TECHNICAL TRAINING ON PLASTICS AND TOOLING TOPICS

ROBUST MOLDING PROCESS

  • Introduction to Robust Molding Process
  • Cavity to cavity consistency
  • Part-to-Part Consistency
  • Run-to-Run Consistency
  • Overall mold and process consistency

PLASTIC RAW MATERIAL BASICS

  • Introduction to Polymers
  • Polymer Pyramid: Categorizing Polymers
  • Commodity Plastics
  • Engineering Plastics
  • Specialty Plastics
  • Amorphous Plastics
  • Semi-Crystalline Plastics
  • Properties and Behaviours of Polymers

PLASTIC RAW MATERIAL SELECTION

  • Factors Influencing Polymer Selection
  • Selection based on performance Requirements and applications
  • Quickly narrow down and select best suitable polymer
  • Best Practices for Polymer Selection

PLASTIC RAW MATERIAL ADVANCED

  • Homo Polymers: Definition and Characteristics
  • Polymer Blends: Introduction and Benefits
  • Copolymers:Interpreting Polymer Datasheets
  • Understanding properties in detail

THE MANUFACTURING PROCESS AND MACHINE

  • Introduction to Plastic Manufacturing Processes
  • Overview of different conversion process like injection molding, blow molding, rotation molding, extrusion, thermoforming, compression molding.
  • Detail understanding on injection molding process and machine
  • Injection Moulding Machine Screw. Heating principle, design function, Typical damages
  • Clamping unit overview and calculations
  • Molding machine selection guidelines

MATERIAL PREPERATION

  • Storage of Raw Material
  • Transport and Mixing of Raw Material
  • Pre-Drying of Raw Material
  • Methods of Drying
  • Considerations based on different polymers
  • Over drying and its adverse effect
  • Cumulative drying time
  • Signs of Undried Material
  • Moisture Absorption Facts
  • Moisture Analyzer

PROCESS ESTABLISHMENT

  • Procedure to establishing and fine-tuning molding
  • Mold qualification flow chart.
  • Understanding fill, pack, switchover point.
  • Pressure drop in the feed system and how to derive it.
  • Gate freezing analysis.
  • Precise understanding on feed system correction as per pressure drop and gate freezing study.
  • Mold cooling process
  • How to qualify a mold that replicates the same quality on different machines

PRODUCT DESIGN

  • What is a good part
  • Plastic part design principles, guidelines for designing various features like ribs, bossed, dog house etc..
  • Draft angle, parting lines, Ejection, appearance, radius, shrinkage, tolerance, undercuts
  • Understanding flow length of different polymer grades
  • Dimensional stability and achievable tolerance for different polymer compounds.
  • Good design practices and techniques

MOLD DESIGN

  • Types of Injection Molds
  • Mold qualification flow chart.
  • Feed System Design and Sizing.
  • Runner Balancing
  • Nozzle Sizing.
  • Cold Slug.
  • Types of Gate
  • Gate Size Derivation
  • Gate Freezing Time
  • Gate Positioning and Number of Gates
  • Runner Cross-Section and Gate Correlation
  • Cooling System, Thermal Stability and Mold Insulation
  • Air Venting for Different Polymers
  • Undercut Release Mechanism
  • Mold Design Tips for Engineering Plastics

TROUBLE SHOOTING

  • Molding Defects root cause and Solutions.
  • Silver Streaks and Diesel Effect.
  • Silver Streaks and Diesel Effect.
  • Gate Blush and Record Grooves.
  • Flash and Short Shot.
  • Blisters and Jetting
  • Sink Marks and Warpage
  • Black Specks and Scoring
  • Molded-in Stress and Part Failures
  • Solutions for Molded-in Stress
  • Nozzle Effect on Resin and Degradation
  • Nozzle Effect on Resin and Degradation

APPLICATION DEVELOPMENT

  • Understanding of various polymer applications
  • Antistatic Applications.
  • Anti-fog Applications.
  • Fire Retardant Polymer Applications.
  • Water Management Applications.
  • Outdoor Applications.
  • Thermally Conductive Polymer Applications.
  • EMI Shielding Applications.
  • Painting and Plating Applications.
  • Medical Bio-Compatible Applications.
  • Lubricating and Low Friction Applications
  • Aerospace Polymer Applications

MOLDFLOW REPORT INTERPRETATION

  • Understanding analysis objectives
  • MPA and MPI flow analysis tools overview
  • Analysis steps framework understanding
  • Mesh types and selection.
  • Case study.
  • In-depth understanding of how to interpret various mold flow report segments like Fill time, V/P switchover, Flow front temperature, Clamping force, Air traps, Weld lines, Sink mark, Distortion (Warpage), shear rate, suggestions, etc..