Orbital Plastics Consulting Injection Molding Troubleshooting: Flash & Burn Marks Contact Information Orbital Plastics Consulting www.orbitalplastics.com umberto@orbitalplastics.com (770) 390 - 0949 Paulson Training Programs www.paulsontraining.com spaulson@paulsontraining.com About Orbital Plastics Consulting, Inc. Co-founder & Partner in Paulson School of Molding Injection molding processing & troubleshooting Injection molding training processing & part design Expertise in selecting and implementing in-mold instrumentation. Provides suggestions regarding material selection and plastic part design. About the Presenter Umberto F. Catignani Co-founder, Partner and Principal Instructor in Paulson School of Molding President of Orbital Plastics Consulting, Inc 2007-2008 President of Southern Section of SPE Work Experience: 13 + Years Hands-On BS Materials Engineering. University of Cincinnati. MS Polymer Engineering. The University of Akron. Jointly published papers in: SPE Technical Papers, The Journal of Polymer Science and Polymer Engineering & Science. SPE Speaker on Injection Molding Instrumentation. About Paulson Training Programs For over three decades, Paulson Training Programs has been the leading source for training in the plastics industry. 3,000+ plants and over 30,000 employees trained. Strong training alliances with over 80 colleges and universities. Library includes over 300 hours of interactive plastics training and 2,000+ hours of additional business and manufacturing training titles. New SkillBuilder and SimTech products, software based injection molding machine simulation programs. Record of innovation and quality. Partner and co-founder in Paulson School of Molding with Orbital Plastics Consulting. Presentation Overview Welcome, Introductions & Overview Flash & Burn Marks Causes Problem Analysis Solutions Conclusion, Summary & Questions The Four Primary Plastic Conditions Flash Molded Part Problems - Flash Flash is plastic that flows beyond the mold parting lines or between metal inserts. Flash Locations Flash can be on the runner. Flash Locations Flash can be on the part. Molded Part Problems - Flash Molders should avoid flashing a moldeven if the plastic parts can be trimmed, the flash damages the parting line of the mold. Flash- How Problem Develops Flash - Review: Statement of Problem Flash - Note Flash Question D Problem Analysis The Four Primary Plastic Conditions Flash - Problem Analysis An increase in the clamp force is usually the first adjustment. Flash Question B Question Explanation Flash - Problem Analysis The next plastic condition that can cause flash is plastic cavity pressure. Flash - Problem Analysis Plastic flow rate can also cause flash. Reduce flow rate. Flash - Problem Analysis Plastic flow rate can also cause flash. Flash Question Flash - Problem Analysis Raising or lowering plastic melt temperature can also cause flash. Flash - Problem Analysis Lowering the melt temperature will increase the plastic viscosity and lower the cavity pressure. The flash problem is reduced. But a lower melt temperature may require higher injection pressures to fill the cavity resulting in a larger pressure loss across the cavity. Higher pressures may exist near the runner or gate area and may cause flash in the runner or gate-end of the part. Flash - Problem Analysis Raising the Melt Temperature will reduce the plastic viscosity and increase the cavity pressure. The flash problem will be increased. However, the pressure needed to fill and pack the cavities can then be reduced resulting in reduced flash. Flash - Problem Analysis Flash - Problem Analysis Raising or lowering melt temperature can reduce flashCavity pressure is the key!!! Flash - Problem Analysis Plastic entering parting line cools fastercannot flow far. Flash Problem Locations Flash Problem Locations Flash Problems on Toggle Style Clamps The cavities should be placed so that the plastic pressure is taken up equally by all the machine tie bars. The projected area that the plastic fills should not be concentrated on one side of the mold. Flash - Mold Design Solutions Very low viscosity plastics such as Nylon and Polypropylene can flow into very small parting lines; they flash easily. The high viscosity plastics such as Polycarbonate do not flash easily. Most plastics fall in between. Flash - Material Solutions Flash - Conclusions All 4 primary plastic variables can affect flash. Burn Marks Molded Part Problems Burn Marks Examples of molded parts where the plastic has burned at its leading edge. Molded Part Problems Burn Marks This part is not completely filled out and the edge of the part where flow stopped is charred. Molded Part Problems Burn Marks This part is filled out, but the last region of the part to fill has a burn mark. Molded Part Problems Burn Marks This part has a dark spot surrounded by plastic. It's a burn mark. Functions of the Mold Escape of Air Burn Marks Burn Mark Question C Burn Mark Question C Burn Mark Question C Burn Mark Problem Analysis Burn Mark - Clean Vents Venting- Escape of Air Venting Considerations The critical dimension on a vent is the depth or D1. Located at last place to fill or may cut primary vent to form a continuous venting channel. Vent Depths for Various Resins Resin Depth (inches) ABS 0.0010 - 0.0015 Acetal 0.0005 - 0.0010 Acrylic 0.0015 - 0.0020 Nylon 0.0003 - 0.0005 PPO/PS (Noryl) 0.0010 - 0.0020 Polycarbonate 0.0015 - 0.0025 PET, PBT, Polyesters 0.0005 - 0.0007 Polysulfone 0.0010 - 0.0020 Polyethylene 0.0005 - 0.0012 Polypropylene 0.0005 - 0.0012 Polystyrene 0.0007 - 0.0010 T/P Elastomer 0.0005 - 0.0007 Burn Mark Problem Analysis If the vents are compressed, air will have difficulty escaping. Burn Mark Problem Analysis Burn Question Burn Mark Question C Burn Mark Design Solutions Vent on Ejector Burn Mark Design Solutions Burn Mark Design Problem Burn Mark Question - Design Problem B Race tracking Burn Mark Design Solutions Summary Burn Mark Conclusions Thank You Paulson Training Programs www.paulsontraining.com spaulson@paulsontraining.com Orbital Plastics Consulting www.orbitalplastics.com umberto@orbitalplastics.com