Optimized 2-Stage Process in Plastic Injection Molding

Optimized processes are set up in plastic injection molding machines so the best process
for making a plastic part or parts can be achieved. They consist of seven different steps
that are listed below in order:
Optimize Velocity
Optimize Hold Pressure
Optimize Hold Time
Set Cooling !ecovery Time
"inimize Clamp #ressure
Set Other $ariables
Set Safeties
Only velocity% hold pressure% and hold time will be discussed because they are the most
important steps in finding an optimized process. &ll of these are important and will be
taught in the sophomore level of plastics engineering technology.
Optimize Velocity:
The first step is to get your part '() full by increasing your shot size on the machine.
Shot size is the amount of plastic flowing into the mold. Then being to reduce your
injection velocity by *+) and record your fill time and fill pressure which is the pressure
needed to fill the mold cavity to make the part. Continue doing this until you achieve a
fill time of *+,*( seconds and continue to reduce your injection velocity. "ake sure the
numbers are recorded. -e.t% the viscosity needs to be calculated. The viscosity is the
plastic materials resistance to flow. The formula for calculating this is to multiply your
fill time times your fill pressure. The shear rate needs to be calculated also% so take *
divided by your fill time. #lot your points /shear rate and viscosity0 and an e.ample of
what your table and graph should look like is listed below /1igure *0.
1igure *: Optimum $elocity
Source: (Young, Brian), PLET 222, <https://cms.psu.edu/rames.asp!"
The optimum velocity is determined from the graph. 2ook at where the curve starts to
level out and at the end of the line. 1or an e.ample% the starting point would be .3++ and
the end point would be .(44. #ick the point that is in the middle of the two points which
is .5*6. Taking this point and locating the velocity on the table gives the optimum
velocity of 5+ insec.
Optimize Hold Pressure:
&fter the optimized velocity is found which from the previous e.ample is 5+ insec% enter
that value into the machine. -e.t% begin by making your parts completely full and having
no voids or sinks in them. $oids and sinks are noticeable defects in the part that will look
like a hole or missing edges of a part. -e.t increase the hold pressure until your parts just
begin to flash. 1lashing is a term that describes when a part is too full. The part will have
e.tra plastic on the sides. Calculate the hold pressure by taking the hold pressure of
where the parts started to flash and subtracting where they were full. Then divide this
number by 36. -e.t add this to your full part number and this is your optimized hold
pressure.
Optimize Hold Time:
To optimize the hold time% a gate freeze study must be performed. To do this% start
increasing the cooling time and decreasing the hold time on the machine recording your
numbers of this and weighing the parts. "ake a table of cooling time% hold time% and part
weight. -e.t% plot a graph of your weight vs. hold time. &n e.ample /1igure 30 is given
below.

1igure 3: 7ate 1reeze Time
Source: (Young, Brian), PLET 222, <https://cms.psu.edu/rames.asp!"

To find where the gate freezes at% observe your table and graph. 8here the curve starts to
level off% pick the first point that it does so. 9n e.ample figure 3% the point where the
curve starts to level is at a hold time of ' seconds. This is your optimized hold time.