30th September, 2019 - 3rd October, 2019 (4 days)
2nd December, 2019 - 5th December, 2019 (4 days)
Duration: 4 days
Location: 7 Centre Court, Blyry Business and Commercial Park, Athlone.
Accreditation: Injection Moulding Process Optimisation
Full Fee: €1495 including course manual, certification, lunch and refreshments
Course code: 5N3036
This course is a troubleshooting course. It is suitable for Operators/ Technicians/ Supervisors/ Engineers with at least a few months moulding experience or having completed the Module 1 course or similar.
It starts by covering the cycle with an in-depth review of each of the parameters making up the stages in the cycle. Theory sessions (2 hours each, one per day) include Parameters and their control, Setting up a mould with no setting sheet (7 point plan), Plastic Materials, Mould Design and Troubleshooting – with a major emphasis on troubleshooting during all sessions.
The remainder of the course is practical, setting up moulds from scratch, selecting pressures, speeds, times and strokes before building the shot up and dealing with defects as they arise. We concentrate on understanding the process with an in-depth explanation of what is happening to the material and the many ways the defect can be avoided. Using injection/ holding profiles is covered in the theory sessions and practiced on a hard-to-fill and poorly vented training mould.
A major benefit of the course is the restriction in numbers to ensure hands-on experience, and we also cover a lot of theory informally during the practical sessions.
Where possible we restrict Injection Moulding course numbers to just six places using up to four machines.
Safety Shoes – Required on this course
We can deliver a shorter tailored programme at our centre in Athlone for you/ or on-site if you have injection moulding capability there.
At the end of the course trainees should be able to:
- Explain in detail what happens during a full injection moulding cycle from start to finish
- Describe the logical troubleshooting steps to take to fix Flash, Burn Marks, Short Shots, Sink Marks, Weld Lines, Voids, Bubbles, Jetting, Surface drag marks, Splay.
- Demonstrate the logical troubleshooting steps to take to fix Flash, Burn Marks, Short Shots, Sink Marks, Weld Lines.
- List the positive and negative effects of increasing and decreasing the main injection moulding parameters – Shot Size, Switchover Position, Injection Speed, Injection Pressure, Injection Time, Holding Pressure, Holding Time, Back Pressure, RPM Speed, Decompression Distance, Decompression Speed.
- List the main part design recommendations for plastic parts.
- Explain the main difference between Thermoplastic and Thermoset materials.
- Describe the main difference in polymer chain structure of Amorphous vs Crystalline plastic materials
- Briefly explain how the differences between Amorphous and Crystalline material structures affects the mechanical and flow properties of the materials.
- Explain what is shown on injection speed/ pressure/ stroke curves during the injection, holding, plasticising and decompression stages.
- Set up and optimise injection speed profiles to minimise the actual injection time and switchover pressure.
- Set up and optimise holding pressure profiles to minimise sink marks and flash
- Describe what the term melt cushion means, what it is used for and how various injection unit settings affect it.
- Demonstrate how to adjust the shot size and switchover position to change the melt cushion value without affecting the parts being produced.
Who is the course for
This course builds on the content covered in our Injection Moulding Module 1 programme and so is aimed at those who have already completed Module 1, who wish to develop their troubleshooting skills. Candidates who have extensive injection moulding experience may be able to attend this course without completing Module 1, ‘if’ they have otherwise gained the knowledge and are able to:
- List the steps in the injection moulding cycle
- List the parameters that make up the moulding cycle and explain what these parameters do
- Explain what Back Pressure and Decompression are used for.
- Describe basic logical troubleshooting techniques for flash, short shots, sink marks and weld lines.
- Start up and shut down a moulding machine
- Remove a mould and install a new mould
- Set up mould opening/ closing speeds, strokes and pressures, set up mould safety start and stop positions and safety force and calculate clamp force requirements.
- Set up ejector speeds, pressures and find the correct ejector start and stop positions.
Shop Practice and Safe Operating Procedures
Analysis of the Moulding Cycle
Basic Machine Set Up
Basic Machine Optimisation
Design and Construction
Processing of various thermoplastics
Correct material handling & preparation
Processing factors relating to thermoplastic materials
Process variables & how they influence part quality/product consistency
Selection of correct process parameters
Screw speed optimisation
Material and mould temperature selection
Profile injection speed
Holding pressure optimisation
Influence of one processing variable change on other variables
Practical session on machine
Optimisation of the moulding process
Setting for consistency
Practical optimisation of the moulding machine
Analysis of mould faults
Steve O’ Leary has delivered training in Injection Moulding for First Polymer Training since 2000, initially joining FPT Skillnet as the Training Center Manager. Previous to this he worked as an Extrusion/ Injection Moulding Engineer with Boston Scientific in Galway, Extrusion Technician and Extrusion Supervisor with Sherwood Medical in Tullamore (currently Medtronic Tullamore) and as an Injection Moulding Technician with Tubex in Nenagh, Co. Tipperary. He graduated from Athlone IT having studied Plastics Engineering from 1988 to 1992.
This programme is a QQI component (minor) award, certified at Level 5 on the national framework of qualifications – see www.nfq.ie and is a mandatory component of major award 5M3080 – Plastics Injection Moulding.