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Definition / Introduction:
Injection Molding is an old technique in which various product is made by using the injection machine. By using a required amount of forces for their developed finished product.
Various injection molding machine is introduced in the last few years. But the Technics and principle of working are similar to the old ones.
Injection molding is used to make the various finished product. By introducing the new product design and its existence in the required field.
In today’s world product is highly good quality and finished with a good edge. Cost operative so the demand for the product. The required manner and so the matter of the product will manage. The cost and their sustainability in the market as per the demand.
Injection molding will make the product very fast and the rate of production is quick. So the come into the mass production of the product. In India, the product quality is more preferred and the consideration of cost also matters and injection molding hold it both side of the product.
Injection molding started with a host of the material mainly include the metals. The particle is the unit of fed into a heated barrel, mixed (using helically shaped).
Injection molding is invented by JohnWesley in American Inventor 1872. The Construction of the machine is very simple as compared now day’s machine.
It work like a hypodermic punch, using a piston and plunger, Injection of plastic through a cylinder whose temperature is very high into the cavity of mold The industry of injection molding is progressed a very slow at the time of invention over many years, at that time the product made by this process is hair comb, buttons, and other product.
In 1903 the inventor invents cellulose acetate, it is less burnable than other cellulose its was made in powder situation from which it readily to injected it into the mold.
In world war 2 the demand of the product is budget, large production of the invention, the elastic injection moldings industry have progressed over the ago for the manufacture of buttons and scrutinizes to produce a large sequence of the product of many companies like the automobile, airway, required product and construction product.
Parts/ Construction of Injection Molding:
The diagram of the molding machine are given below and their detail is shown in the figure the main component of the machine are designated by their name and the terminology which is suitable for that:
Hopper: Here we insert the ingredients of plastic material for the molding process.
Screw Motion / Archimedean Screw: It pushes the ingredients of plastic material into a forward direction.
Heaters: It is used to increase the temperature of the system to prepare the product in a good finished and we can say that the heater works is to melt the ingredients plastic polymers.
Nozzle: Here the material temperature increases such an extent it quickly enters into the mold cavity.
Extraction Pin: It works like split molds and the shape formed to remove from it and further process to be carried out.
Split Mold / Cooling channels: Cooling of the product done into the system.
Clamping unit: It is used to clamp the tool.
Injection unit: In Injection unit it can be used to inject the mold (Plastics).
Drive unit: Driving unit is used to ram the mold in the cavity.
Hydraulic system: Raming the mold by the press.
Working Machine Process:
Material particles are nourished into a hopper then from hopper it comes into the system. There is an Archimedean screw which works is to rotate and sends forward the present material. Now it comes to the heated area here it gets heated between ingredients plastic polymer. At the nozzle the temp having high at such extent it send fast to the Mould cavity and here cooling process is done as shown in the above diagram.
Now Extraction pin removes the mold cavity parts and the formed products remove it which is helmet as shown in the diagram.
Here you can make any of product like a bucket, Mobile parts, Helmet and many more. Actually, the below diagram shown is about Helmet process making but at the mold cavity section if you have set for a bucket then the bucket will be formed.
Injection Moulding is a modern technique in which the grain is made up of the desired material like PVC, Plastics, etc.
Advantages, Disadvantages, and Application of Injection Molding:
Advantage / Merits:
- Quick production.
- Small labor wages.
- Large production of the product.
- Many particles (material) used at the single or same instant.
- The small product part is easily manufactured.
- Leaves very less scrap during the production of a product.
- Ability to create a hole on the product.
- The color is easily controlled in production.
- Finishing is required in very less amount.
- Dimension is very appropriate.
The product manufactured from this technique is good and the result is that all the factor are adopted to get the desired product by using a machine of injection molding.
Disadvantages / Demerits / Limitation:
High initial tooling and machinery cost.
Molds are also very costly
Another disadvantage to injection molding is that the designs will have to be created before any process can begin. This could put production behind schedule or cost more money for the company.
There are also some limitations to what types of designs can be made with this process. The process could be a possible set back for certain companies who don’t have a set rule to follow.
Application / Used:
Used for molding thermoplastic polymers. The shape may be simple or complex.
This molding process is used for various products making like:
- Hard Plastic Chair
- Laptop fan
- Plastic tubes
- Mobile Parts
- Ice block trays and many more.
The injection molding is one of the most adaptable technique used in today industrial requirement and their existing market and sustainability the product production by this technique is good and all the product is quality-wise good and their market value is also the good product is available at Reasonable price and capable to hold it for a long period of time.
The Injection molding has some pros and cons but the overall impact on the industrial area is that all the factor is going to be adopted to get the desired product and all the thing is consider for it as for their requirement.
Injection molding is used for mass production of a product of the same structure so this is widely adopted.
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