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Injection Molding Machines downloaded from www.hanser-elibrary.com by 113.185.77.180 on April 22, 2021 For personal use only.



Friedrich Johannaber



Injection Molding Machines A User's Guide



4th Edition



Injection Molding Machines downloaded from www.hanser-elibrary.com by 113.185.77.180 on April 22, 2021 For personal use only.



Injection Molding Machines downloaded from www.hanser-elibrary.com by 113.185.77.180 on April 22, 2021 For personal use only.



Friedrich Johannaber Injection Molding Machines



Injection Molding Machines downloaded from www.hanser-elibrary.com by 113.185.77.180 on April 22, 2021 For personal use only.



Injection Molding Machines downloaded from www.hanser-elibrary.com by 113.185.77.180 on April 22, 2021 For personal use only.



Friedrich Johannaber



Injection Molding Machines A User’s Guide



4th Edition



Carl Hanser Publishers, Munich • Hanser Gardner Publications, Cincinnati



The Author: Dr.-Ing. Friedrich Johannaber, Wahlscheider Straße 95, D-53797 Lohmar, Germany



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Distributed in the USA and in Canada by Hanser Gardner Publications, Inc. 6915 Valley Avenue, Cincinnati, Ohio 45244-3029, USA Fax: (513) 527-8801 Phone: (513) 527-8977 or 1-800-950-8977 www.hansergardner.com Distributed in all other countries by Carl Hanser Verlag Postfach 86 04 20, 81631 Munich, Germany Fax: +49 (89) 98 48 09 www.hanser.de The use of general descriptive names, trademarks, etc., in this publication, even if the former are not especially identified, is not to be taken as a sign that such names, as understood by the Trade Marks and Merchandise Marks Act, may accordingly be used freely by anyone. While the advice and information in this book are believed to be true and accurate at the date of going to press, neither the authors nor the editors nor the publisher can accept any legal responsibility for any errors or omissions that may be made. The publisher makes no warranty, express or implied, with respect to the material contained herein.



Library of Congress Cataloging-in-Publication Data Johannaber, Friedrich. [Spritzgiessmaschinen. English] Injection molding machines / Friedrich Johannaber. -- 4th ed. p. cm. ISBN 978-1-56990-418-3 (hardcover) 1. Injection molding of plastics. I. Title. TP1150.J6413 2007 668.4‘12--dc22 2007023962



Bibliografische Information Der Deutschen Bibliothek: Die Deutsche Bibliothek verzeichnet diese Publikation in der Deutschen Nationalbibliografie; detaillierte bibliografische Daten sind im Internet über abrufbar. ISBN: 978-3-446-22581-7



All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying or by any information storage and retrieval system, without permission in writing from the publisher. © Carl Hanser Verlag, Munich 2008 Production Management: Oswald Immel Typeset by PTP-Berlin, Berlin, Germany Coverconcept: Marc Müller-Bremer, Rebranding, Munich, Germany Coverillustration: © Husky Injection Molding Systems Inc., Bolton, Canada Coverdesign: MCP • Susanne Kraus GbR, Holzkirchen, Germany Printed and bound by Druckhaus »Thomas Müntzer «, Bad Langensalza, Germany



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Foreword The list of books-in-print on plastics processing and injection molding in particular is long. Most of them are primarily aimed at specialists who have a scientific background, but are often unconcerned with the practical aspects of running a molding shop. Hence the need for an expert with that rare combination of both qualities. This remains the case even after all the years since the publication of the first edition of this book. Although in the meantime no great changes have taken place in the basic technology, there has been considerable progress in certain process applications that make special demands on machinery and their control functions in particular. The most interesting such instances have been selected and included in this fourth edition. After completing a degree at the Institute for Plastics Processing in Aachen (IKV), Germany, the author has spent several decades designing injection molding machines, managing molding plants and training their operators. The present book could only have been written by someone with such extensive experience. It joins the small number of standard reference books for the industry which have a solid foundation in both theory and practice. It is exhaustive yet easily understood and thus a “Guide” in the true sense. The author provides an elegant, succinct description of the injection molding process. By concentrating on a few key parameters, such as pressure, temperature, their rates, and their influence on the properties of moldings, he gives his reader a clear insight into this technology. The subsequent comprehensive presentation of technical data relating to individual machine components and performance is unique and will be especially appreciated by machine manufacturers. It goes without saying that the entire book represents the state of the art. This book is a valuable tool for both trainees and students pursuing degrees at technical institutes, as well as for specialists involved in designing and processing. It will almost certainly become required reading for everyone involved in the vast field of injection molding. The interested reader will certainly not want to put it down before reaching the last page. Aachen, March 2007



Prof. Dr.-Ing. G. Menges



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Preface to the Fourth Edition “The future of plastics and that of injection molding as well – has just begun” Polymers and plastic parts are at the heart of current industrial developments. Worldwide per capita consumption is expected to just about double in the next 15 years. The lion’s share of this will fall in industrially developed countries. This will be the case, even if growth there will amount to only approx. 30% and, in terms of percentage, will be clearly exceeded in the rest of the world. Growth in industrialized countries will add to an already high level of use. Machine manufacturers and injection molders, as well, will have to realign themselves strategically as globalization quickens. Taking proven technology as their basis, they will have to create and provide their customers, the injection molding processors, with global marketing concepts and comprehensive customer service. Production methods keep getting more complex and flexible. Quality and design demand ever more accurate injection molding machines capable of handling even the most special injection molding jobs. This implies an increasing number of machine versions. The number of system solutions for machines and peripheral equipment keeps on growing. Support for the injection molder is of utmost importance. But this is not the road to progress. These might then appear to be difficult times. On the other hand, such situations set the stage for new impulses, new ideas and entrepreneurship. “Current developments are often inspired by the polymer.” “Success is achieved by using machine technology intelligently” Looking over company images in the market place, we see clearly that the ones that stand out are also innovators when it comes to machine and mold development, as well as to the mechanical know-how required for special techniques. The trump card for these companies is the strength of their developmental and application-technical departments. Without them, innovation comes to naught. “Today’s most convincing showroom is a smooth-running pilot plant” The fourth edition of “Injection Molding Machines” is now going to print. This edition has been clearly expanded in some areas to provide the reader with more information. At the same time, it is no secret that there is often a discrepancy between the machines offered and the possibilities for using them. Nor is there any attempt to cover up weaknesses. For another thing, processes are described that have been tested, but have not found application for reasons of suitability. This makes for some interesting hindsight, which is significant, since many an “invention” has been made since the start of our retrospective in 1960 that we today recognize as having been a simple recapitulation. The most famous of these is the invention of the screw in 1943: its patent application was turned down with reference to previous patents from 1905. In machine technology, and drive technology in particular, comparable situations have also arisen regarding direct electrical drives that were in use prior to 1956. Such repetitions go to show that print records of the state of technological development have their justification. A visit to the library is worth one’s time. That is one way to avoid repetitions that usually cost a pretty penny.



VIII



Preface to the Fourth Edition



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Virtually all machine manufacturers and their writers regularly list all the positive features of a given machine technology when presenting it. Prospectuses and articles tend to gloss over the disadvantages. But advantages are often hard to conceive of without some measure of comparison. This book attempts to provide that measure of comparison whenever one may be available. To be sure, it is not in the nature of the undertaking to be able to offer absolute standards of comparison. You, dear reader, are invited to include your own experience for evaluation purposes, since actual conditions differ from one application to another. As the author, I am curious to know your reactions, since the book does not exist that cannot be improved by reader input in later editions. Friedrich Johannaber



Lohmar, Germany, June 2007



Acknowledgments For their willingness to provide me with very detailed technical information, I would like to thank the following companies: Arburg GmbH +Co KG, Battenfeld GmbH, CTK Tauscha KG, Demag Plastics Group, Engel, Ferromatik Millacron, Husky Ltd., Krauss Maffei AG and Netstal AG. Without their assistance, this work would not have been possible. I also wish to thank Dipl.-Ing. H. Thoma, Dipl.-Ing. H. Recker and Dr.-Ing. L. Spix for allowing me to adopt substantial parts of their chapters dealing with machines and measuring and control systems in the “Kunststoff Maschinenfu¨ hrer”, 4th edition. Special thanks are due to my wife, Monica, for her patience with me during the completion of this work. “Injection molding is a creative and exciting technology”



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Contents Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



V



Preface to the Fourth Edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



VII



1



Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 The Economic Significance of Injection Molding . . . . . . . . . . . . . . . . . . . . . . 1.2 History of Injection Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



1 1 4



2



Materials for Injection Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Processing Data for Thermoplastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.1 Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.2 Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.3 Drying of Thermoplastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.4 Mixing and Coloring of Thermoplastics During Injection Molding . 2.2 Processing Data for Thermosets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Processing Data for Elastomers (Rubber) . . . . . . . . . . . . . . . . . . . . . . . . . . . .



9 9 9 15 17 23 26 26



3



General Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Characterization of the Injection Molding Process . . . . . . . . . . . . . . . . . . . . . 3.1.1 Functional Process Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2 Injection Molding Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.3 Significance of Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Influence of Temperature on the Molding Process . . . . . . . . . . . . . . . . . . . . . 3.2.1 Temperature of the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.2 Melt Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.3 Mold Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Velocity, Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Physical Description of the Molding Process . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 Effect of Molding Technique on Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.1 Dimensional Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.2 Mechanical and Physical Properties . . . . . . . . . . . . . . . . . . . . . . . . . .



29 31 31 33 34 44 44 44 45 45 47 49 49 49



4



Injection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Performance Parameters of the Injection Unit . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Injection Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 Feeding Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3 Injection Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.4 Screw Speed/Circumferential Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.5 Plasticating Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.6 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Standard Screws for Thermoplastics . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Special Screws for Thermoplastics . . . . . . . . . . . . . . . . . . . . . . . . . . .



61 63 63 69 73 77 78 81 82 83 86



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X



Contents



4.2.3 Special Plastication Units for Thermoplastics . . . . . . . . . . . . . . . . . . 4.2.4 Screws for Rigid PVC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.5 Screws for Vented Barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.6 Screws for Thermosets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.7 Screws for Elastomers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.8 Screws for Processing Silicones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.9 Screw Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.10 Non-Return Valve (Check Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.1 Open Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.2 Shut-Off Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.3 Nozzles with Material Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.4 Internally Heated Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.5 Nozzles with Mixing Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wear and Wear Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1 Causes of Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.2 Wear Protection Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screw Drive Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.1 Translational Drive System for Screws . . . . . . . . . . . . . . . . . . . . . . . . 4.6.2 Rotatory Screw Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage Guide for the Injection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessories for the Injection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



87 94 94 97 98 100 100 101 109 110 111 113 118 121 122 122 122 126 131 132 137 139 142



5



The Clamping Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Clamping Sequence During Opening and Closing . . . . . . . . . . . . . . . . . . . . . 5.2 Clamping Force, Locking Force, Reaction Force . . . . . . . . . . . . . . . . . . . . . . . 5.3 Designs of Clamping Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 Mechanical Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2 Hydraulic Clamping Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.3 Tie-Bar-Less Clamping Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.4 Special Clamping Units for Production of Compact Discs . . . . . . . . 5.4 Accessories for the Clamping Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.1 Ejector Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.2 Removal Equipment for Tie-Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.3 Clamping Systems for Molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.4 Unscrewing Equipment for Cores Inside the Mold . . . . . . . . . . . . . . 5.4.5 Magnetic Mold Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.6 Standard Equipment for Clamping Units . . . . . . . . . . . . . . . . . . . . . .



145 147 151 155 156 157 164 167 169 170 171 172 172 172 173



6



The Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 Electrohydraulic Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.1 Pump Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.2 Speed-Controlled Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.3 Hydraulic Drive Systems Featuring an Accumulator . . . . . . . . . . . . . 6.1.4 Elements of Hydromechanical Drives . . . . . . . . . . . . . . . . . . . . . . . . .



177 178 179 188 192 195



4.3 4.4



4.5 4.6 4.7 4.8



Contents



XI



Electromechanical Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.1 Mechanical Gears for Electromechanical Drives . . . . . . . . . . . . . . . . 6.2.2 Elements of Electromechanical Drives . . . . . . . . . . . . . . . . . . . . . . . .



212 215 219



7



The Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Process Control Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Open-Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2 Closed-Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.1 Temperature Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.2 Temperature Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.1 Pressure in Front of the Screw Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.2 Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.3 Cavity Pressure During Injection Molding . . . . . . . . . . . . . . . . . . . . 7.3.4 Force Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.5 Displacement (Position) Measurement . . . . . . . . . . . . . . . . . . . . . . . 7.4 Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.1 Standard Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.2 Control Panel and Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.3 Objectives of Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.4 Components of the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.5 Disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.6 Methods of Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Electronic Data Processing in Injection Molding . . . . . . . . . . . . . . . . . . . . . . 7.6 Computer-Controlled Automatic Injection Molding Installation . . . . . . . . .



227 228 228 230 231 231 236 242 242 244 244 247 248 250 250 251 252 253 255 256 266 268



8



Efficiency and Energy Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 Hydromechanical Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 Electromechanical Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 Comparison of Hydromechanical and Electromechanical Injection Molding Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



273 273 279



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6.2



9



Injection Molding Machines for Special Processes (Special Machines) . . . . . . . . 9.1 Modifications of Standard Injection Molding Machines . . . . . . . . . . . . . . . . 9.2 Plunger Injection Molding Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.1 Plunger Injection Molding Machines with Plunger Preplastication . 9.2.2 Plunger Injection Molding Machines with Screw Preplastication and Plunger Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.3 Screw Preplastication with Plunger Metering (Accumulator) and Plunger Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 Multi-Station Injection Molding Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3.1 Multi-Station Machines with Horizontal Clamping Unit . . . . . . . . . 9.3.2 Tandem Injection Molding Machines . . . . . . . . . . . . . . . . . . . . . . . . . 9.3.3 Two-Platen Injection Molding Machines (Tandem Arrangement) with Opposed Injection Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



280 285 287 288 289 290 291 292 292 293 295



XII



Contents



9.4 9.5



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9.6 9.7



9.8 9.9 9.10 9.11



9.12 9.13 9.14 9.15



Small Injection Molding Machines and Micro Injection Molding Machines . 9.4.1 Terminology of Micro Injection Molding Machines . . . . . . . . . . . . . 9.4.2 Mini and Micro Injection Molding Machine Designs . . . . . . . . . . . . Multi-Component Injection Molding Machines . . . . . . . . . . . . . . . . . . . . . . . 9.5.1 Machine Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5.2 Nozzle Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5.3 Mold Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5.4 Sandwich (Two-Component) Injection Molding Machines . . . . . . . Injection Molding Machines for In-Mold Decoration (IMD) and In-Mold Lamination (IML) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas- or Fluid-Assisted Injection Molding Machines . . . . . . . . . . . . . . . . . . . . 9.7.1 Equipment for Gas-Assisted Injection Molding (GIT) . . . . . . . . . . . 9.7.2 Surface Gas Pressure Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7.3 Water-Assisted Injection Molding Technology (WIT) . . . . . . . . . . . . Injection Molding Machines with Compounding Functions . . . . . . . . . . . . . Injection Molding Machines for Processing Polyester Molding Compounds Injection Molding Machines for Processing Elastomers . . . . . . . . . . . . . . . . . 9.10.1 Injection Molding Machines for Rubber Processing . . . . . . . . . . . . . 9.10.2 LSR Injection Molding Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low-Pressure Injection Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.1 Low-Pressure Injection Molding Machines for Recycled Thermoplastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.2 Structural Foam Injection Molding Machines . . . . . . . . . . . . . . . . . . 9.11.3 Machines for Producing Microcellular Foams . . . . . . . . . . . . . . . . . . High-Pressure Injection Molding Machines . . . . . . . . . . . . . . . . . . . . . . . . . . Push-Pull Injection Molding Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fusible-Core Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ceramic and Metal Injection Molding Machines . . . . . . . . . . . . . . . . . . . . . . 9.15.1 Powder Injection Molding (PIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15.2 Thixomolding (Magnesium Injection Molding: THIM) . . . . . . . . . .



296 296 298 302 302 306 306 308 310 315 315 315 318 319 320 322 322 324 326 326 328 330 332 334 335 337 337 338



10 Machine Sizes and Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 Machine Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.1 Performance Data of the Injection Unit . . . . . . . . . . . . . . . . . . . . . . . 10.2.2 Performance Data of the Clamping Unit . . . . . . . . . . . . . . . . . . . . . . 10.2.3 General Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



341 341 344 345 352 358



11 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Injection Molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Auxiliary Equipment for Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



361 361 367 368



Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



375