This book attempts to survey the state of the science and technology of the injection molding process. It represents a comprehensive, balanced mix of practical and theoretical aspects for a wide range of injection molding applications. The authors of the 21 chapters are experts and leaders in their respective areas of specialization in the injection molding field. While it is not possible to cover all aspects of such a dynamic growing field, we hope that the reader will find sufficient information and background to become acquainted, at various levels of depth, with key components of the science and technology of injection molding.
Contents:
Injection Molding: Introduction and General Background
Injection Molding Machines, Tools, and Processes
The Plasticating System for Injection Molding Machines
Non-Conventional Injection Molds
Gas Assisted Injection Molding
Water Injection Techniques (WIT)
Flow Induced Fiber Micro-Structure in Injection Molding of Fiber
Reinforced Materials
Injection Foam Molding
Powder Metal Injection Molding
Micro Injection Molding
Internal Visualization of Mold Cavity and Heating Cylinder
Injection Molding Control
Optimal Design for Injection Molding
Development of Injection Molding Simulation
Three-Dimensional Injection Molding Simulation
Viscoelastic Instabilities in Injection Molding
Evolution of Structural Hierarchy in Injection Molded Semicrystalline
Polymers
Modeling Aspects of Post-Filling Steps in Injection Molding
Volumetric and Anisotropic Shrinkage in Injection Moldings of
Thermoplastics
Three-Dimensional Simulation of Gas-Assisted and Co-Injection
Molding Processes
Co-Injection Molding of Polymers

1;Preface;6 2;Part I: Background and Overview;26 2.1;1 Injection Molding: Introduction and General Background;28 2.1.1;1.1Scope;28 2.1.2;1.2Introduction;28 2.1.2.1;1.2.1Polymer Processing;28 2.1.2.1.1;1.2.1.1The Plastics Processing System;29 2.1.2.1.2;1.2.1.2Processing Properties of Polymers and Their Compounds;30 2.1.2.2;1.2.2Injection Molding;30 2.1.2.2.1;1.2.2.1Introduction;30 2.1.2.2.2;1.2.2.2General Injection Molding Process Sequence;31 2.1.3;1.3Injection Molding Process Characteritics;34 2.1.3.1;1.3.1The Plastication Stage;34 2.1.3.1.1;1.3.1.1The Melting Zone;36 2.1.3.1.2;1.3.1.2Temperature distribution in the nozzle;38 2.1.3.2;1.3.2The Filling Stage;42 2.1.3.2.1;1.3.2.1Flow Lines and Weld Lines;42 2.1.3.2.2;1.3.2.2Jetting;44 2.1.3.2.3;1.3.2.3Fountain Flow;45 2.1.3.3;1.3.3Heat Transfer in the Cavity;49 2.1.3.3.1;1.3.3.1Measurement of Temperature Distribution in the Cavity;49 2.1.3.3.2;1.3.3.2Numerical Simulation of Heat Transfer in Injection Molding;53 2.1.3.3.3;1.3.3.3Crystallization Kinetics;55 2.1.4;1.4Microstructure of Injection Molded Parts;56 2.1.4.1;1.4.1Crystallinity;57 2.1.4.1.1;1.4.1.1Effect of Crystallinity and Orientation on Birefringence and Tensile Modulus;58 2.1.4.2;1.4.2Morphology;61 2.1.4.3;1.4.3Residual Stresses;65 2.1.4.3.1;1.4.3.1Calculation of Residual Stresses;67 2.1.4.4;1.4.4Microstructure of Fiber Reinforced Thermoplastics;71 2.1.4.4.1;1.4.4.1Fiber Length and Concentration Distributions;71 2.1.4.4.2;1.4.4.2Matrix Crystallinity;72 2.1.4.4.3;1.4.4.3Fiber and Matrix Orientation;73 2.1.4.4.4;1.4.4.4Composites Incorporating Conductive Fibers;76 2.1.4.5;1.4.5Distribution of Cure in Thermosets;76 2.1.5;1.5Properties of Injection Molding Compounds and Products;79 2.1.6;Symbol List;86 2.1.7;References;88 3;Part II: Injection Molding Machinery and Systems;96 3.1;2 Injection Molding Machines, Tools, and Processes;98 3.1.1;2.1Injection Molding Machines;98 3.1.1.1;2.1.1Types of Injection Molding Machines;98 3.1.1.1.1;2.1.1.1Horizontal Injection Molding Machines;98 3.1.1.1.2;2.1.1.2Vertical Injection Molding Machines;99 3.1.1.1.3;2.1.1.3Hybrid Injection Molding Machine Composed of Vertical and Horizontal Units;100 3.1.1.2;2.1.2Screw and Barrel Unit;100 3.1.1.2.1;2.1.2.1In-Line Screw Type Injection Molding Machines;101 3.1.1.2.2;2.1.2.2Screw Design for Injection Molding Machines;101 3.1.1.2.3;2.1.2.3Barrels for Injection Molding Machines;102 3.1.1.3;2.1.3Driving Principles;104 3.1.1.3.1;2.1.3.1Hydraulic Injection Molding Machines;105 3.1.1.3.2;2.1.3.2Electric Injection Molding Machines;105 3.1.1.3.2.1;2.1.3.2.1Control Systems for an Electric Injection Molding Machine;106 3.1.1.3.2.2;2.1.3.2.2Injection Mechanism for an Electric Machine;107 3.1.1.3.2.3;2.1.3.2.3Nozzle Contact Mechanism for an Electric Injection Molding Machine;108 3.1.1.3.2.4;2.1.3.2.4Electric Clamping Mechanism;108 3.1.1.3.2.5;2.1.3.2.5Electric Ejection Mechanism;109 3.1.1.3.3;2.1.3.3Man-Machine Interface and Communication Control;109 3.1.1.3.3.1;2.1.3.3.1Man-Machine Interface for an Injection Molding Machine;109 3.1.1.3.3.2;2.1.3.3.2Communication Control;111 3.1.1.4;2.1.4Process Control;111 3.1.1.4.1;2.1.4.1Control of the Filling Process;112 3.1.1.4.2;2.1.4.2Control of the Hold-Pressure Switching Process;112 3.1.1.4.3;2.1.4.3Control of the Hold-Pressure Process;113 3.1.1.4.4;2.1.4.4Control of the Metering Process;114 3.1.1.4.5;2.1.4.5Control of the Mold Opening/Closing Process;114 3.1.1.4.6;2.1.4.6Temperature Control of Each Barrel And Nozzle;114 3.1.1.4.7;2.1.4.7Control of the Injection Compression Process;114 3.1.2;2.2Molds for Injection Molding;115 3.1.2.1;2.2.1Functions of Mold Components;116 3.1.2.2;2.2.2Classification of Molds;119 3.1.2.2.1;2.2.2.1Cold Runner Mold Systems;119 3.1.2.2.1.1;2.2.2.1.12-Plate Molds;119 3.1.2.2.1.2;2.2.2.1.23-Plate Molds;119 3.1.2.2.2;2.2.2.2Hot Runner Mold Systems;121 3.1.2.3;2.2.3Sprue, Runners, and Gates;123 3.1.2.3.1;2.2.3.1Runners;123 3.1.2.3.2;2.2.3.2Gates;123 3.1.2.3.3;2.2.3.3Gate Balance;127 3.1.2.3.4;2.