Injection Moulding Module 2 - Process Optimisation
First Polymer Training Skillnet
Dates: 6th - 9th October 2014
1,495. Inclusive of course manual, lunch and refreshments and FETAC Level 5 Exam.
This course is a troubleshooting course. It is suitable for Operators / Technicians / Supervisors / Engineers with at least a few months moulding experience, or having completed the Module 1 course or similar.
It starts by covering the cycle with an in-depth review of each of the parameters making up the stages in the cycle. Theory sessions (2 hours each, one per day) include Parameters and their control, Setting up a mould with no setting sheet (7 point plan), Plastic Materials, Mould Design and Troubleshooting - with a major emphasis on troubleshooting during all sessions.
The remainder of the course is practical, setting up moulds from scratch, selecting pressures, speeds, times and strokes before building the shot up and dealing with defects as they arise. We concentrate on understanding the process with an in-depth explanation of what is happening to the material and the many ways the defect can be avoided. Using injection/ holding profiles is covered in the theory sessions and practiced on a hard-to-fill and poorly vented training mould.
A major benefit of the course is the restriction in numbers to ensure hands-on experience, and we also cover a lot of theory informally during the practical sessions.
Our training centre has three Injection Moulding Machines:
Fanuc All Electric Roboshot 100T
Arburg 320c Golden Edition (Hydraulic) 50T ( new)
Demag Ergotech NC4 (Hydraulic) 35T
Krauss Maffei KM50-125c (Hydraulic) 50T
Where possible we restrict Injection Moulding course numbers to just six places using up to four machines. Our courses can be run in-company if required, or we can modify any course to your needs. FETAC certification is included in the course costs - The FETAC approved examination conducted at the end of the course counts as one credit towards our Vocational Certificate in Polymer Processing.
Who Should Attend?
This course is aimed at anyone who wants to get a very comprehensive understanding of the moulding process. The course material has a very practical application with approximately 70% of the time spent on the machines.
The assessment at the end of the programme, if successfully completed, will lead to one credit towards a major(compound) award, of which 8 credits are needed in total. Please see How to achieve a FETAC major award with FPT. Some of our programmes have assignments as part of the assessment which should be completed by the learner after the programme has finished. Full instructions, time-lines and ongoing guidance will be given by the course tutor. Most assessments are completed during the programme and results will be made available to learners as soon as they have gone through our Quality Assurance procedures and final submission to FETAC.
Shop Practice and Safe Operating Procedures
Analysis of the Moulding Cycle
Basic Machine Set Up
Basic Machine Optimisation
Design and Construction
Balance / Gating / Clamping
Requirements / Part Design
Processing of various thermoplastics
Correct material handling & preparation
Processing factors relating to thermoplastic materials
Process variables & how they influence part quality/product consistency
Selection of correct process parameters
Screw speed optimisation
Material and mould temperature selection
Profile injection speed
Holding pressure optimisation
Influence of one processing variable change on other variables
Practical session on machine
Optimisation of the moulding process
Setting for consistency
Practical optimisation of the moulding machine
Analysis of mould faults
This programme is a FETAC component (minor) award, certified at Level 5 on the national framework of qualifications (www.nfq.ie).
5N3036: Injection Moulding Process Optimisation