DEVELOPMENTS IN INJECTION MOULDING-3

Transcription

1 DEVELOPMENTS IN INJECTION MOULDING-3

2 CONTENTS OF VOLUMES 1 and 2 Volume 1 Edited by A. Whelan and J. L. Craft 1. Digital Hydraulics. H. BLUML 2. Clamping Systems. R. A. IRELAND 3. Mould Design and Manufacture. 1. NIGHTINGALE 4. Screw and Barrel Assembly Development. 1. B. SMITH 5. Materials Modification in Injection Moulding. R. C. MCGREGOR 6. Economic Material Use in Injection Moulding. G. CHEATER 7. Training and Education. C. D. BARNETT 8. Temperature Control. P. H. 1. INGHAM 9. Solid State Systems. F. COOKE 10. Process Control. G. F. TURNBULL Index Volume 2 Edited by A. Whelan and J. L. Craft 1. Energy Use in Injection Moulding. A. WHELAN and R. C. MCGREGOR 2. The Injection Moulding Unit. V. T. GARDNER and H. HELMY 3. Injection Unit Control. G. R. ENDERBY 4. Designing for Production. 1. E. NIGHTINGALE 5. Efficient Mould Cooling. D. C. COOPER 6. Machine Control Using Microprocessors. P. T. K. FARRAR 7. The Case for the Simple Machine. J. BOWN 8. Machine Design for Specific Purposes. M. OLDAKER 9. Plant Layout and Materials Handling. J. BOWN Index

3 DEVELOPMENTS IN INJECTION MOULDING-3 Edited by A. WHELAN and J. P. GOFF Senior Lecturers, London School of Polymer Technology, Holloway, London, UK ELSEVIER APPLIED SCIENCE PUBLISHERS LONDON and NEW YORK

4 ELSEVIER APPLIED SCIENCE PUBLISHERS LTD Crown House, Linton Road, Barking, Essex IGll 8JU, England Sale Distributor in the USA and Canada ELSEVIER SCIENCE PUBLISHING CO., INC. 52 Vanderbilt Avenue, New York, NY 10017, USA WITH 35 TABLES AND 125 ILLUSTRATIONS ELSEVIER APPLIED SCIENCE PUBLISHERS LTD 1985 Softcover reprint ofthe hardcover 1 st edition 1985 British Library Cataloguing in Publication Data Developments in injection moulding.-(the Developments series) 3 1. Injection moulding of plastics 2. Thermoplastics I. Whelan, A. II. Goff, 1. P '23 TP1150 Library of Congress Cataloging in Publication Data (Revised for volume 3) Developments in injection moulding. (Developments series) Vol. 3 edited by A. Whelan and J. P. Goff. Includes bibliographical references and indexes. 1. Injection molding of plastics-collected works. I. Whelan, A. II. Craft, J. L. III. Goff, J. P. IV. Series. TP1150.D ' ISBN-13: e-isbn-13: DOl: / The selection and presentation of material and the opinions expressed in this publication are the sole responsibility of the authors concerned. Special regulations for readers in the USA This publication has been registered with the Copyright Clearance Center Inc. (CCC), Salem, Massachusetts. Information can be obtained from the CCC about conditions under which photocopies of parts of this publication may be made in the USA. All other copyright questions, including photocopying outside of the USA, should be referred to the publisher. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher.

5 PREFACE In the field of polymer technology, injection moulding is the most important moulding process. Because of the size of that industry and the rate of development which it attracts, it is impossible to present, in a single reasonably sized volume, all of the developments that have taken place in recent years. The purpose of this book is therefore to present selected topics which contribute to, or exemplify, developments in this important area. Each year considerable development takes place in the area of machine and process control and these developments receive considerable publicity in the trade press. Another area which advances at the same pace, but which seems to receive far less publicity, although it is equally important, is the area of mould design and manufacture. It is important because profitability is dependent upon the design, manufacture and operation of the mould. It is for this reason that several chapters relating to mould design have been included in this, the third volume in this series. The topics covered include advances in mould manufacture, the use of runnerless systems to aid productivity, and others showing how the applications of computers can greatly assist the moulder to obtain a more productive unit. The other chapters reflect the interest of the industry in subjects such as rheology, reinforcement and process modification. Each of the selected topics is described by a specialist in the field and to them we, the editors, extend our sincere thanks as it is not an easy task to v

6 vi PREFACE prepare a chapter whilst still working. Because of the background and experience of the authors, the contributions should, however, be of immediate relevance to those engaged in the business of injection moulding. A. WHELAN J. P. GOFF

7 CONTENTS Preface List of Contributors v ix 1. Injection Moulding Derivatives 1 D. H. MORTON-JONES 2. Mould Manufacture 41 P. J. C. GOUGH 3. Computer-Aided Part and Mould Design 111 C. AUSTIN 4. Sprueless and Runnerless Moulding 161 Ross E. ROCKENBAUGH 5. Mould Cooling Circuits by Computer. 207 KEITH SCHAUER 6. The Injection Moulding of Reinforced Thermoplastics 243 STEVEN D. GERBIG 7. The Rheology and Injection Moulding of Reinforced and Liquid Crystalline Polymers. 271 G. AKAY Index 317 vii

8 LIST OF CONTRIBUTORS G. AKAY School of Industrial Science, Cranfield Institute of Technology, Cranfield, Bedford, MK43 OAL, UK. Present address: Unilever Research, Port Sunlight Laboratory, Quarry Road East, Bebington, Wirral, Merseyside L63 3JE, UK C. AUSTIN Moldflow Australia Pty Ltd, 5 Chandler Road, PO Box 394, Boronia, Victoria 3155, Australia STEVEN D. GERBIG Wilson-Fiberfil International, 2267 West Mill Road, PO Box 3333, Evansville, Indiana 47732, USA P. J. C. GOUGH Cheshire Engineering and Design Consultants Ltd, Buxton Road, Buglawton, Congleton, Cheshire CW122DW, UK D. H. MORTON-JONES Department of Chemistry, University of Lancaster, Bailrigg, Lancaster LA 1 4W A, UK IX

9 x LIST OF CONTRIBUTORS Ross E. ROCKENBAUGH Columbia Products Inc, 465 Locust Street, PO Box 40, Dallas Town, Pennsylvania 17313, USA KEITH SCHAUER Application Engineering Corporation, 801 AEC Drive, Wood Dale, Illinois 60191, USA