troubleshooting for injection molding by ides
TRANSCRIPT
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Scientific Troubleshootingof Common Injection
Molding Defects
presented by:
www.traininteractive.com | (tel) 978.957.0700
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FREE Information
Please visit: www.IDES.com• Free Material Information• Free Design Guides• Free Articles and Newsletters• Ongoing Informational Webinars
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FREE Information
Please visit: www.traininteractive.com• Free Weekly Focused Training Modules• Free Training Report & Payback Calculator• Ongoing Informational Webinars
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FREE Information
2009 Upcoming Webinars
Part Design forReducing Cycle Time
February 18, 2009
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FREE Information
2009 Upcoming Webinars
Practical ScientificMolding Techniques
March 11, 2009
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FREE Information
2009 Upcoming Webinars
10 Easy Ways to AnalyzeYour Plastic Parts
April 1, 2009
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FREE Information
2009 Upcoming Webinars
10 Procedures to Fine-TuneAny Molding Process
April 15, 2009
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FREE Information
2009 Upcoming Webinars
Best MoldingPractices
April 29, 2009
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Intelligent Molder
in·tel· li·gentAccording to Encarta:
1 : the ability to learn facts and skills andapply them, especially when this abilityis highly developed
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Intelligent Molder
According to the New YorkTimes… Intelligence is defined
as problem solving ability
This is the basis of this presentation
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FREE 10-Day Online Training Offer
Intelligent Molder Series: Process Evaluation• In-Mold Rheology Test• Gate Seal Worksheet• Decoupled II Process Worksheet• More Details at the End of the Presentation
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Scientific Troubleshootingof Common Defects
• Real-Life Troubleshooting Scenarios• Who is a Scientific Troubleshooter?• Process Documentation• Causes for Common Defects• Troubleshooting Methods• FREE Training Offer• Q & A Session
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Real-Life Troubleshooting Scenarios
Case #1 – Material Issue - Problem• Scenario:
– Connector Mold– New Material Supplier with “Identical Material”– Could Not Maintain Desired Cycle Times– 13.9 seconds vs. 11.2 seconds
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Real-Life Troubleshooting Scenarios
Case #1 – Material Issue – Solution• Process, machine, & mold – identical• What changed… Material
– Internal lubricant was not the same– Internal lubricant not at the same percentages
• Established:– Correct internal lubricant– Correct percentages of lubricant
• Resulting in a cycle time under 9 seconds!
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Real-Life Troubleshooting Scenarios
Case #2 – Part Design Issue - Problem• Scenario:
– Kitchen shelving support– Operating at 17.2 second cycle time– Needed to maintain critical dimensions– Wanted to optimize process
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Real-Life Troubleshooting Scenarios
Case #2 – Part Design Issue – Solution• Design Change
– Added 0.25º draft angle
• Resulting in a cycle time under 12 seconds!
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Real-Life Troubleshooting Scenarios
Case #3 – Machine Issue - Problem• Scenario:
– 3 plate mold replaced with hot runner mold– 6 second capable automation added– New machine could not plasticize fast enough– New machine could not move all machine
functions at simultaneously
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Real-Life Troubleshooting Scenarios
Case #3 – Machine Issue – Solution• Specified new machine with:
– Better screw design– Independent machine functions
• Resulting in cycle time under 4 seconds!• Machine could outrun the automation!
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Real-Life Troubleshooting Scenarios
Case #4 – Mold Issue - Problem• Scenario:
– Theft protection tag– 3 plate mold has slow process– Cycle time above 23 seconds– High scrap rate ~35%
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Real-Life Troubleshooting Scenarios
Case #4 – Mold Issue – Solution• Specified mold with hot runner system• Significantly reduced scrap• Resulting in cycle time under 10 seconds!
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Real-Life Troubleshooting Scenarios
Case #5 – Technology Issue - Problem• Scenario:
– Tubular coat hanger– Intermittent short shots– Due to viscosity variations in off-spec materials
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Real-Life Troubleshooting Scenarios
Case #5 – Technology Issue – Solution• Specified process monitoring system with:
– Cavity pressure transducer– Integration to boost cutoff
• Resulting in elimination of short shots• Variations in material viscosity had little to
no change in process
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Who is a Scientific Troubleshooter?
trou·ble·shoot·erAccording to Merriam-Webster:
1 : a skilled worker employed to locatetrouble and make repairs in machineryand technical equipment
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Who is a Scientific Troubleshooter?
A Typical Troubleshooter:• acts upon learned behavior• makes multiple changes at one time• rarely documents anything• often blames the tool or material• avoids speaking in specifics
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Who is a Scientific Troubleshooter?
sci·enceAccording to Merriam-Webster:
1 : the state of knowing : knowledge asdistinguished from ignorance ormisunderstanding
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Who is a Scientific Troubleshooter?
sci·ence + trou·ble·shoot·er =
'a skilled worker who acts from astate of knowing'
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Who is a Scientific Troubleshooter?
A Scientific Troubleshooter:• knows the history of the process, mold,
machine, material, technology• determines what has changed• acts on knowledge• verifies the results of any change
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Process Documentation
Machine Inputsvs.
Process Outputs
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Process Documentation
Setup Technicians Typically Document:• machine-dependent inputs• speed settings• time settings• temperature settings• pressure settings• tonnage settings
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Process Documentation
Scientific Troubleshooters Document:• machine-independent process outputs
– temperatures– times– plastic pressures– weights– additional data
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Process Documentation
Process Outputs - Temperatures:• plastic melt temperature• coolant temperature in• coolant temperature out
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Process Documentation
Process Outputs - Times:• fill time• pack time• hold time• gate seal time• cycle time• recovery time
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Process Documentation
Process Outputs - Plastic Pressures:• back pressure• pressure at transfer
– and/or peak pressure
• pack pressure• hold pressure
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Process Documentation
Process Outputs - Weights:• fill weight• pack weight• final weight
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Process Documentation
Process Outputs - Additional Data:• cavity measurements• quality measurements• clamp tonnage• photographs• observations• cavity balance
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Process Documentation
The Scientific Troubleshooter UsesDocumentation To:• know how the process ran• determine what changed• act on knowledge• verify the results
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Causes/Symptoms for Common Defects
The Typical Troubleshooter Asks:
'what buttons do I pushto correct the defect?’
they often rely on learned behavior & troubleshooting guides
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Causes/Symptoms for Common Defects
The Scientific Troubleshooter Asks:
‘what change occurredto cause this defect?’
process documentation is crucial for these people
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Flash
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Flash
What Changed:– high melt temperature or degradation
Causes:– reduced melt viscosity– more material enters cavity during fill
Symptom:– flash anywhere on part– decreased plastic pressure at transfer
• or peak pressure during fill
– increased fill weight– change in screw recovery time
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Flash
What Changed:– low melt temperature
Causes:– high melt viscosity– more pressure is required to fill mold
Symptom:– flash near gate or center of mold– increased plastic pressure at transfer
• or peak pressure during fill
– decreased fill weight
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Flash
What Changed:– decreased fill time due to high flow rate
Causes:– lower viscosity due to shear thinning– excessive material enters mold during fill
Symptom:– flash anywhere on part– increased fill weight– decreased fill time– increased pressure at transfer
• or peak pressure during fill
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Flash
What Changed:– increased fill time due to a low transfer setpoint
Causes:– excessive material enters mold during fill
Symptom:– flash anywhere on part– increased fill weight– increased fill time– increased pressure at transfer
• or peak pressure during fill
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Flash
What Changed:– increased pack and hold pressure
Causes:– excessive pressure within mold
Symptom:– flash anywhere on part– increased pack weight– increased final weight
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Flash
What Changed:– low clamp tonnage
Causes:– insufficient tonnage to hold mold closed
Symptom:– little change in outputs– increased pack weight– flash anywhere on part
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Flash
What Changed:– high cavity imbalance
Causes:– excessive material enters during fill
Symptom:– not all cavities may flash– intermittent shorts– intermittent flash– incorrect fill time– flash anywhere on part
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Flash
What Changed:– inconsistent check ring
Causes:– inconsistent material during fill
Symptom:– intermittent shorts– intermittent flash– inconsistent fill time– flash anywhere on part
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Flash
What Changed:– excessive mold and platen deflection
Causes:– inconsistent tonnage across parting line
Symptom:– little change in outputs– flash near center of the mold
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Flash
What Changed:– mold damage or wear
Causes:– wear or damage occurs
Symptom:– little change in outputs– flash in a unique area– flash near a moving component
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Sinks and Voids
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Sinks and Voids
What Changed:– high melt temperature
Causes:– excessive shrinkage occurs
Symptom:– shrinkage anywhere on the part– decreased pressure at transfer
• or peak pressure during fill
– increased fill weight
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Sinks and Voids
What Changed:– low melt temperature
Causes:– excessive pressure loss occurs
Symptom:– shrinkage near the end of fill– increased pressure at transfer
• or peak pressure during fill
– decreased fill weight
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Sinks and Voids
What Changed:– increased fill time due to low flow rate
Causes:– excessive pressure loss occurs
Symptom:– shrinkage near the end of fill– decrease pressure at transfer
• or peak pressure during fill
– change in fill weight
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Sinks and Voids
What Changed:– decreased fill time due to a high transfer
setpoint
Causes:– insufficient material enters mold during fill
Symptom:– shrinkage near the end of fill– decrease pressure at transfer
• or peak pressure during fill
– decrease in fill weight
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Sinks and Voids
What Changed:– decreased pack and hold pressure
Causes:– inadequate pressure within mold
Symptom:– shrinkage anywhere on part– decreased pack weight– decreased final weight
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Sinks and Voids
What Changed:– poor gate seal due to a low hold time
Causes:– material exits the cavity through the gate
Symptom:– shrinkage near the gate– decreased final weight
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Sinks and Voids
What Changed:– high mold temperature
Causes:– excessive shrinkage occurs
Symptom:– shrinkage anywhere on the part– decreased pressure at transfer
• or peak pressure during fill
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Voids
What Changed:– low mold temperature
Causes:– polymer freezes to mold surface as part shrinks
Symptom:– voids anywhere on the part– increased pressure at transfer
• or peak pressure during fill
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Short Shots
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Short Shots
What Changed:– low melt temperature
Causes:– excessive pressure loss occurs
Symptom:– increased pressure at transfer
• or peak pressure during fill
– decreased fill weight– decreased pack weight– decreased final weight
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Short Shots
What Changed:– increased fill time due to low flow rate
Causes:– excessive pressure loss occurs
Symptom:– decrease pressure at transfer
• or peak pressure during fill
– change in fill weight– decreased pack weight– decreased final weight
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Short Shots
What Changed:– decreased fill time due to a high transfer
setpoint
Causes:– insufficient material enters mold during fill
Symptom:– decrease pressure at transfer
• or peak pressure during fill
– decrease in fill weight– decreased pack weight– decreased final weight
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Short Shots
What Changed:– decreased pack pressure
Causes:– inadequate pressure to complete mold filling
after transfer
Symptom:– decreased pack weight– decreased final weight
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Jetting
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Jetting
What Changed:– low melt temperature
Causes:– high viscosity prevents fountain flow
Symptom:– increase pressure at transfer
• or peak pressure during fill
– decreased fill weight
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Jetting
What Changed:– decreased fill time due to high flow rate
Causes:– high flow rate prevents fountain flow
Symptom:– increase pressure at transfer
• or peak pressure during fill
– increased fill weight– decreased fill time
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Jetting
What Changed:– low mold temperature
Causes:– poor adhesion to mold surface prevents
fountain flow
Symptom:– increased pressure at transfer
• or peak pressure during fill
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Causes/Symptoms for Common Defects
as you can see…
if the process is documented,the scientific troubleshooter canquickly identify what changed
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Troubleshooting Methods
Again… A Scientific Troubleshooter:• knows the history of the process, mold,
machine, material, and technology• determines what has changed• acts on knowledge (intelligence)• verifies the results of any change
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Troubleshooting Methods
Step 1: Examine the Part to Ensure:• proper diagnosis• no other defects are present
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Troubleshooting Methods
Step 2: Rule Out Obvious Causes:• check the simple causes
– where applicable
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Troubleshooting Methods
Step 3: Compare with DocumentedProcess Outputs• focus on related outputs• process of elimination
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Troubleshooting Methods
Step 4: Return Process to DocumentedStandard• change one parameter at a time• allow each change time to affect the
process
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Troubleshooting Methods
Step 5: Verify Other Process Outputs• verify any relevant parameters• a full verification may be necessary• if cause not found, check the mold,
machine, & material
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Troubleshooting Methods
Step 6: Document Any Changes Made• record actions and causes• ensures others can follow
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Scientific Troubleshooting
In conclusion: it is not only abouttroubleshooting a process…
All factors such as material, mold,machine, part design and
technology must be documented.
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Scientific Troubleshootingof Common Defects
Q & ASession