Injection molding is a widely used plastic molding technology, by injecting melted plastic into a mold and cooling it to obtain a plastic product of the desired shape. Scientific injection molding, as an efficient and low-loss production method, optimizes injection-related resources, including injection molding machines, molds, injection process parameters, raw materials, and the environment, in order to achieve stable, efficient, and sustainable production. This report aims to comprehensively explain the basic principles, practical cases and real data of scientific injection molding so that laymen can clearly understand the connotation and advantages of scientific injection molding.
1. Basic Principles of Scientific Injection Molding
The basic principle of scientific injection molding is to use an injection machine to inject molten plastic into a mold, and then solidify it through cooling. The injection machine usually consists of an injection unit, a melting unit and a cooling unit. The injection unit is responsible for injecting molten plastic into the mold, the melting unit heats the solid plastic to a molten state, and the cooling unit rapidly cools and solidifies the plastic through a cooling medium.
At the heart of scientific injection molding lies a data-driven approach to developing, documenting, and maintaining the injection molding process and troubleshooting injection molding problems. This approach is based on the fundamental principle of plastic compressibility and reduces costs by scientifically reducing the grammage of the product and lowering the amount of raw material used. At the same time, with the help of digital tools such as mold flow analysis, problems that may lead to lower yields, such as product design defects, mold design defects, etc., can be analyzed in the early stages of the project.
2. Actual cases of scientific injection molding
An injection molding company conducted an injection molding process optimization experiment, using polypropylene (PP) as the injection material. By adjusting the temperature, injection speed, pressure and other parameters of the injection molding machine, as well as optimizing the design and parameter settings of the hot runner system, the quality of the injection molded products and the production efficiency were improved. Here are some experimental data and results:
Injection molding machine temperature: too high a temperature leads to product deformation or burnout, and too low a temperature affects the filling and densification of the product. Through optimization, the best temperature range of the injection molding machine was determined.
Injection speed: Too fast injection speed causes burrs or indentation of the products, too slow injection speed causes the surface of the products not smooth. The optimal injection speed is determined through adjustment.
Pressure: Appropriate pressure ensures the structural integrity of the product, but too high pressure may lead to deformation or damage of the product. Through optimization, the best pressure range is determined.
Hot runner system: The design and parameter settings of the hot runner system were optimized to improve the filling degree and uniformity of the injection molded products.
Experimental data and results show that by optimizing the injection molding process, the quality of products and production efficiency can be significantly improved.
3. Advantages of scientific injection molding
Scientific injection molding has the following advantages over traditional injection molding methods:
Stability: By optimizing the injection molding process and mold design, stable production output can be achieved, reducing fluctuations and uncertainties in the production process.
High Efficiency: Production efficiency can be significantly improved by increasing the utilization rate of the injection molding machine and reducing waste in the production process.
Low Loss: Costs can be reduced by scientifically reducing product grammage and raw material usage.
Sustainability: Contributes to green production and sustainable development by optimizing energy management and reducing waste generation.
Conclusion
Scientific injection molding, as a high-efficiency and low-loss injection molding production method, achieves stable, high-efficiency and sustainable production by optimizing injection molding-related resources and process parameters. The actual cases of Midea Group’s intelligent injection molding factory and the data from the injection molding process optimization experiments show that scientific injection molding can significantly improve the quality and production efficiency of products, reduce costs, and achieve green production and sustainable development. Therefore, scientific injection molding has a wide range of application prospects and promotion value in the injection molding industry.
