1;Foreword;62;Preface;82.1;Lessons;82.2;Key Questions;82.3;Prerequisite Knowledge;82.4;Review Questions;92.5;An Example: The Compact Disk (CD);92.6;Appendices;92.7;Acknowledgments;93;Contents;104;Introduction Injection Molding - An Ideal Manufacturing Method;124.1;Key Questions;124.2;Contents;124.3;Injection Molding - A Young Production Method;134.4;Injection Molding - A Discontinuous Single-State Process;134.5;Injection Molding - The Injection Molding Machine and Mold;145;Lesson 1 Basic Principles of Plastics;165.1;Key Questions;165.2;Contents;165.3;1.1 Classification and Identification of Polymeric Materials (Plastics and Elastomers);175.4;1.2 Deformation Characteristics of Plastics;195.5;1.3 Molding Compounds and Shaping Methods;225.6;1.4 Plastics Melts;235.6.1;1.4.1 Viscosity;235.6.2;1.4.2 Shear Stress and Shear Rate;245.6.3;1.4.3 Viscosity and Temperature;255.7;Review Questions;296;Lesson 2 The Injection Molding Machine;306.1;Key Questions;306.2;Contents;306.3;Prerequisite Knowledge;306.4;2.1 Classification of Injection Molding Machines;316.5;2.2 Structural Units of Injection Molding Machines;356.6;2.3 Special Injection Molding Processes;376.6.1;2.3.1 Structural Foam Molding;376.6.2;2.3.2 Multi-Injection Molding Process;386.6.3;2.3.3 Injection-Compression Molding;396.6.4;2.3.4 Back-Injection Technology;396.7;Review Questions;417;Lesson 3 The Plasticating and Injection Unit;427.1;Key Questions;427.2;Contents;427.3;Prerequisite Knowledge;427.4;3.1 Tasks of the Plasticating and Injection Unit;437.5;3.2 Plasticating;467.6;3.3 Injection;487.7;Review Questions;518;Lesson 4 The Mold;528.1;Key Questions;528.2;Contents;528.3;Prerequisite Knowledge;528.4;4.1 Tasks and Modes of Operation;538.5;4.2 Gating and Runner System;548.5.1;4.2.1 Basic Principles;548.5.2;4.2.2 Gate Design;558.6;4.3 Cavity;588.7;4.4 Heating/Cooling Systems;608.8;4.5 Ejection System;618.9;Review Questions;659;Lesson 5 The Clamping Unit;669.1;Key Questions;669.2;Contents;669.3;Prerequisite Knowledge;669.4;5.1 Function and Structure;679.5;5.2 Mechanical Clamping Units;689.6;5.3 Hydraulic Clamping Units;709.7;Review Questions;7310;Lesson 6 Drive System and Controls;7410.1;Key Questions;7410.2;Contents;7410.3;Prerequisite Knowledge;7410.4;6.1 Drive System;7510.4.1;6.1.1 Hydraulic Drive;7510.4.2;6.1.2 Electric Drives;7710.5;6.2 Controls;7810.6;Review Questions;7911;Lesson 7 The Injection Molding Process;8011.1;Key Questions;8011.2;Contents;8011.3;Prerequisite Knowledge;8011.4;7.1 Phases of an Injection Molding Cycle;8111.5;7.2 Start;8311.5.1;7.2.1 Mold and Clamping Unit;8311.5.2;7.2.2 Plasticating Unit;8311.5.3;7.2.3 Controls;8311.5.4;7.2.4 Hydraulic- and Electrical Systems;8411.6;7.3 Injection Phase;8511.6.1;7.3.1 Mold and Clamping Unit;8511.6.2;7.3.2 Plasticating Unit;8511.6.3;7.3.3 Controls;8611.6.4;7.3.4 Hydraulics;8611.7;7.4 Holding Pressure Phase;8811.7.1;7.4.1 Mold and Clamping Unit;8911.7.2;7.4.2 Plasticating Unit;8911.7.3;7.4.3 Controls;9011.7.4;7.4.4 Hydraulics;9011.7.5;7.4.5 Cooling Phase;9011.7.6;7.4.6 Feed Phase;9011.8;7.5 Cooling Phase;9111.8.1;7.5.1 Cooling Time Equation;9111.8.2;7.5.2 Mold and Clamping Unit;9211.8.3;7.5.3 Plasticating Unit;9211.8.4;7.5.4 Control and Hydraulic Systems;9211.9;7.6 Feed Phase;9311.9.1;7.6.1 Mold and Clamping Unit;9411.9.2;7.6.2 Plasticating Unit;9411.10;7.7 Removal from the Mold;9411.10.1;7.7.1 Mold and Clamping Unit;9511.10.2;7.7.2 Plasticating Unit;9611.10.3;7.7.3 Hydraulics and Controls;9611.11;Review Questions;9712;Lesson 8 Mold Design;9812.1;Key Questions;9812.2;Contents;9812.3;Prerequisite Knowledge;9812.4;8.1 Tasks and Specifications of Injection Molding Tools;9912.5;8.2 The Designer's Tasks;9912.6;8.3 Mold Layout;10112.6.1;8.3.1 Overview;10112.6.2;8.3.2 Rheological Mold Layout;10212.6.3;8.3.3 Thermal Mold Layout;10512.6.4;8.3.4 Mechanical Mold Layout;10612.7;Review Questions;10913;Lesson 9 Qua