Joe Oliveri 585-746-9611
Represented By Adam Kreuter Associates
Westland Corporation
INJECTION MOLDING POCKET GUIDE
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Jim Carlin 585-202-0974
Westland Corporation Joe Oliveri 585-746-9611
Represented By Adam Kreuter Associates
Jim Carlin 585-202-0974
SCREW DESIGN GUIDELINES
RESIN
MOLECULAR TYPE
CRITICAL TEMP ºF (a) 228 Tg
DENSITY G/cm3 SOLID
SCREW DESIGN BASED ON
MELT
METER CHANNEL DEPTH (b)
TRANSITION LENGTH (c)
COMPRESSION RATIO (d)
SELECTED TRADE NAMES
ABS
Amorphous
1.08
.97
Deep
Long
Low
Cycolac, Magnum, Lustran
CA
Crystalline*
NA
1.22
1.14
Deep
Medium
Low
Tenite
CAB
Crystalline*
NA
1.15
1.08
Deep
Medium
Low
Tenite
CAP
Crystalline*
NA
1.17
1.10
Deep
Medium
Low
Tenite
FEP
Crystalline
527 Tm
2.12
1.49
Medium
Short
Medium
Teflon
HDPE
Crystalline
278 Tm
.95
.73
Medium
Medium
Medium
Dowlex, Marlex, Petrothene, Alathon
HIPS
Amorphous
210 Tg
1.05
.97
Deep
Long
Low
Ionomer
Crystalline
205 Tm
.93
.73
Medium
Medium
Medium
LCP
Crystalline
525 Tm
1.35
Unk
Shallow
Medium
Medium
Vectra, Xydar, Ekkcel
LDPE
Crystalline
221 Tm
.92
.76
Medium
Medium
Medium
Petrothene, Tenite, Escorene
LLDPE
Crystalline
250 Tm
.93
.70
Medium
Medium
Medium
Petrothene, Dowlex, Escorene, Attane
Styron, Lustrex, RTP Surlyn, Latek, Formion
PA 66
Crystalline
500 Tm
1.14
.97
Shallow
Medium
High
Zytel, Ultramid, Wellamid, Vydyne
PBT
Crystalline*
470 Tm
1.34
1.11
Medium
Medium
Low
Valox, Celanex Lexan, Makrolon, Calibre
PC
Amorphous
302 Tg
1.20
1.02
Deep
Long
Low
PEI
Amorphous
420 Tg
1.27
1.08
Medium
Medium
Medium
PET
Crystalline**
460 Tm
1.40
1.10
Medium
Medium
Medium
Kodapak, Petlon, Rynite (reinforced)
PFA
Crystalline
582 Tm
2.15
Unk
Medium
Short
Medium
Teflon
PMMA
Amorphous
203 Tg
1.20
1.05
Deep
Long
Low
POM
Crystalline
358 Tm
1.42
1.17
Shallow
Medium
Medium
Delrin (H); Celcon (C) Marlex, Hifax, Escorene, Nortuff
Ultem
(Acrylic) Plexiglas, Acrylite
PP
Crystalline
348 Tm
.90
.75
Medium
Medium
Medium
PPE-PPO
Amorphous
Unk
1.08
.90
Medium
Medium
Low
PS
Amorphous
193 Tg
1.05
.97
Medium
Medium
Medium
Styron
PSU
Amorphous
374 Tg
1.24
1.16
Medium
Medium
Medium
Udel, Ultrason S
PVC-F
Amorphous
194 Tg
1.30
1.20
Deep
Medium
Low
Geon
PVC-R
Amorphous
188 Tg
1.40
1.22
Deep
Long
Low
Geon
SAN
Amorphous
300 Tg
1.07
1.00
Medium
Medium
Medium
(a) (b) (c) (d)
Tm = Melting Point Tg = Glass Transition Point (mean of temps) Degree of meter channel depth. Example: Medium for 2” (50 mm) diameter .100” to .125”. Short = 4D or less; Medium = 5D to 7D; Long = 8D or more Low - less than 2.5:1; Medium - 2.5 to 3.4:1; High - 3.5:1 and above
DRIVE COUPLING DIA
FEED OPENING
SPLIT RING GROOVE DIA FEED DEPTH
LEAD
Noryl, Prevex
Lustran-SAN, Tyril, Luran * Processes like amorphous ** Bottle grade material H = Homopolymer C = Copolymer
THERMOCOUPLE HOLE BARREL LINER
METER DEPTH
RELIEF DIA
FLIGHT POCKET BEARING
FEED ROOT DIA FEED SECTION
SHANK LENGTH
FLIGHTED LENGTH
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SCREW OVERALL LENGTH
SCREW O.D. TRANSITION SECTION
METER ROOT DIA METER SECTION
VALVE ASSEMBLY ENDCAP
Joe Oliveri 585-746-9611
Represented By Adam Kreuter Associates
CALCULATIONS
DECIMAL • METRIC EQUIVALENTS
Ounces/Second = D2 x 2.3 x Mfd x (Sg/225) x RPM Where: Mfd = Meter Flight Depth Sg = Material Density @ Melt Temp Pounds/Hr = oz/sec ÷ .00444 Screw Capacity (oz) = D2 x .7854 x Stroke x Sg x .5778 x .9 Where: Sg = Material Density @ Melt Temp Stroke = in inches per manufacturer Ounces x 28.3 = grams
Grams x .0353 = Ounces
Stroke (inches) For Specified Shot = [Shot size (oz)/(D2 x .4538 x Sg)] x 1.03 Where: Sg = Material Density @ Melt Temp Residence Time (Minutes) or RT Rated Shot Capacity/1.05 x Sg = Inventory RT = Inventory/Shot Size x Cycle Time/60 Where: Sg = Material Density @ Room Temp
REPLACE OR REPAIR WORN COMPONENTS Two separate and independent studies have clearly indicated the importance of repairing or replacing worn cylinders or screws. Both studies indicated that when the flight/barrel clearance is doubled, the drop in production rate can be as high as 20 to 25 percent. Follow our Rule: “If the combined cylinder/screw wear is twice the total clearance (see below), the cylinder or screw (or both) should be repaired or replaced.” METRIC MAXIMUM MINIMUM TOTAL SIZE CYLINDER ID SCREW OD CLEARANCE* 30mm 35mm 40mm 45mm 50mm 55mm 60mm 65mm 70mm 80mm 90mm 100mm 105mm 115mm 120mm 135mm
1.182” 1.379” 1.577” 1.774” 1.971” 2.167” 2.364” 2.561” 2.758” 3.152” 3.545” 3.939” 4.136” 4.530” 4.726” 5.317”
1.175” 1.372” 1.568” 1.765” 1.962” 2.158” 2.355” 2.552” 2.749” 3.142” 3.533” 3.927” 4.122” 4.516” 4.712” 5.301”
Jim Carlin 585-202-0974
.007” .007” .009” .009” .009” .009” .009” .009” .009” .010” .012” .012” .014” .014” .014” .016”
*Total Clearance ÷ 2 = clearance per side
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To convert inches to millimeters, use inches x 25.4. To convert millimeters to inches, use millimeters ÷ 25.4. m/m 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
inches 0.0394 0.0787 0.1181 0.1575 0.1969 0.2362 0.2756 0.3150 0.3543 0.3937 0.4331 0.4724 0.5118 0.5512 0.5906 0.6299 0.6693 0.7087 0.7480 0.7874 0.8268 0.8661 0.9055 0.9449 0.9843 1.0236 1.0630 1.1024 1.1417 1.1811 1.2205 1.2598 1.2992 1.3386 1.3780 1.4173 1.4567 1.4961 1.5354 1.5748 1.6142 1.6535 1.6929 1.7323 1.7717 1.8110 1.8504 1.8898 1.9291 1.9685
m/m 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
inches 2.0079 2.0472 2.0866 2.1260 2.1654 2.2047 2.2441 2.2835 2.3228 2.3622 2.4016 2.4409 2.4803 2.5197 2.5591 2.5984 2.6378 2.6772 2.7165 2.7559 2.7953 2.8346 2.8740 2.9134 2.9528 2.9921 3.0315 3.0709 3.1102 3.1496 3.1890 3.2283 3.2677 3.3071 3.3465 3.3858 3.4252 3.4646 3.5039 3.5433 3.5827 3.6220 3.6614 3.7008 3.7402 3.7795 3.8189 3.8583 3.8976 3.9370
m/m 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150
inches 3.9764 4.0157 4.0551 4.0945 4.1339 4.1732 4.2126 4.2520 4.2913 4.3307 4.3701 4.4094 4.4488 4.4882 4.5276 4.5669 4.6063 4.6457 4.6850 4.7244 4.7638 4.8032 4.8425 4.8819 4.9213 4.9606 5.0000 5.0394 5.0787 5.1181 5.1575 5.1969 5.2362 5.2756 5.3150 5.3543 5.3937 5.4331 5.4724 5.5118 5.5512 5.5906 5.6299 5.6693 5.7087 5.7480 5.7874 5.8268 5.8661 5.9055
Westland Corporation
m/m 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200
inches 5.9449 5.9843 6.0236 6.0630 6.1024 6.1417 6.1811 6.2205 6.2598 6.2992 6.3386 6.3780 6.4173 6.4567 6.4961 6.5354 6.5748 6.6142 6.6535 6.6929 6.7323 6.7717 6.8110 6.8504 6.8898 6.9291 6.9685 7.0079 7.0472 7.0866 7.1260 7.1654 7.2047 7.2441 7.2835 7.3228 7.3622 7.4016 7.4409 7.4803 7.5197 7.5591 7.5984 7.6378 7.6772 7.7165 7.7559 7.7953 7.8346 7.8740
1735 S. Maize Rd • Wichita KS 67209 316-721-1144 • 800-247-1144 • Fax 316-721-1495 www.westlandusa.com •
[email protected]
Westland Corporation Joe Oliveri 585-746-9611
Represented By Adam Kreuter Associates
Jim Carlin 585-202-0974
HEAT PROFILE DECISION CHART Set Heater Band Settings Based on Reference Table Is Center Zone overriding?
No
Yes
Is SRP too high? Lower Backpressure. Raise Rear Zone 10F, then raise Center Zone 5F. Stabilize & repeat.
Is SRP too high?
Yes
Is Center Zone still overriding? Yes
No
Yes
No
Raise Rear Zone 10F & Center Zone 5F until SRP is OK
Is Front Zone overriding?
No
No
Yes Lower Backpressure. Raise Center Zone 10F then Front 10F. If Front Zone drops, repeat until override stops.
Raise Rear 5F, then Center 5F. Repeat until SRP is OK
Is Front Zone still overriding? No
Yes
Check Melt Temp with pyrometer. Is temp too high? Yes
No
Lower Front Zone 5F & Raise Rear Zone 5F. Repeat twice, if needed.
Use Less Restrictive Valve. Check for screw & barrel wear. Check for proper screw design and restrictive mixers, and repair or replace. Repeat steps.
Is Melt Temp still too high? Yes
No
When Aim Melt Temp is achieved, record Benchmark Settings for all heat zones & SRP. Also note screw and valve type used. This is the optimum combination for balancing the heat energy sources.
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Westland Corporation Joe Oliveri 585-746-9611
Represented By Adam Kreuter Associates
Jim Carlin 585-202-0974
HEAT PROFILE REFERENCE TABLE % SHOT CAPACITY
RESIDENCE TIME
HEAT PROFILE TYPE
REAR ZONE
CENTER ZONE
Melt Adj (3)
FRONT ZONE
25% or less
2 min or more
Ascending
Resin (1)
Average of Rear and Front Zones
25% or less
Less than 2 min
Flat
Melt (2)
Melt (2)
Melt Adj (3)
25 to 35%
2 min or more
Flat
Melt (2)
Melt (2)
Melt Adj (3)
25 to 35%
Less than 2 min
Hump
Resin (1)
Melt (2) + 30 to 45°F
Melt Adj (3)
35 to 45%
2 min or more
Hump
Resin (1)
Melt (2) + 30 to 45°F
Melt Adj (3)
35 to 45%
Less than 2 min
Reverse
Melt (2) + Average of Rear and 30 to 45°F Front Zones
Melt Adj (3)
More than 45%
2 min or more
Reverse
Melt (2) + Average of Rear and Front Zones 30 to 45°F
Melt Adj (3)
More than 45%
Less than 2 min
Reverse
Melt (2) + Average of Rear and 40 to 60°F Front Zones
Melt Adj (3)
Notes: (1) Rear zone temperature recommended by the resin manufacturer. (2) Desired melt temperature. (3) Within a range of desired melt temp to 10°F below desired melt temperature
The guidelines for initial heater band settings presented in this table are for the injection molding of non-reinforced thermoplastics with a shot size in the range of 25% to 75% of the machine shot capacity. It should be noted that residence times, screw RPM, additives and other factors are variables that must be considered when setting the heat profile. The heat profile guidelines described above provide a starting point and should be adjusted (See Heat Profile Decision Chart) to produce the best melt quality at the lowest possible moldable temperature with all heater band zones cycling ... and remember to check the Screw Rotate Pressure (SRP).
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