Injection Molding Advanced Troubleshooting Guide

The 4M Approach
ISBN: 978-1-56990-645-3
Copyright: 2018
Hardcover: 491 pages
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$179.99 (US)

Contents:

Troubleshooting Methodology. Troubleshooting Tool Kit. Decoupled® or Scientific Molding. Gating Details. Mold Hydraulics. Mold Texture and Polish. Venting. Machine Performance. Drying. Purging. Hot Runners. Cavity Balance. Cavity Instrumentation. Mold Cooling. Black or Brown Specks. Blush. Brown Streaks. Bubbles. Buildup. Burns. Cloudiness. Color Swirls. Contamination. Cracking. Delamination. Dimensions. Excessive Cycle Time. High Fill Pressure. Flaking. Flash. Flow Lines. Glass Fibers on Surface. Gloss Variation. Jetting. Part Sticking on Cover. Part Sticking on Ejector. Pin Push. Read-through. Scuffs and Scratches. Short Shot. Sink. Splay. Sprue Sticking. Stringers. Voids. Warp. Weld Lines.

Description:

The 4M Approach:  Molding Process. Mold. Machine. Material.

This highly practical troubleshooting guide solves injection molding problems systematically and quickly. The rigorous but user-friendly approach employs the authors' proven STOP methodology, considering molding process, mold, machine and material (4Ms) as possible sources of part defects. Importantly, the interaction between tooling, processing, and material is emphasized, allowing successful resolution of difficult problems where other by-the-book approaches fail.

Starting with troubleshooting methodology and tools, this book focuses on key areas that impact troubleshooting, in particular the 4Ms. This is followed by an in-depth troubleshooting guide for various molding defects, structured logically by type of problem/solution. Insightful case studies throughout the book show the strengths of the STOP method to get real processes to run smoothly and reliably, producing quality parts with optimal cycle time and cost.

Drawing on a wealth of hands-on experience from the authors, who have built strong reputations in the field, this book serves as an ideal reference to be consulted at the machine, suitable for both beginning and experienced molders.

With valuable information on robust process windows, cycle time evaluations, scrap savings, and runners/gates, no other book provides the unique insights found here.

Author Info:

Kerkstra, R.

Randy Kerkstra has worked in the plastics industry for over 29 years, with specialism in troubleshooting injection molding. He also has much experience with injection molds, with 14 years in the tool shop environment as a mold maker/designer and over 15 maintaining and repairing/troubleshooting thousands of molds in the production environment. He has years of research with gate geometry, runner/sprue waste, and reducing part defects with a focus on the mold and how it impacts these issues. He also co-owns KB Molding Solutions, a training and consulting company. He currently works in sales and product development for PCS Company.

Brammer, S.

 

Steve Brammer has held a variety of positions for multiple custom and captive molders working in the furniture, appliance, automotive, and consumer products markets. He is currently Molding Technical Manager for a Tier One automotive component supplier. Steve is also an Instructor at Grand Rapids Community College, teaching courses in applied injection molding, plastics processing, and manufacturing. He also co-owns KB Molding Solutions, a training and consulting company. Steve has a Bachelor of Science degree in Plastics Engineering Technology from Ferris State University.

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