Plastic, Injection Molding

The Plastics Technician's Toolbox, injection Molding

The Plastics Technician's Toolbox
Written By Industry Experts Toolbox includes: Fundamentals book; Injection Molding book; Troubleshooting Pocket Guide

The Toolbox includes practical materials and aides the technician will use daily on-the-job, such as charts, tables and problem solving skills. The intent of the Toolbox is to provide technicians with the technical foundation they need to identify and logically troubleshoot root causes of problems. It contains both the depth and breadth needed for a thorough, practical knowledge base. The Technician's Toolbox contains all of the nuts and bolts required for creating and maintaining a high level of productivity in a plastics processing facility - for both the novice and master technician. The range of tools runs the gamut from the knowledge of fundamentals for all aspects of the operation for the student learning the technology, to the depth of knowledge required to set up, operate, maintain and troubleshoot manufacturing operations. Materials, machinery, molds, dies, tooling, quality and other facets of a complete plastics processing company are all brought together with handy reference tables for use in the shop. An extensive troubleshooting guide combines all the facets of the technology to solve day-to-day problems. Toolbox Scope SPE is publishing The Plastics Technician's Toolbox™ for Injection Molders, an extensive guide to practical information for technicians of all levels. A well-rounded steering committee is championing the development of this benchmark Toolbox, authored by several SPE industry experts. The Toolbox encompasses years of career experience from authors throughout the industry, and is written with the goal of addressing what a technician needs to know, to bring American manufacturing up to the next level. The Injection Molding Toolbox includes a Fundamentals Book and an Injection Molding book. Additionally, extra tools include a troubleshooting pocket guide and laminated handy reference charts. The Injection Molding Toolbox will be followed by other process specific toolboxes. Fundamentals Book - Topics Math for Technicians Practical conversions: Algebraic functions and graphs, trigonometry, analytical geometry, calculus differentiation and basics of integration, charts & graphs. Math for Technicians Basic application to quality control concepts and techniques (information collection and analysis; probability model; statistical quality control methods) Polymer Basics The differences in plastics and what they mean to a processor - thermosets; thermoplastics; properties & temperature effects; rheology; molecular weight distribution effects; additives and fillers, fluid dynamics) Machinery Operating Basics What a technician needs to know to operate and maintain equipment without abusing it (electricity, hydraulics, heat transfer) Print Reading Blueprint reading, circuits, hydraulic and electromechanical Safety General shop rules with references on where to get details (standards for personal safety protection; control of hazardous energy sources, OSHA/ANSI type requirements, electrical/mechanical/hydraulic safety; chemical/lab safety; motor vehicle driving regulations; general equipment procedures, hot work safety procedures, fire prevention and equipment, housekeeping) Plastics Testing How to interpret a physical property sheet. Descriptions of the tests involved (standards; preparation of test specimens, test atmosphere; mechanical properties; thermal properties, rheology testing; opticals) Quality Typical quality control schemes and verification of process consistency (introduction; the technician's contribution to the quality of an operation, observational standards, statistical quality control, statistical process control, the use of monitoring systems, QC begins when plastics is received, economic significance of quality, and computer integrated mfg) Design of Experiments Objective of the DOE, shotgun approach versus cubed corners, typical designs up to three factors, response variations, results and interpretation Problem Solving Skills Basics in cause and effect relationships and analysis of root cause Injection Molding Book - Topics 1. Injection Molding Machinery - Includes subtopics: clamp end, injection unit, controls, sequence of operation of a molding machine, auxiliary equipment, hygroscopic plastics, drying plastics, Tie Bar-less Machines, Electric Machines 2. Molds - basic part design, conventional molds, three plate mold, hot runner, insulated runner, mold temperature control, core pulls, mold design critique, set-up, vents, cold slugs, gates, runner, standards for new molds. Keep in mind that we are teaching a minimum for a technician - but with further depth as deemed suitable. 3. Processing - plastic flow in the injection mold, tools, what if?, testing a mold, setting up the process parameters, optimizing the molding cycle, tips for supervisors and technicians, special cases, shut down machine procedures, related topics 4. Troubleshooting - correcting molding faults which includes such topics as short shots, flashing, sink marks, weld lines, brittleness, discoloration surface defects, warpage and shrinkage, sticking in the mold and black specks. WHAT SHOULD THE TECHNICIAN KNOW WHEN HE'S FINISHED WITH THE INJECTION MOLDING TECHNICIAN'S TOOLBOX? Understand the fundamental concepts in math, statistics, plastics testing, polymer chemistry, problem solving and experimental design and the application of these concepts. Understand the terms used in a molding shop Know how to identify unsafe conditions Be able to perform day to day calculations on the floor Be familiar with the injection and clamp units of an injection molding machine. Understand mold design principles Understand maintenance concerns Understand runnerless systems Understand electrical functions of a machine Understand hydraulic functions of a machine Proper techniques for installing and removing molds Be able to run the process from start up to shut down Optimize run parameters Inspect product Use a monitoring device to verify equipment operation and optimize productivity Interpret machine instructions and part design information Troubleshoot Be aware of newer technologies. Know "What to do when nothing else works"

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