Mde Injection Molding Troubleshooting Guide
Mde Injection Molding Troubleshooting Guide
Mde Injection Molding Troubleshooting Guide
Suggested Remedy
Replace with new material Check for over run/over heating a) Clean screw and barrel b) Check for hang up areas in screw and check valve areas a) Lower melt temperature b) Lower back pressure c) Lower screw RPM
4.
Degraded Polymer
Suggested Remedy
Check moisture levels of material and dry if needed
2.
Air Entrapment
a) Check vents and clean if needed b) Reduce clamp pressure to minimum amount needed c) Increase back pressure a) Lower melt temperature b) Lower back pressure c) Lower Screw RPM
3.
Degraded polymer
2.
3.
4.
Contamination
5. 6.
Reduce regrind % (general rule- 25-30%) a) Increase gate size to obtain optimum filling b) Relocate gate away from potential stress areas
2.
3.
2.
Over clamping
3.
Inadequate vents
Add vents
4.
5.
Cracking/Crazing
Possible Cause 1. Contamination Suggested Remedy a) Change to different lot of material b) Eliminate regrind as contamination source c) Remove colorant
2.
Part removal
a) Redesign knockout system for balanced ejection force b) Rework mold and provide adequate draft angles and eliminate excessive undercuts
3.
a) Decrease pack pressure b) Decrease shot size c) Increase transfer point to lower peak injection pressure d) Decrease injection time
4.
5.
Chemical contamination
3.
Try virgin only run to verify and change color to a compatible concentrate if needed Increase injection rate Increase venting Increase mold temperature
4. 5. 6.
Dimensional Inconsistency
Possible Cause 1. Non-uniform feeding of material Suggested Remedy a) Adjust temperature for optimum filling b) Increase shot size to maintain proper cushion c) Replace check valve if cushion cannot be maintained Increase injection forward time and pressure to ensure gate freeze off a) Review regrind blending procedures b) Decrease level of regrind Increase fill pressure to maintain the selected velocity of most runs a) Increase holding pressure to maximum b) Increase injection rate c) Balance runner and gate sizes to provide balanced filling
2.
3.
4.
5.
Discoloration
Possible Cause 1. Material Overheating Suggested Remedy a) Decrease melt temperature b) Decrease screw RPM c) Decrease back pressure d) Decrease residence time e) Check barrel and nozzle heater bands and thermocouples Set drying temperature at manufactures recommended settings a) Review material handling procedures b) Purge injection cylinder
2.
3.
2.
3.
4.
a) Check machine throat and hopper for blockage b) Check for worn screw and barrel
Flashing
Possible Cause 1. Excessive melt/mold temperature 2. 3. Excessive packing of material Injection pressure to high a) b) c) d) Suggested Remedy Reduce melt and mold temperatures Decrease packing pressure Decrease injection pressure Decrease boost time Decrease injection rate Increase transfer position Switch to larger tonnage machine
4.
5.
a) Remove mold and carefully inspect and repair parting lines b) Repair cavities and cores that do not have a positive shut-off
6.
a) Increase clamping pressure b) Check parting line for obstruction c) Check press platens for parallelism
7.
a) Balance/increase runner and gate sizes to obtain uniform filling b) Properly balance cavity layout for maintaining uniform cavity pressure
Nozzle Drooling
Possible Cause 1. Nozzle temperature to hot Suggested Remedy a) Decrease nozzle temperature b) Decrease melt temperature c) Reduce back pressure d) Increase screw decompression a) Review material handling procedures to eliminate moisture pick up b) Dry material according to manufactures recommendations
2.
Moisture in material
2.
3.
4.
5.
6.
4.
5.
2.
3.
a) b) c) d)
Reduce screw RPM Increase gate and runner size Decrease injection rate Check nozzle for obstruction
4.
Air entrapment
5.
a) Increase mold temperature b) Clean mold surface c) Minimize use of mold release
6.
3.
4.
Sprue Sticking
Possible Cause 1. Nozzle orifice is larger then sprue orifice 2. Insufficient taper on sprue bushing Imperfections on inside of sprue Suggested Remedy Use nozzle that has an orifice at least .010 smaller then the sprue orifice Increase taper on sprue bushing (Minimum of 1.5 over the length of the sprue) Eliminate imperfections and polish surface in direction of draw a) Reduce pack and hold time b) Decrease injection forward time c) Utilize machine sprue break a) Increase nozzle temperature b) Use reverse taper nozzle
3.
4.
5.
Surface Imperfections
Possible Cause 1. Melt temperature to low 2. 3. 4. Mold temperature to low Insufficient packing of the part Insufficient material in mold
5.
6.
a) Increase mold temperature b) Look for water leaks and repair if needed
9.
Inadequate venting
Warpage
Possible Cause 1. Part ejected while too hot Suggested Remedy a) Decrease melt temperature b) Decrease mold temperature c) Increase cooling time d) Cool part in warm water after ejection e) Use secondary fixture to hold part dimensions a) b) c) d) e) Increase injection rate Increase pack pressure Balance runners and gates Increase runner and gate size Increase/decrease injection time Increase melt temperature to provide better pack out of part
2.
3.
4.
5.
6.
7.
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4.
a) Increase vents at weld area b) Decrease injection speed to allow air removal c) Decrease clamp pressure to minimum pressure a) Increase injection speed b) Increase boost time c) Increase first stage injection pressure
5.
6.
a) Relocate gate or use multiple gating b) Utilize overflow tab in mold to increase strength in weld line area
To the best of our knowledge the information contained in this document is accurate, however, we do not assume any liability whatsoever for the accuracy or completeness of such information. Since we have no control over the use to which others may put our product, we cannot guarantee that results the same, as those described in this document will be obtained. The Buyer assumes sole responsibility for results obtained in reliance upon this publication. We recommend that persons intending to rely on any recommendation or to use any equipment, processing technique or material mentioned in this publication should satisfy themselves as to such suitability and that they can meet all applicable safety and health standards.
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