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This informative blog allows plastics professionals to discuss plastics training and technology. Brought to you by Routsis Training: the plastic industry's premiere training provider.

Cavitation Reduction Concerns

Cavitation reduction is not as simple as blocking off a couple cavities and continuing to run. The process should be as close as possible to the original process, but this will require an adjustment to the process inputs.

Question:

Do you have a good process for blocking cavities?

My Response:

The process is almost identical to the original, but these are some of the characteristics of the new process:

Process Inputs/Outputs which should not change from the Standard Process:

  • 2nd Stage Packing Time
  • 2nd Stage Packing Pressure
  • Cooling Time
  • Back Pressure

Process Outputs which should not change from the Standard Process (may require a change to the process inputs):

  • 1st Stage Injection Time
  • Recovery Time
  • Coolant Temperature
  • Cycle Time

Process Outputs which will change from the Standard Process (may require a change to the process inputs):

  • 1st Stage Injection Weight = (Standard 1st Stage Weight)*(New Cavitation)/(Standard Cavitation)
  • 2nd Stage Final Part Weight = (Standard 2nd Stage Weight)*(New Cavitation)/(Standard Cavitation)
  • Clamp Tonnage = (minimum tonnage required)*(1.1)

Additional Comments:

Cavitation reduction should always be avoided or remedied whenever possible. Since the cycle time does not change, a 25% reduction in cavitation requires 33% more cycles to produce the same number of parts. Such a process is always less stable than full cavitation, so the defect rate will also increase with reduced cavitation. This can quickly reduce overall production capacity and often make the difference between profit and loss.

PVC Packing vs. Thin Wall Molding

Thin wall molding is a relative term that implies the flow length is long with respect to the part thickness and material viscosity…

Question:

Our thick PVC parts require a higher packing pressure than the injection pressure, yet the training states this is typically the case for thin-wall molding. In our case, the parts are often over 0.300″ thick… can you please explain this?

My Response:

In your case, the walls are thin relative to the flow length for the very high polymer viscosity of rigid PVC. I recommend running a rheology curve (or at least a speed study), take a picture of the shorts and take notes at each speed (ie gate appearance, part appearance, burning, etc.). With PVC (& CPVC), the viscosity is very high, but the polymer is also very sensitive to shear thinning which allows for some reduction.

Some Causes for Premature Tie Bar Failure…

Keep in mind that clamp maintenance should be routine and comprehensive. Once a tie bar breaks, it is critical that you ensure everything is level, parallel, lubricated, and functioning properly. If you are unsure, have an expert come in to perform a detailed analysis of your tie bars, platen movement, lubrication, bushings, and leveling.
Question:
What are the various causes of a broken Tie-Bar on a Toggle-Type Injection Molding Machine?

My Response:
The tie bars are designed to last a long time, but only if ALL the following conditions are met:
All the tie bars are parallel
The mold travels perpendicular to the platen surface
All the tie bars are properly level
The machine is properly leveled and supported
The force is applied evenly across all tie bars
The mold is properly sized and centered
The tonnage requirements are centered (balanced)
The platens and tie bars do not get too hot
Proper lubrication is applied
Below are many of the factors that cause premature tie bar failure 
Ex-centric (off-center) mold
Mold with an off-center tonnage requirement
Machine not level or properly supported
Too much unsupported weight on the movable side 
Travel is not perpendicular to platen surface
Platens not parallel
Hot runner molds without insulator plate
Over-clamping a mold
Uneven mold wear
Bent or twisted machine base 
Mold too small for the machine
Poor initial construction
Poor or uneven lubrication
Excessive platen concavity
Cracked platen
Uneven mold bolting
Excessive platen stoning
-Andy

Check Your Short Shot when Troubleshooting…

Recently we were assisting a customer in troubleshooting a problem with inconsistent recovery via email. This was a great reminder that it is always important to check and ensure there is a short shot at the start of troubleshooting most problems.

Customer Issue (shortened): 
During a rear zone study, the customer was encountering complications with the process. After further evaluation, it was found that the screw recovery was fluctuating nearly 40% from shot to shot.
Analysis:
In our experience, an inconsistent recovery is most often caused by an inconsistent cushion (at end of packing). The customer reported a cushion which was consistently at .038in, so at first glance it appeared this was not the problem. Upon further correspondance, it was found that the transfer position was set to 0.040in and a short shot was not being molded. In this case, the machine determined the ‘cushion’ as the forward-most position before screw bounce back occurred.
Correction:
The customer adjusted the transfer up to 0.070in. This obtained a short shot during first stage and provided a consistent recovery time, which was the original intent.
-Andy

Check Ring Test on a 2-Shot Machine…

It is always best to isolate the barrel so the check ring is the only thing being tested, and outside influences are minimized.
Question:
With a 2-shot machine, how do I perform a check ring capability study on my 2nd shot?
My Response:
You want to run the shot by itself if possible. Using both barrels will result in a less reliable number. If you were forced to use both shots, the fill and pack the first shot and then subtract that weight from the final weight.
Additional Thoughts: 
When using a two shot machine, have a way to segregate the parts from the two cores. If the check ring shows high variation, you can run the numbers again separately. 
For example if the combined variation is 5%, but the variation in shot 1 and shot 2 may only be 1% by themselves. In such a case, the ring is fine, but the tooling needs help.
Adversely if a high variation is present in one or both of the shots when calculated alone, then the check ring is inconsistent.
-Andy