FACULTY OF MECHANICAL ENGINEERING

BMM 3611 MANUFACTURING PROCESSES LABORATORY

SOLIDIFICATION PROCESSING LAB

(Injection Moulding)

Laboratory Date

Submission Date

Lecturer

JP/PJP

1)

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 manufacturing process.

Members ID Section Signature

BMM3611(1112)_SPL Lab

Prepared by:

MZS@FKM,UMP(2012)

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

Activity Task Form

Safety 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

Acknowledgement

of safety

requirement form

Know tools,

equipment and

materials

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..)

Give your answer

in lab report

Intro to SPL JP/PJP give brief explainaton on all machines in SPL ( their

function advantages & limitation)

Student must give attention. Prefer to take a note.

JP/PJP brief

Case study 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

Describe in details

in lab report

Safety in lab

Know tools and processes materials

Brief on all machines

Case study

BMM3611(1112)_SPL Lab

Prepared by:

MZS@FKM,UMP(2012)

3. Case study : Injection Moulding (ARBURG)

Process setup

o Determine effect of pressure and temperature settings.

Pressure Temperature Sketch/Describe the

outputs

High = High =

High = Low =

Low= High =

Low= Low

o Sketch the relationship of injection pressure and cooling time to the cycle time.

Design consideration

o Determine shrinkage for polymer used in this lab.

o 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;

(1 ( )c mold ambientL L T T where:

α = coefficient of thermal expansion

Tmold = mold temperature in ºC

Tambient = 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 σL.

3. Calculate the shrinkage rate for the polymer S using the following equation:

c ave

c

L LS

L

o 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.

o 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, Case 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 : ____________________________________________