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Recorded: April 29, 2009
Join Andy Routsis, founder and president of A. Routsis Associates, as he shares the tools and resources that help world-class molding facilities succeed.
The most successful operations are ones which don't overlook small details which make their molds and processes robust. Andy shares some lesser known Best Practices both effective injection mold design and plastics processing. This seminar can benefit mold designers, part designers, processors, and anyone involved in the production environment.
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Questions & Answers from the Webinar
Q: What is the maximum tolerance for platen paralism?
A: This will depend on the application and process you are running. For example, a micro-molding machine needs a significantly closer tolerance than a larger machine molding lawn chairs.
Q: Andy, what is the best guideline or steps to establish most efficient preventive maintenance?
A: The best place to start is to look at the manufacturer's recommendations. If you are running different machine types, you can determine a common schedule which will work for most, or all of your molding machines.
Q: Andy, what is your email address?
A: andyr@traininteractive.com or call me at 978.957.0700
Q: Why are electric machines so energy efficient?
A: (1) There is no pump running while the machine is idle (2) Energy use is on Demand (3) Hydraulic power is not very efficient
Q: How often should I level my injection molding machines?
A: It Depends... but typically Larger machines every 6 months, smaller machines every 12 months, and new machines every 3 months for the first year.
Q: How can I get an energy audit performed?
A: There are many industry experts available if you search... or you call me at 978.957.0700 to discuss.
Q: We are in the process of buying a new machine, what should we look for with respect to energy consumption?
A: Ask for OEM energy studies, discuss with other customers, and weight the any productivity benefits vs. energy savings.
Q: Can you send me a copy of today presentation?
A: This can be downloaded viewed or downloaded from the link above.
Q: Do you offer any tech. book for molding?
A: We provide extensive training on injection molding from beginner to advanced, please visit www.traininteractive.com
Q: Barrel Soak Time? Is there a rule of thumb for material types? Diameter of screw?
A: The best course of action is to determine the optimum rear zone temperature and then set the screw recovery to consume 80% of the cooling time. At this point, you can also reduce residence time by increasing the screw delay time or reducing the screw cushion.
Q: Can I use square cross sectional cooling channels instead of circular?
A: Square cooling channels will provide better turbulence and increased surface area, they are just more difficult to machine into the mold.
Q: Can you speak to your experiences with mold flow vs. part design vs. launch timing - given a "automotive environment".
A: The earlier in the design process you can perform a mold flow analysis, the better. The information provided can help you build the tooling, even if you have no latitude in the part design process.
Q: Do you have an introductory training program for polymers and processing?
A: Yes, we have training for all skill levels from beginner to engineering level. Please feel free to visit www.traininteractive.com
Q: Do you recommend running at different pressures when performing gate freeze studies?
A: You should first determine the optimum pressure using a relatively large 2nd stage time. Afterwards, determine the optimal 2nd stage time.
Q: Can you go over screw return setting again?
A: Please feel free to view the presentation provided above, or download the presentation in .pdf format.
Q: How common is the use of magnetic type plates for improving mold changeover?
A: Magnetic platens are a great investment, especially for custom molders. There are other systems available which provide virtually the same amount of time savings. The key is to investigate which systems are best for your molds and machines.
Q: How much energy is wasted by using more clamping tonnage than necessary?
A: Unless you have equipment complications such as pressure leaks, excessive clamp tonnage does not waste much energy. Excessive clamp tonnage can waste money in the long run since it tends to put wear on the machine and mold. It may also lose money through part quality as the vents, parting line, and slide locks wear.
Q: How often check platen parallelism on 90T tiebarless?
A: Check with the manufacturer, but I would recommend a nine to twelve month schedule.
Q: What problems arise if machine not fully level?
A: Excessive wear on tie bars, platen feet, foot plate, mold vents, parting lines. This condition can also cause the machine to 'walk' or move out of level. Once this happens, the machine base can also crack, bend, or warp.
Q: Where can I get a mold design guideline?
A: Please feel free to download the guide from the link provided above.
Q: Who should i call to check electric output of a molding press?
A: The machine OEM can provide data on the machine's output. You can also use an AMP probe to determine the actual consumption of a machine.
Q: Reducing temperatures is good for cost savings, but may also present a risk to part quality. What practice do you recommend for ensuring part quality is still achieved at the initial qualified level?
A: If you measure the actual melt temperature using a pyrometer, then you can ensure the melt temperature is within specifications.
Q: As an OEM should this be a requirement we should push on our supplier to drive efficiency?
A: Every OEM who wishes to thrive in today's market should document the efficiency of their equipment.
Q: What is the cost of a basic melt rheometer? Would you recommend a specific make/model?
A: There are many different makes/models of melt rheometers available today, both new and used. You may also want to talk to the local labs or colleges to see what they use and why. If you have a small amount of material to test, you can always work with these institutions to get reduced pricing for routine tests.
Q: How do we determine if the rheology results are good enough or robust for the injection molding process?
A: Although there are many case dependent ways to answer this question... the easiest option is be to determine the results from materials which runs well, and then perform a comparative analysis. This information not only identifies 'bad' material, but can identify similar lots of material, allowing you to anticipate process variations.
Q: When doing a gate freeze study, why don’t you start with a long hold time then bring time down?
A: This is perfectly acceptable.
Q: Which problem we can have if a machine is not in level?
A: Unlevel machines can cause tie bar strain, platen twist, uneven clamping, and it can cause the machine to 'walk' over time.
Q: Would you advise an OEM to have a tooling standard?
A: Anyone who procures tooling should have a standard provided to the tooling vendors prior to quoting. This will ensure all the competitive quotes are similar in mold quality.
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