机电专业英语.Lesson 9.pptVIP

Lesson 9 Injection Molding Text Injection molding is essentially the same process as hot-chamber die casting. The pellets or granules are fed into a heated cylinder, where they are melted. The melt is then forced into a split-die chamber (Fig.9.1a), either by a hydraulic plunger or by the rotating screw system of an extruder. Newer equipment is of the reciprocating screw type(Fig.9.1b). As the pressure builds up at the die entrance, the rotating screw begins to move backward under pressure to a predetermined distance, thus controlling the volume of material to be injected. The screw stops rotating and is pushed forward hydraulically, forcing the molten plastic into the die cavity. Typical injection-molded products are cups, containers, housings, tool handles, knobs, electrical and communication components (such as telephone receivers), toys, and plumbing fittings. Although for thermoplastics the dies are relatively cool, thermosets are molded in heated dies where polymerization and cross-linking take place. In either case, after the part is sufficiently cooled (for thermoplastics) or set or cured (for thermosets), the dies are opened and the part is ejected. The dies are then closed and the process is repeated automatically. Elastomers also are injection molded by these processes. Because the material is molten when injected into the mold, complex shapes and good dimensional accuracy can be achieved, as in die casting. Dies with moving and unscrewing mandrels are not unusual, and allow the molding of parts with multiple cavities and internal and external threads. Injection molding is a high-rate production process, with good dimensional control. Typical cycle times range from 5 to 60 seconds, but can be several minutes for thermosetting materials. The dies, generally made of tool steels or beryllium copper, may have multiple cavities so that more than one part can be made in one cycle. Proper die design and control of material flow in the die cavities are importan