INTRODUCTION FOR PLASTIC INJECTION MOULDING – MOULD SETTER TRAINING

This program covers the die-setting process from start to finish with an emphasis on safety. Proper procedures for mold inspection, preparation and installation are outlined. Injection Mold Setup also covers setup procedures for hydraulic, toggle and hydro-mechanical clamp systems.

COURSE OBJECTIVES 

1. Material preparation, drying and mixing
2. Screw and barrel cleaning
3. Guidelines for setting each processing parameter
4. Procedures for proper injection velocity profile set-up
5. Proper clamp and part removal settings

COURSE CONTENT 

• Safety
  • Dangers
  • Proper dress
  • Personal Protective Equipment (PPE)
    • Eye protection
    • Ear Protection
  • Safeguards
  • Good housekeeping
  • Lockout/Tagout
  • Press inspection
  • Handling tools
  • MSDS

• Moulding Operations
  • Molding process
  • Terms
  • Molding machine operation
    • Components
    • Controller
    • Accessing and loading stored information
  • Mold mounting system
    • Mounting – step by step
    • Unloading – step by step
    • Alignment
  • Temperature control system
  • Raw material
  • Part inspection
  • Screw/barrel cleaning procedure
  • Moulding machine parameter optimization

• Surface Defects
  • Flow lines and jetting
  • Splay (moisture or trapped air)
  • Haze, blush, and poor gloss
  • Orange peel and surface ripples
  • Gate blush and gate splay

• Burning and Contamination Problems
  • Burn marks and black specks
  • Burn streaks
  • Contamination
  • Discoloration or poor color match

• Physical Problems
  • Flash and short shots
  • Sink marks
  • Vacuum voids and bubbles
  • Blisters and delamination

• Geometry Maintenance Problems
  • Under- or over-sized dimensions
  • Poor dimensional repeatability (poor Cpk)
  • Warpage and bowing

• Structural Defects
  • Cracking, crazing, and brittleness
  • Weld lines
  • Stuck parts and pin push marks
  • Long gates and plugged gates
  • Drag marks and mold damage

• Troubleshooting Procedures and Logic
  • How to effectively approach, analyze, and implement troubleshooting procedures.

DURATION

• 2 days

INTENDED AUDIENCE

• Setup technicians
• Supervisors

METHODOLOGY

• 50% classroom & 50% on the machine
• 1 machine will be used as sample
• Sample mould and testing material to be ready

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