monitoring system can verify results obvious sign of quality, or its lack. Naturally, surface quality
of experiments, solve problems and lead to a better overall requirements for these products are high and continually
understanding of the injection moulding process. rising. However, as quality levels have been increasing,
wall thicknesses of large parts have been decreasing. A
USA
typical wall today is 2-3 mm thick; a few years ago it was
Accession no.636722 4-6 mm. As wall sections become thinner, weld and flow
lines become more visible. Multiple gating is one solution
Item 285 to the problem, but frequently it affects the parts
Antec 97. Volume I. Conference proceedings. mechanical and optical properties. It can also impair paint
Toronto, 27th April-2nd May 1997, p.532-7. 012 adhesion in the finishing commonly done with large parts.
OCCURRENCE OF FLOW MARKS DURING Fortunately, weld and flow line problems can also be solved
INJECTION MOULDING OF LINEAR by actively influencing mould filling to gain exact control
POLYETHYLENE of flow-front formation. Details are given.
Heuzey M-C; Dealy J M; Gao D M; Garcia-Rejon A EUROTOOL HOT RUNNER SYSTEMS
McGill University; Canada,National Research Council EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY;
(SPE) WESTERN EUROPE
Accession no.635783
Injection moulded parts often show several types of
surface defect. It has been hypothesised that wall slip is
associated with some of these defects. The occurrence of Item 288
flow marks during injection moulding of linear PE are Plastics Technology
analysed and its possible relation to wall slip evaluated. 43, No.4, April 1997, p.38-43
It is found that injection speed is the controlling factor 50 WAYS TO CUT YOUR INJECTION
for the generation of flow marks. As the resin shows no MOULDING CYCLE TIMES
tendency to slip in capillary flow experiments, and as a Ogando J
PTFE coating does not affect the occurrence of flow Fifty tips on how to introduce injection moulding cycle
marks, it can be concluded that there is no relationship time improvements are presented. Once all the time-
between wall slip and the generation of flow marks. consuming aspects of the cycle have been identified, there
Microscopic observation of moulded surfaces suggests are still incremental gains to be achieved by focusing on
instead that flow marks result from the filamentation and materials selection, screw design and process
stretching of semi-solidified material in the optimisation.
neighbourhood of the three-phase contact line. 15 refs. USA
CANADA
Accession no.631885
Accession no.636712
Item 289
Item 286 European Plastics News
Injection Moulding International 24, No.5, May 1997, p.33-4
2, No.2, April/May 1997, p.72-5 HOLE STORY
PRACTICAL REMEDIES FOR THERMOSET Anscombe N
SURFACE DEFECTS
When Electrolux wanted to reduce the cycle time for a
The five most common surface defects resulting during high volume part, a levelling foot, it decided to concentrate
the injection moulding process - porosity, blistering, on the mould design. The company uses a porous mould
cracks, clouds and colour streaks - are discussed, together steel, Toolvac developed by Aga, to vent air from the
with their causes and a troubleshooting guide. cavities during the production of the part. Cycle times

have been cut from 32 to 20 seconds and quality has also Item 292
improved. International Mold Steels markets a permeable Injection Molding
mould steel developed in Japan by Sintokogio. Called 5, No.3, March 1997, p.39/42
Porcerax, the steel solves a number of gas-related TROUBLESHOOTING DESIGNS FOR
problems including burning, weld lines and shrinkage. ENGINEERING RESINS
AGA AB; INTERNATIONAL MOLD STEEL INC. Maniscalco M
SCANDINAVIA; SWEDEN; USA; WESTERN EUROPE
It is reported that when investigating the causes behind
Accession no.631459 aesthetic defects and part performance shortcomings, it
can be tempting to blame the material. Before succumbing
Item 290 to this theory, however, the many other factors that affect
Injection Molding the final part should be considered, such as mould design,
5, No.3, March 1997, p.106-9 gate location, runner systems, process temperatures,
TROUBLESHOOTER. XII. HOT RUNNERS residence time, part design, filling patterns, etc. Where
Hatch R engineering resins are concerned, the interactions among
Prime Alliance Inc. all of these variables can be critical. Details are given.
ENTEC POLYMERS
Problems with hot runners and heated sprue bushings
USA
always seem to be in one of three places. The first problem
area is usually the gate diameter, second is the gate land, Accession no.630720
and third is the size of the nozzle orifice. When
troubleshooting hot runner problems, the gate diameter and Item 293
land length are the first places to look. The gate diameter Injection Molding
should be at least half the wall thickness for PE and PP and 5, No.3, March 1997, p.24/8
bigger for the more shear sensitive amorphous materials MACHINE STATES
such as ABS, acrylics, and polycarbonates. The land length Woodrell W
of these hot tip gates should be 0.005 inch, usually indicated Woodrell Project Management
as a sharp edge on prints. When the flow path is restricted In the course of troubleshooting, it is very useful to break
because of a small gate diameter or a long land length, you the machines cycle down into basic states to quickly
will usually see higher heat settings being used by the analyse the problem at hand and get the machines back
moulding technicians to get the parts to fill and pack out. on line. There are dozens of individual steps that take
The problem with this approach is that it usually causes place in any cycle; these steps are identified, breaking
warpage of the parts, cosmetic defects around the gate area, them down into ten easily recognisable stages and a couple
and long moulding cycles. Other troubleshooting advice of auxiliary stages that are basic to all moulding
on the hot runner aspects of injection moulding is presented. equipment. It is assumed that a normal cycle on either a
USA toggle or standard hydraulic clamp with a single
Accession no.630733 reciprocating screw is currently run; that is, without sprue
break or nozzle valve function. References to cores are
also left out due to the many different configurations that
Item 291
may be applied depending on the mould.
Injection Molding
5, No.3, March 1997, p.83/5 Accession no.630717
ON/OFF TIPS FOR DIRECT GATING PETP
Kirkland C Item 294
PETP is reported to have emerged as a better alternative March 1997, p.18-20
to glass in a number of markets, including blood collection HYDRAULIC PRESSURE MONITORING IS NOT
phials in the medical industry, but the materials highly GOOD ENOUGH FOR PRECISION MOULDING
crystalline nature can make direct gate, hot runner Griesser E
moulding of such products difficult. Extremely rapid Sensotron Inc.
cooling is required to prevent white marks, caused by
crystallisation, from forming in the finished products. The problem with injection moulding machines is that
Rapid melting and cooling at the gate area can be peak filling pressure and packing pressure generally vary
extremely difficult in a hot runner mould. Seiki Spear too much for precision applications. Hydraulic pressure
System America has developed open-tip probes and valve variations have a direct bearing on nozzle pressure and
gate systems using its field-proven temperature control hence on shot weight variation. This article discusses the
systems to solve these problems. Details are given. selection of an appropriate injection pressure sensor to
replace and improve on the hydraulic system transducer.
SEIKI SPEAR SYSTEM AMERICA INC.
USA USA

Item 295 Hatch R

Injection Molding Prime Alliance Inc.
5, No.2, Feb.1997, p.76/81
The problems encountered with unbalanced runners in
MOULD VENTING
injection moulding are addressed and solutions proposed.
Hatch B
USA
Prime Alliance Inc.
Accession no.618643
A problem in an injection moulding shop concerning
noticeable knit lines and poor surface cosmetics was Item 299
traced to lack of vents in the mould. Moulders routinely Kunststoffe Plast Europe
slow down injection speeds to get rid of burns, but 86, No.11, Nov.1996, p.13-4
materials perform better if they are injected quickly. The 100% CONTROL OF SURFACE QUALITY
design of runner, parting line, ejector and core pin vents Burger T
and blind vent pockets are discussed.
USA Inspection of the component surfaces in plastics injection
moulding is becoming increasingly important because the
Accession no.624882
faults often occur very abruptly and cannot be determined
by means of conventional methods of quality assurance
Item 296 using random samples. There is a certain naivety of some
Injection Molding quality assurance advisers who build up SPC systems to
5, No.2, Feb.1997, p.69 replace 100% control. Apart from specific applications
EJECTOR PIN PUSH-BACK BLUES of statistical process control, practice increasingly
Sloan J approaches 100% control, the main reason being product
A toolmaker in Michigan recently reported problems with liability legislation. Today image processing means more
ejector pin push-back causing wart-like pads on the parts than two-dimensional measurement, completeness
coming out of the mould. Pencil Logic, a mould services checks, position determination and identification of
company, says the amount of bending the toolmaker was markings. Specifically with components from the
experiencing was probably due to the size of the mould automotive and electrical industries, quality
and the injection pressures from the press. Inadequate characteristics such as a homogeneous and perfect surface
support for the ejector plate is a common problem and also are of great importance. In most cases the numbers
Pencil Logic recommends that a stop button (pin) be of parts produced by series production can no longer be
installed at least every six inches and nearest the point of subjected to a manual 100% surface quality control within
greatest injection pressure. reasonable cost limits. Details are given.
PENCIL LOGIC EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY;
USA WESTERN EUROPE
Item 300
Item 297 Plastics and Rubber Weekly
Injection Molding No.1666, 13th Dec.1996, p.7
5, No.2, Feb.1997, p.11/5 PERENNIAL PROBLEMS PERSIST
MACHINE STATES
Woodrell W There are still too few plastics product designers who call
Woodrell Project Management in the moulder and toolmaker at an early enough time for
them to have an influence on design, according to the
In the course of troubleshooting, it is useful to break the
Gauge & Tool Makers Associations Moulds and Dies
injection moulding machines cycle down into basic states
Section. The continuing difficulties by mouldmakers to
in order to analyse the problem at hand. This article
produce perfect moulds for customers, which appear to
examines the first five states of moulding: clamp close,
be the same year after year, are described.
mould protect, clamp lockup, injection forward and
injection pack/hold. GAUGE & TOOL MAKERS ASSN.
USA WESTERN EUROPE
Item 298 Item 301

4, No.12, Dec.1996, p.68-9 4, No.11, Nov.1996, p.154-5
TROUBLESHOOTER. X. UNBALANCED TROUBLESHOOTER. IX. WARP AND
RUNNERS DISTORTION

Hatch R COINJECTION HOT RUNNER BASICS

Prime Alliance Kirkland C
Practical advice is offered to solve problems encountered Coinjection moulding with hot runners is a popular topic.
in injection moulding; emphasis is placed on the problems Coinjection, or sandwich moulding, is the injection
of warpage and distortion. moulding of two or more plastic materials where a thin
USA outer skin layer (for instance an expensive engineering
Accession no.614299 resin) is formed surrounding one or more core layers (an
inexpensive material or recyclate). The benefits of the
process increase when hot runners are used. However,
Item 302 according to Dyniscos Kona Hot Runner Systems, little
Injection Molding information has been published acquainting moulders
4, No.11, Nov.1996, p.152-3 with basic details about the process. The following
HOW TO FIX COLOUR STREAKING AND solutions to basic processing problems should help to
REDUCE CYCLE AT SAME TIME familiarise with the advantages and disadvantages of
Sloan J coinjection moulding.
Custom moulder Sun Plastics had experienced a colouring DYNISCO INC.; KONA HOT RUNNER SYSTEMS
problem, and had been awarded a contract to mould red USA
PP medical waste bins with a quoted cycle time of 18 Accession no.614294
seconds. The problem was that the red colourant required
a cycle time of 22 seconds to properly mix the melt, or
Item 305
the bins were red streaked, not solid red. An attempt was
Plastics Technology
made to install a dispersion disk and a mixing nozzle, to
42, No.11, Nov.1996, p.50-2
no avail. Sun could not reduce the cycle time to below 22
NO MORE STREAKS!
seconds. To solve the problem, the company turned to
Martin M; Salamon B
Koch Engineering and the KMH mixing head series. Sun
Dow Plastics
installed the mixer on the 375-ton press. The company
reports that part improvement and colour uniformity were Black and brown streaks and splay are reported to be
immediate. In a week, the average cycle time was reduced among the most common flaws seen in polycarbonate
to 18.5 seconds and machine efficiency increased from parts. Streaks are the visible signs of heat degradation
87% to more than 95%. Details are given. caused by a combination of time and temperature. Another
SUN PLASTICS INC.; KOCH ENGINEERING CO. degradation effect, splay, is caused by bubbles of gas that
USA form at the flow front. Typical causes of both problems
Accession no.614298 include moisture from improperly dried resins, exposure
of the melt to an iron-rich surface, or machine-design
factors such as the screw, check valve, end-cap, or
Item 303 temperature control. Severity of streaking or splay can
Injection Molding increase significantly when these factors combine to
4, No.11, Nov.1996, p.142/6 create a corrosive environment in which moisture-
UNDERSTANDING AND PREVENTING SCREW degraded polycarbonate reacts with exposed iron surfaces.
WEAR The critical importance of these factors - especially those
It is evident that the injection screw is wearing when related to equipment design - was demonstrated by a
slippage is noted and there is a failure to develop enough laboratory study performed by Dow Plastics on a
pressure. Eventually the parts become unacceptably moulding project of a manufacturer of HVAC equipment.
inconsistent. It is common to continue moulding because During the evaluation of materials to be used in an
either there is not enough time to stop the job long enough appliance cover, the moulder observed streaking in parts
to pull the screw, or there is no replacement. An moulded from a beige ignition-resistant polycarbonate.
understanding of how screws (and barrels and nozzles Details are given.
and valves) wear, and what can be done to anticipate it, USA
will help keep an injection moulding operation running Accession no.614280
smoothly. Details are given.
WESTLAND CORP. Item 306
USA
Accession no.614296 86, No.9, Sept.1996, p.7-9
REDUCING MOULD-GAP WIDTHS
Item 304 Mueller D H; Feng Y
Injection Molding Bremer Instituts fuer Konstruktionstechnik;
4, No.11, Nov.1996, p.106/12 Tongji,University

Factors affecting mould gap widths and the subsequent This is a table showing potential errors in moulded parts
deformations caused by flash in the parting plane of injection that can occur with the gas-assisted injection moulding
moulding machines, are examined. This problem is discussed process, and the elimination steps that can be taken to
with particular reference to the injection moulding of prevent them.
elastomers when injection pressures are high. Gaps between IKV
the mould halves may be avoided by very rigid designs or EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY;
by designs that ensure that the deformations are identical in WESTERN EUROPE
the mould cavity regions. The use of computer models for Accession no.609876
the analysis of deformations is discussed.
Item 310
WESTERN EUROPE
Asian Plastics News
Accession no.610533 Nov. 1996, p.19/21
GAS INJECTION PART TWO: PROCESS
Item 307 OPTIONS AND TROUBLESHOOTING
Injection Molding
This article forms the second part of a series of four
4, No.10, Oct.1996, p.96/8
articles on gas-assisted injection moulding. Here,
THE TROUBLESHOOTER. PART 8: ACETAL
process engineering options and troubleshooting are
WITH SPLAY PROBLEM
focused upon, with a particular look at nozzle selection
Hatch B
and wall thickness.
Prime Alliance Inc.
IKV
Problems are examined associated with splay on the EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY;
surface halfway between the gate and the end of fill on a WESTERN EUROPE
large acetal part with .180-inch nominal wall. Corrections Accession no.609875
made to the injection moulding process to amend this fault
are described, and include the attempt to simulate higher
compression ratio by increasing back pressure with Item 311
existing screw, and the use of lower heats and a machine Asian Plastics News
with a bigger injection unit to reduce cycle time. Nov. 1996, p.17
HOLE STORY
USA
Accession no.610498 This article reports on an air-permeable steel,
developed in Japan by Sintokogio, that is helping to
overcome many of the gas venting problems faced by
Item 308 injection moulders. The heart of the success of
Injection Molding Porcerax II is explained.
4, No.10, Oct.1996, p.78/80
RAISING THE BAR ON TEXTURING SINTOKOGIO
JAPAN; USA
STANDARDS
Gurr A Accession no.609874
The need for a Master Grain and Gloss Standard plaque

is examined, and the problems involved with producing Item 312
such a standard discussed. Collaboration between GM Modern Plastics International
Motors, Schulman Inc., Bernard Mould, and International 26, No.11, Nov.1996, p.54-9
Mold Steel resulted in the production of a Standard plaque MOULDERS CONFRONT CHALLENGES OF AT-
which reproduces maximum texture and gloss definition. THE-PRESS COLOURING
It involved the use of Porcerax II porous mould steel to Snyder M R
solve venting problems. As the practice of introducing colourants at the press
GENERAL MOTORS CORP.; SCHULMAN INC.; becomes more widespread, injection moulders are more
BERNARD MOULD LTD.; INTERNATIONAL able to solve colour problems, frequently in close working
MOLD STEEL INC. relationships with suppliers of colourants, feeding
USA equipment and mixing screws. Examples of recent case
Accession no.610494 histories are given to illustrate how problems were
resolved. These include streaking in orange recreational
vehicle fenders moulded in HDPE, and problems with
Item 309
unmelted particles and inadequate colour dispersion in a
Asian Plastics News
PP part.
Nov. 1996, p.20
USA
GAS-ASSISTED INJECTION MOULDING
TROUBLE-SHOOTING Accession no.608961

Item 313 mould modifications, and the actual process conditions

Antec 96. Volume III. Conference proceedings. are reported.
Indianapolis, 5th-10th May 1996, p.3502-4 USA
STUDYING PROCESSING EFFECTS ON Accession no.608154
SHRINKAGE OF A HYGROSCOPIC MATERIAL
Fulton D
Pennsylvania,State University Item 316
(SPE) Injection Molding
4, No.8, Aug.1996, p.86-8
Absorption of water after injection moulding of PART & SPRUE STICKING
hygroscopic materials, such as polyphthalamide or nylon, Hatch B
causes changes in the dimensions of the final product. Prime Alliance
This can cause a problem with dimensional stability and
may cause a part that is within tolerance after moulding This article is one in a series of troubleshooting reports
to fall out of the tolerance before it reaches the customer. concerning the problem of parts sticking to moulds and
For this reason two- and three-stage injection moulding sprue bushings. The problem was identified as a loss of
strategies, % moisture when moulded, mould temperature temperature in the drier, causing residual moisture in the
and regrind values are analysed to determine the most nylon that made it flow too easily. Increasing the heat setting
stable process when the part begins to reabsorb moisture. on the drier to achieve thorough drying solved the problem.
The findings appear to show that the mould temperature USA
was the major factor in controlling the effect of moisture Accession no.604494
on the final dimensions of the part. A follow-up study is
being conducted to separate the effects of annealing and
moisture absorption on the part dimensions. 2 refs. Item 317
Injection Molding
USA
4, No.7, July 1996, p.84/6
Accession no.608838 TROUBLESHOOTER - PART 5: DISTORTION/
BLUSH
Item 314 Hatch B
Plastics News(USA) Prime Alliance
8, No.27, 2nd Sept.1996, p.5
This article is part 5 of a continuing series of trouble-
MARINE MOULDER HOPES FOR SMOOTHER
shooting reports in which injection moulding
SAILING
manufacturing problems are solved by Bob Hatch,
Lauzon M
manager of technical service for Prime Alliance of the
The difficulties are described, which are being USA. This article investigates distortion and blush.
experienced by Otron Tech Inc. in the injection moulding USA
of large HDPE and PP sheets for marine deck applications. Accession no.603688
The company has invested in a Hettinga injection unit
with a shot capacity of 176 pounds, but is having problems
reducing the current cycle time to make the sheets which Item 318
have a closed-cell foam core. Antec 96. Vol.I. Conference Proceedings.
Indianapolis, 5th-10th May 1996, p.466-9. 012
OTRON TECH INC.
USA
MOULDING ENGINEERING RESINS INTO
THIN-WALL APPLICATIONS: ISSUES AND
Accession no.608245
ANSWERS
Cosma L R
Item 315 GE Plastics
Injection Molding (SPE)
4, No.9, Sept.1996, p.92/4
THE TROUBLESHOOTER. PART 7: CYCLE Approaches to the successful injection moulding of thin-
TIMES FOR THICK PARTS walled portable electronic components such as cellular
Hatch B telephones and computer housings in engineering plastics
Prime Alliance Inc. are discussed. Aspects of flow length and machine design,
methods for improving the aesthetic qualities of
A troubleshooting guide is presented which deals with mouldings, impact strength requirements and advantages
the question of cycle times for thick-walled parts. of thin-wall moulding in terms of reduced cycle times
Aspects considered include barrel heats, heats in relation are examined.
to materials, barrel sizes, size of shot, and the
USA
optimisation of flow paths. The example of a large airfoil
made from HDPE is used to illustrate the necessary Accession no.602955

Item 319 Item 322

Plastics Technology Injection Molding
42, No.7, July 1996, p.100 4, No.6, June 1996, p.108/10
NO-SWEAT MOLDING RAISES BOTTLE THE TROUBLESHOOTER PART 4:
OUTPUT STRESSED OUT
Hatch B
This article explains how Graham Packaging of the USA,
Prime Alliance
who produce HDPE motor oil bottles, overcame mould
sweating problems with a mould dehumidifier system A case study involving a cracking problem in a hollow
from the Cargocaire Div. of Munters Corp. The system is polycarbonate T-connector, being part of an airline
described in detail. application, is examined. Such cracking problems in a
GRAHAM PACKAGING; MUNTERS CORP. thermoplastic part, that occurs after moulding when the
USA part is exposed to external pressure or force such as
Accession no.598907 assembly pressures, are claimed often to be caused by
moulded-in stresses. Moulded-in stress is most likely to
occur, it is explained, when molten material, injected into
Item 320 a cavity under excessive pressure, is forced to cool
Plast 21 quickly. Squeezed through undersize flow paths, polymer
No.42, April 1995, p.50-3 molecules can become unnaturally aligned or stressed.
Spanish USA
FAULT DIAGNOSIS BY A MANUFACTURER OF
Accession no.594209
VEHICLE LIGHTS
Azcarreta R; Barrutia C; Basagoiti J; Gil A M
Rinder Industrial SA Item 323
Injection Molding
Results are presented of a study undertaken by Rinder 4, No.6, June 1996, p.79/82
Industrial of Spain to determine the causes of defects in REVERSE GATING DRIVES BLUSHES AND
injection moulded vehicle lights. BLEMISHES AWAY
EUROPEAN COMMUNITY; EUROPEAN UNION; SPAIN; Kirkland C
WESTERN EUROPE
Accession no.598398 The use is described of reverse gating techniques which
eliminate gate marks in parts moulded with hot or cold
runner systems. Advantages of the system are discussed,
Item 321 and details are given of Kona technology which allows
Kunststoffe Plast Europe moulders to produce reverse gated parts while gaining
86, No.6, June 1996, p.10-2 all the benefits of hot runner moulding. Kona has used
WEAR RESISTANT PLASTICISING UNITS finite element analysis to solve the problems of the
Heinze M different temperatures of the material in the gate area and
For a long time, wear problems have been associated with hot material at processing temperatures further upstream
plastics treatment and processing in plasticising units, and which result in a cloudy blush when using hot runners,
the resulting economical impact is no surprise. Wear affects by its patented seal technology to optimise tip and insert
those machine components that are in contact with the geometry. In addition, its patented heat pipe technology
moulding material to be processed, i.e. cylinders, screw, helps by providing a uniform temperature over the length
non-return valve, and possibly also the forming mould. A of the flow path. Successful applications are reported.
BMFT investigation performed in Germany estimates the KONA HOT RUNNER SYSTEMS
costs arising from wear in plasticising units at 750 million USA
DM. Even the replacement parts for screw compounders Accession no.594201
used for plastics treatment give rise to expenses that are
assessed at 220 million DM worldwide. Total wear-related
Item 324
costs, including indirect loss (production downtime, rejects,
Injection Molding
customer complaints, and depreciation for unused
4, No.5, May 1996, p.88/90
investments) are probably much higher. This creates the
THE TROUBLESHOOTER PART 3: CYCLE
necessity to reduce this wear as far as possible by adequate
TIME
tailor-made measures. Protection against wear is based on
Hatch B
two major approaches: suitable material selection
Prime Alliance Inc.
respecting material treatment, and load-related constructive
design of toe corresponding machine components. A case history is presented as an example of
EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; troubleshooting cycle times. The use of process settings
WESTERN EUROPE that differ from the norm should only be as a step in
Accession no.596166 reaction to unanticipated independent and temporary

variations in the moulding process, it is warned, and that instability that can be achieved with the Scorim process with
if a moulder habitually operates too far off the optimum both unfilled and filled engineering and high temperature
norm, then he will have no room left to manoeuvre when thermoplastics and thermosets. Information and data on fibre
the unexpected happens. An example of a PP ribbed orientation in reinforced plastics are presented. Finally,
structure with too long a cycle time is investigated and application use and practice are described. 2 refs.
several suspicious process conditions are examined which USA
lead to the primary cause of undersized flow paths being Accession no.591700
identified.
USA
Item 327
Accession no.592431 British Plastics and Rubber
June 1996, p.8/10
Item 325 COOLING BY NUMBERS
Plastics World Maier C
54, No.6, June 1996, p.17-20
Cooling time accounts for quite a slice of the average
WHAT PROCESSORS NEED TO KNOW ABOUT
injection moulding cycle, yet cooling circuit design is often
RELEASE AGENTS
a minor consideration when laying down a tool. Kestrel
McCarthy D F; Dyer M R
Injection Moulders added MF/Cool cooling analysis to its
Franklynn Industries Inc.
existing Moldflow mould filling software on the strength
The thermosetting urethane materials used in RIM/SRIM of a study made by Moldflow on a Hellerman fibre optic
and open casting are prone to aggressive sticking. Because cable connector moulded in PP. Computer simulation
these processes involve chemical reactions, it is critical exposed problems in conventional best practice and allowed
that the release agent has a positive impact on the process. various solutions to be tried at virtually no cost. The final
Water-based semi-permanent releasants alleviate many cooling circuit design provided efficient and uniform heat
of the concerns raised with solvent-based systems extraction plus reduced cooling time.
including VOCs, exposure concerns, combustibility, and KESTREL INJECTION MOULDERS
handling. Water-based systems are well proven for EUROPEAN COMMUNITY; EUROPEAN UNION; UK;
multiple release of injection moulded parts, with little or WESTERN EUROPE
no transfer to the finished part. Given the wide number Accession no.591177
of variables in RIM and SRIM processing, it is critical to
select a mould release supplier capable of providing a
formulation specifically tailored to meet processor needs. Item 328
A troubleshooting table is presented. Injection Molding
4, No.3, March 1996, p.77/80
USA
PROCESSING. THE TROUBLESHOOTER PART
Accession no.592179 1: POSTMOULDING CRACKS
Hatch B
Item 326 Prime Alliance
Emerging Technologies Retec 95. Conference An example of troubleshooting a production problem is
proceedings. given, with reference to cracking and crazing appearing
Erie, Pa., 9th-10th Aug.1995, paper 11. 8 after a moulded part was assembled and put into service.
PRINCIPLES, CAPABILITIES AND It involved a cover on a consumer leisure item made from
APPLICATIONS easy-flow polycarbonate. Solutions offered are discussed,
Grossman E M and include the change to a stiffer flow polycarbonate,
Scortec Inc. increased flow paths, radiused sharp corners and edges,
(SPE,Northwestern Pennsylvania Section; Penn State and increased height of support bosses.
Erie,Behrend College Plastics Technology Deployment
Center; US,National Tooling & Machining Assn.) Accession no.590990
Scorim is a new injection moulding process which, for the

Item 329
first time, creates dynamics to the molten plastic inside the
Plastics Southern Africa
mould cavity. This process offers useful and economic
25, No.9, Feb.1996, p.20
solutions to existing problems in thin and thick sectioned
FLASHING - CONFLICTING VIEWS ACTUALLY
parts and has considerable value to the moulder, the resin
BOTH CORRECT
supplier, the product and part designer, the plastics and
Fourie J
applications engineer, and the quality and reliability
Cape Technikon
specialist. Test results are presented to demonstrate the
improved mechanical characteristics and the reduction in This comprehensive article outlines a number of factors
weld and flow lines, sinks and voids, and dimensional which can cause flashing to occur in the injection

moulding process. The article describes the faults that MODELLING AND SIMULATION OF
can occur, together with a chart which provides a system THERMALLY INDUCED STRESS AND
of checks and solutions to rectify the faults causing the WARPAGE IN INJECTION MOULDED
flashing to occur. THERMOPLASTICS
SOUTH AFRICA Shih-Jung Liu
Accession no.590147 Chang Gung College of Medicine & Technology
Thermally induced stress and the relevant warpage
Item 330 caused by inappropriate mould design and processing
Kunststoffe Plast Europe conditions are problems that confound the overall
86, No.4, April 1996, p.11-12 success of injection moulding. A viscoelastic phase
QUALITY CONTROL OF OPTICAL transformation model, using a standard linear solid for
COMPONENTS - MODERN CONTROL the solidified polymer and a viscous fluid model for the
STRATEGY IN INJECTION MOULDING polymer melt, of two-dimensional finite element scheme
Michaeli W; Kudlik N; Vaculik R with 8 noded overlay isoparametric elements was used
Aachen,RWTH; IKV to simulate and predict the residual stress and warpage
within injection moulded articles as induced during the
A highly sensitive measurement system based on digital cooling stage of the injection moulding cycle. The
imaging, which can detect extremely small faults, is approach proposed is to examine and simulate the
described for use in quality control of optical components
injection moulding solidification process with the intent
such as lenses. A surface camera records a line grid imaged
of understanding and resolving more inclusive and
by the lens and transmits it to the image evaluator. An
realistic problems. 29 refs.
evaluation algorithm determines through half tone analysis
TAIWAN
the deviation of the imaged lines from a reference image.
The distortions of the lines by the lens are a direct measure Accession no.588801
of its optical properties. At the same time, surface defects
such as streaks can be determined and classified. (Translated Item 333
from Kunststoffe, 86, No.4, April 1996, p.478-80) Injection Molding
EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; 4, No.4, April 1996, p.76/9
WESTERN EUROPE TROUBLESHOOTER. II. BLISTERING
Accession no.590058 Hatch R
Prime Alliance Inc.
Item 331 Troubleshooting the injection moulding process is
Kunststoffe Plast Europe reported to be best accomplished by a careful and
86, No.4, April 1996, p.8-10 controlled step-by-step procedure. A systematic approach
SYSTEMATIC REDUCTION OF FAULT requires discipline. The best troubleshooters have this
POTENTIAL - POKA-YOKE APPROACH IN quality and they are invaluable for being able to provide
INJECTION MOULDING PRODUCTION lasting profitable solutions. This kind of approach to
Bourdon R solving a plastics moulding problem is especially
Rodinger Kunststoff-Technik GmbH necessary when working with complicated processes like
A report is presented on Poka-Yoke, a total quality hot runner systems, which present a far greater number
management system developed by Toyota which offers many of variables in more areas, compared to traditional cold
different and effective possibilities for implementation in runner jobs. Details are given.
injection moulding. The aim of the system is systematic USA
minimisation of fault potential in routine plant operation. Accession no.587581
Practical examples of fault reduction in mould installation
include hoses for the mould temp. control system, flow rate Item 334
through the temp. control system, incompletely filled parts Injection Molding
and granulators. (Translated from Kunststoffe, 86, No.4, 4, No.4, April 1996, p.59-60
April 1996, p.472-4) TOOLING: WHY CAVITIES CRACK
TOYOTA Tobin W; Groves D
EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; WJT Associates Inc.; Alpha Mold
WESTERN EUROPE
Accession no.590057 The most common reason for a mould cavity cracking is
reported to be using inferior mould steel. The design of
moulds to avoid this problem is discussed.
Item 332
USA
36, No.6, March 1996, p.807-18 Accession no.587575

Item 335 Shepard T A; OConnell M; Powell K; Charwinsky S

Journal of Applied Polymer Science Becton Dickinson Research Center
60, No.3, 18th April 1996, p.353-62
Maldistribution of flow around the core pin during
CORRELATION BETWEEN FLOW MARK AND
packing is shown to be the primary cause of core-pin
INTERNAL STRUCTURE OF THIN PC/ABS
displacement, and a process window that minimises the
BLEND INJECTION MOULDINGS
problem is determined. A fast injection speed is
Hamada H; Tsunasawa H
recommended, and the need to balance pack time and pack
Kyoto,Institute of Technology
pressure between minimising coreshift and maximising
Clarification is given of a mechanism of the flow mark part weight, is emphasised. 7 refs
that appears on the surface of thin polycarbonate/ABS USA
blend injection mouldings through the observation of the Accession no.582788
internal structure at various processing conditions. The
flow mark had two different constitutions, such as a lustre
part and a cloud part, alternately on the both surfaces. 9 Item 338
refs. Injection Molding
4, No.2, Feb.1996, p.81/4
JAPAN
TEN THINGS YOU SHOULD KNOW ABOUT
Accession no.586932 GAS-ASSIST
Bertacchi G; Bernhardt A
Item 336 Plastics & Computer International Srl; Plastics &
Innovations in Interior and Exterior Plastics for Computer Inc.
Automotive Applications. Retec proceedings. Ten pointers towards successful gas assisted injection
Dearborn, Mi., 8th-9th Nov.1995, p.173-81. 63Tr.Ro moulding are presented. It acts as a troubleshooting guide
BENEFITS OF A SEQUENTIAL FILL VALVE as well as offering advice on best techniques, and how to
GATE HOT RUNNER SYSTEM FOR MOULDING avoid potential problem areas.
AUTOMOTIVE BUMPER FASCIAS
EUROPEAN COMMUNITY; EUROPEAN UNION; ITALY; USA;
Betters J E WESTERN EUROPE
JEB Consulting; Kona Corp.
Accession no.582780
(SPE,Detroit Section; SPE,Automotive Div.)
Automotive bumper fascias have become very complex Item 339
over the past several years; design engineers are Injection Molding
integrating many features into the bumper such as grilles 4, No.2, Feb.1996, p.42
and light openings to reduce tooling and manufacturing Y-SITES: THICK SECTIONS AND CORE PULLS
costs. Also, to save material, bumpers are designed with Maniscalco M
thinner walls and hot runner systems are incorporated in
the mould design. Due to the complex cavity geometries Solutions are offered to processing problems involving
and increased flow length vs. wall thickness ratios, it is Y-sites in design. In particular, cooling is discussed, since
difficult to predict the actual flow pattern during mould two core pins meet directly under the thickest section
filling. Although computer aided design software is used where the two tubes come together. For large- and small-
in the design stage to determine optimum processing bore categories the design of core pins and other methods
conditions, gauge locations and runner diameters for a of controlling thickness transition are described.
balanced fill, variations in steel dimensions, mould EASTMAN CHEMICAL CO.
cooling and inadequate venting alter the predicted filling USA
pattern. Process engineers are therefore faced with a non- Accession no.582774
uniform fill resulting in poor dimensional stability of the
bumper along with surface appearance and paint adhesion
Item 340
problems. Details are given of a technique developed by
Injection Molding
a consortium for controlling the fill pattern during the
4, No.1, Jan.1996, p.74-5
actual filling phase. 10 refs.
A FLEXIBLE URETHANE CHALLENGE
USA Rosen M
Accession no.583858
Problems associated with the moulding of a flexible
thermoplastic urethane medical implant were solved by the
Item 337 use of a multilaminate, finite element filling and packing
Plastics Engineering analysis using Fillcalc V from Rapra Technology Ltd. The
52, No.2, Feb.1996, p.27-9 medical device designed by ICI Corp. contained two halves
MINIMISING CORESHIFT IN INJECTION which were solvent welded together after moulding. An
MOULDED CONTAINERS aluminium prototype mould was used, details of which are

given, but which led to warpage, shrinkage, gas trapping, (SPE)

and high fill pressure. The results of the analysis, combined The use of thermal insulation to improve packing
with a proper understanding of the flow behaviour of problems associated with a thin to thick flow is
urethane, enabled modifications to be made to the mould. considered. Specially-designed cavity inserts with
These included removing the submarine gate, and adding insulating air gaps are used for this thermal insulation of
a gate at the ejector pin, and venting. the thin area. Stainless steel is also used as a cavity insert
ICI CORP.; RAPRA TECHNOLOGY LTD. material to thermally isolate the thin area of an actual
EUROPEAN COMMUNITY; EUROPEAN UNION; UK; USA; problem moulding. Results show these two techniques
WESTERN EUROPE
isolate the thin area from the moulds cooling system and
Accession no.579555 visibly improve the packing in the problem moulding
studied. 4 refs.
Item 341 USA
4, No.1, Jan.1996, p.40
EFFECTIVE MEDICAL PART DESIGN: PART 1.
Item 344
CONNECTOR DESIGN KEEPS PROCESS IN
European Plastics News
MIND
22, No.11, Dec.1995, p.31
Maniscalco M
BUMPER SAVINGS
Design hints for moulding for the medical industry are Anscombe N
presented by Eastman Chemical. Details are given of ways
Fords plant in Genk, Belgium, has achieved huge savings
of designing for processability with reference to a
by changing the screws in its injection moulding
connector moulded from polyester. Problems with cooling
machines. The machines fitted with the innovative screw
were eliminated by redesigning the part with a thinner
are being used to mould bumpers for the Mondeo. The
flange, and by using two shorter bimetallic core pins.
Barr Energy Transfer screw has been developed especially
EASTMAN CHEMICAL CO. for use with high viscosity engineering thermoplastics
USA
and is a type of barrier screw. The ET screw has been
Accession no.579548 designed to improve mixing, but keep shear as low as
possible. The low shear rate is important for the Ford
Item 342 bumper which is produced using GE Plastics Xenoy, a
Antec 95. Volume III. Conference proceedings. blend of polycarbonate and PBTP. Cycle times have been
Boston, Ma., 7th-11th May 1995, p.4392-7. 012 cut from 78 to 70 seconds, part weight is down by 50
IMPACT OF ENVIRONMENTAL grammes (1.5%), part weight consistency has improved
TEMPERATURE AND HUMIDITY ON REJECT and part reject rate has been reduced from 8 to 2%.
RATE IN A PLASTIC INJECTION MOULDING FORD MOTOR CO.
PLANT BELGIUM; EUROPEAN COMMUNITY; EUROPEAN UNION;
Carter R V WESTERN EUROPE
Penn State Erie Plastics Technical Center Accession no.576423
(SPE)
The effects of temperature and humidity on reject rate Item 345
during injection moulding are discussed. It is determined Medical Design & Manufacturing Orlando. Conference
by examining the output graphs that, in order to reduce proceedings.
reject rates at the plant, the shop should be dehumidified, Orlando, Fl., 20th Sept.1995, p.107-13. 6S
but not air conditioned. Dehumidifying the shop area will MECHANISM FOR CORE SHIFT IN INJECTION
reduce moisture in the air and lower the dew point, MOULDED CONTAINERS
decreasing the chance that condensation will occur on the Shepard T A; OConnell M; Powell K; Charwinsky S
mould surface, and, in turn, lowering the reject rate. 4 refs. Becton Dickinson Research Center
USA (Canon Communications Inc.; Medical Device &
Accession no.577996 Diagnostic Industry Magazine; SPE,Medical Plastics Div.)
Variations in wall thickness of thin-walled parts, due to
Item 343 displacement of the corepin, is a common problem. The
Antec 95. Volume III. Conference proceedings. mechanism by which core shift occurs is described and a
Boston, Ma., 7th-11th May 1995, p.4314-8. 012 process window to minimise the problem is identified.
IMPROVING PACKING IN THIN TO THICK Maldistribution of flow around the corepin during packing
MOULDED PARTS is the primary cause of pin displacement. 7 refs.
Rydbom M USA
Penn State Erie Plastics Technical Center Accession no.575811

Item 346 Bichler M

Asian Plastics News Mannesmann Demag Kunststofftechnik
March/April 1995, p.83 It is explained that the quality of an injection moulded
INJECTION MOULDING TROUBLESHOOTING part is affected by a variety of factors which change from
GUIDE - PART 11 application to application. The quality shortcomings can
Advanced Elastomer Systems Singapore Pte.Ltd. be caused by incorrect settings of machine or process
Part 11 of this injection moulding troubleshooting guide parameters, and inappropriate mould design or design of
relates to thermoplastic elastomers. Potential problems and injection moulded parts. This article looks at some of the
possible solutions are offered for a variety of problems such common faults such as sink marks, unmelted granules,
as poor finish, weld lines, distortion, and colour degradation. and gloss deviations. It considers possible approaches to
SINGAPORE eliminate these faults.
Accession no.572753 EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY;
WESTERN EUROPE
Accession no.561232
Item 347
Plastics Technology
41, No.11, Nov.1995, p.15 Item 350
SCREW DESIGN CURES SPLAY PROBLEMS Modern Plastics International
Ogando J 25, No.9, Sept.1995, p.38/41
HOT RUNNER REDUCES MOULD DESIGN
It is reported that when injection moulding splay problems TIME
arise, it could be the screw design at fault rather than the Snyder M R
material. Two major automotive operations have experienced
Joint efforts undertaken by Toro and three outside parties
this problem over the past year, both overcoming splay
helped the consumer-products maker design, optimise and
problems with polycarbonate blends after adopting a
build a hot runner moulding system to produce a 510mm
proprietary screw design from Great Lakes Feedscrews. The
blower tube. Toros original specifications for the
ET II screw is built under licence from Robert Barr, with
component included heavy decorative bands on both sides
Great Lakes Feedscrews having the sole licence to this design
and around the small end. The material was Valtra, a rubber-
for the injection moulding market. Details are given.
modified styrenic polymer. Advanced Plastics Design was
GREAT LAKES FEEDSCREWS; BARR R.,INC. asked to carry out a comprehensive mouldability analysis
USA
on the part. Flow analysis indicated an unacceptably high
Accession no.571069 filling pressure and air entrapment problems. Toro began
solving the air entrapment problem by coring out the heavy
Item 348 bands. Finite element stress analysis was carried out to
Plastics World determine the magnitude of the core deflection. The
53, No.9, Sept.1995, p.29-30 problems were solved by relocating the gate, increasing
SOLVING THE WELD-LINE PUZZLE the polymer melt temperature and increasing wall
Malloy R A thicknesses locally to aid flow.
One of the manufacturing related problems that is TORO CO.
USA
commonly encountered when moulding parts is that of weld
line formation. Weld lines are often visible to the naked Accession no.560802
eye, and as a result, represent a significant cosmetic
concern. In addition, the local mechanical strength and Item 351
chemical resistance in the weld zone can be significantly Injection Molding
lower compared to other areas of the same part. Computer 3, No.8, Aug.1995, p.74-5
aided mould filling simulations can be used to predict the HOW MANY GATES?
areas of the part where welds will form. Once in production,
A flow analysis case study is described: a solid-top
process variables such as increasing melt temperature or
exercise floor tile moulded of PP. Initial moulded parts
injection speed will tend to have a positive effect on weld
are badly warped, have poor surface appearance and
performance by promoting molecular diffusion.
require an excessively long moulding cycle. Results of
USA
mould filling indicate that the primary source of the
Accession no.563339 problem is the gating layout.
PLASTICS DESIGN LIBRARY; RAPRA
Item 349 TECHNOLOGY LTD.; ROUTSIS A.,ASSOCIATES;
Plast Europe Kunststoffe MATEFLEX
7, No.1, April 1995, p.20-3 USA
SURFACE FAULTS IN INJECTION MOULDING Accession no.560600

Item 352 reference to the differences in the course of cooling of

Antec 95. Volume I. Conference proceedings. crystalline and amorphous plastics. The potential of
Boston,Ma., 7th-11th May 1995, p.684-701. 012 analytical and numerical calculations were characterised
MODELLING AND SIMULATION OF and a solution was presented, using the finite difference
THERMALLY INDUCED STRESS AND method, to the problem of calculating the cooling time of
WARPAGE IN INJECTION MOULDED crystalline plastics. A computer program was developed
THERMOPLASTICS which made it possible to calculate the cooling time of
Liu S-J; Rietveld J X crystalline and amorphous plastics and was used for
Chang Gung College of Medicine & Technology; simulation of the injection moulding process conditions
Wisconsin-Madison,University on the curve of cooling of the plastic in the mould. 7 refs.
(SPE) (Full translation of Polim.Tworz.Wielk., No.2, 1995, p.109)
EASTERN EUROPE; POLAND
The warpage of a plastics product can be seen as primarily
due to non-uniform differential shrinkages within the Accession no.557954
product which lead to the development of uneven residual
stresses within the product. In order to predict the residual Item 355
stress and warpage in a polymer product, the effects of Antec 94. Conference Proceedings.
the processing conditions, the material behaviour and the San Francisco, Ca., 1st-5th May 1994, Vol.III, p.3455-
geometric effects must be accounted for. To date, several 9. 012
numerical models have been proposed to simulate the PREDICTING SURFACE DEFECTS IN
formation of thermally-induced stresses. The current INJECTION MOULDED PVC COMPONENTS
numerical approaches to the residual stress and warpage Weir S J
problem tend to fall within two categories: a complex Geon Co.
material model applied to a simple part geometry, or a (SPE)
simple material model applied to a complex part geometry. A study was made of the possibility of capturing the
It is proposed to examine the thermally-induced stress critical value of shear stress for a PVC compound in order
and warpage problem using a novel material description to predict surface defects such as gate blush in injection
and a more comprehensive geometric description with moulded parts. Material testing was performed using a
the intent of either reaching or understanding more capillary viscometer, followed by mould filling simulation
inclusive/realistic problems. 24 refs. and verification testing of a moulded part using a four-
TAIWAN; USA cavity colour chip mould. The results suggested that some
Accession no.558962 correlation could be made between analytical predictions
of shear stress exceeding a critical value and visible
Item 353 defects in the surface of a moulded part. 2 refs.
Antec 95. Volume I. Conference proceedings. USA
Boston,Ma., 7th-11th May 1995, p.1050-6. 012 Accession no.557812
EJECTOR PINS: ANALYSIS OF OPTIMUM
MATERIALS AND TREATMENTS Item 356
Starkey G Plastics World
Progressive Components/D&L Inc. 53, No.7, July 1995, p.29/34
(SPE) FOLLOW THE 4 MS TO TROUBLESHOOT
Causes of ejector pin failure are described. Optimum PROBLEMS
criteria are then established followed by an analysis of Czazasty J
materials and treatments which meet the defined criteria. Dynisco Instruments Inc.
USA Quality problems in mouldings are a function of the inter-
Accession no.558583 relationship between the material quality, the machine and
its settings, the mould and the man or operator. The
relationship between melt temperature and thermal
Item 354
degradation of the material is one reason to consider
International Polymer Science and Technology
monitoring melt temperature using the new infrared in-
22, No.2, 1995, p.T/98-102
nozzle temperature sensors. A good way to detect
CALCULATION OF THE COOLING TIME OF
variations in material is by looking for variations in
PLASTICS IN THE INJECTION MOULDING
viscosity. The causes of bubbles or trapped gas in
PROCESS
mouldings and faults such as short shots are examined.
Wilczynski K; Tyszkiewicz A
Selecting the best process variables to monitor is critical.
The problem of cooling of mouldings (in the form of plates) Appropriate instrumentation such as the previously
during injection moulding was examined with particular mentioned temperature sensors or in-cavity pressure and

temperature sensors are excellent tools since they act as Item 360
windows into the process. Plastics Technology
USA 41, No.2, Feb.1995, p.54/63
Accession no.556725 PORTABLE ANALISERS FIND WHAT AILS
YOUR PROCESS
Ogando J
Item 357
World Class Injection Moulding. Retec proceedings. This comprehensive article supplies a detailed review of
Charlotte, NC, 25th-27th Sept.1994, p.103-18. 831 portable machine analysers. These data-acquisition and
INJECTION MOULDING CONDUCTIVE monitoring devices hook up to moulding machines and
THERMOPLASTICS auxiliary equipment, gathering information that helps to
Nielsen J M identify the root causes of processing problems. The article
RTP Co. compares the various features and advantages of various
(SPE,Carolinas Section; SPE,Injection Molding Div.) portable machine analysers currently on the market.
BRANDEN T.G.,CORP.; HUNKAR LABORATORIES
Conductive thermoplastic materials and applications are
INC.; NICOLLET PROCESS ENGINEERING; RJG
reported to make up the fastest growing segment of the plastics
TECHNOLOGIES INC.
industry. The areas of concern facing moulders of conductive
USA
thermoplastic composite materials are explored, and proven
techniques to prevent processing problems are offered. Accession no.546250
USA
Plastics Technology (Hong Kong)
No.18, Oct.1994, p.38-49
Item 358 Chinese; English
World Class Injection Moulding. Retec proceedings. INJECTION MOULDING OF POLYAMIDE 6
Charlotte, NC, 25th-27th Sept.1994, p.7-9. 831 AND POLYAMIDE 66
MISUSE AND ABUSE OF PLASTIC PROCESS
SIMULATION A review is presented of the injection moulding
Engelstein G procedures for use with polyamide 6 and 66, and the
GR Technical Services Inc. differences between them in terms of handling, machinery,
(SPE,Carolinas Section; SPE,Injection Molding Div.) and processing conditions. Included also is a
troubleshooting guide. The materials used in this article
Mould filling, cooling and warpage analyses are very
refer to Akulon polyamides from DSM.
powerful diagnostic and troubleshooting tools. However,
three are some limitations to what the simulations can be DSM NV
EUROPEAN COMMUNITY; EUROPEAN UNION;
expected to do. Most bad analysis experiences arise from NETHERLANDS; WESTERN EUROPE
misapplying the technology to problems which are
Accession no.546177
unsuitable. A wide variety of these limitations are discussed,
arising from simulation assumptions, algorithmic
Item 362
implementations, rheological data and other sources.
Injection Molding
USA
3, No.2, Feb.1995, p.71/3
Accession no.553609 MOULDING THICK-WALL PARTS WITH NO
TRADE-OFFS
Item 359 Maniscalco M
Antec 94. Conference Proceedings. Problems associated with injection moulding thick-walled
San Francisco, Ca., 1st-5th May 1994, Vol.II, p.1908- parts are discussed, with reference to warpage and
10. 012 differential shrinkage. Practical guidelines from experts at
EFFECTS OF DRYING TIME ON Creative Techniques Inc. are offered in order to assist in
HYDROSCOPIC POLYMERS the avoidance of processing mistakes moulders can make
Dunham J when trying to eliminate warpage in thick-walled parts.
Massachusetts,University
CREATIVE TECHNIQUES INC.
(SPE)
USA
The effects of drying time on the impact strength and Accession no.544990
surface finish of injection moulded samples of virgin and
regrind ABS and polycarbonate were investigated. Item 363
LOWELL,UNIVERSITY Injection Molding
USA 3, No.2, Feb.1995, p.62-3
Accession no.546538 REDUCING THERMOSET WARPAGE

Solutions are offered to warpage problems in a car Item 367

headlight reflector and indicator unit which resulted in Antec 94. Conference Proceedings.
distortion causing the headlights not to reflect in the right San Francisco, Ca., 1st-5th May 1994, Vol.I, p.766-9. 012
direction. It was found that uneven cooling due to gate USE OF A DIFFERENTIAL SCANNING
location caused temperature variation and uneven filling. CALORIMETER AS A TROUBLE SHOOTING
The gate was moved to a different location to balance the TOOL FOR INJECTION MOULDING
resin flow. The use of Fillcalc V thermoset filling Thompson S L
simulation software is discussed as an analysis tool. Pennsylvania,State University
EUROPE-GENERAL (SPE)
Accession no.544988 The use of DSC for studying the effects of moulding
conditions on crystallinity in injection moulded PP
Item 364 components is described. 3 refs.
Plastics Technology USA
41, No.3, March 1995, p.48-52 Accession no.541195
GUIDELINES FOR TROUBLE-FREE GAS-
ASSIST MOULDING
Item 368
Caropreso M; Zuber P
Antec 94. Conference Proceedings.
GE Plastics
San Francisco, Ca., 1st-5th May 1994, Vol.I, p.626-30. 012
GE Plastics has produced a booklet in which practical MOVING BOUNDARY TECHNIQUE TO
guidelines to part and tool design, moulding and control STRENGTHEN WELD LINES IN INJECTION
techniques in gas-assisted injection moulding are detailed. MOULDING
Selected recommendations are excerpted in this article, Gardner G; Malloy R
which includes a troubleshooting guide. Massachusetts,University
USA (SPE)
Accession no.544958 The effects of an in-mould moving boundary system
promoting local mixing in the weld line area during mould
Item 365 filling on the tensile and flexural strengths of the weld
Plastics Technology lines of injection moulded composite parts were
41, No.1, Jan.1995, p.47-9 investigated. The process used a cam operated
HOT RUNNERS FOR QUICK COLOUR reciprocating pin, or two such pins, to promote lateral
CHANGES displacement of the melt during mould filling. The
Dewar N; Vettor D systems evaluated were shown to be extremely effective
Mold-Masters Ltd. in strengthening weld lines in parts made from glass fibre-
The article outlines the problems encountered by injection reinforced PP and a glass fibre-reinforced ABS/
moulders, where frequent colour changes interrupt polycarbonate blend, without giving rise to other types
injection moulding runs. The article supplies detailed of defects. 12 refs.
guidelines for selecting and operating a hot runner system LOWELL,UNIVERSITY
that will save both time and material. USA
CANADA Accession no.541169
Accession no.543807
Item 369
Item 366 Plastics World
Injection Molding 53, No.1, Jan.1995, p.21
2, No.9, Oct.1994, p.55 DESIGNING AROUND RIBS
PROCESSING - SOLVING A BIG VOID Malloy R A
PROBLEM U-Mass Lowell
This describes how General Industries of the USA handled Many injection moulded plastic parts contain ribs to
a project to provide HDPE fittings for very large natural increase the torsional or bending stiffness of the part. From
gas pipes, for Phillips Driscopipe Inc. In particular, how a purely mechanical or structural point of view, the
General Industries overcame the biggest processing designer is concerned with variables such as rib
problem of air entrapment - voids - is explained. placement, rib spacing and the individual rib dimensions
GENERAL INDUSTRIES; PHILLIPS DRISCOPIPE as these all influence the overall stiffness of the plastic
INC.; PHILLIPS PETROLEUM part. Unfortunately the rib manufacturing problems are
USA more difficult to quantify. The sink mark that occurs
Accession no.542031 opposite the rib is a particular concern in many consumer

product applications. The options open to part designers styrene-acrylate terpolymer. The findings suggested that a
when dealing with sink marks are outlined. flow instability mechanism led to the observed surface
USA defects, including step defects, chevrons and non-uniform
Accession no.539244 haze. The injected melt encountered a step increase in cavity
thickness between the gate and the cavity, giving rise to a
slip condition which initiated flow instability. It was
Item 370 proposed that recoverable shear strain, shear stress and
Antec 94. Conference Proceedings. coefficient of friction between the melt and the mould were
San Francisco, Ca., 1st-5th May 1994, Vol.I, p.408-10. 012 key controlling factors for surface defect formation. 8 refs.
INFLUENCE OF PROCESSING PARAMETERS
USA
ON QUALITY OF GAS-ASSISTED INJECTION
MOULDED PARTS Accession no.537985
Yang S Y; Liou S J
Taiwan,National University Item 373
(SPE) Antec 94. Conference Proceedings.
Taguchi experimental design was used to study the influence
TOTAL SYSTEM APPROACH TO IMPROVING
of processing variables on the quality of PS parts produced
AN INJECTION MOULDED PLASTIC PART
by gas-assisted injection moulding. Part quality was judged
QUALITY
on the basis of the average depth of sink marks. The variables
Zou Q; Ari G
examined included melt temperature, gas pressure, gas
Black & Decker Inc.; Bowles Fluidics Corp.
injection delay, injection rate, injection pressure and short
(SPE)
shot size. Melt temperature and short shot size were found
to have the most significant effect. 14 refs. An account is given of a programme undertaken to
TAIWAN; USA improve the quality of injection moulded springs in
Accession no.537993 vehicle windscreen washer nozzles which had given
unacceptably high breakage rates. 6 refs.
USA
Item 371
Accession no.537984
VISUAL ANALYSES OF FLOW MARK Item 374
GENERATION PROCESS USING GLASS- Antec 94. Conference Proceedings.
INSERTED MOULD. I. MICRO-GROOVED San Francisco, Ca., 1st-5th May 1994, Vol.I, p.342-7. 012
FLOW MARKS PROCESS QUALITY ASSURANCE FOR
Yokoi H; Nagami S; Kawasaki A; Murata Y INJECTION MOULDING OF THERMOPLASTIC
Tokyo,University; Mitsui Petrochemical Industries POLYMERS
Ltd.; Sekisui Chemical Co.Ltd. Rowland J C; Ho-Le K
(SPE) Moldflow Pty.Ltd.
(SPE)
The generation of micro-grooved flow marks on injection
moulded parts was observed by the use of a glass-inserted The setting of injection moulding machines for the
mould. The significant factors in flow mark generation were production of high quality thermoplastic components and
flow front velocity and mould temperature, while gate shape the continuous monitoring of the moulding process to
and resin temperature were insignificant. 1 ref. achieve consistent part quality is discussed. Particular
JAPAN; USA attention is paid to injection velocity and holding pressure
Accession no.537986 profiling and the matching of theoretical filling profiles
to real life situations. 4 refs.
AUSTRALIA; USA
Item 372
Accession no.537982
STUDY OF SURFACE DEFECTS IN THE Item 375
INJECTION MOULDING OF RUBBER- Plastverarbeiter
MODIFIED THERMOPLASTICS 45, No.11, Nov.1994, p.88/94
Chang M C O German
Monsanto Co. VENTING OF INJECTION MOULDS
(SPE) Notz F
A study was made of surface defects occurring in parts The problems are analysed which are associated with
injection moulded in a rubber-modified acrylonitrile- inadequate venting of injection moulds. These include burn

marks on mouldings, higher costs for repair and maintenance, Item 379
a shorter service life of the machine, and the health hazards Asian Plastics News
which exist from escaping fumes. Design criteria are March 1994, p.37
examined for the construction of a vented injection mould. INJECTION MOULDING TROUBLESHOOTING
EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; GUIDE. VI. PVC
WESTERN EUROPE
The sixth part of a troubleshooting guide for injection
Accession no.534649 moulding is presented, with emphasis on PVC. Problems
discussed include short shot, sink or shrink marks, smudges
Item 376 and orange peel, dull streaks and flow lines, poor weld
Kunststoff Journal lines, flashing, blisters or bubbles, burned spots, burning
28, No.4, Aug.1994, p.34-6 in one part only, burning in part and runner, excessive
German shrinkage, and black flecks but no discoloured streaks.
PROVEN TECHNOLOGY ASHLAND PLASTICS AUSTRALIA
AUSTRALIA
Tools for thermoplastics, thermosets and elastomers,
which are very expensive to manufacture, are subject to Accession no.529982
abrasion from chemicals and adhesives. Interruptions in
use result in poor demoulding and similar problems, Item 380
requiring frequent mould cleaning. Hard surface tool Asian Plastics News
coatings made of PVD offer a good solution to these Jan/Feb.1994, p.18
problems. Balinit A is three times as hard as glass fibre. INJECTION MOULDING TROUBLESHOOTING
Coating is carried out by a plasma high-vacuum process. GUIDE. V. ABS
EUROPEAN COMMUNITY; EUROPEAN UNION; GERMANY; The fifth part of a troubleshooting guide for injection
WESTERN EUROPE
moulding, with emphasis on problems encountered when
Accession no.532999 processing ABS. Problems covered include: short shots;
trapped gas, bubbles, burn spots; surface imperfections,
Item 377 poor weld lines, sink spots or shrinkage, mould flashing,
Asian Plastics News sticking in the sprue or cavity; and black streaking.
Sept/Oct.1994, p.56 ASHLAND PLASTICS AUSTRALIA
INJECTION MOULDING TROUBLESHOOTING AUSTRALIA
GUIDE. IX. ACRYLIC Accession no.529967
The ninth part of an injection moulding troubleshooting
guide is presented, with emphasis on the processing of Item 381
acrylic polymers. Problems addressed include splay European Plastics News
marks, splash, silver streaks, mica surface and flow lines; 21, No.9, Oct.1994, p.23/6
weld and knit lines; sink marks; short shots and rippled MAKING THE RIGHT CHOICE
surface finish; burning, or trapped air in mould; warping; Reade L
internal bubbles; crazing; delamination temperature; and This article discusses choosing an injection moulding
breaking or cracking of part when mould opens. machine and what criteria should be used when selecting
ASHLAND PLASTICS AUSTRALIA a machine. The role that machine specification plays in
AUSTRALIA achieving zero defect production is examined. An
Accession no.530010 illustration is given of how rule-of-thumb techniques
can lead to the specification of unnecessarily large
machines. A graph for determining cavity pressure
Item 378
requirements is presented. Evaluation of a machines
Asian Plastics News
performance is also discussed. The primary emphasis of
July/Aug.1994, p.39
the evaluation should be to quantify the injection units
INJECTION MOULDING TROUBLESHOOTING
ability to delivery plastic with the maximum consistency.
GUIDE. VII. POLYESTER
It is also important to determine the clamps ability to
The eighth part of an injection moulding troubleshooting minimise mould deflections during the process.
guide, with emphasis on the processing of polyester. WORLD
Aspects covered include short shots and ripples, splay Accession no.529217
marks, drooling at nozzle, warping and distortion, sink
marks, voids, delamination and part sticking in cavity. Item 382
ASHLAND PLASTICS AUSTRALIA Plastics Technology
AUSTRALIA 40, No.1, Jan.1994, p.86
Accession no.529997 DONT LET MOULD SWEATING SLOW

YOU DOWN ejector pins/draft are examined. It is claimed that the vast
majority of troubleshooting calls can probably be resolved
The article supplies details of a portable desiccant-bed
more by referring to the suppliers processing guide,
dehumidification system manufactured by Bry-Air Inc.
calling the local technical service representative or by
The mould dehumidifier solves the problem of mould
following these basic guidelines.
sweating - condensation on the mould which causes water
USA
spots that mar the surface of the parts being moulded.
Mould sweating increases cycle time and causes Accession no.519435
unacceptable levels of rejects. The dehumidifier is an
inexpensive way of solving the problem. Item 386
Plastics World
PLASTIC INJECTORS; BRY-AIR INC.
USA
52, No.4, April 1994, p.19-21
PROCESS CONSISTENCY IS A KEY TO
Accession no.524960
SUCCESSFUL MOLDING
Smock D
Item 383
Injection Molding This article provides a guide to polystyrene processing,
2, No.5, May/June 1994, p.46/9 investigating common problems encountered and basic
HARD WATER PROBLEMS? TRY MAGNETS errors made, with the help of troubleshooting experts from
Kirkland C several large companies. A thorough troubleshooting
guide-list is included.
The use is discussed of magnetics to prevent scale
BASF; DOW PLASTICS; GE PLASTICS;
formation in injection moulds which use water for cooling.
CHEVRON; FINA
Improved heat transfer in equipment and less downtime USA
for scaled equipment are benefits provided by the use of
Accession no.513696
magnets which suspend particles of calcium carbonate in
a solution which can be passed through the water system.
Item 387
STEPCO CORP.; GLOBAL INDUSTRIES INC. British Plastics and Rubber
USA
April 1994, p.20
Accession no.524006 COLD HOT RUNNER SOLVES COMPLEX
FILLING PROBLEM
Item 384 Vogel H
Plastics News International Ewikon GmbH
June 1994, p.14-5
The injection moulded polycarbonate speaker grilles
MOULDING POLYCARBONATES - WHATS
being used today by the automotive and electronics
CHANGED?
industries are said to be complex mouldings which present
McGough J
a range of problems for the mouldmaker. The ways in
This comprehensive article considers the problems which an internally-heated hot runner manifold provided
encountered in the injection moulding of polycarbonates, the precision necessary for the multiple gating of the
such as in die design, gating and drying. The article outlines polycarbonate grille are described.
the keys to successful moulding of polycarbonates EUROPEAN COMMUNITY; GERMANY; WESTERN EUROPE
including the choice of mould materials, prototype tooling, Accession no.510985
sprues and runners, gating tolerances and shrinkage, mould
temperature control and drying conditions. Item 388
GE PLASTICS Plastics Technology (Hong Kong)
AUSTRALIA No.14, Feb. 1994, p.40-9
Accession no.521224 INJECTION MOULDING OF
POLYPROPYLENE (PP)
Item 385 This article provides comprehensive information on injection
Plastics World moulding with PP. PPs chemical and mechanical
52, No.6, June 1994, Part I, p.62-4 characteristics are explained. An insight is provided into part
ABCS OF PROCESSING ABS designing considerations and mould design considerations.
Pettit R Injection moulding machine requirements are also examined.
GE Plastics A troubleshooting list is included of all the common PP
The problems of injection moulding ABS and possible moulding problems, with possible causes suggested.
ways of overcoming them are discussed. The most likely HIMONT
troublespots of drying, screw design, non-return valves USA
or check rings, gate design, mould temperatures and Accession no.508969

Subject Index
Subject Index
A ANCILLARY EQUIPMENT, 15 C
261 321 360 365 382
ABRASION, 281 303 ANISOTROPY, 23 132 156 263 CALCIUM CARBONATE, 48 126
ABRASION RESISTANCE, 10 63 ANNEALING, 73 132 199 383
69 79 183 321 376 ANTI-ADHERENT, 215 CALCIUM SILICATE, 126
ABRASIVE MATERIAL, 79 223 ANTIOXIDANT, 126 168 195 CAPACITY, 41 319 360 388
248 ANTI-STICK COATING, 257 CAPILLARY FLOW, 355 388
ABS, 10 13 18 21 46 60 62 66 70 APPEARANCE, 66 88 109 190 CAPILLARY RHEOMETRY, 66
74 77 88 103 134 153 154 182 196 198 201 232 349 355 372 117 350 372
187 198 202 224 226 227 231 AUTOMATION, 116 117 133 206 CARBIDE, 73
232 238 250 254 274 275 276 211 245 288 320 374 381 CARBON BLACK, 225 249 274
289 308 318 323 333 335 359 372
CARBON FIBRE-REINFORCED
368 380 385 386 B PLASTIC, 357
ACCURACY, 294 355
ACETAL COPOLYMER, 91 146 BACK PRESSURE, 70 95 217 247 CASE HISTORY, 39 62 71 88 89
307 307 312 361 381 385 99 100 101 102 103 106 108
ACID ETCHING, 308 BACKFLOW, 70 227 117 124 126 147 148 168 176
ACID RESISTANCE, 79 BALANCING, 21 182 184 197 199 202 203 231
ACRYLIC, 10 35 62 88 106 129 BARREL, 10 29 35 41 62 88 106 233 282 324
143 148 190 278 147 197 233 248 249 303 318 CAVITY, 29 35 69 106 107 111
ACRYLIC POLYMER, 83 165 227 381 124 125 129 148 168 169 176
254 377 BARREL TEMPERATURE, 4 95 182 197 225 231 249 282 289
ACRYLONITRILE-STYRENE- 112 134 143 237 278 315 318 309 329
ACRYLATE TERPOLYMER, BARRIER SCREW, 344 CAVITY FILLING, 42 64 130
66 274 372 BELT, 88 CAVITY PRESSURE, 21 68 81 97
ADDITIVE, 3 8 56 61 66 79 80 84 BLEND, 18 21 26 66 80 90 95 103 98 154 228 256 265 362 381
112 139 149 179 186 187 215 CELLULAR MATERIAL, 48 54
108 111 117 126 131 140 152
235 260 310 318 335 339 344 61
159 162 164 198 208 215 223
347 368 372 373 CHANNEL, 22 327 369
229 235 236 244 257 262 279
BLISTERING, 286 333 CHANNEL FLOW, 364
302 318 356 358 372
BLOOMING, 84 CHEMICAL DEPOSITION, 79
ADHESION, 36 48 66 67 215 225
BLOW MOULDING, 35 90 CHEMICAL RESISTANCE, 35 63
235 336 372
BLOWING AGENT, 48 54 61 199 79 348 376 388
AESTHETIC, 83 224 275 318 323
BLUSH RESISTANCE, 64 224 CHROMIUM, 35 79 225
AGEING, 184
247 275 317 CLAMP FORCE, 4 17 34 41 45 54
AIR BUBBLE, 153 162 240
BOSS, 64 125 318 328 61 69 71 160 170 294 306 312
AIR DRYING, 244 320 359
BOTTLE, 147 319 329 349 350 364 370 381 388
AIR ENTRAPMENT, 40 102 185 BOWING, 247 CLAMPING UNIT, 297
215 223 240 247 277 289 295 BREAKAGE, 150 235 373 CLARITY, 11 35 82 165 359
350 BRITTLENESS, 1 5 23 98 186 235 CLEAN ROOM, 11 220
AIR FLOW, 244 368 239 243 246 359 373 CLEANING, 12 35 53 87 137 183
AIR PRESSURE, 368 BUBBLE, 100 157 186 327 349 215 234
ALIGNMENT, 144 188 318 BUBBLE FORMATION, 100 270 CLEANLINESS, 188
ALLOY, 73 79 90 125 160 190 225 356 CLOSURE, 47 90 225 241 294 312
289 BUBBLE GROWTH, 100 CLOUD POINT, 335
ALUMINIUM, 35 79 229 232 244 BUMPER, 312 336 344 COATING, 31 35 161 215 225 257
340 BURNING, 53 100 185 289 376
AMORPHOUS, 24 35 37 62 122 BUSHING, 62 106 124 182 183 COHESIVE FAILURE, 67
131 132 159 162 240 354 367 249 316 322 COINJECTION MOULDING, 48
ANALYSIS, 6 27 28 38 65 66 80 BUSINESS MACHINE, 35 65 117 61 90 304
81 90 94 96 97 98 101 118 131 129 COLD MOULDING, 149
136 160 194 195 209 219 230 BUTADIENE-ACRYLONITRILE COLD RUNNER, 42 55 61 62 88
236 240 244 258 262 269 271 COPOLYMER, 36 186 91 138 275 318 323 355
272 275 306 350 355 367 371 BUTYL ACRYLATE COLOUR, 61 66 80 97 126 161
372 374 COPOLYMER, 372 198 215 236 346 349

Subject Index
COLOUR CHANGING, 47 95 97 COOLING, 21 27 32 38 40 44 48 D

365 61 66 68 69 80 81 98 107 110
COLOUR DISPERSION, 50 99 124 125 129 131 132 136 153 DAMAGE, 12 41 69 184 192 193
COLOURANT, 3 164 229 262 312 158 160 175 179 180 189 235 235 244
COMPACT DISC, 68 79 240 247 289 293 314 318 319 DEBOTTLENECK, 288
COMPOSITE, 6 8 15 19 23 29 35 332 339 341 343 352 363 366 DECOMPOSITION, 214 215 236
48 49 56 57 58 64 67 73 79 81 367 371 374 383 388 257
89 90 95 128 130 132 141 155 COOLING RATE, 27 98 130 131 DECOMPOSITION PRODUCT, 53
156 158 159 161 162 186 199 132 136 179 180 185 217 371 215 236
200 213 214 215 223 235 236 DECORATION, 61 308 350
COOLING SYSTEM, 21 110 136
240 244 249 253 260 261 262 DEFECT, 12 35 46 48 53 57 61 66
153
263 266 269 271 277 279 281 68 79 80 81 82 84 87 88 97 98
COOLING TIME, 4 6 27 61 68 80 104 109 128 131 132 135 136
289 310 318 329 357 361 363
110 122 136 153 154 160 180 153 157 159 162 185 196 217
368
240 271 327 354 367 218 223 224 226 235 236 237
COMPOUNDING, 51 56 71
COPPER, 110 122 125 225 241 240 242 243 244 246 275 318
COMPUTER AIDED ANALYSIS,
27 28 65 275 306 340 355 367 CORE, 35 48 69 78 225 235 327 320 330 355 368 370 371 372
374 337 350 370 374 381
COMPUTER AIDED DESIGN, 14 CORE PIN, 295 DEFLECTION, 98 359 373
21 40 52 90 102 111 115 123 CORE-PULLING, 339 DEFORMATION, 48 66 98 151 156
142 153 160 178 200 244 245 162 209 235 241 244 306 320
CORE SHIFT, 337 345
DEGASSING, 318
300 348 351 363 CORROSION, 281 303 DEGRADATION, 19 49 61 66 71
COMPUTER AIDED CORROSION RESISTANCE, 10 161 168 184 185 203 213 233
ENGINEERING, 21 28 65 102 79 320 239 245 247 373 381
115 136 142 160 177 178 245
COST, 18 35 38 47 50 51 60 69 70 DEGRADATION RESISTANCE,
355 358
71 79 83 108 117 123 124 126 291
COMPUTER AIDED
131 133 142 144 151 153 159 DEHUMIDIFIER, 319 342 382
MANUFACTURE, 52 142 185 DELAMINATION, 187 231 243
162 167 199 203 220 233 234
245 349 377
248 311 312 321 336 342 344
COMPUTER AIDED POLYMER DEMOULDING, 74 79 84 136 160
360 365 373 376 382
SELECTION, 153 162 170 209 349 376
COMPUTER AIDED PROCESS COUNTER-PRESSURE, 223 235
236 DEPOSIT, 215 257 270
CONTROL, 33 374 DEPTH, 13 78 79 122 217 295 370
COMPUTER SIMULATION, 21 CRACKING, 28 68 97 143 149
371
23 27 28 32 97 102 110 115 128 235 243 250 278 286 328
DESIGN, 1 7 10 14 16 17 21 23 24
136 153 160 175 178 185 200 CRATE, 191 28 29 32 37 38 40 48 52 66 69
209 241 254 258 272 280 287 CRAZING, 84 235 243 328 71 77 78 80 83 85 88 90 93 96
288 327 352 355 363 374 CRYSTALLINITY, 1 27 80 89 98 102 103 107 110 111 113 115
CONDENSATION, 79 110 243 130 131 132 186 235 307 313 123 125 130 131 133 136 142
244 382 367 150 153 154 159 160 162 164
CONDITIONING, 244 361 CRYSTALLISATION, 27 80 94 170 171 172 174 178 180 181
CONNECTOR, 35 200 322 341 122 131 132 136 159 162 203 198 200 201 205 206 211 215
CONSISTENCY, 114 256 265 386 223 235 240 244 291 367 224 231 232 233 238 244 245
CONTAINER, 128 190 197 225 250 260 261 263 264 268 269
CRYSTALLISATION RATE, 6 80
302 337 272 273 278 281 283 289 298
131 240 271 277
CONTAMINATION, 23 47 48 53 300 301 323 326 328 333 334
CUSTOM MOULDING, 133 253 339 341 343 345 347 350 352
94 129 137 144 147 151 168
183 186 188 189 203 215 223 CYCLE TIME, 4 12 38 55 61 62 358 362 363 373 384 388
234 243 247 257 320 68 69 70 71 95 97 98 106 110 DEVELOPMENT, 11 12 40 54 117
CONTRACTION, 118 123 124 125 129 131 132 134 129 153 220
CONTROL EQUIPMENT, 33 65 136 137 143 149 153 155 160 DIAMETER, 8 10 21 29 35 48 61
69 90 144 176 188 194 207 267 162 168 176 182 190 197 201 62 64 77 88 97 111 112 124 134
284 310 364 370 381 217 218 224 225 232 236 240 143 146 149 182 190 197 201
CONTROL SYSTEM, 33 61 68 241 247 264 275 278 280 288 244 247 249 250 261 278 279
114 116 207 236 269 364 370 289 302 307 312 314 315 317 295 311 317 367 381
CONVEYOR, 63 318 323 324 327 336 340 344 DIFFERENTIAL THERMAL
CONVEYOR BELT, 88 351 362 364 381 382 386 388 ANALYSIS, 94 98 122 151 230
COOLANT, 69 136 185 327 CYLINDER, 97 361 236 239 262 269 367

Subject Index
DIGITAL VERSATILE DISC, 129 270 271 277 279 280 292 318 FILTER, 29 147 188 210
DIMENSION, 21 24 61 68 79 97 98 384 FILTRATION, 137 188 234
132 136 169 244 367 372 374 ENTRANCE FLOW, 61 FINITE ELEMENT ANALYSIS,
DIMENSIONAL STABILITY, 8 54 ENVIRONMENTAL STRESS 28 96 97 219 244 272 306 323
101 130 131 132 152 159 160 CRACKING, 163 332 340 350 355 373
162 235 244 245 246 279 336 EQUIPMENT, 2 9 12 24 29 35 38 FISH EYE, 186
358 363 364 367 63 76 88 89 104 108 133 137 FLASH, 68 79 84 101 185 237 277
DIMENSIONAL TOLERANCE, 1 198 212 220 222 244 261 346
101 ETCHING, 335 FLASHING, 12 48 62 246 329
DISC, 68 79 ETHYLENE-PROPYLENE FLAW, 6 35 46 48 85 86 105 107
DISC GATE, 218 264 COPOLYMER, 26 66 80 111 115 122 154 157 158 166
DISCOLOURATION, 99 223 236 ETHYLENE-VINYL ACETATE 185 217 218 224 232 245 246
243 244 246 270 COPOLYMER, 54 271 273 275 276 277 279 295
DISTORTION, 35 84 200 280 301 EXPANSION, 54 159 162 296
317 EXPANSION COEFFICIENT, 32 FLEXIBILITY, 29 184 232 319
DOMESTIC APPLIANCE, 117 160 63 296 340 373
289 EXTERNAL LUBRICANT, 187 FLEXURAL PROPERTIES, 1 35
DOSE RATE, 95 89 98 107 108 117 130 159 162
DOSING, 170 199 215 232 235 328 368 369
DOWNTIME, 12 47 65 71 133 167
F 386 388
253 259 FAILURE, 1 12 28 36 38 39 48 67 FLOW, 21 22 26 27 29 35 48 61 66
DRYER, 88 244 316 320 89 94 98 108 111 124 126 142 68 77 80 81 95 97 106 107 111
DRYING, 12 35 71 203 215 217 150 163 168 173 176 184 197 124 125 134 136 140 148 153
223 243 244 305 307 318 320 199 201 202 203 212 213 214 159 162 181 182 201 215 223
359 361 384 385 225 230 231 233 234 235 244 244 277 278 304 318 337 355
DRYING TIME, 244 318 359 249 250 278 282 290 303 309 368 370 371 372 373 374 386
DWELL PRESSURE, 361 334 349 359 373 388
DWELL TIME, 21 215 223 236 243 FAILURE ANALYSIS, 1 5 28 39 FLOW ANALYSIS, 26 27 42 81 97
247 257 270 151 177 246 258 373 241 244 327 350 351 371 374
FAMILY MOULD, 21 61 FLOW CONTROL, 42
E FATIGUE, 28 79 203 208 FLOW FRONT, 21 61 66 80 81
FAULT, 26 27 39 43 44 99 100 101 215 223 240 260
EDGE-GATE, 64 113 179 181 186 193 196 216 FLOW INJECTION ANALYSIS,
EJECTION, 107 128 185 225 243 330 331 349 181
289 FAULT DIAGNOSIS, 26 27 28 39 FLOW INSTABILITY, 22 43 57 66
EJECTOR, 41 79 136 318 43 97 99 100 101 115 116 159 80
EJECTOR PIN, 7 64 295 296 318 179 181 193 194 196 320 FLOW LENGTH, 81 244 279
353 385 FEED, 158 242 361 FLOW LINE, 48 66 84 134 146
ELASTOMER, 2 7 26 31 34 36 40 FEED ZONE, 236 229 237 255 276 278 285 335
45 51 66 67 80 84 90 161 170 FEEDING, 8 35 87 111 124 126 FLOW MARK, 43 66 118 218 226
172 186 216 220 235 244 266 134 279 312 FLOW ORIENTATION, 26
298 306 311 319 326 346 350 FEEDSTOCK, 203 FLOW PATH, 10 40 46 155 218
372 376 386 FIBRE, 29 35 126 156 161 186 235 224 255 278 315 322 323 324
ELECTRICAL APPLICATION, 281 328 340
117 221 299 387 FIBRE CONTENT, 23 130 162 FLOW PATTERN, 26 27 181 215
ELECTROEROSION, 136 235 289 368 312
ELECTRONIC APPLICATION, 18 FIBRE DISTRIBUTION, 100 128 FLOW PROPERTIES, 22 26 43 57
318 FIBRE ORIENTATION, 23 81 128 66 80 181 314 328 361 363
ELONGATION AT BREAK, 162 130 162 215 235 260 368 FLOW RATE, 27 30 61 80 81 121
235 240 244 FIBRE-REINFORCED PLASTIC, 322 327 331 355 371 374 381
ELONGATIONAL FLOW, 66 80 141 156 214 FLOW RESTRICTION, 215
ENGINEERING APPLICATION, FIBRE SHORTENING, 244 FLOW VISUALISATION, 66 118
63 66 111 131 132 159 162 215 FILLER, 48 56 57 58 80 84 89 108 371
223 236 240 244 270 271 277 124 126 140 162 198 199 208 FLUSHING, 216
280 292 318 384 223 318 372 FOAM, 48 54 61 264 325
ENGINEERING PLASTIC, 6 8 35 FILLER CONTENT, 1 372 FORMULATION, 3 164 214 233
63 66 111 131 132 159 162 215 FILLING, 29 48 62 69 107 111 124 312
223 236 240 244 257 260 269 141 197 213 282 FOULING, 189

Subject Index
FOUNTAIN FLOW, 66 80 81 371 H HOUSING, 250 274 289 318

372 HUMIDITY, 67 192 342
FOUR-CAVITY, 21 61 HALO EFFECT, 179 HYDRAULIC, 61 68 69 133 137
FRACTURE, 29 98 162 235 246 HANDLE, 46 82 252 176 189 234 326 368 381
271 368 HANDLING, 29 63 170 247 299 HYDRAULIC FLUID, 117 144
FRICTIONAL PROPERTIES, 79 320 325 361 188
159 248 372 HARDNESS, 31 35 69 73 79 199 HYDRAULIC PRESSURE, 68 294
248 335 367 376 318
FROZEN, 81
HAZE, 35 224 275 372 HYDROGEN CHLORIDE, 79
HEAT DEFLECTION, 89 108 386 HYDROLYSIS, 19 35 49 223
G HEAT DEGRADATION, 19 81 97 HYDROSCOPIC, 159 223 313 359
160 186 223 236 270 305 HYPODERMIC SYRINGE, 78
GAS-ASSISTED, 40 44 61 90 113 HEAT DISSIPATION, 81 117 159
135 141 157 280 309 310 338 215 320
364 369 370 HEAT LOSS, 81 136
I
GAS BUBBLE, 157 186 HEAT RESISTANCE, 51 67 159 IMPACT MODIFIER, 215 235 257
GAS FLUSHING, 216 215 372
GAS INJECTION, 154 280 370 HEAT SENSITIVITY, 323 IMPACT PROPERTIES, 1 11 63
GAS PENETRATION, 44 HEAT SINK, 327 98 131 162 165 180 187 195
GAS PRESSURE, 61 154 HEAT TRANSFER, 32 225 236 199 203 235 236 244 245 270
GATE, 7 21 29 35 48 61 62 69 88 241 269 323 327 343 383 323
97 98 102 106 111 124 146 148 HEATER, 137 188 IMPACT STRENGTH, 1 63 98 108
149 168 182 190 197 201 217 HEATING, 32 35 40 54 74 98 131 131 162 180 195 203 235 236
224 226 231 237 249 252 255 136 194 215 223 236 260 361 244 245 318 359 386 388
261 276 307 317 318 338 340 367 373 IMPURITY, 87
355 362 363 368 371 372 374 HIGH DENSITY IN-MOULD DECORATING, 61
385 388 POLYETHYLENE, 1 4 5 43 66 INDUSTRIAL ROBOT, 288 320
GATE BLUSH, 97 101 112 134 118 152 180 186 233 239 312 INFRARED SENSOR, 97
318 323 355 314 315 319 366 388 INJECTION BLOW MOULDING,
GATE CLOSING, 61 HIGH SPEED MOULDING, 66 90
GATE MARK, 58 218 323 132 INJECTION CHANNEL, 223 236
HIGH TEMPERATURE, 66 132 244
GATE OPENING, 61 217
HIGH-VISCOSITY, 66 371 INJECTION COMPRESSION
GATE VALVE, 61 323
HINGE, 45 240 277 388 MOULDING, 72
GATING, 6 8 10 37 40 55 64 77 82
HOLDING PRESSURE, 6 8 23 68 INJECTION MOULD, 16 17 21 28
107 112 120 130 134 155 158
98 122 130 131 134 136 143 30 31 45 61 66 68 79 80 81 91
164 200 204 205 211 230 247
154 160 215 223 240 244 260 97 98 110 113 123 128 131 136
257 260 274 275 277 278 279
271 277 279 350 373 374 138 153 159 160 167 174 178
290 291 304 348 350 351 381
HOLDING STAGE, 68 98 131 136 181 193 194 206 215 216 223
384
HOLDING TIME, 6 8 68 98 122 235 236 240 244 268 283 296
GAUGE, 60 251 308 318 320 343 353 355 359
131 160 185 227 240 244 271
GEOMETRY, 61 66 68 85 98 109 279 361 367 368 370 371 372 373 374
136 153 235 348 HOLE, 78 104 375
GLASS FIBRE-REINFORCED HOLLOW ARTICLE, 364 INJECTION MOULDING
PLASTIC, 6 10 15 19 23 29 35 HOMOGENEITY, 119 121 221 MACHINE, 7 12 17 29 32 35
49 89 95 130 132 141 155 156 270 302 41 45 56 68 69 73 74 88 116
162 199 200 203 205 208 213 HOPPER, 29 87 122 127 129 133 144 147 167
215 218 219 223 235 236 244 HOT CHANNEL SPRUE, 169 172 182 183 188 189 197 202
249 252 260 266 269 277 279 HOT RUNNER, 4 9 10 16 17 30 33 231 234 236 259 306 310 316
289 313 318 361 363 368 376 42 61 66 69 71 74 75 106 123 323 344 349 360 361 364 366
GLASS TRANSITION 134 138 146 150 155 168 190 381 383 386 388
TEMPERATURE, 35 89 94 156 191 194 215 223 231 242 252 INJECTION PISTON, 54
203 239 367 254 255 257 261 266 267 275 INJECTION PORT, 40
GLOSS, 48 66 80 97 109 124 146 276 287 290 294 304 318 323 INJECTION PRESS, 68
155 198 247 307 308 372 374 333 336 350 365 387 INJECTION PRESSURE, 8 18 21
386 HOT-RUNNER MOULD, 61 66 55 81 85 97 131 143 153 155
GRANULE, 192 244 349 361 215 223 158 160 217 236 237 243 244
GROOVE, 371 HOT SPRUE, 373 264 277 279 294 296 297 306

Subject Index
318 322 355 356 361 364 368 LIQUID MOULDING, 67 90 97 102 119 128 136 141 153
370 372 374 381 LIQUID POLYMER, 90 289 159 179 213 215 219 223 240
INJECTION RATE, 80 122 185 LIQUID RUBBER, 7 170 172 244 254 260 276 280 318 328
260 279 318 370 371 374 LIVING HINGE, 39 348 355 364 368 370 371 372
INJECTION SCREW, 243 LOADING, 29 98 160 374
INJECTION SPEED, 4 18 43 63 LOW DENSITY MELT FLOW INDEX, 98 153 256
66 68 131 132 146 158 160 179 POLYETHYLENE, 37 66 85 315 320 373 386
215 223 235 285 295 307 315 225 254 MELT FLOW RATE, 1 5 71 141
318 348 355 356 361 368 372 LOW TEMPERATURE, 63 179 217 237 247 388
381 LOW VISCOSITY, 240 MELT FRACTURE, 66 82 355
INJECTION SYSTEM, 18 381 LUBRICANT, 126 187 188 243 MELT PRESSURE, 61 68 119 129
INJECTION TEMPERATURE, 66 LUBRICATION, 137 144 256 338 356
81 97 98 132 235 236 361 LUSTRE, 335 MELT PROPERTIES, 179 381
INJECTION TIME, 4 61 68 97 98 MELT STABILITY, 71 372
136 160 217 355 368 MELT TEMPERATURE, 5 11 18
INJECTION UNIT, 45 68 131 170 M 19 21 42 43 61 68 70 80 81 85
223 MACHINE SET-UP, 297 95 97 122 128 130 131 132 136
INJECTION VELOCITY, 97 285 MACHINE WEAR, 10 141 143 146 149 151 153 155
374 158 160 165 179 180 185 190
MACHINERY, 2 3 7 9 12 17 24 25
INJECTION VOLUME, 223 215 223 224 236 257 264 270
29 32 34 35 38 41 45 56 61 65
INSERT, 2 4 22 40 159 174 240 295 312 315 318 338 340 348
68 69 73 74 75 76 79 80 81 87
254 255 308 350 356 367 368 370 371 372
88 90 92 97 98 104 116 121 122
INSERT MOULD, 45 227 253 266 374 381
127 129 131 133 136 137 138
343 MELT VISCOSITY, 19 66 68 81
144 147 153 159 160 167 172
INSERT MOULDING, 11 67 91 97 131 240 318 355 371 373
182 183 188 189 192 193 197
117 207 240 277 374
202 210 215 220 222 223 231
INSPECTION, 167 320 MELT VISCOSITY INDEX, 98
234 236 240 244 247 259 281
INTEGRAL HINGE, 240 277 153 256
INTERNAL LUBRICANT, 187 288 290 293 298 303 304 305
306 310 312 318 319 320 331 MELTING POINT, 63 89 131 151
INTERNAL STRESS, 40 46 68 168 233 236 270 361
130 131 132 160 162 235 243 342 350 355 356 361 367 368
370 371 372 373 374 MESH, 363
IR THERMOMETER, 356
MAGNET, 29 383 METAL INSERT, 159 240
MAINTENANCE, 12 29 31 47 79 METALLIC, 161 229 312
J 116 137 144 167 183 188 259 METALLISING, 320
288 METERING, 221 312
JETTING, 8 134 244 246 372 374 METHYL METHACRYLATE
MANIFOLD, 9 30 35 69 74 75 194
242 318 COPOLYMER, 372
K MANUFACTURE, 46 52 142 185 MICROINJECTION MOULDING,
245 221 222
KNIT LINE, 46 197 237 275 295 MANUFACTURING, 12 129 198 MICROPOROSITY, 6 240 271
318 202 212 231 317 MIGRATION, 195 372
KNOB, 82 MARBLISING, 58 MINERAL FILLER, 58 162 223
MATERIALS DATABASE, 153 318
MINIATURISATION, 18
L MATERIALS HANDLING, 247
MISALIGNMENT, 69
320
LAMINAR FLOW, 223 MATERIALS SELECTION, 1 76 MIXING, 29 56 60 66 90 95 126
LAND LENGTH, 112 134 261 93 106 108 110 115 130 153 170 302 312 344 368 385
LARGE-COMPONENT, 61 66 159 162 199 203 261 281 283 MOBILE PHONE, 129
LEAD TIME, 40 321 325 334 353 365 384 MODEL, 21 22 97 110 153 332
LEAKAGE, 137 183 MATT FINISH, 66 80 335 355
LENGTH, 98 385 MEDICAL APPLICATION, 35 78 MOISTURE, 79 162 223 244 320
LENS, 35 129 330 220 267 291 302 339 340 341 349
LEVELLING, 144 188 345 MOISTURE ABSORPTION, 5 35
LICENCE, 40 42 314 347 MEDICAL EQUIPMENT, 169 256 159 162 244 305 307 356 359
LID, 35 225 MELT, 9 48 88 106 107 157 201 MOISTURE CONTENT, 5 19 49
LIGHT REFLECTION, 80 221 309 365 368 372 388 71 140 217 223 243 305 320
LIQUID INJECTION MELT FILTER, 147 191 342 359
MOULDING, 172 MELT FLOW, 9 42 61 66 68 80 81 MOISTURE REMOVAL, 244 359

Subject Index
MOLECULAR ORIENTATION, 204 205 209 215 219 223 235 MOULDING PRESSURE, 21 81
80 81 98 122 132 237 240 243 244 245 247 254 97 131 153 160 236 244 318
MOLECULAR STRUCTURE, 51 255 258 260 264 271 275 278 355 368 370 372 374
90 126 131 162 192 240 372 279 284 287 288 294 297 318 MOULDING TIME, 61 97 98 136
MOLECULAR WEIGHT, 1 5 49 320 322 323 327 340 348 350 MOULDMAKING, 2 30 31 42 54
93 126 139 151 186 213 233 355 363 368 369 370 374 381 110 174 194 206 268 272 283
372 MOULD FLOW, 14 16 21 30 52 61 300 314 334 343 353 376
MOLYBDENUM, 73 66 68 80 81 97 136 138 153 MULTI-CAVITY, 21 61 282 388
MONITORING, 52 65 88 116 117 155 159 171 200 209 215 223 MULTI-CAVITY MOULD, 1 16
137 167 176 207 284 294 356 240 241 244 263 318 351 368 17 21 22 28 42 61 68 91 102
360 374 381 370 371 372 136 138 181 205 219 228 240
MONOSANDWICH, 45 MOULD FOULING, 36 84 215 254 266 278 334 337 350 355
MORPHOLOGY, 26 66 80 141 257 MULTI-COLOUR MOULD, 45
195 MOULD FOULING INHIBITOR, MULTI-GATE, 318
MOULD, 1 2 9 12 16 17 21 22 28 36 MULTI-MATERIAL MOULDING,
29 31 38 42 48 61 65 66 68 69 MOULD GEOMETRY, 181 200 45
75 76 79 80 81 91 97 98 102 MOULD HEATING, 34 55 136 MULTIPLE INJECTION
103 106 111 118 119 124 125 215 223 244 MOULDING, 181
131 133 136 138 148 153 159 MOULD HOLDER, 54 MULTIPLE LIVE FEED
160 167 181 183 189 197 205 MOULD INSERT, 32 122 150 215 INJECTION MOULDING, 318
215 219 222 223 225 228 235 318 371
236 240 241 243 244 247 254 MOULD OPENING, 4 136 247
261 266 268 278 282 300 308 MOULD PACKING, 61 68 80 81 N
309 311 317 318 320 329 349 85 98 131 143 255 256 264 318 NEEDLE VALVE, 61 74
355 367 368 370 371 372 373 340 374 381 NICKEL, 35 69 79
374 383 387 MOULD PRESSURE, 68 141 174 NITRID, 79
MOULD BALANCING, 21 181 MOULD RELEASE, 20 126 238 NITRIDATION, 215
254 MOULD RELEASE AGENT, 20 NITROGEN, 35 216 370
MOULD CAVITY, 10 21 68 79 81 36 243 325 NON-ISOTHERMAL, 22
82 109 136 150 215 318 334 MOULD SEAL, 154 NON-RETURN VALVE, 385
361 368 370 371 372 386 MOULD SHRINKAGE, 61 68 98 NON-STICK COATING, 257
MOULD CHANGING, 12 71 202 131 132 159 160 162 215 223 NOTCH, 98 235
MOULD CLEANING, 36 257 325 235 236 240 244 367 370 374 NOTCHED IMPACT STRENGTH,
376 MOULD SIZE, 41 1 98 108
MOULD CLOSING, 4 61 136 297 MOULD SUPPORT, 237 NOZZLE, 10 12 29 35 46 55 61 62
MOULD COATING, 20 43 MOULD SURFACE, 11 43 79 77 79 95 97 104 106 111 112
MOULD COOLING, 21 23 61 66 MOULD TEMPERATURE, 4 21 124 134 137 143 148 149 155
68 80 98 128 130 132 136 138 34 43 66 68 80 81 85 97 122 158 176 182 190 202 215 217
153 160 171 240 241 254 268 131 132 136 141 146 149 153 223 236 246 247 249 278 280
288 327 367 369 383 160 179 180 215 217 224 235 287 298 301 309 310 317 322
MOULD CORE, 134 158 318 368 236 237 243 247 254 257 260
356 361 364 370
MOULD CORE PIN, 78 269 278 307 313 318 322 324
NOZZLE PRESSURE, 294
MOULD CYCLE, 61 68 97 98 131 338 340 355 359 361 362 368
NYLON, 5 13 62 70 119 121 131
132 136 153 160 162 236 240 371 372 373 374 385
132 154 155 158 159 162 198
318 MOULD TREATMENT, 79
202 215 218 223 236 240 243
MOULD DESIGN, 1 7 16 17 21 23 MOULD VENT, 13 158 215 224
244 249 252 254 257 260 269
28 32 38 40 52 71 77 83 96 102 226 295 318
270 271 279 289 295 313
103 110 113 123 130 131 136 MOULDABILITY, 160 350 369
NYLON-6, 49 58 89 94 121 141
142 150 153 154 160 170 171 MOULDED-IN, 318 322 328 362
162 236
172 174 178 200 205 206 211 MOULDED-IN STRESS, 149
NYLON-6,12, 151
215 224 238 245 260 263 264 MOULDING FAULT, 53 57 58 61
NYLON-6,6, 6 94 124 131 132 151
269 272 283 289 300 327 332 66 68 71 72 77 79 80 81 82 85
162 203 218 236 240 244 270
334 340 343 351 352 353 364 86 87 88 97 98 99 100 101 102
365 369 375 103 104 105 109 112 118 122
MOULD EJECTOR, 245 131 132 136 141 153 162 179 O
MOULD FILLING, 8 14 16 18 21 180 181 195 216 217 223 235
22 23 30 40 46 55 61 68 80 81 236 240 244 285 307 318 320 ODOUR, 236 270 307
97 102 103 123 128 131 136 335 347 355 359 368 370 371 OIL, 35 137 234
153 160 162 171 179 181 185 372 374 OPTICAL APPLICATION, 25 35

Subject Index
72 129 330 PNEUMATIC, 29 61 368 332 350 370 371 386

OPTICAL DISC, 68 79 POLISHING, 11 48 69 295 POLYSULFONE, 163
OPTICAL PROPERTIES, 9 35 61 POLYACETAL, 6 60 62 70 91 119 POLYTETRAFLUORO-
66 80 131 165 215 236 244 278 121 130 131 159 162 215 223 ETHYLENE, 69 186
359 372 236 240 244 257 260 269 270 POLYURETHANE, 35 36 192 325
OPTIMISATION, 13 65 97 113 271 279 307 340
160 178 211 POLYAMIDE, 5 13 62 70 119 121 POLYVINYL CHLORIDE, 31 79
ORANGE PEELING, 246 131 132 154 155 158 159 162 97 117 119 121 184 186 187
ORGANOSILOXANE 198 202 215 218 223 236 240 214 219 233 259 289 355 379
POLYMER, 289 243 244 249 252 254 257 260 PORE SIZE, 174 289 311
ORIENTATION, 66 80 235 362 269 270 271 279 289 295 313 POROSITY, 6 84 162 174 214 235
OUTPUT, 1 17 54 319 388 316 240 271 283 286 289 311
OVERHEATING, 66 223 373 POLYAMIDE-6, 49 58 89 141 162 POST-MOULD, 54 132 159 328
OVERMOULDING, 45 227 253 236 361 362 363
266 POLYAMIDE-6,12, 151 POWDERED METAL
OXIDATION, 53 168 223 233 234 POLYAMIDE-6,6, 6 270 361 INJECTION MOULDING, 265
OXIDATION RESISTANCE, 79 POLYBUTYLENE PRECISION MOULD, 119
OXIDATIVE DEGRADATION, 53 TEREPHTHALATE, 6 19 47 PRECISION MOULDING, 55 256
168 223 233 234 49 55 62 131 162 175 200 215 265
223 233 236 240 244 254 257 PREHEATING, 236
260 269 270 271 279 323 344 PRESS, 12 88 133 183 199 234
P POLYCAPROLACTAM, 58 141 311
PACKAGING, 18 63 241 312 POLYCARBONATE, 1 5 9 10 11 PRESSURE, 29 35 48 61 65 68 69
PACKING DENSITY, 6 18 21 25 35 47 62 64 66 71 83 81 97 107 111 114 124 125 148
PACKING PRESSURE, 21 61 68 86 89 103 104 112 120 130 149 153 154 175 176 182 190 197
80 85 130 143 273 315 337 374 153 163 190 197 198 201 203 207 212 215 223 249 272 282
PART REMOVAL, 160 213 232 239 250 256 281 289 283 284 294 309 310 311 318
PART WEIGHT, 11 17 21 23 61 68 294 295 305 317 318 322 323 323 324 329 345 349 350 355
71 98 131 160 271 312 350 328 335 344 347 359 368 381 370 371 374 388
PARTING LINE, 13 136 170 224 384 386 387 PRESSURE CONTROL, 68 114
252 278 295 306 308 339 346 POLYETHERIMIDE, 230 265 318 370
PATENT, 18 30 70 283 323 326 POLYETHERSULFONE, 230 PRESSURE DEPENDENCE, 114
PELLET, 29 35 164 168 203 213 POLYETHYLENE, 1 4 5 10 37 43 141 179 180
359 62 63 66 85 118 126 128 131 PRESSURE DROP, 61 68 136
PERFORMANCE, 108 184 199 151 152 171 180 186 198 203 PRESSURE GAUGE, 60
203 213 233 381 386 213 225 233 239 254 312 314 PRESSURE LOSS, 68 223 224
PERMEABILITY, 289 311 315 319 366 388 PRESSURE PROFILE, 294 374
PHENOLIC RESIN, 31 POLYETHYLENE PRESSURE SENSOR, 68 97 256
PHYSICAL PROPERTIES, 63 89 TEREPHTHALATE, 6 19 23 368
131 151 168 199 233 236 270 95 104 131 162 215 223 236 PRESSURE TRANSDUCER, 68
PIGMENT, 1 3 48 79 95 126 152 240 244 257 260 269 270 271 117 374
159 161 164 215 223 229 257 279 291 PROBE, 97 236 270 320 370
302 312 POLYFLUOROETHYLENE, 69 PROBLEM PREVENTION, 3 6 8
PIN, 69 125 183 327 186 10 12 13 19 20 23 29 35 37 43
PINHOLE, 8 111 POLYMETHYL 44 48 50 51 55 56 62 63 64 65
PINHOLING, 240 244 279 METHACRYLATE, 34 129 69 71 77 78 82 83 84 86 87 88
PIPE FITTING, 97 187 366 POLYOXYMETHYLENE, 186 89 91 93 94 95 99 100 101 104
PLAQUE, 308 368 POLYPHENYLENE OXIDE, 23 106 108 111 112 116 120 124
PLASTICISATION, 56 68 136 240 239 362 386 125 126 127 133 134 135 138
367 POLYPROPYLENE, 5 10 17 26 27 143 145 146 147 148 149 150
PLASTICISER, 161 184 43 44 47 57 60 62 66 98 122 155 158 164 165 166 168 170
PLASTICISING, 70 321 374 126 131 151 168 175 179 186 172 173 176 182 183 184 188
PLATE, 69 354 191 195 198 199 208 213 235 190 194 196 197 199 201 202
PLATEN, 12 41 68 69 92 133 137 254 255 264 266 267 273 289 203 204 212 214 217 218 224
188 318 301 302 308 312 314 327 337 226 230 231 237 242 243 245
PLATING, 79 224 345 351 367 368 388 246 247 252 255 257 259 260
PLUG, 117 158 POLYSTYRENE, 31 34 35 62 70 261 264 266 269 270 271 274
PLUG FLOW, 95 82 83 85 118 160 198 213 251 275 276 277 278 279 284 286

Subject Index
288 290 292 293 295 297 298 RECLAIM, 45 61 210 244 320 311 319 326 346 350 372 376
301 304 305 307 309 310 316 359 373 386
325 329 360 373 385 RECYCLED CONTENT, 5 45 49 RUBBER-MODIFIED, 27 66 80
PROBLEM SOLVING, 46 50 177 95 191 217 243 320 235 350 372
196 249 250 261 262 316 329 RECYCLING, 51 87 147 210 359 RUNNER, 8 13 21 22 24 29 37 40
360 384 REGRIND, 5 29 48 49 147 148 46 62 64 77 82 112 134 138 149
PROCESS CONTROL, 18 33 52 243 244 247 320 356 359 361 158 197 201 219 224 226 249
54 65 68 95 99 100 101 113 114 373 388 252 272 278 279 295 298 301
115 121 137 176 189 220 249 REINFORCED PLASTIC, 6 8 15 RUNNERLESS MOULD, 147
265 294 310 312 324 364 373 19 23 29 35 48 49 56 64 73 79 RUNNERLESS MOULDING, 61
374 386 81 89 90 95 128 130 132 141 66 215 223
PROCESSABILITY, 187 341 361 155 156 158 159 161 162 186
386 199 200 205 208 213 214 215
PRODUCT DESIGN, 1 23 66 78 223 235 236 240 244 249 253 S
83 130 131 153 159 160 162 260 261 262 263 266 269 271 SAFETY, 69 76 137
215 244 278 348 373 277 279 281 289 310 318 329 SAFETY DEVICE, 188
PRODUCT DEVELOPMENT, 11 357 361 363 368 SAFETY GUARD, 144
40 54 117 153 350 REJECT, 129 265 381 SANDWICH STRUCTURE, 45
PRODUCTION, 12 125 133 189 REJECT RATE, 11 12 47 70 123 SATURATED POLYESTER, 5 104
202 231 319 265 325 342 344 149 221 244 339 378
PRODUCTION COST, 117 131 RELEASE AGENT, 20 36 243 SCALE INHIBITOR, 383
151 153 162 167 323 338 REPAIR, 137 183 SCORCH, 246
PRODUCTION RATE, 11 REPAIRING, 116 SCRAP, 71
PRODUCTIVITY, 52 61 65 131 REPEATABILITY, 153 245 294 SCRAP POLYMER, 12 87 201 210
132 159 167 221 259 324 373 381 382
PROPORTIONAL VALVE, 61 REPRODUCIBILITY, 11 SCRAP REDUCTION, 47 65 95
PROTOTYPE, 97 314 373 384 RESEARCH, 117 222 364 265 289
PUMP, 29 63 125 RESIDENCE TIME, 21 215 223 SCRATCH RESISTANCE, 199
236 243 247 257 315 318 323 SCRATCHING, 320
PURGING, 35 215
350 373 SCREW, 29 35 54 61 68 70 79 90
PURGING COMPOUND, 47 215
RESIDUAL MOISTURE, 316 112 126 129 131 133 176 233
PYROMETRY, 131 236 355
RESIDUAL STRESS, 23 96 250 248 281 303 307 312 347 381
332 352 388
Q RESIDUE, 168 SCREW DESIGN, 60 131 288 303
RESPONSE TIME, 97 294 305 312 344 347 385
QUALITY, 12 48 61 68 70 111 131 REVERSE GATING, 323 SCREW DIAMETER, 68 131 257
137 151 176 189 234 240 245 REVIEW, 22 36 75 76 84 90 109 370
282 311 324 341 349 370 116 196 360 361 SCREW FLIGHT, 60
QUALITY CONTROL, 25 65 68 RHEOLOGICAL PROPERTIES, SCREW GEOMETRY, 236 361
117 119 131 140 153 159 166 21 22 30 42 43 49 57 58 61 63 SCREW PLASTICISATION, 95
167 173 186 194 198 199 205 66 68 80 81 97 98 117 118 119 SCREW SPEED, 63 95 223 235
206 207 208 222 239 289 299 121 131 136 139 153 159 162 236 312 318 361
300 320 325 330 342 356 366 170 171 172 179 187 192 203 SEAL, 7 51 243 323
373 374 209 215 223 234 236 240 244 SELF-CLEANING, 215
QUENCH, 367 254 256 310 318 320 335 350 SELF-DRYING, 12 35 71 203 215
QUICK COLOUR CHANGING, 355 356 368 370 371 372 373 217 223 243 244 305 307
47 95 374 SELF-LUBRICATING, 63
RIB, 64 107 125 162 215 217 223 SEMICRYSTALLINE, 6 24 62 94
R 232 318 111 122 131 162 215 223 236
RIBBED, 85 122 154 369 370 388 240 244 279
RADIANT HEATING, 136 RIGID, 83 89 232 SENSOR, 61 68 97 207 228 253
RADIUS, 122 143 388 RIGIDITY, 146 150 155 373 256 265 294 320 356 368
RAM VELOCITY, 355 374 ROBOT, 133 176 288 SEQUENTIAL VALVE GATING,
RAW MATERIAL, 151 168 193 ROLLER, 45 266 61
203 247 261 262 ROUGHNESS, 22 66 223 371 SERVICE LIFE, 70 79 248
REACTION INJECTION RUBBER, 2 7 26 31 36 40 51 66 SERVICE TEMPERATURE, 162
MOULDING, 90 325 67 80 84 90 161 170 172 186 SHAPE, 201 371
RECIPROCATING PIN, 368 216 220 235 244 266 298 306 SHAPE FACTOR, 77

Subject Index
SHEAR, 8 29 35 61 77 82 88 112 178 194 197 209 212 245 263 STRIPE, 26
215 223 244 254 257 318 371 265 272 273 327 350 352 355 STRUCTURAL FOAM
374 360 363 MOULDING, 90
SHEAR DEFORMATION, 235 SOLIDIFICATION, 81 98 223 332 STRUCTURAL REACTION
SHEAR DEGRADATION, 97 374 SPECIFICATION, 108 213 233 INJECTION MOULDING, 325
SHEAR PROPERTIES, 66 80 81 234 STYRENE-ACRYLONITRILE
97 98 136 160 182 219 235 SPEED, 29 35 48 69 88 148 197 COPOLYMER, 190 198 372
SHEAR RATE, 16 21 30 97 117 249 309 STYRENE-BUTADIENE-
139 160 171 244 279 323 344 SPLAY, 71 82 88 100 104 112 217 STYRENE BLOCK
355 374 307 347 359 COPOLYMER, 51
SHEAR STRAIN, 372 SPRAY DRYING, 12 35 71 203 SURFACE, 26 35 48 69 124 129
SHEAR STRENGTH, 182 215 217 223 243 244 305 307 182 184 201 216 349
SHEAR STRESS, 66 80 81 97 98 SPRUE, 22 29 46 55 62 64 69 77 SURFACE ANALYSIS, 66 195
136 160 235 355 372 88 91 106 112 120 124 134 143 335
SHEAR VELOCITY, 371 148 149 155 182 190 197 201 SURFACE DEFECT, 61 66 79 80
SHEAR VISCOSITY, 272 202 204 205 218 249 264 276 84 97 98 104 157 196 218 224
SHEET, 35 80 314 319 290 298 316 373 226 275
SHEET MOULDING SPRUE BUSH, 10 104 158 261 SURFACE FINISH, 3 25 26 27 43
COMPOUND, 214 278 322 46 57 58 61 66 73 80 97 131
SHOE SOLE, 325 SPRUE SEPARATION, 7 246 134 139 141 151 154 162 218
SHORT FIBRE, 29 156 186 235 STABILISER, 11 51 71 108 126 223 236 240 242 244 246 247
281 184 187 215 269 277 279 286 287 289 299
SHORT-SHOT, 62 81 127 181 185 STABILITY, 67 215 305 320 323 325 348 351 359
237 246 356 STACK MOULD, 17 45 364 369 374 377
SHOT CAPACITY, 314 318 381 STAGNATION POINT, 80 215 223 SURFACE MORPHOLOGY, 66 80
SHOT SIZE, 41 315 318 361 370 STAINING, 184 141
SHOT WEIGHT, 17 282 294 STAINLESS STEEL, 35 79 168 SURFACE PROPERTIES, 26 43
SHRINKAGE, 6 8 23 27 35 51 61 174 225 343 66 80 84 97 104 109 141 157
68 84 98 107 111 128 130 131 STANDARD, 108 161 198 213 233 216 223 236 242 299 335 355
132 136 143 152 153 154 159 234 308 359 370 371 372
160 162 170 175 185 190 200 START-UP, 388 SURFACE REFLECTION, 80
209 214 215 217 223 235 236 STATISTICAL PROCESS SURFACE STRUCTURE, 26 141
240 241 244 251 260 269 271 CONTROL, 65 299 320 373 216 371
273 277 279 280 282 289 313 STEEL, 2 28 35 69 79 110 124 125 SURFACE TEMPERATURE, 160
318 340 358 361 362 367 369 160 168 174 225 232 241 268 223 269
370 374 384 388 283 311 334 SURFACE TREATMENT, 31 35
SHUT-OFF, 18 STIFFNESS, 1 35 89 98 107 108 36 61 73 79 225 248 318 320
SILICATE, 48 80 126 151 130 159 162 199 215 232 235 336 376
SILICONE OIL, 372 328 369 388 SWELLING, 66 131
SILICONE RUBBER, 7 31 67 170 STRAIN, 159 160 162 242 368 SYNTHETIC RUBBER, 90 216
172 STREAKING, 95 312 330 306
SIMULATION, 21 96 97 98 136 STRENGTH, 23 208 368 SYRINGE, 17 35 78 345
153 160 211 332 354 355 374 STRESS, 23 28 61 66 68 79 91 96
SINGLE-CAVITY, 264 368 97 98 128 131 132 136 160 162
SINGLE-SCREW, 56 166 235 240 242 250 318 322
T
SINK MARK, 6 35 46 48 85 86 328 355 362 363 369 374 T-SHAPED, 322
105 107 111 115 122 154 157 STRESS ANALYSIS, 160 TALC, 48 80 126 151 199
158 166 185 217 218 224 232 STRESS CONCENTRATION, 28 TEMPERATURE, 22 32 35 40 48
245 246 271 273 275 276 277 235 61 69 79 81 88 89 97 98 106
279 318 346 369 370 374 STRESS CRACK RESISTANCE, 108 110 124 125 132 136 159
SIZE, 12 29 35 62 69 107 111 133 388 160 162 168 175 176 182 184
148 190 197 201 311 STRESS CRACKING, 28 163 245 189 197 201 203 213 214 217
SKIN, 48 235 274 322 223 225 233 235 244 249 269
SLUG, 8 STRESS CRAZING, 28 163 245 272 309 318 319 320 324 327
SMALL COMPONENT, 55 169 STRESS DISTRIBUTION, 28 355 329 355 359 367 373 374 381
SMOOTHNESS, 66 STRESS-STRAIN PROPERTIES, 388
SOFTWARE, 4 21 40 52 65 97 115 149 160 162 238 TEMPERATURE CONTROL, 10
142 144 145 153 160 167 171 STRINGINESS, 62 71 131 194 215 223 236 247

Subject Index
257 269 316 323 331 363 384 239 242 253 262 263 268 281 V
385 283 284 286 288 298 299 300
TEMPERATURE DEPENDENCE, 301 303 307 311 313 325 326 VACUUM, 53 69 216 376
43 110 141 179 180 329 347 358 363 376 VACUUM DEPOSITION, 79
TEMPERATURE THERMOSTAT, 289 320 VACUUM INJECTION
DISTRIBUTION, 61 160 THICK-WALL, 68 82 143 153 162 MOULDING, 66 216
TEMPERATURE GRADIENT, 97 240 264 277 278 315 338 362 VALVE, 29 61 63 69 70 137 218
131 136 219 371 THICKNESS, 11 21 27 32 40 62 381
TEMPERATURE PROBE, 97 236 66 80 81 83 97 98 104 131 136 VALVE GATE, 33 61 147 191 318
270 150 160 217 232 236 367 372 VAPOUR DEPOSITION, 79
TEMPERATURE PROFILE, 42 97 373 388 VARIABILITY, 114 294
236 270 THIN-WALL, 18 35 61 68 69 92 VEHICLE HEADLIGHT, 320 363
TENSILE PROPERTIES, 34 63 98 103 131 132 143 151 153 162 VEHICLE INTERIOR, 47
108 160 162 195 235 367 368 187 226 240 277 278 280 318 VEHICLE TRIM, 14 273
386 337 368 345 VEHICLE WINDOW, 11
TEST, 30 57 58 66 80 97 98 118 THREE-PLATE MOULDING, 134 VELOCITY, 65 365 371 374 381
121 139 142 161 162 199 207 TIEBAR, 306 VELOCITY PROFILE, 81 374
210 213 225 236 239 241 311 TIEBARLESS, 253 VENT, 69 278 318 388
320 321 332 353 355 359 367 TITANIUM, 79 126 215 225 VENTED BARREL, 315
368 372 373 374 TOGGLE, 137 188 VENTING, 13 40 46 48 62 82 88
TESTING, 34 51 52 71 89 90 98 TOLERANCE, 54 124 159 198 107 124 148 149 155 170 174
108 117 151 168 177 184 188 214 265 384 182 201 215 218 224 226 237
192 194 198 203 233 262 356 TOOLING, 12 16 35 62 69 79 88 247 249 257 275 276 289 308
364 373 381 106 122 124 125 148 168 182 311 315 333 340 348 375 385
TEXTURE, 35 66 79 308 318 183 189 190 197 201 202 203 VIBRATIONAL
THERMAL CONDUCTIVITY, 212 213 233 261 288 373 384 SPECTROSCOPY, 5 19 66 94
110 125 136 159 160 162 225 387 VISCOSITY, 30 42 49 63 66 68 80
327 332 352 TOOLS, 76 262 81 97 121 131 153 162 170 172
THERMAL CONTRACTION, 118 TRAINING, 12 48 59 177 183 259 203 234 236 240 254 256 272
THERMAL CYCLING, 67 TRANSDUCER, 68 117 207 294 310 318 327 329 355 356 361
THERMAL DECOMPOSITION, TRANSPARENCY, 9 35 72 83 131 362 365 371 373 374 381
215 236 257 143 VOID, 6 8 48 99 111 143 186 235
THERMAL DEGRADATION, 19 TRANSVERSE, 132 215 240 240 244 246 255 264 271 277
81 97 160 186 223 236 270 305 TRAY, 160 280 279 346 362
318 356 361 373 TRIAXIAL STRESS, 235 VOLATILE ORGANIC
THERMAL EXPANSION, 159 162 TUBE, 182 190 337 345 350 COMPOUND, 161 325
THERMAL EXPANSION TUBING, 29 35 VOLUME, 62 111 175 190 272
COEFFICIENT, 32 63 263 296 TURBULENT FLOW, 327 282
THERMAL HISTORY, 318 367 TWO-CAVITY, 9 150 240 280 VOLUME CHANGE, 68 152 236
THERMAL PROPERTIES, 21 40 TWO-COLOUR INJECTION
58 61 63 68 80 81 90 97 98 110 MOULDING, 90
118 125 131 132 136 153 159 TWO-COMPONENT, 17 170 358 W
160 162 171 215 223 235 236 TWO-STAGE INJECTION WALL THICKNESS, 4 6 8 23 24
240 244 262 318 367 368 370 MOULDING, 11 35 37 44 61 62 64 68 69 81 88
371 372 374 106 107 108 111 120 124 129
THERMAL STABILITY, 51 67
159 215
U 130 131 133 134 136 143 153
154 155 160 162 190 199 215
THERMAL STRESS, 32 96 160 UHMWPE, 63 186 218 223 226 232 240 244 250
235 332 352 UNDERCUT, 85 238 388 260 271 279 280 287 309 310
THERMOCOUPLE, 40 236 269 UNDULATION, 372 317 318 322 339 340 345 348
THERMOPLASTIC UNFILLED, 66 350 361 364 367 369 381 388
ELASTOMER, 7 26 34 40 45 UNIAXIAL ORIENTATION, 80 WARPAGE, 6 12 23 35 61 96 108
51 244 266 346 UNSATURATED POLYESTER, 110 111 124 130 131 149 152
THERMOSET, 2 3 14 15 16 25 30 15 16 363 160 185 214 215 240 244 246
31 35 65 76 79 90 92 93 136 URETHANE ELASTOMER, 36 247 260 263 264 271 277 279
138 140 142 159 161 163 164 UV DEGRADATION, 5 274 280 282 301 318 324 332 340
169 170 171 172 173 186 193 UV RADIATION, 129 184 249 388 351 352 358 362 363 370 374
204 205 206 211 214 229 230 UV STABILISER, 11 126 WARPING, 245 249

Subject Index
WATER-ASSISTED INJECTION
MOULDING, 44
WATER COOLING, 44 98 136 158
160
WATER SUPPLY, 144 188
WAVINESS, 80
WEAR, 10 73 151 159 230 248
281 303
WEAR RESISTANCE, 10 63 69
79 183 321
WEATHER RESISTANCE, 184
274 388
WEDGE SHAPED, 64
WEIGHT, 48 98 131 133 169 240
244 254 282 309 374
WEIGHT REDUCTION, 18 160
344 364
WELD LINE, 3 22 23 34 35 61 66
80 93 101 129 131 136 153 159
160 162 180 185 195 200 201
211 215 216 223 240 245 246
277 287 289 326 346 348 362
368 374 386
WHITENING, 97 223
Y
YELLOWING, 35 244

Subject Index

Company Index
Company Index
A BOWLES FLUIDICS CORP., 373 DEALEYS MOLD
BPTA, 145 ENGINEERING, 41 110 241
AACHEN,RWTH, 330 BRADFORD,UNIVERSITY, 114 DEUTSCHES KUNSTSTOFF-
ADVANCED ELASTOMER 119 121 INSTITUT, 286
SYSTEMS SINGAPORE BRANDEN T.G.,CORP., 360 DICKTEN & MASCH MFG.CO.,
PTE.LTD., 346 BRANDEN TECHNOLOGIES 1 5 19 71 89 94 108 126 151
AGA AB, 289 INC., 176 163 168 184 199 203 208 213
AGA GAS, 268 BRAZIL,CENTRO DE 230 233 239 262
AKRON,UNIVERSITY, 186 MECANICA DE PRECISAO DME CO., 33
ALBANY INTERNATIONAL DE JOINVILLE, 178 DONNELLY CUSTOM
CORP., 15 MANUFACTURING CO., 12
BREMER INSTITUTS FUER
ALCOY,ESCUELA DOUAI,ECOLE DES MINES, 66
KONSTRUKTIONSTECHNIK,
POLITECNICA SUPERIOR, 235
306
81 DOW, 232
BRY-AIR INC., 382
ALD, 173 DOW CHEMICAL, 108
BUTZ-IEPER AUTOMOTIVE DOW CORNING STI LTD., 170
ALPHA MOLD, 334 GMBH, 14
172
ALPHAGARY LTD., 51
DOW MATERIALS
APPLIED IMAGE GROUP/
OPTICS, 129 C ENGINEERING CENTER, 250
DOW PLASTICS, 212 242 305
ARBURG, 7 265 C-MOLD INC., 153 386
ASCAMM, 136 CALMAR INDUSTRIES, 183 DREXEL,UNIVERSITY, 122
ASHLAND PLASTICS
CANADA,NATIONAL DSM NV, 361
AUSTRALIA, 377 378 379 380 RESEARCH COUNCIL, 285 DSM PETROCHEMICALS, 57
ASOCIACION DE LA DTM PRODUCTS INC., 256
CAPE TECHNIKON, 329
INDUSTRIA NAVARRA, 79 DUPONT, 6 8 70 111
CATALUNYA,UNIVERSIDAD
AUTOPLAS, 189 DUPONT CO., 257 260 269 270
POLITECNICA, 98
AVON PLASTIC PRODUCTS 271 277 279
CENTRE CATALA DEL
INC., 60 DU PONT DE NEMOURS
PLASTIC, 98
CHANG GUNG COLLEGE OF (DEUTSCHLAND) GMBH,
B MEDICINE & 215 223 236 240 244
DU PONT DE NEMOURS E.I.,&
TECHNOLOGY, 332 352
BALES MOLD SERVICE INC., 31 CHANG GUNG,UNIVERSITY, 85 CO.INC., 162
BARR R.,INC., 347 141 DU PONT DE NEMOURS
BASELL POLYOLEFINS, 26 FRANCE SA, 215 223 236 240
CHEVRON, 386
BASF, 49 238 386 244
CINCINNATI MILACRON, 231
BATH,UNIVERSITY, 36 DUPONT INDIA, 246
CINPRES LTD., 280
BATTENFELD AG, 154 DYNISCO INC., 304
CLEVELAND,STATE DYNISCO INSTRUMENTS INC.,
BATTENFELD OF AMERICA, 48
UNIVERSITY, 140 356
BAYER AG, 129
COKO-WERK GMBH, 14 DYSON APPLIANCES LTD., 59
BEALL G.,PLASTICS LTD., 78 93
166 CORETECH SYSTEM CO.LTD.,
BEAUMONT RUNNER 21 102
TECHNOLOGIES INC., 16 30 CREATIVE TECHNIQUES INC., E
42 362
EASTMAN CHEMICAL CO., 339
BECTON DICKINSON CYRO INDUSTRIES, 83 341
RESEARCH CENTER, 337 CZESTOCHOWSKA, EASTMAN KODAK CO., 225
345 POLITECHNIKA, 22 ECKART AMERICA LP, 229
BEHREND COLLEGE, 138 175 ECOLE DES MINES DE DOUAI,
BERNARD MOULD LTD., 308 D 109
BLACK & DECKER INC., 373 ECOLE SUPERIEURE DE
BOEHRINGER MANNHEIM D-M-E, 190 PLASTURGIE, 80
GMBH, 169 DAIMLERCHRYSLER, 133 EISENHUTH GMBH KG
BOSCH-SIEMENS DALIAN,UNIVERSITY OF PRAEZISIONS-
HAUSGERAETE GMBH, 2 TECHNOLOGY, 96 135 FORMENBAU, 2

Company Index
ELASTOGRAN GMBH, 192 H KRAUSS-MAFFEI AG, 25

ELECTROLUX, 268 KRAUSS-MAFFEI
EMPLAST, 197 HANNA M.A.,COLOR KUNSTSTOFFTECHNIK
ENGEL, 133 TECHNICAL CENTER, 164 GMBH, 56 72
ENGINEERED PROCESS HB-PLASTIC GMBH, 221 KUNSTSTOFF-INSTITUT FUR
COOLING SYSTEMS, 189 HENKEL KGAA, 187 DIE MITT WIRTS NRW
ENTEC POLYMERS, 292 HIMONT, 388 GMBH, 193
ENVIROTECH CORP., 11 HORN-CHI PRECISION KYOTO,INSTITUTE OF
EUDIL, 235 MACHINERY CO.LTD., 102 TECHNOLOGY, 335
EUROKMI GMBH, 167 HPM CORP., 133
EUROTOOL HOT RUNNER HUNKAR LABORATORIES L
SYSTEMS, 287 INC., 360
EWIKON GMBH, 387 HUSKY, 190 LEGO GROUP, 54
EXO, 54 HUSKY INJECTION MOLDING LEOBEN,UNIVERSITY, 156
SYSTEMS LTD., 92 133 LEXMARK INTERNATIONAL
INC., 115 272
F I LG CHEMICAL LTD., 34
LNP ENGINEERING PLASTICS
FAGOR INC., 29 130
ELECTRODOMESTICOS, 160 ICI CORP., 340
IKV, 258 309 310 330 LOWELL,UNIVERSITY, 359 368
FERROMATIK, 129 LUBLIN,POLYTECHNIC, 22
IMERYS MINERALS LTD., 58
FERROMATIK MILACRON, 137 LUCENT TECHNOLOGIES, 103
INCOE CORP., 123 147
FERROMATIK MILACRON 284
INCOE INTERNATIONAL INC.,
MASCHINENBAU GMBH, 45 LUEDENSCHEID,PLASTICS
61
FINA, 386 INSTITUTE, 73
INDIAN PETROCHEMICALS
FORD MOTOR CO., 273 344
CORP.LTD., 23 214
FORD RESEARCH
LABORATORY, 195
INSTITUT FUER KUNSTSTOFF- M
VERARBEITUNG, 200
FRANKLYNN INDUSTRIES INTERNATIONAL MOLD STEEL MACK MOLDING CO., 113
INC., 325 INC., 174 283 289 308 MAIN GROUP SPA, 54
FRAUNHOFER-INSTITUT FUER INTERNATIONAL PLASTICS MAKINO DIE/MOLD GROUP, 20
CHEMISCHE CONSULTING CORP., 12 MANNESMANN DEMAG
TECHNOLOGIE, 157 IOWA STATE UNIVERSITY, 180 KUNSTSTOFFTECHNIK, 349
JBL FEEDSCREWS LTD., 248 MARKISCHEN,
FACHHOCHSCHULE, 116
G MARSHALL TUFFLEX, 259
GAIKER,CENTRO J MASSACHUSETTS,
TECNOLOGICO, 160 UNIVERSITY, 32 44 211 359
JEB CONSULTING, 336
GAUGE & TOOL MAKERS 368
JOHNSON CONTROLS INC., 110
ASSN., 300 MATEFLEX, 351
JSW PLASTICS MACHINERY
GE PLASTICS, 69 318 364 384 MCGILL UNIVERSITY, 285
INC., 133
MICHIGAN,STATE
385 386
UNIVERSITY, 26
GENERAL INDUSTRIES, 366
GENERAL MOTORS CORP., 308 K MICHIGAN,UNIVERSITY, 185
MILACRON INC., 188
GEON CO., 355 KESTREL INJECTION MINOLTA CORP., 198
GLENN BEALL PLASTICS LTD., MOULDERS, 327 MITSUI PETROCHEMICAL
107 KISTLER INSTRUMENTE AG, INDUSTRIES LTD., 371
GLOBAL INDUSTRIES INC., 383 207 228 MMT SRL, 206
GR TECHNICAL SERVICES KISTLER SA, 68 MOLD-MASTERS, 190
INC., 358 KMI, 116 MOLD-MASTERS LTD., 365
GRAHAM PACKAGING, 319 KOBE STEEL LTD., 263 MOLDFLOW (EUROPE) LTD., 52
GREAT LAKES FEEDSCREWS, KOCH ENGINEERING CO., 302 MOLDFLOW CORP., 65
347 KONA CORP., 336 MOLDFLOW PTY.LTD., 374
GTT W.STEINKO GMBH, 38 KONA HOT RUNNER MONSANTO CO., 372
GUENTHER SYSTEMS, 304 323 MONTELL POLYOLEFINS, 122
HEISSKANALTECHNIK, 169 KONICA OPTICS MOULDFLOW CORP., 110
GUINESS TECHNOLOGIES, 76 TECHNOLOGY CO., 129 MUNTERS CORP., 319

Company Index
N PRECISION AUTOMOTIVE STANDARDS BOARD, 129

PLASTICS, 189 SINGAPORE,PRECISION
NATIONAL TSING HUA PRIME ALLIANCE, 4 10 13 24 37 ENGINEERING
UNIVERSITY, 21 46 55 62 64 77 86 88 91 104 APPLICATION CENTRE, 129
NETSTAL, 18 106 112 120 124 134 143 146 SINTOKOGIO, 311
NETSTAL MASCHINEN AG, 129 148 149 155 158 165 182 190 SODICK CO., 129
220 197 201 205 218 224 226 231 SOLVAY & CIE.SA, 171
NICOLLET PROCESS 249 252 255 261 264 266 274 SOLVAY ENGINEERED
ENGINEERING, 360 275 276 278 290 295 298 301 POLYMERS, 139 179
NIPPON ZEON CO., 129 307 315 316 317 322 324 328 STATISTICAL PLASTICS CORP.,
333 176
PROCESSING NEW STEPCO CORP., 383
O TECHNOLOGIES STEPHEN SALES LTD., 133
OAKLAND,UNIVERSITY, 32 CONSULTING, 131 SULZER CHEMTECH, 95
OHIO,STATE UNIVERSITY, 43 PROGRESSIVE COMPONENTS/ SUMITOMO HEAVY
OMNI PLASTICS, 280 D&L INC., 353 INDUSTRIES, 129
OSNABRUECK, SUN PLASTICS INC., 302
FACHHOCHSCHULE, 192 R
OSRAM SYLVANIA PRODUCTS T
INC., 138 181 RADICI GROUP, 132
OTRON TECH INC., 314 RALSTON FOODS, 105 241 TAIWAN,NATIONAL TSING
RAPRA TECHNOLOGY LTD., HUA UNIVERSITY, 102
163 340 351 TAIWAN,NATIONAL
P RESIN EXPRESS GMBH, 14 UNIVERSITY, 370
PARIS,ECOLE DES MINES, 80 REUTTE, 73 TAKAOTEC CORP., 21
PENCIL LOGIC, 296 RHODE ISLAND,SCHOOL OF TALLER DE INYECCION DE LA
PENN STATE ERIE PLASTICS DESIGN, 90 INDUSTRIA DEL PLASTICO,
TECHNICAL CENTER, 219 RIECO INDUSTRIES LTD., 87 97
342 343 RINDER INDUSTRIAL SA, 320 TECHTRAX, 183 234
PENN STATE UNIVERSITY, 30 RJG TECHNOLOGIES INC., 360 TEIJIN BAYER POLYTEC, 129
254 RMIT UNIVERSITY, 27 TEIJIN CHEMICALS, 129
PENNSYLVANIA,STATE ERIE, ROBBINS SCIENTIFIC CORP., TEKNOR COLOR CO., 198
181 92 TEXAS PLASTIC
PENNSYLVANIA,STATE RODINGER KUNSTSTOFF- TECHNOLOGIES INC., 217
UNIVERSITY, 28 99 100 101 TECHNIK GMBH, 331 237 243 247
313 367 ROEHM GMBH, 129 TICONA, 35
PETRA GMBH PAUL BRAUN, 200 ROUTSIS A.,ASSOCIATES, 351 TICONA GMBH, 63 129
PHILLIPS DRISCOPIPE INC., RTP CO., 357 TICONA LLC, 177
366 RWTH, 200 258 TOKYO,INSTITUTE OF
PHILLIPS PETROLEUM, 366 TECHNOLOGY, 118
TOKYO,UNIVERSITY, 371
PHILLIPS PLASTICS, 227 S TOKYO,UNIVERSITY OF
PLANSEE AG, 73
PLASTIC FALLO, 90 SALERNO,UNIVERSITY, 251 ELECTRO-
PLASTIC INJECTORS, 382 SAMSUNG ELECTRONICS COMMUNICATIONS, 118
PLASTICS & COMPUTER INC., CO.LTD., 129 TONGJI,UNIVERSITY, 306
338 SCHILL & SEILACHER GMBH, 84 TORO CO., 350
PLASTICS & COMPUTER SCHULMAN INC., 308 TOSHIBA, 133
INTERNATIONAL SRL, 338 SCORTEC INC., 326 TOYOTA, 331
PLASTICS DESIGN LIBRARY, 351 SEIKI SPEAR SYSTEM TRIQUEST PRECISION
POLE EUROPEEN DE AMERICA INC., 291 PLASTICS, 176
PLASTURGIE, 80 SEKISUI CHEMICAL CO.LTD., TYCOS TOOL, 194
POLYMER DIAGNOSTICS 371
INC., 39 SENSOTRON INC., 294 U
POLYMER INSIGHTS, 114 SHIN-ETSU CHEMICAL
POLYONE CORP., 50 CO.LTD., 67 U-MASS LOWELL, 369
POWDER PLAST, 245 SIGMA ENGINEERING GMBH, 40 UBE MACHINERY INC., 133
POWER PLASTIC SILBERLINE LTD., 3 UK,NATIONAL PHYSICAL
CONSULTANTS, 142 SINGAPORE PRODUCTIVITY & LABORATORY, 152

Company Index
V
VAN DORN DEMAG, 133 234
VIADELO, 153
VICTORINOX, 207 228
VIENNA,TECHNICAL
UNIVERSITY, 222
VISION PLASTICS, 176
VOLEX POWERCORDS, 117
W
WESTERN
MICHIGAN,UNIVERSITY,
105 110 241
WESTLAND CORP., 60 303
WHITE OAK PLASTICS INC.,
253
WIDIA GMBH, 200
WIENER NEUSTAEDTER
BILDUNGS- UND
FORSCHUNGSGESMBH, 222
WINDSOR MOLD, 189
WISCONSIN-
MADISON,UNIVERSITY, 352
WJT ASSOCIATES, 125 150 202
334
WOODRELL PROJECT
MANAGEMENT, 293 297
Y
YUE KI INDUSTRIAL CO.LTD.,
21
Z
ZARAGOZA,UNIVERSITY, 97
ZHENGZHOU,UNIVERSITY, 96

(Arburg) Troubleshooting Injection Moulding

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ISSN: 0889-3144

Rapra Review Reports Troubleshooting Injection

Volume 15, Number 4, 2004

Expert overviews covering the

2. Detection, Classification and Troubleshooting Defects ........................................................................ 5

2.13 Visible Ejector Marks ................................................................................................................... 29

4. Effects of Injection Moulding Parameters .......................................................................................... 40

5. Machine Specifications .......................................................................................................................... 44

5.3 Feeding Hopper ............................................................................................................................. 46

Abbreviations and Acronyms ....................................................................................................................... 50

Abstracts from the Polymer Library Database .......................................................................................... 51

Subject Index ............................................................................................................................................... 123

Company Index ............................................................................................................................................ 135

1 Introduction 4. Weld line (Section 2.6)

5. Jetting (Section 2.7)

12. Deformation during demoulding (Section 2.14)

For each defect, the diagram slides into different

effective holding pressure time too short

Sink marks Sink marks

(1) optimise holding pressure time

(1) optimise holding pressure time

Sink marks directly after

(1) increase cooling time

reduce melt temperature

(1) reduce cycle time

(1) avoid dead spots and flow impeding

(1) lower injection rate (injection

* use rheological mould design

(1) check mould cooling for leaks

* application appropriate if:

2.4.3 Colour Streaks Similar to thermoplastics, pigments and dyes are

2.4.3.2 Correcting Colour Streaks 2.4.4.2 Physical Cause

the defect becomes smaller with lower screw

Improve mechanical melt homogeneity:

Can other granules be used? Yes (1) use smaller granules

* pay attention to processing instructions by

(1) reduce screw return speed during

(1) adapt injection rate (-)

(1) increase injection rate

(1) use shorter glass fibres

move gate (move weld line to

* significant improvement of the defect possible;

2.5.1 Physical Cause Gloss differences are caused by different projection

Different gloss gives

Different gloss levels

Inquiry Polished surfaces:

Improve thermal melt homogeneity:

Gloss differences on textured

Inquiry Avoid pressure peaks in the mould:

(1) adapt geometry of perforation

(1) increase mould wall temperature

(1) optimise holding pressure time

(1) optimise holding pressure time

(1) change colour of material

(1) use smaller pigments

(1) increase mould wall temperature*

(1) reduce injection speed or

(1) check position of mould