(NOTE: The generic outlines found on this website are provided solely as examples of what a particular individual course might offer. Remember, we will work with your company to custom design each course to fit your particular situation.)
Clamping Unit
Types of Clamping Units (focus on differences that affect the process)
Function of Parts and Understanding Clamp Operation
Contrast differences between Hydraulic vs Toggle
(include All-Electric and Hydro-Mechanical systems)
Ejectors (also discuss cores, slides etc.)
Controls (both general controls and specific controllers)
Setting Clamp Action, Tonnage, Core Pulls/Sets
Injection Unit
Primary Screw Zone Functions (including non-return valve)
Barrel Temperature Settings with respect to the Screw Zones (includes feed throat, oil, and nozzle temps)
Screw Retraction – Parameters and their Functions and Interrelationships
Backpressure
Screw Speed
Decompression(s)
Plastication Delay
Ram Forward (Injection) - Parameters and their Functions and Interrelationships
Relationship between Pressure and Velocity
Pressure Drops and the need for the Intensification Ratio
Fill/Boost Phase including transfer; Packing/Holding Phases
Velocity Profiling
Methods of Transfer
Sprue Break - Parameters and Functions
Controls (both general controls and specific controllers)
Tooling
Major Mold Components and Parts and their Functions
Mold Types and Options
2-plate and 3-plate Molds
Hydraulic Ejection (includes Side-Mounted Cylinders)
Slides/Horn Pins/Heel Blocks
Hot-Runner Manifold and Hot-Tip Drop (also Start-Up Considerations)
Part Cooling (Mold Temperature)
Amorphous vs Semi-crystalline
Differential Cooling
Cooling Medium
Laminar vs Turbulent Flow
Part Removal
Ejection
Core Sequencing
Calculations: Appropriate Clamp Tonnage, Intensification Ratio, Maximum Screw Speed, Reynold’s Number for Turbulent Flow, Velocity Profiling
The Three Modes of Press Operation (including Mold Safety)
Timers and Time Monitors
A Step-By-Step Method of Molding Machine Set-up (Goal Setting)
Fill/Pack/Hold (3-stage) Machines
Meaning of terms such as “Couple/Decouple” et al
Determining the correct Velocity Profiles and Transfer location
Safety Considerations
Clothing, Tool Use, Machine Safety Interlocks, Forklift/Hoist Safety Issues
Rheology – Flow Behavior
Temperature and Viscosity Dependence
Non-Newtonian Flow Behavior
Flow Rate and Viscosity Dependence
Fountain Flow (at flow front)
Plug Flow (in channel flow)
Molecular Orientation
Flow Rate relationship to Orientation Development
Temperature/Pressure relationship to Orientation Retention
Skin Formation and Effects on Orientation
Compression and Tension within a Molded Part
Effects on Shrinkage
Injection Control Systems (Only Very Brief Descriptions)
Sensors (transducers) – for temperature, pressure, position, rotation
Basic Hydraulic Components: Direct-Acting Relief Valve, Pilot-Operated
Pressure Relief Valve, Simple Needle Valve, Pressure Compensated Flow
Control Valve, Servo-Control Valves, Proportional Valves (flow dividers)
Recording Devices
Process Monitoring and Process Controlling
Open Loop vs Closed-Loop
Basic Control Loops
PID control
Utilizing Cavity Pressure to Optimize, Trouble-shoot, Cycle Set-up
Evaluating Hydraulic/Cavity Pressure Profile, Screw Position Curves
Amorphous vs Semi-Crystalline
Moisture Sensitivity (Hygroscopic)
Hydrolysis Effects (Material Degradation)
Moisture Measurements
Control of Moisture in Material
Identifying Hygroscopic Materials and Plastics that undergo Hydrolysis
Proper Storage and Drying of Hygroscopic Materials
Individual Material Processing Characteristics (Flow Behavior, Material Specific
Processing Procedures and Processing/Material Safety)
Processing Effects of Fillers/Reinforcements
Trouble-Shooting: Sticking Sprues
Part Sticking
Drooling
Stringing
Short Shots
Flashing
Delamination/Lamination
Splay (Silver Streaking)
Flow Lines (Weld Lines)
Sink Marks
Bubbles and Voids
Warping
Gate Blush (Sun-burst, Shadowing, Orange Peel, etc)
Black Spots (Compression Burns)
Black or Brown Streaks
Contamination (Black Specks, etc)
Gloss
“J”-Hooks
Color Streaks
Ejector Marks
Stress Cracks (Micro-fracturing)
Record Grooves
Production Floor Activity
Introduction to the Controllers
Manual Controls
Keypad/Screen or Console/Layout
Making Changes
Production Floor Activity
Searches (supports the concept of machine generalization):
Find important machine specifications
Locate clamp/ejector/injection/plastication machine operating parameters
Production Floor Activity
Obtaining the Correct Set-up of an Injection Molding Machine Processing Cycle
(All four types of controllers)
Production Floor Activity
Creating and Solving Specific Molding Problems