Lab Polymer Processing

FACULTY OF MECHANICAL ENGINEERING BMM 3611 MANUFACTURING PROCESSES LABORATORY

SOLIDIFICATION PROCESSING LAB

(Injection Moulding) Laboratory Date Submission Date

Lecturer 1) JP/PJP

2) 3)

Learning objectives

By the end of semester, students should be able to: 1. Know safe practices in manufacturing processing area. 2. Know tools, equipment and raw material for the respective lab. 3. Know standard operating procedure for the demonstrated machine. 4. Analyzed specific case study related to manufac turing process.

Members

ID

Section

Signature

1. Introduction

The objective of this laboratory is to provide hands on experience of injection moulding  process. It is the most important plastics manufacturing process; adopted in producing thermoplastic products in large quantities in single production time. Among the type of injection moulding products are bottle tops; sink plugs, children's toys, containers, model kits, disposable razors and parts of cameras. It is also used to manufacture larger items such as dustbins, and milk crates. Injection moulding used to be operated by people but highly controlled by a central  processing unit. 2. Lab activities

Safety in lab

Know tools and processes materials

Brief on all machines

Case study

Activity Safety

Know tools, equipment and materials Intro to SPL Case study

Task

Form

Each student gather in group  In sequence, each student read the saftety clause. If not understand, put a note and JP/PJP will explain later.  Sign the acknowledgement forms  JP/PJP will give 10 questions about raw material, tool and equipment application in this lab.  Student must find out the answer. (Eg. tool name & their  purpose, raw material description and the final product, etc..)  JP/PJP give brief explainaton on all machines in SPL ( their function advantages & limitation)  Student must give attention. Prefer to take a note.  A case study requires student to find out an answer on the specific problem in production.  Based on the chosen case study, JP/PJP will explain and demonstrate process sequence (SOP) for the selected process.  In certain cases, student will be asked to do spesific task.  Student must explain thoroughly on outcome of their investigation 

Acknowledgement of safety requirement form Give your answer in lab report

JP/PJP brief

Describe in details in lab report

BMM3611(1112)_SPL Lab Prepared by: MZS@FKM,UMP(2012)

3. Case study : Injection Moulding (ARBURG) Process setup Determine effect of pressure and temperature settings. o Pressure Temperature Sketch/Describe the outputs High = High = High = Low = Low= High = Low= Low Sketch the relationship of injection pressure and cooling time to the cycle time. o 



Design consideration o o

Determine shrinkage for polymer used in this lab. Specific tasks for this lab exercise are as follows: 1. Measure the length dimension L in the tensile test specimen injection mold. Note that this dimension will change as the mold is heated up due to the circulating water. Based on the  previous equation, the actual mold cavity length Lc during injection molding will be;  Lc  L(1   (Tmold  T ambient )  where: α = coefficient of thermal expansion T mold = mold temperature in ºC T ambient = ambient temperature of the in ºC. 2. For a particular polymer, injection mold tensile test specimens. Measure the lengths of the good quality specimens after they cool to room temperature using a Vernier Caliper, and calculate the average length  Lave and standard deviation σ  L. 3. Calculate the shrinkage rate for the polymer S using the following equation: S  

o

o

 Lc



Lave

 Lc

Describes the results of the shrinkage rate measurements, discusses the variability in the data as measured above, and includes all of the raw measurement data. Compare with the other type of polymers (if available)

4. Lab report For your project report, provide the following: 1. Use a cover page similar to the labsheet format. 2. Contents for the report are; Introduction, Raw materials, Process tools, Machines and their applications, C ase study  –  Process setting / Design consideration/ Product defect & countermeasure, Conclusion/Lesson learned, References 3. Discuss the strengths and weaknesses of this laboratory. Did the laboratory help you to learn the material better? Explain why or why not. 4. The report should be done in MS Word and an equation editor should be used for all equations. 5. Equations should be numbered and plots should be numbered and referenced with a descriptive caption. 

BMM3611(1112)_SPL Lab Prepared by: MZS@FKM,UMP(2012)

BMM 3611 Process Sheet (Injection Moulding)

Mould details

Type

:_______________________________ (2 or 3 plate mold)

 Number of cavity

:_______________________________

Cooling system

:_______________________________

Machine Parameters (fixed) Model

: _____________________________

Tonnage

: _____________________________

Injection Unit Type

: __________________________________________________

Clamp Unit Type

: ___________________________________________________

Maximum Shot Capacity

: _____________________________

Injection Flow Rate

: ______________________________

Barrel Diameter

: ______________________________

Machine Parameters (controllable) Injection Stroke

: ____________________________________________

Injection Pressure

: ____________________________________________

High Squeeze Pressure

: ____________________________________________

Injection (barrel) Temperature

: ____________________________________________

Clamp Force Required

: ____________________________________________

BMM3611(1112)_SPL Lab Prepared by: MZS@FKM,UMP(2012)