The Ultimate Guide to Choosing high-precision Bakelite injection moulding machine

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Precision molding is a complicated process, and it is an injection molding method that requires high precision. The concept of precision injection molding is mainly different from "traditional injection molding". The precision plastic parts produced are often used to replace high-precision metal parts in the fields of instruments, electronics, optics, and medical equipment.

In this article, you will learn about:

 

Precision molding is the latest technology in the field of plastic injection molding. Precision injection is an injection molding method whose precision far exceeds the requirements of conventional injection molding processes. It is based on the rapid development of polymer materials, replacing high-precision metal parts with precision plastic parts in the field of instruments and electronics.

Precision molding is a type of plastic molding, and precision molding is the most expensive and complex mold design process on the market. It is only used on small and rare occasions in the manufacturing process when product development requires exceptionally precise plastic injection molded forms.

 

When a project requires parts to be used in high-tech applications and requires high volume production, precision injection molding may be a wise choice for the following reasons:

Cost-effective

Automation and repeatability of precision injection molding helps reduce labor costs while increasing productivity

Complexity

High level of detail can be mass produced

Strength

By adding fillers or compounds, the plastic used can be very strong, even at reduced cost

Efficiency

Precision injection molding is much faster than other traditional molding methods and allows more parts to be made with only one mold

Design freedom

Precision molds are custom made to project requirements, allowing for greater customization and control

 

• The most important technical index of precision injection molding products is the precision of injection molding products (dimensional tolerance, shape tolerance and product surface finish).

• The parts have high precision and small tolerance, that is, the precision dimension limit is high.

• The product has high requirements, and it is required to maintain dimensional stability for a long time.

• The rigidity of the mold is good, the dimensional accuracy of the cavity, the smoothness and the positioning accuracy between the templates are high.

• Adopt precision injection machine to replace traditional injection machine.

• Using precision injection molding process.

• Select materials suitable for precision injection molding.

 

 

• The precision of precision injection molding machine

  High temperatures affect the viscosity of the hydraulic fluid in the molding machine, which can create speed and pressure increases during the molding cycle. This variation can result in inconsistent dimensions from shot to shot during the molding process.

• Material Consistency

  Many plastics are hygroscopic, meaning they absorb moisture on a molecular level. Therefore, the material needs to be dried in a drying system before molding. Any moisture absorbed by the material in the forming equipment after drying can negatively affect the consistency and physical properties of the material as it hydrolyzes during the forming process. The higher the humidity, the more difficult it is to keep dry material. This is a major issue for quality, high-precision molding.

• Thermodynamic control of the mold

  In general, high factory temperatures and temperature variations make precise mold temperature control very difficult. Injection molds are designed with waterlines to thermodynamically balance heat loss from the plastic material to achieve a specific plastic shrinkage and thus part size. The mold operates with a separate water temperature controller to achieve the desired temperature. Consistent control of mold temperature and resulting plastic shrinkage is critical for high-precision injection molding. Ambient temperature changes undermine the goal of consistency.

 

• The injection pressure of the precision injection machine is high, and the rigidity of the mold clamping system is large. The parallelism of moving and fixed templates is controlled within the range of 0.05-0.08mm.

  Contact us to discuss your requirements of high-precision Bakelite injection moulding machine. Our experienced sales team can help you identify the options that best suit your needs.

• It requires the protection of low-pressure molds and the control of clamping force precision. Because the size of the mold clamping force will affect the degree of deformation of the mold, which will eventually affect the dimensional tolerance of the part.

• The mold opening and closing speed is fast.

• Plasticizing parts: screw, screw head, non-return ring, barrel, etc., should be designed in a structural form with strong plasticizing ability, good homogenization degree, and high injection efficiency. The screw drive has a large torque and can be infinitely variable.

• It is necessary to be able to stably control the repeatability and mass repeatability of the product.

• Due to the high speed requirements of precision injection molding machines, it is necessary to emphasize the response speed of the system. the

• Precision injection molding machines must be high-pressure, because it affects the precision and quality of precision products and improves injection molding efficiency.

 

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Selecting the right plastic injection molding machine is crucial for manufacturers aiming for efficiency and high-quality output. By understanding the key parameters of each injection molding machine, like injection pressure, clamping force, and cycle time, you can make an informed decision.

 

 

What is Injection Molding Machine Specification?

The specifications of injection molding machines are vital as they dictate the machine's capabilities and appropriateness for specific applications. These specifications include parameters related to the injection unit, clamping unit, power unit, and others. Each parameter has significance and impact, playing a critical role in the overall performance and efficiency of the machine.

 

 

Key Specifications of Injection Molding Machine

Here&#;s a detailed overview of the most important specifications:

 

1. Injection Unit Specifications

The injection unit controls the process of injecting molten injection molding material into the mold. Important parameters are:

The Barrel Item Unit Definition Importance Screw Dimension mm The diameter of the injection screw. This determines the volume of material that can be processed. Larger screws can process more material. Injection Pressure kg/cm² The pressure/force of the melt acting on the head of the screw during injection molding. It is used to overcome the resistance to plastic flow through the nozzle, runner, gate, and mold cavity, and to compact the cavity pressure.

Engineering plastics need higher injection pressure due to their higher viscosity, complex structures, and higher melting points, which make them more resistant to flow. Similarly, thin-walled parts require higher pressure to overcome the increased resistance in narrow flow paths, ensuring complete mold filling and maintaining part integrity. Shot Volume cm³ The total volume of molten plastic injected into the mold during each injection cycle of the injection molding process. This determines the maximum shot weight.

For safety and optimal performance, the shot volume should be between 60% and 80% of the injection molding machine's maximum injection capacity. Shot Weight (PS) g or oz The total amount of molten plastic, measured in weight (usually grams or ounces), injected into the mold during each injection cycle in the injection molding process. Shot Weight=Shot Volume*Melt Density of Raw Material

For safety and optimal performance, the shot weight should be between 60% and 80% of the injection molding machine's maximum injection capacity. Injection Speed mm/sec The velocity at which the screw or plunger moves to inject the molten plastic into the mold cavity per second.

It focuses on the movement of the injection mechanism. This ensures that the mold cavity is completely filled, preventing defects such as incomplete filling or flashing, and affecting cycle time and final product quality. Injection Rate cm³/sec The volume of molten plastic delivered into the mold cavity per second.

It focuses on the amount of material being injected. Injection Rate=Shot Volume/Injection Time

Influences volume of material injected control and cycle efficiency.

 

2. Clamping Unit Specifications

The clamping unit's primary function is to hold the mold securely during the injection and cooling process. Key parameters include:

Tie Bar Distance Item Unit Definition Importance Clamping Force tons The force applied by the clamping unit to keep the mold closed during the injection and cooling phases of the molding cycle. Essential for counteracting the pressure exerted by the molten plastic during injection into the mold, preventing the mold from opening and ensuring that the molded part maintains its desired shape and dimensions. Tie Bar Distance (HxV) mm The horizontal and vertical distance between the tie bars. Determines the maximum mold size that machine can be accommodated. Mold Platen (HxV) mm The height and width of the mold platen, which holds the mold. Affects the size of the mold that can be installed. Larger platens can support bigger molds. Total Daylight Stroke
(or called Opening Stroke) mm The maximum distance between the mold halves when fully open, which allow for finished part ejection and mold maintenance. Sufficient stroke length is necessary for easy removal of the molded part.

For better results, the opening stroke should be greater than the sum of the sprue length and twice the height of the plastic product. Mold Thickness mm The minimum and maximum mold thickness that the machine can accommodate. Ensures compatibility with different mold sizes. Ejector Stroke mm The distance the ejector pins move to push the final product out of the mold. Adequate stroke length ensures parts are smooth and fully ejected without damage. Mold Hole mm The mold's positioning ring cooperates with the injection machine's fixed ring, making it easier to install the mold on the machine table. The mold hole is the diameter of the machine's fixed ring. Essential for proper mold alignment and installation.

 

3. Power Unit and Other Specifications

The power unit and others control the machine's movements and functions, impacting your injection machine's operational cost and environmental footprint.

Item Unit Definition Importance Pump Motors
or Servo Motors HP
kW The power and type of motor used in the machine. Influences the precision and efficiency of machine operations, affecting overall performance. Number of Heating Zones zones The number of independently controlled heating zones. Allows for precise temperature control, critical for processing different types of plastics. Total Heating Wattage kW The total power consumed by the heating elements. Affects energy efficiency and operational costs. System Pressure kg/cm² The operating pressure of the hydraulic system. Affects the machine's force and ensures the reliable operation of the machine during molding. Oil Capacity L The volume of hydraulic oil the machine holds. Sufficient capacity is necessary for smooth and efficient hydraulic operations. Machine Dimension (LxWxH) m The overall dimensions of the machine. Important for planning floor space and ensuring the machine fits within the production area. Machine Weight tons The total weight of the machine. Influences transportation and installation requirements.

 

 

Why Injection Molding Machine Specification Matter?

The specification defines how well a machine can perform its intended functions and how efficiently it operates. Here&#;s why these specifications matter:

1. Performance and Capability
   • Machine Capacity: Specifications like clamping force, injection capacity, and shot size determine the maximum size and complexity of the parts that can be produced. Understanding these specifications helps you select a machine that meets your production needs.
   • Precision and Accuracy: Details such as the machine&#;s tolerance, control systems, and motor specifications influence the precision and accuracy of the molded parts. Accurate specifications ensure that parts meet the required dimensions and quality standards.
2. Efficiency and Cost
   • Energy Efficiency: Specifications for motor power, hydraulic systems, and energy consumption impact the overall operational cost. Efficient machines use less energy and can lower production costs.
   • Production Speed: Parameters such as injection speed and cycle time affect how quickly parts are produced. Faster cycle times can increase overall production efficiency and reduce lead times.
3. Compatibility and Integration
   • Mold Compatibility: Specifications help determine if a machine can accommodate the molds you plan to use. This includes mold size, weight, and type (e.g., multi-cavity or insert molds).
   • Auxiliary Equipment: Understanding the machine&#;s specifications allows for proper integration with other equipment, such as robots, conveyors, and cooling systems, ensuring a seamless production of the injection molding process.
4. Safety and Reliability
   • Operational Safety: Proper specifications ensure that the machine operates within its designed limits, reducing the risk of accidents and equipment failure. Safety features and emergency stops are also part of these specifications.
   • Maintenance and Longevity: Machines with well-defined specifications are less likely to experience unexpected breakdowns. Regular maintenance can be planned according to the machine&#;s operational parameters, increasing longevity.
5. Investment and ROI
   • Cost-Benefit Analysis: Understanding the specifications helps evaluate the machine's cost-effectiveness. It also allows for comparing different models and manufacturers to ensure the best investment.
   • Future-Proofing: Choosing a machine with the right specifications can accommodate future production needs or technological changes, providing better long-term value.

 

 

Injection Molding Machine Specification Conclusion

Injection molding machine specifications are crucial for selecting the machine that is appropriate for your production needs. By comprehensively understanding the injection, hydraulic, clamping, power unit, and others' specifications, you can ensure that you choose a machine that meets your specific requirements, leading to efficient and cost-effective manufacturing. 

 

Reputation Machine Manufacturer - Huarong

When investing in injection machines, in addition to the technical specifications, it is also important to consider the manufacturer's reputation and support when purchasing. As an experienced injection molding machine manufacturer, Huarong is here to help you find the perfect solution for your manufacturing requirements.

 

 

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